JPS627337B2 - - Google Patents

Description

[Detailed description of the invention]

TECHNICAL FIELD The present invention relates to a building insulation board that is used by being adhesively integrated into a building. Conventionally, in insulation work for buildings, a construction method has been used in which concrete and insulation material are joined and integrated into a formwork panel in which a plate-shaped insulation material is temporarily installed, and then the formwork panel is removed. However, in such a construction method, when a synthetic resin foam is used as a heat insulating material, there is a problem in that the bonding strength between the foam and concrete is weak. In order to improve this bonding strength, it has been proposed to provide a bonding layer on the surface of the heat insulating material with a nonwoven fabric mainly made of glass fiber, which has relatively good bonding properties. However, it has the disadvantage that it has little resistance to the alkali of concrete, and its bonding strength decreases when used for a long period of time. In contrast, nonwoven fabrics made of synthetic fibers with good alkali resistance have been used. This was also proposed in Utility Model Publication No. 54-2969. However, although such conventional synthetic fiber nonwoven fabrics have strong resistance to alkali, they lack adhesive bonding strength with concrete, and cannot be put to practical use. Furthermore, since such conventional synthetic fiber non-woven fabrics have low tensile strength and relatively high elongation, they are moved while being pulled, and a foamable synthetic resin is attached on top of the fabric, causing the synthetic resin to foam. When obtaining a heat insulating board made by integrally forming a non-woven fabric and a synthetic resin foam, the non-woven fabric stretches during manufacturing and is therefore manufactured with a large degree of warpage, and the resulting insulating board may not recover as the non-woven fabric recovers over time. Warping and deformation may occur due to force. The major drawback was that nothing that could be put to practical use could be obtained. In order to compensate for this drawback, it is easy to solve this problem by installing a base material with low elongation and high tensile strength, such as kraft paper, between the nonwoven fabric and the moisture barrier layer, but in this case, concrete Moisture during pouring weakens kraft paper, etc., and may even cause delamination of the paper due to external force when removing the formwork. In the case of continuously obtaining architectural insulation boards having bonding layers in this way, there are quality defects due to the structure of the insulation board during the manufacturing process,
Due to the disadvantages of using heat insulating boards, it has not been possible to continuously obtain heat insulating boards with excellent bonding properties. It is an object of the present invention to solve these problems and provide a continuously molded thermal insulation board for construction that has excellent bonding properties. That is, in the construction insulation board of the present invention, the foamable synthetic resin is adhered to the front surface material or the back surface material while continuously moving the front surface material and the back surface material,
In a heat insulating board integrally formed with a surface material and a back material obtained by foaming the synthetic resin, the back material has a moisture-proof layer made of a low-moisture-permeable plastic film or a laminate film facing the synthetic resin foam, and the moisture-proof layer. 3.0, consisting of a bonding layer made of a non-woven fabric sandwiched between them, and the non-woven fabric of the bonding layer is made of a synthetic fiber having a thickness of 2 deniers or more and a fiber length of 1 inch or more, and a thermosetting resin binder; When tensioned at Kg/15mm, the elongation is less than 6.0% in the longitudinal direction and 12% in the transverse direction.
It is characterized by the following elongation. The present inventors have studied the conditions that a heat insulating board should have in order to eliminate the drawbacks of the conventional products, and have found that the following conditions are necessary. The adhesive force between the bonding layer of the insulation board and the concrete is 1.5 kg/1.5 kg in surface peel strength, considering earthquake resistance.
^cm2 or more, preferably 2.0Kg/ ^cm2 or more. When removing the formwork after pouring concrete, the concrete is not completely dry and the bonding layer in contact with it is also impregnated with moisture, so if the wet strength of the bonding layer is weak, delamination of the bonding layer may occur. is likely to occur. Therefore, the wet strength of the bonding layer must be at least half the tensile strength of the dry strength. The moisture barrier layer must be a film-like material that does not allow moisture to pass through. During continuous molding, tensile force is applied to the backing material, including the bonding layer, as it is moved by tension, so if the tensile strength is weak, it may not be able to withstand this tensile force and break, or even if the tensile strength is sufficient, it may stretch. After forming an insulation board, the board warps or deforms, or wavy wrinkles appear on the back side. Therefore, it is necessary to have high tensile strength and low elongation. The bonding layer is integrated with the moisture-proof layer to form the backing material of the insulation board, and in the case of continuous molding, it is used in a shape such as rolled up.
Also, from a functional and economic point of view, it is sufficient to be thin, so it should be thin and flexible. Non-woven fabrics can be considered as fabric-like materials that meet these conditions.In particular, from the point of view of the relationship between bonding strength, tensile strength, and elongation, only non-woven fabrics that are mainly made of glass fibers are weak in the alkali resistance of concrete. Synthetic fiber non-woven fabrics are unsuitable and have strong alkali resistance, but the fabrics conventionally used generally have a texture similar to that of cloth and have a high elongation of around 20% under low loads (for example, about 3 kg/15 mm). It is unsuitable for applications where it is used under constant tension, and there are products that are suitable for applications where elongation is a concern, such as those with a paper-like finish by reducing the fineness or increasing the amount of binder, but these are too dense. The surface becomes smooth and lacks bonding strength with concrete. The nonwoven fabric described in the present invention is one commonly used in the textile industry. There are two types of nonwoven fabrics: dry nonwoven fabrics and wet nonwoven fabrics. Dry nonwoven fabrics are further classified into adhesive type, mechanical bonding type, and spinning type. Adhesive type includes dipping method, printing method, powder method, and bonded fiber method. Mechanically bonded methods include the felt method, needle punch method, and stitch method, and spinning methods include the short fiber method and filament method. Wet-processed nonwoven fabrics are paper-making methods, and include fibrillation method, adhesive fiber method, thermocompression bonding method, solvent method,
There is an adhesive method. Among such nonwoven fabrics, there are the following elements that satisfy the above conditions. ○B Fibers and fiber length have a large influence on the relationship between the tensile strength and elongation of nonwoven fabrics and on the bonding strength with concrete.
Fibers with lengths of inches or more are preferred. If the fineness is less than 2 deniers, the nonwoven fabric becomes dense and the bonding strength with concrete decreases, and nonwoven fabrics with fiber lengths of less than 1 inch have the disadvantage of being easy to stretch. There is insufficient bonding strength. ○B As a binder, thermosetting synthetic resins such as acrylic and melamine synthetic resins are essential to improve water resistance during concrete placement. In addition, when using a thermosetting binder, it has excellent heat resistance even when heated during continuous molding of insulation boards, so it is suitable for use as it does not cause problems such as deterioration of physical properties or deformation due to the effects of heating. It is. ○C The amount of binder used is preferably 60% or less of the total weight of the nonwoven fabric. When it exceeds 60%, the porosity decreases,
The strength of the bond with concrete decreases. ○D The basis weight of the nonwoven fabric is preferably 40g/ ^m2 or more and 200g/ ^m2 or less. If it is less than 40g/m ² , the tensile strength will be insufficient and the bonding strength with concrete will also decrease. If it exceeds 200 g/m ² , the fibers become too dense, the surface of the nonwoven fabric becomes smooth, and the bonding strength with concrete decreases. ○E Since it must have excellent alkali resistance, nonwoven fabrics made of synthetic fibers are suitable. ○F The relationship between the tensile strength and elongation of nonwoven fabrics has a significant impact on the continuous production of insulation boards. In other words, if the insulation material is made of hard urethane foam or phenol foam, which foams and hardens through a chemical reaction, a face material such as non-woven fabric is placed in close contact with a hot plate, and the raw material liquid sprinkled on it is heated. The foam is cured by foaming, but in order to improve the adhesion to the hot plate, usually many slits are provided in the hot plate, and the effect is doubled by drawing a vacuum from the opposite side, but due to the resistance caused by these. A large tensile force is applied to the surface material such as non-woven fabric. This tensile force is different between the upper and lower materials. Therefore, it is impossible to adjust the tensile force of the upper and lower panels to be exactly the same for a panel material that is easily stretched by tensile force, resulting in the disadvantage that the obtained insulation board will warp significantly in one direction. Normally, this tensile force is about 3 kg/15 mm, and if the longitudinal elongation is 6% or more, it is impossible to prevent warping by mechanical adjustment, so it is preferable to keep the elongation to 4.0% or less. What you have is good. Also, the lateral elongation is 12% when loaded with 3Kg/15mm.
It is better to have an elongation of 3 times or less, preferably 2.5 times or less, than the elongation in the longitudinal direction under the same load when the load is less than that, and the elongation that is 3 times or more is the longitudinal tensile strength. This causes wavy wrinkles in the vertical direction and warping in the horizontal direction.
This relationship between tensile strength and elongation is a major factor in preventing warpage, deformation, and surface wrinkles in the insulation board obtained during continuous molding of the insulation board. The relationship between the tensile strength and elongation in the longitudinal and transverse directions can be arbitrarily obtained by adjusting the arrangement of the fibers used in the nonwoven fabric applied to the present invention.
Nowadays, many types of nonwoven fabrics with different physical properties are being produced, depending not only on the type, thickness, and length of the fibers used, but also on the method of forming the web and the method of fixing the web. As mentioned above, the basic properties of a nonwoven fabric suitable for this purpose include excellent tensile properties and concrete adhesion. Considering the suitability of nonwoven fabric manufacturing methods from the viewpoint of tensile properties, it is generally preferable to use a wet method, a dry adhesive impregnation method, or a spunbond method.
Particularly preferred are manufacturing methods that have similar lateral tensile properties, such as the air-lay method and card cross-type method among dry methods. The needle punching method and the stitch bonding method are not very preferable because it is difficult to produce thin products of 100 g/m ² or less, and the products obtained are often cotton-like or cloth-like with high elongation. However, this does not limit the method of manufacturing the nonwoven fabric. In addition, synthetic fibers with a fineness of less than 2 denier and synthetic fibers with a fiber length of less than 1 inch, and glass fibers may be contained as long as they do not affect the basic physical properties mentioned above, that is, 20% or less. . In the present invention, it is essential to use such a special nonwoven fabric as the bonding layer of the heat insulating board. The heat insulation board of the present invention will be explained according to the drawings. FIG. 1 is a cross-sectional view of the architectural insulation board of the present invention. A bonding layer 1 and a heat insulating layer 3 are integrally formed with a moisture-proof layer 2 in between, and a suitable surface material 4 is integrally formed on the other surface of the heat insulating layer 3. Bonding layer 1 is the above-mentioned special nonwoven fabric. The moisture-proof layer 2 is made of a synthetic resin film with low moisture permeability, such as polyvinyl chloride, polyethylene, polypropylene, or the like. Alternatively, a laminate film in which a synthetic resin film is laminated onto a paper base material, or a film impregnated or coated with a moisture-proofing material such as asphalt may be used. Even those with low tensile force and high elongation can be used without any problems. The heat insulating layer 3 is preferably made of synthetic resin foam;
Hard polyurethane foam, phenolic resin foam, epoxy resin foam, urea resin foam, etc. are suitable. There is no problem even if the surface material 4 is the same as the back material 5. Decorative plywood, gypsum board, wood wool board, iron board, etc. can be selected as appropriate depending on the purpose of the building. FIG. 2 explains one embodiment of the apparatus for continuously forming the building insulation board of the present invention.
This is not intended to limit the invention in any way. In FIG. 2, the back material 5 moves at a constant speed in the direction of the arrow, and a foamable synthetic resin is deposited on one side thereof by a means 6 for depositing the foamable synthetic resin. This attachment means 6 may be any ordinary attachment means such as a spray, roll coater, bar coater, knife coater, etc., and any means capable of attaching the foamable synthetic resin at a constant speed may be used, but the simplest method is The thing is a spray.
The foamable synthetic resin attached to the backing material adheres to one side of the backing material due to its own adhesiveness,
It is fed while being foamed by a normal method, and is pressed into contact with the surface material 4 moving at the same speed in the direction of the arrow while foaming or while in an uncured state after foaming. This structure is then transported while being adjusted to a constant thickness by transport means 7, 8 such as upper and lower belt conveyors, during which time the foamable synthetic resin is sufficiently foamed and hardened. In this way, a heat insulating board 9 is obtained in which the back material, the foamed synthetic resin layer, and the surface material are integrated. The backing material 5 is made by bonding and integrating the sheet material of the bonding layer 1 and the film material of the moisture-proof layer 2 in advance, and the foamable synthetic resin is attached to the moisture-proof layer 2 side. In order to move the back material 5 and the front material 4, it is normal to apply a tensile force from the direction of movement. The architectural insulation board according to the present invention is thus obtained by continuous molding, but since the backing material is made of a special non-woven fabric, a strong tensile force is applied to the backing material during continuous molding. Despite this, the resulting insulation board does not warp or deform, exhibits strong bonding strength even when integrated with concrete, and has excellent waterproof properties, making it an excellent insulation board for buildings. The board is what you get. Next, FIGS. 3 to 5 show how the effect of each element constituting the nonwoven fabric used in the present invention on the bonding force with concrete changes depending on the variables of each element. In Figures 3 and 4, two types of fineness are illustrated, 3 denier and 7 denier, and 5
In the figure, examples are given for the basis weights of 40 g/m ² and 60 g/m ² . Binder content in Figure 3,
It is clear that the bonding force with concrete increases and then gradually decreases as each element changes, such as the basis weight in Figure 4 and the fineness in Figure 5, and the quantitative effective limit of each element is It shows that there is. Examples, conventional examples, and comparative examples will be described below. (Example 1) A web was formed by a dry card random method using vinylon fibers having a fineness of 3 denier and 7 denier and a fiber length of 2 inches, and HA-16 containing 20 parts of trimethylolmelamine. (manufactured by Nippon Acrylic Co., Ltd.) was used as a binder to obtain a nonwoven fabric having a basis weight of 62 g/m ² . This one has a thickness of 40μ
A backing material sheet was created by extrusion laminating polyethylene onto m and integrating a moisture-proof layer. Using this backing material, the backing material 5 is
A hard urethane foam stock solution 10 was discharged and foamed onto the surface of the polyethylene moisture-proof layer to obtain a heat insulating board 9 with nonwoven fabric laminated on both sides. To measure the tensile properties of nonwoven fabrics (TSB, EB, elongation at 3Kg/15mm load), use Tensilon to measure a 15mm wide sample.
This was done by pulling at a speed of 100 mm/min.
In addition, the bonding strength with concrete is determined by installing a 50 mm square board on the side of the nonwoven fabric with a moisture barrier layer that does not have a moisture barrier layer, pouring concrete into it, curing it for two weeks, and then gluing T-shaped metal fittings to the concrete surface and the moisture barrier layer surface. This was fixed to the chuck of Tensilon and pulled at a speed of 100 mm/min to measure the surface peel strength. The results are shown in Table-1. (Conventional Examples 1 to 6) Nonwoven fabrics serving as bonding layers were selected from commercially available nonwoven fabrics with relatively low elongation when stretched, and the same tests as in Example 1 were conducted. The results are shown in Table-1. (Comparative Examples 1 to 13, Examples 2 to 16) Nonwoven fabrics were manufactured using vinylon fibers using a dry air lay adhesive impregnation method, and their tensile properties, bonding strength with concrete, and compatibility with insulation board manufacturing conditions were evaluated. Measurement was performed in the same manner as in Example-1. The results are shown in Table-2. From these Examples and Comparative Examples, it is clear that it is essential to use a new nonwoven fabric manufactured under unprecedentedly strict conditions as a heat insulating board that is integrally joined to concrete during concrete pouring.

【table】

【table】

【table】

【table】 [Brief explanation of the drawing]

Fig. 1 is a cross-sectional view of the heat insulating board of the present invention, Fig. 2 is a diagram of an embodiment of a heat insulating board manufacturing apparatus, Fig. 3,
FIGS. 4 and 5 are explanatory diagrams showing how the effect of each element constituting the nonwoven fabric used in the present invention on the bonding force with concrete changes depending on the variables of each element. 1... Bonding layer, 2... Moisture-proof layer, 3... Heat insulation layer,
4... Surface material.

Claims (1)

[Claims] 1 While continuously moving the front material and back material,
A heat insulating board in which a front surface material and a back surface material obtained by adhering a foamable synthetic resin to the front surface material or the back surface material and foaming the synthetic resin are integrally formed,
The backing material is composed of a moisture-proof layer made of a low moisture permeable plastic film or a laminate film facing the synthetic resin foam, and a bonding layer made of a non-woven fabric sandwiching the moisture-proof layer, and the non-woven fabric of the bonding layer is 2 denier. It is made of synthetic fibers with a fiber length of 1 inch or more and a thermosetting resin binder, and has an elongation of 6.0% or less in the longitudinal direction and 12% in the transverse direction when tensioned at 3.0 kg/15 mm. An architectural insulation board characterized by an elongation of less than %.