JP2019183585A - Fireproof panel material - Google Patents

Abstract

An object of the present invention is to provide a fire panel material which is lightweight and has sufficient heat resistance and fire protection performance. The first aluminum layer 2 having a thickness of 9 μm, the second aluminum layer 3 having a thickness of 10 to 50 μm, and the foamed resin base material layer 4 are sequentially bonded. The total thickness of the fire prevention panel material 10 is, for example, 9.0 to 30.0 mm, which is as light as 2.0 kg / m 2 or less. [Selection diagram] Fig. 1

Description

  The present invention relates to a fireproof panel material.

  Interior standards such as ceiling materials and wall materials for medium- and high-rise buildings and buildings with a total floor area of a certain size or larger are required to use fire-proof materials (non-combustible materials, semi-incombustible materials, and flame-retardant materials) under the Building Standard Law. Furthermore, in addition to the fire prevention performance according to the regulations, high design is required in the station premises, buildings, and places where many people gather. For this reason, for these interiors, panels made of a metal base material such as an aluminum alloy, and ceramic building materials in which surface processing and decorative materials are combined are often used.

  Moreover, there is a demand for interior materials that require lightness in addition to design properties, and fireproof interior materials integrated with a corresponding structure have been put into practical use. For example, in Patent Document 1, a flammable heat insulating material (foamed plastic heat insulating material, aluminum foil is attached to the front and back surfaces) and flame retardant (flammable, non-flammable) are used for the structural face material. An invention relating to a heat-resistant and fire-resistant structure in which a heat insulating material (calcium silicate or gypsum board) and an exterior material are sequentially attached is disclosed.

JP 2014-9500 A

In the case of a panel material using a metal as a base material, the fireproof performance is excellent, but there is a limit to weight reduction. Earthquake resistance is also required for interior materials such as ceiling materials and wall materials. In particular, in a highly public building such as a ceiling material in a station, if the ceiling material falls when an earthquake occurs, serious damage may occur. Sufficient seismic performance is required when it falls under the “specific ceiling” specified in the MLIT notification. The specific ceiling means “rooms, corridors and other places where people enter everyday”, “ceilings exceeding 6 m in height and including areas exceeding 200 m ² ” and “per unit area” A material satisfying “a mass (unit mass of the sum of the surfaced panel and a base material such as a field edge holding the panel) exceeding 2 kg” is satisfied. Therefore, when using the panel material which makes a metal a base material, it is necessary to provide the suspension structure which has sufficient earthquake resistance.

Here, if the ceiling panel has a mass of about 1.0 kg / m ² , the mass has recently increased from 0.7 to 1.0 kg / m from the idea that even if it falls due to an earthquake, a serious accident will not occur. A lightweight ceiling system using ^two base materials has been developed. A material made of foamed resin is known as a base material for lightweight interior materials. For example, in the above-mentioned Patent Document 1, a foamed resin in which both surfaces of an expanded resin are covered with aluminum foil is used. However, in patent document 1, it is supposed that the incombustible heat insulating material which consists of a calcium silicate or a gypsum board is used, and weight reduction is difficult.

  As a countermeasure for this weight reduction, there is a sheet-like thin panel. A sheet-like thin panel is obtained by combining a sheet or a film with a core material of a non-combustible or flame-retardant material such as glass wool or glass fiber, and there is a limit to three-dimensional design expression. For this reason, there is no three-dimensional feeling which a metal panel and ceramic building materials have, and the spread is not progressing.

  An object of the present invention is to provide a fireproof panel material that is lightweight, capable of expressing a three-dimensional design, and having fireproof performance.

  The present inventor considered using a foamed resin base material as a flame-retardant material that is lightweight and capable of three-dimensional design expression. Unlike the above-described sheet-like thin panel, the foamed resin base material can be three-dimensionally processed on the surface by “casting (shape)” or “cutting” in the process of forming the base material. And if a decorative sheet is composited (wrapped) on the surface that has been three-dimensionally processed, a fireproof panel material that has the same three-dimensional feeling as a spandrel (siding panel), for example, high design properties of metal panels and ceramic building materials Found that you can.

  In addition to the above, the present inventor examined the fireproof performance of fireproof panel materials using a foamed resin base material. Specifically, the following knowledge was acquired as a result of manufacturing the fire prevention panel material of various structures, and implementing the cone calorimeter test. The corn calorimeter test is a test for evaluating the rate of heat generation, the total calorific value, and the presence of back surface penetration (penetration cracks reaching the back surface) when the sample surface is heated with corn calories.

  First, a cone calorimeter test was performed on a panel in which an aluminum foil (thickness: 30 μm) was pasted on both sides of a flame retardant foamed resin (for example, phenol foam) composed of an organic resin. In any of the total calorific values, good results were obtained, and no back surface penetration occurred. This is because the heat from the cone calorimeter reflects the aluminum foil on the surface efficiently, making it difficult for heat to pass through the foamed resin inside. It is considered that the cracks and the fire-damaging remarkable deformation did not occur, and the performance as a non-combustible material was satisfied.

  Next, in the case of a panel with a decorative layer (printed decorative paper or olefin sheet) affixed to the above panel, the fire resistance of the surface layer burns and carbonizes significantly, and the total calorific value exceeds the standard value. Back surface penetration occurred. This tendency was not changed even when the thickness of the aluminum foil was increased to about 60 μm. This is because the heat-reflecting performance of the aluminum foil deteriorates because the carbonized layer produced by heating adheres to the aluminum foil. As a result, it is considered that the heat is easily transmitted to the foamed resin, the foamed resin is thermally decomposed, the amount of generated heat is increased, and a through crack or deformation to the back surface occurs.

Further, a cone calorimeter using a decorative printing paper having a small organic layer and a non-combustible material such as glass cloth or glass nonwoven fabric (paper) inserted between the decorative layer and the panel having a thickness of 15 mm is used. When the test was conducted, the fireproof performance was at the level of “flame retardant” or “quasi-incombustible”. The performance levels of fireproof materials include “Flame retardant”, “Semi-incombustible”, and “Non-combustible”. The performance evaluation items, “heat generation rate”, “total heat”, and “back surface penetration” are as follows. Although it is the same conformity standard, the fire test time is different from 5 minutes, 10 minutes and 20 minutes, respectively.
・ Criteria of heat generation rate: The time when the maximum heat generation rate has continued to exceed 200 kW / m ² is within 10 seconds ・ Total heat generation: Within 8 MJ / m ²・ Significant deformation harmful to fire (penetration to back side, dimensional shrinkage Or not): not

  Accordingly, it has been found that when the aluminum layer interposed between the decorative layer and the foamed resin base material has a two-layer structure and the thickness of the aluminum layer on the decorative layer side is reduced, the fireproof performance is excellent.

    This invention is completed based on said knowledge, and makes the following invention a summary.

(1) a makeup layer;
A first aluminum layer having a thickness of 0.5 to 9 μm;
A second aluminum layer having a thickness of 10 to 50 μm;
The foamed resin base material layer was adhered in order,
Fireproof panel material.

(2) The decorative sheet is at least one selected from paper, olefin sheet and natural wood.
The fireproof panel material of (1) above.

(3) A glass fiber sheet layer is provided on the adhesive surface between the foamed resin base material layer and the second aluminum layer.
The fireproof panel material according to the above (1) or (2).

(4) The adhesive layer between the first aluminum layer and the second aluminum layer is made of a polyester resin, a polyether resin, a urethane resin, or a polyamide resin.
The fire prevention panel material in any one of said (1)-(3).

(5) The fireproof panel material according to any one of (1) to (4), wherein the foamed resin base material layer has an oxygen index of 21 or more and a bulk specific gravity of 50 kg / m ³ or less.

(6) Used as a ceiling material or a wall material,
The fire prevention panel material in any one of said (1)-(4).

  ADVANTAGE OF THE INVENTION According to this invention, it is lightweight and can provide the fire prevention panel material provided with sufficient heat resistance performance and fire prevention performance.

FIG. 1 is a cross-sectional view showing a configuration of a fireproof panel material according to the present embodiment. FIG. 2 is a diagram showing the results of the cone calorimeter test of Example 1 of the present invention. FIG. 3 is a diagram showing the results of a corn calorimeter test of Example 2 of the present invention. FIG. 4 is a diagram showing the results of a corn calorimeter test of Comparative Example 1. FIG. 5 is a diagram showing the results of a corn calorimeter test of Comparative Example 2. FIG. 6 is a diagram showing the results of a corn calorimeter test of Comparative Example 3. FIG. 7 is a diagram showing the results of a corn calorimeter test of Comparative Example 4.

With reference to FIG. 1, the fire prevention panel material 10 which concerns on this embodiment adhered at least the decorative layer 1, the 1st aluminum layer 2, the 2nd aluminum layer 3, and the foaming resin base material layer 4 in order. Is. The total thickness of the fireproof panel material 10 is, for example, 9.0 to 30.0 mm. This is because it has a light weight of 2.0 kg / m ² or less, more preferably 1.0 kg / m ² or less, and sufficient rigidity and three-dimensional design. This fire prevention panel material 10 is used as a ceiling material or a wall material, for example.

  The decorative layer 1 is a surface material decorated with a predetermined pattern or color, and examples thereof include paper, an olefin sheet, and natural wood. In particular, paper or olefin sheets may be used. Moreover, you may use what was coated on the surface. The decorative layer 1 is preferably thin from the viewpoint of fire resistance. For example, the thickness is preferably 140 μm or less. In particular, 80 μm or less is preferable. Since the texture of the decorative layer 1 is impaired if it is too thin, it is preferably 30 μm or more. In particular, it is preferably 50 μm or more.

  The first aluminum layer 2 is peeled off and burned together with the decorative layer 1 when the decorative layer 1 burns, so that the carbide derived from the decorative layer 1 does not adhere to the second aluminum layer 3 and the second aluminum layer 3 Thus, the heat generation of the foamed resin base material layer 4 can be limited. As a result, excellent fire resistance is imparted to the panel material. In order to obtain this effect, the thickness needs to be 0.5 μm or more. However, if the thickness exceeds 9 μm, it remains in the form of a foil and is integrated with the second, so that the total amount of heat generation cannot be sufficiently reduced and the back surface penetration cannot be prevented. Therefore, the thickness of the 1st aluminum layer 2 shall be 0.5-9 micrometers. In particular, 3 μm or more is preferable, and 5 μm or more is more preferable. Moreover, 7 micrometers or less are preferable.

  The second aluminum layer 3 has an effect of preventing heat generation of the foamed resin base layer 4 by reflecting heat after the first aluminum layer 2 is burned out. In order to obtain this effect, the thickness needs to be 10 μm or more. However, even if the thickness of the second aluminum layer 3 is increased, the effect is saturated and only the mass of the panel material is increased. Therefore, the thickness is set to 50 μm or less. The lower limit of the thickness is preferably 15 μm, and more preferably 20 μm. The upper limit of the thickness is preferably 45 μm, and more preferably 40 μm.

The foamed resin base material layer 4 is for realizing the weight reduction of the fireproof panel material 10 and imparting heat resistance. And since it will lose aesthetics when warp occurs when it is constructed as a ceiling material or the like, it preferably has sufficient rigidity. Therefore, the thickness is preferably 9.0 to 30.0 mm. Moreover, it is preferable that bulk specific gravity is 25-50 g / m < ³ >.

As the material of the foamed resin base material layer 4, it is preferable to select a material having an oxygen index of 21 or more and a bulk specific gravity of 50 kg / m ³ or less. For example, a phenolic resin, a urethane resin, a styrene resin, and the like, and a foam material that is light-weighted by adding a flame-retardant material or a non-flammable material to these resins and then treating the resin with a foaming agent. In particular, it is preferable to use a phenol resin because the oxygen index is 28 or more and the bulk specific gravity is 31 kg / m ³ or less and it is lightweight and fireproof.

The foamed resin base material layer 4 is preferably provided with a glass fiber sheet layer 4b such as glass cloth or glass nonwoven fabric (paper) at the interface (adhesion surface) between the resin layer 4a and the second aluminum layer 3. This is for increasing the adhesive force with the second aluminum layer 3 and increasing the rigidity of the foamed resin base material layer 4 to prevent warping during construction.
Moreover, the fire prevention panel material 10 may adhere | attach the 3rd aluminum layer 5 whose thickness is 10-50 micrometers on the back surface of the foamed resin base material layer 4. FIG. By setting it as such a structure, the rigidity of the foamed resin base material layer 4 can be improved. At this time, the foamed resin base material layer 4 is a polyester fiber nonwoven fabric on the opposite surface (that is, the interface between the resin layer 4a and the third aluminum layer 5) of the interface (adhesion surface) between the resin layer 4a and the second aluminum layer 3. The layer 4c may be provided. Thereby, while improving the adhesive force with the 3rd aluminum layer 5, the rigidity of the foamed resin base material layer 4 can be improved.

There is no restriction | limiting in particular in the contact bonding layer between each layer, The adhesive agents normally employ | adopted, such as a urethane resin adhesive, can be used. However, the adhesive layer between the first aluminum layer 2 and the second aluminum layer 3 has a strong adhesive force in a normal state, but peels off after combustion when heated at about 200 ° C. or higher, and has little combustion energy. You should choose one. As an adhesive satisfying such conditions, polyether resins, polyester resins, urethane resins, and the like may be used, but it is desirable to use polyamide resins having excellent heat resistance and durability. For example, it is desirable to use a polyamide resin (Toyo Motor Co., Ltd. AD-76G1 / AD-76G2, hereinafter referred to as “polyamide resin / epoxy resin”) using an epoxy resin as a crosslinking agent. The amount of the adhesive applied is desirably a solid amount of 10 g / m ² or less.

Various test panel materials were prepared, and a cone calorimeter test was conducted to evaluate the heat generation rate, the total heat generation amount, and the presence or absence of back surface penetration when a flame was applied to the sample surface. The heat generation rate is based on 200 kW / m ² or less. The total calorific value is based on 8 MJ / m ² or less. And it is based on that there is no damage which penetrates a back surface during a 20-minute test.

  As Invention Example 1, a paper decorative layer, an aluminum foil having a thickness of 7 μm, an aluminum foil having a thickness of 30 μm, a foamed resin material (phenolic resin) having a thickness of 14.3 mm, an aluminum foil having a thickness of 30 μm, The panel material for a test which laminated | stacked these in order was prepared. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface with the aluminum foil of a 15 mm foamed resin material, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. Adhesion between aluminum foils was performed using a polyamide resin / epoxy resin adhesive, and a urethane resin adhesive was used for adhesion between other layers. In FIG. 2, the result of the cone calorimeter test of Example 1 of this invention is shown.

As shown in FIG. 2, Example 1 of the present invention has a heat generation rate of 57.66 kW / m ² , a total heat generation amount of 2.46 MJ / m ² , and does not penetrate the back surface during a 20-minute test. Had good fire resistance. Moreover, mass was 0.91 kg / m < ² > and total thickness was 15.0 mm.

  As Invention Example 2, a paper decorative layer, a 7 μm thick aluminum foil, a 30 μm thick aluminum foil, a 44.3 mm thick foamed resin material (phenolic resin), and a 30 μm thick aluminum foil, The panel material for a test which laminated | stacked these in order was prepared. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface between the composite foamed resin material and the aluminum foil, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. Adhesion between aluminum foils was performed using a polyamide resin / epoxy resin adhesive, and a urethane resin adhesive was used for adhesion between other layers. In FIG. 3, the result of the cone calorimeter test of the example 2 of this invention is shown.

As shown in FIG. 3, Example 2 of the present invention has a heat generation rate of 74.79 kW / m ² , a total heat generation amount of 1.47 MJ / m ² , and does not penetrate the back surface during a 20-minute test. Had good fire resistance. Moreover, the mass was 1.7 kg / m ² and the total thickness was 45.0 mm.

  As Comparative Example 1, a test panel material in which a decorative layer of a polyolefin sheet, an aluminum foil having a thickness of 11 μm, an aluminum foil having a thickness of 30 μm, and a foamed resin material (phenolic resin) having a thickness of 14.3 mm are sequentially laminated. Prepared. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface with the aluminum foil of a 15 mm foamed resin material, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. Adhesion between aluminum foils was performed using a polyamide resin / epoxy resin adhesive, and a urethane resin adhesive was used for adhesion between other layers. In FIG. 4, the result of the corn calorimeter test of the comparative example 1 is shown.

As shown in FIG. 4, in Comparative Example 1, the heat generation rate exceeded 200 kW / m ² , the total heat generation amount exceeded 8 MJ / m ² , and penetrated to the back surface in 10 minutes. Moreover, mass was 0.94 kg / m < ² > and total thickness was 15.0 mm.

  As Comparative Example 2, a test panel material in which a paper decorative layer, an aluminum foil having a thickness of 11 μm, an aluminum foil having a thickness of 60 μm, and a foamed resin material (phenolic resin) having a thickness of 14.3 mm are sequentially laminated is prepared. did. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface with the aluminum foil of a 15 mm foamed resin material, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. Adhesion between aluminum foils was performed using a polyamide resin / epoxy resin adhesive, and a urethane resin adhesive was used for adhesion between other layers. In FIG. 5, the result of the corn calorimeter test of the comparative example 2 is shown.

As shown in FIG. 5, in Comparative Example 2, the heat generation rate was 100 kW / m ² , but the total heat generation amount exceeded 8 MJ / m ² and penetrated the back surface in 12 minutes. Moreover, mass was 0.92 kg / m < ² > and total thickness was 45.0 mm.

  As Comparative Example 3, a paper decorative layer, an aluminum vapor deposition layer having a thickness of 0.05 μm provided on the back surface thereof, an aluminum foil having a thickness of 30 μm, a foamed resin material (phenol resin) having a thickness of 44.3 mm, A test panel material in which an aluminum foil having a thickness of 30 μm was sequentially laminated was prepared. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface with the aluminum foil of a 45 mm foamed resin material, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. In FIG. 6, the result of the corn calorimeter test of the comparative example 3 is shown.

As shown in FIG. 6, in Comparative Example 3, the heat generation rate was 150 kW / m ² , but the total heat generation amount exceeded 8 MJ / m ² . However, it did not penetrate the back surface during the 20 minute test. Moreover, the mass was 1.7 kg / m ² and the total thickness was 45.0 mm.

  As Comparative Example 4, a paper decorative layer, a 12 μm thick PET aluminum vapor deposition layer, a 30 μm thick aluminum foil, a 14.3 mm thick foamed resin material (phenolic resin), and a 30 μm thick aluminum foil The panel material for a test which laminated | stacked these in order was prepared. A glass nonwoven fabric having a thickness of 200 μm is provided at the interface with the aluminum foil of a 15 mm foamed resin material, and a polyester fiber nonwoven fabric having a thickness of 150 μm is provided on the opposite surface. The PET aluminum vapor deposition layer having a thickness of 12 μm is obtained by vapor-depositing aluminum having a thickness of 0.05 μm on a PET film having a thickness of 12 mm. In FIG. 7, the result of the cone calorimeter test of the comparative example 4 is shown.

As shown in FIG. 7, Comparative Example 4, although the heat generation rate was 82.8kW / ^{m 2,} the total calorific value, exceeds 8 MJ / ^{m 2.} However, it did not penetrate the back surface during the 20 minute test. Moreover, mass was 0.91 kg / m < ² > and total thickness was 15.0 mm.

  ADVANTAGE OF THE INVENTION According to this invention, it is lightweight and can provide the fire prevention panel material provided with sufficient heat resistance performance and fire prevention performance.

DESCRIPTION OF SYMBOLS 1 Decorative layer 2 First aluminum layer 3 Second aluminum layer 4 Foamed resin base material layer 4a Resin layer 4b Glass fiber sheet layer 4c Polyester fiber nonwoven fabric layer 10 Fireproof panel material according to this embodiment

Claims (6)

A makeup layer,
A first aluminum layer having a thickness of 0.5 to 9 μm;
A second aluminum layer having a thickness of 10 to 50 μm;
The foamed resin base material layer was adhered in order,
Fireproof panel material. The decorative sheet is at least one selected from paper, olefin sheet and natural wood,
The fireproof panel material according to claim 1. The foamed resin base material layer includes a glass fiber sheet layer on an adhesive surface with the second aluminum layer,
The fireproof panel material according to claim 1 or 2. The adhesive layer between the first aluminum layer and the second aluminum layer is made of a polyester resin, a polyether resin, a urethane resin, or a polyamide resin,
The fireproof panel material according to any one of claims 1 to 3. Wherein, the foamed resin base layer, an oxygen index of 21 or more, a bulk specific gravity of 50 kg / m ³ or less, fire panel material according to any one of claims 1 to 4. Used as ceiling or wall material,
The fireproof panel material according to any one of claims 1 to 4.

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