JPH04285078A - Lightweight composite panel - Google Patents
Lightweight composite panelInfo
- Publication number
- JPH04285078A JPH04285078A JP7364991A JP7364991A JPH04285078A JP H04285078 A JPH04285078 A JP H04285078A JP 7364991 A JP7364991 A JP 7364991A JP 7364991 A JP7364991 A JP 7364991A JP H04285078 A JPH04285078 A JP H04285078A
- Authority
- JP
- Japan
- Prior art keywords
- surface layer
- thermosetting resin
- rock wool
- mixture
- mat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002131 composite material Substances 0.000 title claims description 13
- 229920005989 resin Polymers 0.000 claims abstract description 25
- 239000011347 resin Substances 0.000 claims abstract description 25
- 239000000843 powder Substances 0.000 claims abstract description 23
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 22
- 239000002344 surface layer Substances 0.000 claims abstract description 20
- 239000011490 mineral wool Substances 0.000 claims abstract description 19
- 239000012792 core layer Substances 0.000 claims abstract description 14
- 239000012783 reinforcing fiber Substances 0.000 claims abstract description 12
- 239000000203 mixture Substances 0.000 abstract description 14
- 239000000463 material Substances 0.000 abstract description 6
- 239000008262 pumice Substances 0.000 abstract description 5
- 239000000835 fiber Substances 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 239000010881 fly ash Substances 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000010680 novolac-type phenolic resin Substances 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000002956 ash Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 238000005056 compaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000005445 natural material Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
Abstract
Description
【０００１】0001
【産業上の利用分野】本発明は壁材、床材等に使用され
る寸法安定性、耐火性、軽量性に優れた軽量複合パネル
に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight composite panel that is excellent in dimensional stability, fire resistance, and light weight and is used for wall materials, floor materials, etc.
【０００２】0002
【従来技術】一般に、建築物の壁及び床材等に利用され
る複合建材として、軽石を主体とするコア層と、ガラス
繊維で強化された表層からなる軽量成形体については公
知である（特公昭５９−１３４７３号公報）。しかしこ
の方法では、軽石は天然素材であるため安定した品質で
入手するのが難しいこと、物性的には密度、強度に制約
があること、また、この材料はプレス成形で造られるが
、成形作業上、一定厚みの製品とするためには原料管理
が複雑であり、かつ厚み精度を上げ得ないという欠点を
有していた。[Prior Art] Generally, as a composite building material used for walls and floors of buildings, a lightweight molded body consisting of a core layer mainly made of pumice and a surface layer reinforced with glass fiber is known (especially known). Publication number 59-13473). However, with this method, it is difficult to obtain pumice in stable quality because it is a natural material, and there are physical limitations on density and strength. Moreover, raw material management is complicated in order to produce a product with a constant thickness, and the thickness accuracy cannot be improved.
【０００３】0003
【発明が解決しようとする課題】本発明は上記のような
軽石の使用により派生する問題を解決し、さらに軽量化
かつ成形の自由度の大きい複合パネルを提供することを
目的とするものである。[Problems to be Solved by the Invention] It is an object of the present invention to solve the problems arising from the use of pumice as described above, and to provide a composite panel that is lighter in weight and has a greater degree of freedom in shaping. .
【０００４】0004
【課題を解決するための手段】本発明は上記の問題点を
解決するために研究を行い、従来使用の無機質軽量骨材
に代えて粒状のロックウ−ルをコア層の骨材として使用
し、このもとに無機質粉体及び熱硬化性樹脂を配してコ
ア層を形成し、強化用繊維と無機質粉体及び熱硬化性樹
脂を主体とする表面層と一体化することにより、軽量性
、加工性、厚み精度に優れた３層構造の複合材料として
使用出来ることを見出したものである。[Means for Solving the Problems] The present invention has been carried out in order to solve the above-mentioned problems, and in place of the conventionally used inorganic lightweight aggregate, granular rock wool is used as the aggregate for the core layer. By arranging inorganic powder and thermosetting resin on this base to form a core layer, and integrating it with the reinforcing fiber and the surface layer mainly composed of inorganic powder and thermosetting resin, lightweight, It was discovered that it can be used as a three-layer composite material with excellent workability and thickness accuracy.
【０００５】以下本発明を図面に従って詳細に説明する
。図１において、符号１および１´は無機質粉体と熱硬
化性樹脂の混合物、２は強化用繊維、３は粒状ロックウ
−ルである。なお、これらによって表面層４及びコア層
５を構成する。そこで、本発明に係る無機質粉体１及び
１´を構成するものとしては、炭酸カルシュウム、ケイ
砂、アルミナ、マイカ、ガラスパウダ−、ガラスバル−
ン、フライアッシュ、海砂等の一般に熱硬化性樹脂充填
材として用いられる無機質粉体がそれぞれ単独において
、或いは組み合わせて使用可能である。また、熱硬化性
樹脂としては、フェノ−ル樹脂、ユリア樹脂、メラミン
樹脂、エポキシ樹脂、不飽和ポリエステル樹脂等の汎用
のものであれば良い。熱硬化性樹脂の添加量は使用する
無機質粉体の種類や樹脂の種類によって多少異なり、個
々の場合に応じて設定すべきであるが、要求性能、経済
性の観点から、無機質粉体１００重量部に対して熱硬化
性樹脂が１０〜５０部の範囲が望ましい。また、１及び
１´には必要に応じて撥水剤、滑剤等の添加剤を配合す
ることも出来る。The present invention will be explained in detail below with reference to the drawings. In FIG. 1, numerals 1 and 1' are a mixture of inorganic powder and thermosetting resin, 2 is a reinforcing fiber, and 3 is granular rock wool. Note that these constitute the surface layer 4 and the core layer 5. Therefore, the inorganic powders 1 and 1' according to the present invention are composed of calcium carbonate, silica sand, alumina, mica, glass powder, and glass powder.
Inorganic powders commonly used as thermosetting resin fillers, such as ash, fly ash, and sea sand, can be used alone or in combination. Further, the thermosetting resin may be a general-purpose one such as phenol resin, urea resin, melamine resin, epoxy resin, or unsaturated polyester resin. The amount of thermosetting resin added varies somewhat depending on the type of inorganic powder and resin used, and should be set according to each individual case, but from the viewpoint of required performance and economical efficiency, it is recommended to add 100% by weight of inorganic powder % of the thermosetting resin is desirably in the range of 10 to 50 parts. Additionally, additives such as water repellents and lubricants may be added to 1 and 1' as necessary.
【０００６】次に、強化用繊維２については、ガラス繊
維、ロックウ−ル、カ−ボン繊維、金属繊維等の無機質
繊維、ナイロン繊維、ポリエステル繊維、ビニロン繊維
、アラミド繊維等の有機質繊維があるが、成形操作上か
らは収束されたストランド状の繊維が好ましい。更に、
粒状ロックウ−ル３は所定長さに切断した綿状ロックウ
−ルに振動、揺動、回転等を加えて得られた球状凝集物
で、必要に応じて粒径を調製して使用する。Next, as for reinforcing fibers 2, there are inorganic fibers such as glass fiber, rock wool, carbon fiber, and metal fiber, and organic fibers such as nylon fiber, polyester fiber, vinylon fiber, and aramid fiber. From the viewpoint of molding operations, converged strand-like fibers are preferred. Furthermore,
The granular rock wool 3 is a spherical aggregate obtained by subjecting cotton-like rock wool cut to a predetermined length to vibration, rocking, rotation, etc., and is used by adjusting the particle size as necessary.
【０００７】次に、本発明パネルの製造手段の一例につ
いて述べる。表層用原料として、無機質粉体に熱硬化性
樹脂を配合し、両者を混合撹拌或いは混練する。液状樹
脂の場合は必要な流動性となるまで溶剤を蒸発調整し、
無機質粉体と熱硬化性樹脂の乾式混合物１を造る。次い
でこの混合物１に強化用繊維２を配合して、適当な離型
用シ−トの上に一定量散布し、表面層用マットを形成す
る。 このとき特にストランド状の繊維を使用した場合
には、混合物１と強化用繊維２とをあらかじめ混合する
ことなしに、離型用のシ−トの上に混合物１を散布し、
次いでストランド状の繊維を散布し、さらにその上に再
度混合物１を散布する操作によって、強化用繊維２が無
機質粉体と熱硬化性樹脂の混合物１に分散したマットを
形成することができる。この方法によっては繊維を機械
的に損傷せず、同時に配合量の自由度を大きくできる。Next, an example of the means for manufacturing the panel of the present invention will be described. As a raw material for the surface layer, a thermosetting resin is blended with an inorganic powder, and both are mixed, stirred, or kneaded. In the case of liquid resin, adjust the solvent by evaporation until the required fluidity is achieved.
A dry mixture 1 of inorganic powder and thermosetting resin is prepared. Next, reinforcing fibers 2 are blended into this mixture 1, and a certain amount of the reinforcing fibers 2 are sprinkled onto a suitable release sheet to form a mat for the surface layer. At this time, especially when strand-shaped fibers are used, the mixture 1 is sprinkled on the release sheet without mixing the mixture 1 and the reinforcing fibers 2 in advance,
Next, a mat in which reinforcing fibers 2 are dispersed in the mixture 1 of inorganic powder and thermosetting resin can be formed by scattering strand-shaped fibers and then again scattering the mixture 1 thereon. Depending on this method, the fibers are not mechanically damaged and at the same time the degree of freedom in blending amount can be increased.
【０００８】次いで、コア層用原料として、表層と同様
にして無機質粉体と熱硬化性樹脂の混合物１´を造り、
粒状ロックウ−ル３を配合し、 表層用マットの上に散
布する。さらにその上に上述と同様の方法で表層用マッ
トを散布した後、熱プレスによって所定時間加熱圧縮す
る。加熱圧縮により、粒状ロックウ−ルは局部的に変形
し空隙を埋めていき、その後伝熱により熱硬化性樹脂が
反応硬化し、混合物１´は網の目状に粒状ロックウ−ル
の周囲を固める。同時に、表面層も強固に固化するので
３層構造の複合体が形成される。Next, as a raw material for the core layer, a mixture 1' of inorganic powder and thermosetting resin is prepared in the same manner as for the surface layer.
Mix granular rock wool 3 and sprinkle it on the surface mat. Furthermore, a mat for the surface layer is sprinkled thereon in the same manner as described above, and then heated and compressed for a predetermined period of time using a hot press. By heating and compressing, the granular rock wool deforms locally and fills the voids, and then the thermosetting resin reacts and hardens due to heat transfer, and the mixture 1' hardens around the granular rock wool in a network shape. . At the same time, the surface layer is also solidified to form a three-layered composite.
【０００９】[0009]
【作用】このようにして、本発明の複合パネルは軽石に
代えて粒状ロックウ−ルを使用したものである。粒状ロ
ックウ−ルの嵩密度は０．０５〜０．２０ｇ／ｃｍ２で
あるが、圧縮成形時に圧密を受けて容積を１／２〜１／
１０に減じる。このように大きな圧密挙動を示すので、
製品密度幅の設定自由度を大きくでき、また、製品の厚
み調節を容易とすることが出来る。また、ロックウ−ル
と共に無機質粉体と熱硬化性樹脂も圧密を受けてロック
ウ−ルは圧縮方向に主として変形し、空隙を埋めていき
、その後伝熱により熱硬化性樹脂が反応硬化し、粒状ロ
ックウ−ルの周囲を固める。同時に、表面層も強固に固
化し、細胞構造の３次元強化層が形成される。[Operation] Thus, the composite panel of the present invention uses granular rock wool instead of pumice. The bulk density of granular rock wool is 0.05 to 0.20 g/cm2, but the volume is reduced by 1/2 to 1/2 due to compaction during compression molding.
Reduce to 10. Because it shows such a large consolidation behavior,
The degree of freedom in setting the product density width can be increased, and the thickness of the product can be easily adjusted. In addition, the inorganic powder and thermosetting resin are also compacted together with the rock wool, and the rock wool deforms mainly in the direction of compression, filling the voids.Then, the thermosetting resin reacts and hardens due to heat transfer, forming granules. Firm the area around the rock wool. At the same time, the surface layer is also solidified, forming a three-dimensional reinforced layer of cell structure.
【００１０】0010
【実施例】以下、実施例により本発明をさらに具体的に
説明する。ブレ−ン値１５００ｃｍ２／ｇのフライアッ
シュ７４重量部、ノボラックタイプフェノ−ル樹脂１３
重量部、２５ｍｍの長さのガラス繊維チョップドストラ
ンド１３重量部を離型用シ−トの上に毎平方メ−トル当
り１．５３ｋｇの割合で均等に散布し表面層とし、次に
粒径１０ｍｍ〜３ｍｍの範囲に調整した粒状ロックウ−
ル３０重量部にフライアッシュ６０重量部、ノボラック
タイプフェノ−ル樹脂９．５重量部、パラフィン０．５
重量部を混合して表面層の上に散布してコア層とする。
さらにこのコア層の上に再度表面層を散布して３層構
造のマットとする。該マットを熱プレスに挿入して、温
度１５０℃、最大圧力１０ｋｇ／ｃｍ２で１０分間圧縮
して、３層構造の複合パネルを得る。このようにして造
られた複合パネルは次のような性質となる。
厚み １３ｍｍ比重
０．６０曲げ強さ ８０
ｋｇ／ｃｍ２吸水膨張率 ０．２％
コア層の散布量 ４．７４ｋｇ
加工率 鋸による切断、釘打ち固定
可能[Examples] The present invention will be explained in more detail with reference to Examples below. 74 parts by weight of fly ash with a Blaine value of 1500 cm2/g, 13 parts by weight of novolac type phenolic resin
13 parts by weight of chopped glass fiber strands with a length of 25 mm were evenly spread on the mold release sheet at a rate of 1.53 kg per square meter to form a surface layer, and then the particle size was 10 mm. Granular rock powder adjusted to a range of ~3mm
30 parts by weight of oil, 60 parts by weight of fly ash, 9.5 parts by weight of novolac type phenolic resin, 0.5 parts by weight of paraffin
Parts by weight are mixed and dispersed onto the surface layer to form a core layer. Furthermore, a surface layer is again sprinkled on top of this core layer to form a three-layered mat. The mat is inserted into a heat press and compressed for 10 minutes at a temperature of 150° C. and a maximum pressure of 10 kg/cm 2 to obtain a three-layer composite panel. The composite panel made in this way has the following properties. Thickness: 13mm Specific gravity
0.60 bending strength 80
kg/cm2 Water absorption expansion rate 0.2% Spreading amount of core layer 4.74kg Processing rate Can be cut with a saw and fixed by nailing
【００１１】[0011]
【発明の効果】以上述べたように、本発明では、無機質
粉体及び熱硬化性樹脂粒状に粒状のロックウ−ルをコア
層の骨材として使用し、強化用繊維と無機質粉体及び熱
硬化性樹脂を主体とする表面層と一体化することにより
、軽量化、加工性、厚み精度にに優れた３層構造の複合
材料として、特に壁材、床材等の軽量複合パネルとして
利用度の高い製品にある。As described above, in the present invention, inorganic powder, thermosetting resin particles, and granular rock wool are used as the aggregate of the core layer, and reinforcing fibers, inorganic powder, and thermosetting resin are used as aggregates for the core layer. By integrating the surface layer with a surface layer consisting mainly of synthetic resin, it becomes a three-layer composite material with excellent weight reduction, workability, and thickness accuracy, making it particularly useful as lightweight composite panels for wall materials, flooring, etc. It's in expensive products.
【００１２】0012
【図１】本発明によって得られる軽量複合パネルの構造
を示す正面断面図である。FIG. 1 is a front sectional view showing the structure of a lightweight composite panel obtained by the present invention.
１．１´ 無機質粉体と熱硬化性樹脂の混合物、２
強化用繊維、
３ 粒状ロックウ−ル、
４ 表面層、
５ コア層。1.1' Mixture of inorganic powder and thermosetting resin, 2
Reinforcing fiber, 3 granular rock wool, 4 surface layer, 5 core layer.
Claims (1)
樹脂を主体とする表面層と粒状ロックウ−ル、無機質粉
体及び熱硬化性樹脂を主体とするコア層とからなる複層
構造を有することを特徴とする軽量複合パネル。Claim 1: A multilayer structure consisting of reinforcing fibers, a surface layer mainly composed of inorganic powder and thermosetting resin, and a core layer mainly composed of granular rock wool, inorganic powder and thermosetting resin. A lightweight composite panel comprising:
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7364991A JPH04285078A (en) | 1991-03-14 | 1991-03-14 | Lightweight composite panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP7364991A JPH04285078A (en) | 1991-03-14 | 1991-03-14 | Lightweight composite panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH04285078A true JPH04285078A (en) | 1992-10-09 |
Family
ID=13524347
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP7364991A Pending JPH04285078A (en) | 1991-03-14 | 1991-03-14 | Lightweight composite panel |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH04285078A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05178651A (en) * | 1992-01-06 | 1993-07-20 | Daiken Trade & Ind Co Ltd | Production of inorganic building plate |
| CN110642640A (en) * | 2019-11-13 | 2020-01-03 | 天津中材工程研究中心有限公司 | Light high-temperature-resistant heat-insulation filler and preparation method thereof |
-
1991
- 1991-03-14 JP JP7364991A patent/JPH04285078A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05178651A (en) * | 1992-01-06 | 1993-07-20 | Daiken Trade & Ind Co Ltd | Production of inorganic building plate |
| CN110642640A (en) * | 2019-11-13 | 2020-01-03 | 天津中材工程研究中心有限公司 | Light high-temperature-resistant heat-insulation filler and preparation method thereof |
| CN110642640B (en) * | 2019-11-13 | 2020-12-22 | 天津中材工程研究中心有限公司 | Light high-temperature-resistant heat-insulation filler and preparation method thereof |
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