JPH06255010A - Reinforced foam - Google Patents

Abstract

PURPOSE:To provide a strong and lightweight reinforced foam by a small amount of thin facing without deteriorating the characteristics of a foam by sticking cloth constituted of composite fiber consisting of an adhesive component sand a reinforcing component on the surface of the foam and unifying the hardened facing. CONSTITUTION:A reinforced foam is obtained by thermally melt-sticking and bonding cloth 2 consisting of composite fiber or composite yarn on both sides of a foam 1, giving cement composition (cement, sand and water) as a hardening type facing 3 thereto and hardening the same. Cement composition is penetrated into the bonded cloth 2 and hardened together with transpiration of water and strongly fixed in a form wherein it has been held in the bonded cloth 2 and unified. A form such as core/sheath type fiber, bimetal type fiber, multilayer joining type fiber and radial multilayer typer fiber is shown as the preferable form of composite fiber constituting cloth.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a strong, lightweight reinforced foam, as well as a reinforced foam having good flame retardancy.

[0002]

2. Description of the Related Art Conventionally, polystyrene-based foams are small in deformation against external force and have excellent shape retention and dimensional stability, so that they are suitable for packaging and packing electric appliances and precision equipment, cooler boxes, heat insulating building materials, etc. It has been widely used.

[0003]

However, while the polystyrene foam has many advantages as described above, it is extremely brittle against external stress such as impact or bending, and is easily broken or broken by a slight deformation. It had the drawback of leading to total destruction of the body. Therefore, it has been considered as a material that is not suitable for a part that is subjected to a strong impact force or is subjected to a strong bending or twisting.

In order to solve this problem, a method of mixing fibers for reinforcement has been proposed (Japanese Patent Publication No. 47-2809).
No. 7, JP-A-48-100471), a substantial reinforcing effect cannot be obtained due to poor integration between the reinforcing fiber and the foam, and the inventions described in those publications are preferable methods. It was something I couldn't say.

Another disadvantage of the polystyrene foam is that it is easily burned, and its use has been severely restricted in places where fire is handled and in fields requiring flame retardancy, especially in civil engineering and construction applications. .

[0006] As such countermeasures, there is one in which a flame retardant is mixed into the foam to improve the flame retardancy, but it has not been achieved yet to impart a preferable flame retardancy. There is also a composite panel in which asbestos cement board, gypsum board, wood wool cement board, etc. are laminated on the foam board with an adhesive, but there are drawbacks such as heavy, thick, and brittle, and further, productivity is high. There was a problem that it was extremely bad and expensive.

That is, even if a non-combustible / flame-retardant face material is laminated on a foam using an adhesive, it is difficult to bond the foam and the face material. Particularly, the polystyrene foam is vulnerable to a solvent. In addition, the polymer itself is vulnerable to heat, and when heat is applied, the foaming agent remaining in the foam will undergo tertiary foaming, making it difficult to remove the solvent (drying process). Due to problems such as long time, adhesion processing is difficult, productivity is extremely poor, and even if a non-combustible / flame-retardant surface material is simply laminated on the foam, the strength is not sufficient and the brittleness It was not possible to solve the point. Dare
If you try to solve the brittleness with non-combustible / flame-retardant face material, the thickness of the face material will be extremely thick, and as a whole, it will be thick.
Only heavy and inferior heat insulation was obtained.

The present invention has solved the above problems,
It is intended to provide a strong, lightweight reinforced foam with a thin, small amount of face material without deteriorating the properties of the foam, and further, to provide a reinforced foam having good flame retardancy. It is what

[0009]

In order to achieve the above object, the present invention has the following constitution. That is, in the reinforced foam of the present invention, a fabric composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component is adhered to at least one surface of the foam, and
The cloth is characterized in that a cured face material is integrated.

[0010]

The present invention has been made as a result of extensive studies to improve the drawbacks of being light, such as a foam, for example, polystyrene foam, but being brittle, weak, and flammable. As a result, a combination of a specific fabric and a curable material has been obtained. It has been clarified that these weaknesses can be alleviated at once.

In the reinforced foam of the present invention, at least one surface of the foam must first be bonded with a cloth composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component. The cloth fixes and reinforces the foam and the curable surface material. Then, a curable surface material is applied to the adhesive cloth, and the surface material is integrated with the cloth as it is cured. As the curable surface material, any curable material having a film-forming ability such as solvent-free curable material, room temperature curable material, or thermosetting material can be used, but it is a flame-retardant surface material. Is preferred.

When this face material is applied to the cloth, it penetrates into the fiber gaps of the cloth, is fixed in a form having an anchor portion, and is firmly integrated.

With this structure, the present invention can improve the brittleness of the foam, and can significantly improve the fracture resistance and the splash resistance against various external stresses.
It is possible to provide a reinforced foam having preferable flame retardant performance.

The cloth referred to in the present invention means a non-woven fabric or a structure mainly composed of a composite fiber and / or a composite yarn composed of at least two components of an adhesive component which adheres well to a foam and a reinforcing component having high strength. A structure or a composite fabric in which the nonwoven fabric and the tissue structure are combined can be used.

The foam of the present invention is reinforced by firmly adhering it through the adhesive component of the composite fiber constituting the cloth and firmly integrating it. Furthermore, when a flame-retardant face material is used as the face material, the flame-retardant face material penetrates into the gaps between the fibers of the cloth and has an anchor portion in a bite-in state to form a flame-retardant face material layer. Since the foam / fabric / face material is firmly integrated, the foam can be strengthened and flame retardant at the same time.

Here, the reinforced foam of the present invention will be described with reference to the schematic sectional view of FIG. FIG. 1 shows that a cement composition (cement + sand + water) is applied as a curable surface material 3 to a foamed body 1 on which fabrics 2 made of composite fibers or composite yarns are heat-sealed and adhered. It has been cured. The cement composition penetrates into the adhesive cloth 2, water is evaporated and hardened, and the cement composition is firmly fixed and integrated in the form of being held in the adhesive cloth 2.

The foam used in the method of the present invention is, for example, polystyrene, styrene / ethylene copolymer, acrylonitrile / styrene copolymer, polyurethane, bead molding or extrusion of polystyrene resin such as ABS resin. A foamed molded product obtained by molding or a raw material thereof can be preferably applied. In addition, polyethylene,
It can also be applied to foams made from polypropylene, polyester and phenolic resins. In particular, a high-rigidity resin having a small deformation with respect to external stress has a high reinforcing efficiency according to the present invention, and a higher effect can be obtained.

The preferred form of the composite fiber constituting the cloth is a core / sheath type fiber, a bimetal type fiber, a multilayer bonded type fiber, a radial multilayer type fiber, and the like.
A multi-core / sheath type composite fiber, which is a fiber having a structure having many core components in the sheath component, is preferable. For example, it is represented by polymer array fibers, mixed spun fibers and the like.

FIG. 2 to FIG. 8 are schematic cross-sectional model views showing a model of one embodiment of the conjugate fiber used in the present invention.

In such a composite fiber, the adhesive component is preferably arranged on the outer periphery or outer shell of the composite fiber. For example, in the core / sheath type composite fibers as shown in FIGS. 2, 3 and 4, it is preferable to arrange them in the sheath component. Further, in the bimetal type or multi-layer bonding type composite fiber as shown in FIGS. 5, 6, 7 and 8, it may be arranged in any component, but it is arranged in a portion having a large exposed area to the outside. It is more effective and preferable. In these figures, 4 is a composite fiber, 5 and 5'are core components, and 6 is a sheath component.

The thickness of the composite fiber is not particularly limited as long as it is suitable as a reinforcing material for its specific use, but it is generally 0.1 to 1000 for the composite fiber.
The range of denier is suitable, and in the multi-core / sheath type composite fiber, the thickness of the core fiber is usually 1/3 to 1 of the composite fiber.
/ 1000 is preferable, and the number of cores in the composite fiber is preferably in the range of 3 to 10,000.
10 to 1000 are particularly preferable.

As the adhesive component in the composite fiber, it is important to cause thermal deformation or melting by heating to bring about high adhesiveness.
It is preferable that the above is satisfied. That is, A:
A polymer containing the same monomer units as the foam, B:
It is a polymer having good adhesiveness and compatibility with the foam, and in particular, those of A are preferable, but even if they do not contain the same monomer unit as the foam, by thermal deformation or melting, The present invention can be sufficiently achieved as long as an anchor effect or the like is exerted between the foam and the desired adhesion. Such preferable representative examples include polystyrene, a polystyrene copolymer obtained by copolymerizing styrene with a higher alcohol ester of acrylic acid or methacrylic acid, a polyester copolymer having an acid component of terephthalic acid / isophthalic acid, and a glycol component of ethylene glycol. Is mentioned.

On the other hand, as the reinforcing component, polyesters typified by polyethylene terephthalate, polyamides typified by nylon 6, nylon 66, aramids, other polyarylate, polyacrylonitrile, polyethylene, polypropylene, polyvinyl alcohol,
It is possible to apply polymers having various spinnability such as polyurethanes and modified copolymers thereof or mixtures of other components. Depending on the foam type from these polymer groups, One kind or two or more kinds of polymers are used depending on the purpose and application of the foam.

Further, in the above description, the case of the composite fiber obtained by the composite spinning has been described, but the present invention is not limited to the case of using such a composite fiber, and the core component or It is also possible to use a composite yarn such as a sheath component, or a mixed yarn (including a twisted yarn) made of fibers made of a polymer described as an adhesive component or a strong component. That is, in the present invention, a composite yarn using a combination of fibers or yarns made of an adhesive component and fibers or yarns made of a strong component may be used.

As the non-woven fabric, a short fiber (staple) or long fiber (filament) non-woven fabric produced by a card method, a papermaking method, a random webber method, a direct spinning method or the like can be applied.

The tissue structure is a material such as a woven fabric, a knitted fabric, a braid, or a net sheet material, and has a tissue that maintains a sheet form, and any of these can be applied.

As the woven fabric in the tissue structure, plain weave,
Twill weave, satin weave, and various materials based on these structures are applied. As a special thing, even at low density,
Ro-ori, gauze, etc. that do not cause misalignment are preferably applied.
As the knitted fabric, various kinds of weft melias and warp melias can be applied. The net sheet-like material may be a net-like sheet in which the intersections of fibers are bonded or fused to form a net-shaped sheet.

Of course, the constituent fibers of the tissue structure are not limited to the above-mentioned composite fibers and / or composite yarns.
Alternatively, it may be used in combination with other fibers.

The cloth (composite cloth) in which the non-woven fabric and the tissue structure are composite is a laminate of the above-mentioned non-woven fabric and the tissue structure, or a form in which the both are entangled.

As described above, in the fabric, it is a requirement of the present invention that the above-mentioned composite fibers are contained in a sufficient amount for adhering to the foam, but the range in which the adhesiveness is not significantly deteriorated. It may be used in combination with other fibers. In particular, as a preferable example of the non-woven fabric / tissue structure, by using the non-woven fabric made of the composite fiber and the high-strength tissue structure together, the adhesive component has good adhesiveness and integration with the foam, and The reinforcing component in the non-woven fiber and the high tenacity of the tissue structure are sufficiently exhibited, and a foam having good mechanical performance can be obtained. This has better adhesiveness than that reinforced with only a non-woven fabric or a tissue structure, and not only general mechanical performance is improved, but also extremely high impact resistance is obtained. In particular, the reinforced foam to which the non-woven fabric / tissue structure is adhered has an advantage that even if a defect occurs, the propagation of the fracture is stopped at the tissue portion of the tissue structure, so that the entire fracture does not occur. In this case, the component constituting the tissue structure preferably has as high strength as possible, but it may be the same as the reinforcing component in the composite fiber. For example, aramid fiber, polyarylate, high molecular weight polyethylene, high molecular weight polyvinyl alcohol and the like are preferable, and particularly high strength fiber having a fiber strength of 3 g / d or more, particularly 5 g / d or more is preferable.

As another structure structure, which is commonly called geogrid, is a sheet made by extruding a molten polymer from a die and forming a circular hole in the sheet and stretching it in one or two directions. Which is called a geogrid because it is often used for
A so-called geonet is also preferably used because the net has a lattice shape and is often used for civil engineering. Specific examples of these are:
Examples include "Nisseki Conwed Net" manufactured by Nisseki Goju Products Co., Ltd., and "Netron Sheet" manufactured by Mitsui Kasei Co., Ltd. They can be appropriately selected depending on the purpose and application such as the unit weight, the basis weight, and the thickness, and are not particularly limited.

As the curable surface material used in the present invention, a curable material such as a solvent-removable, room temperature curable or thermosetting material is used, and a flame-retardant surface material is preferable.

As the former surface material, cement, mortar, concrete, asphalt, coal tar, gypsum, asbestos cement, calcium silicate board, cement calcium silicate board, asbestos calcium silicate board, pulp cement, calcium asbestos calcium silicate One kind or two or more kinds such as a plate can be used. These face materials are preferably used because they also have flame retardancy. Other materials may be mixed with these flame-retardant face material raw materials as long as flame retardancy and strength are not significantly reduced. Further, as the latter face material, a thermosetting resin such as unsaturated polyester resin, epoxy resin, melamine resin, urea resin or phenol resin can be used.

According to the present invention, since the fabric and the flame-retardant face material can form a strongly integrated structure, even if the combination of the foam / fabric / face material is one having low adhesiveness. However, strong integration can be achieved. This is possible only by the presence of the cloth made of the above-mentioned composite fiber adhered to the surface of the foam, and it is also a remarkable feature of the present invention that the face material is not easily peeled off from the foam / fabric.

As a method for producing the reinforced foam of the present invention, one is to arrange a cloth on the inner surface of a mold having a desired shape, and in the mold, various latent foam-forming materials such as expandable polymer beads. The material is filled, and steam or hot air is supplied to heat it to foam-mold and simultaneously heat-deform and / or melt the adhesive component of the fabric-constituting fibers to bond and integrate the fabric on a part or the entire surface of the foam. Done by that. In addition, a method of forming a foam in advance, pressing the cloth under pressure on the surface of the foam, thermally deforming and / or melting the adhesive component, and adhering to a part or the whole of the surface of the foam to integrally integrate it, Further, a fabric is placed on the surface of the foam, and a heating body such as an iron, a trowel, a roll, and a heat press is pressed against the fabric to heat it, and the adhesive component of the constituent fibers of the nonwoven fabric is thermally deformed and / or melted, It is carried out by a method in which a cloth is bonded and integrated with a part or the whole of the surface of the foam.

Then, as a method of integrating the curable surface material with the foam / fabric, the liquid material of the surface material is applied by means such as coating, spraying, impregnation, etc., and penetrates at least between the fibers of the cloth and anchors. It is carried out by forming a part and further forming a coating film or a film layer on the surface of the fabric. Of course, adhesives such as acrylic resins, styrene-butadiene rubber-based, epoxy-based, vinyl acetate-based, ethylene-vinyl acetate-based, and various other synthetic rubbers are used in the curable surface material formulation to improve the adhesiveness. It may be a mixed mixture.

By the above-mentioned method, the foam and the composite fabric can be firmly and durable adhered to each other to effectively strengthen the foam, and impact resistance, favorable fracture resistance, and favorable fracture resistance can be obtained. Scatterability can be imparted, and moreover, preferable flame retardant properties can be imparted. Also,
Depending on the type of the curable surface material, it is possible to obtain the waterproofing effect.

The reinforced foam of the present invention is used for construction and civil engineering such as road mud prevention materials, various civil engineering materials, various fences, concrete formwork, waterproof layer protective materials, waterproof sheets, etc. It can be preferably applied to the field. In addition, the present invention can be applied to the heat insulating industry field, vehicle field such as automobile insulation materials, packaging / packing field, sports / general goods field.

[0039]

The present invention will be described in more detail with reference to the following examples.

In the examples, all "percentages" are by weight.

Example 1 As a fabric, a polymer array fiber having a sheath component of 80 parts by weight of styrene / 20 parts by weight of 2-ethylhexyl acrylate copolymer and a core component of nylon 6 (fiber length: 51 mm,
The number of islands: 16 and the denier of the composite fiber: 3d) were used to produce a nonwoven web through the steps of card and cross wrapper, and then needle punching was performed to produce two nonwoven fabrics.

An extruded expanded polystyrene plate (30 times expanded product, 25 mm product) was used as the foam, and the above fabric was placed on the foam plate using a heat press machine, and then heat pressed (temperature: 120 ° C., Pressure: 2Kg / cm ² , Time: 45se
Then, the both were adhered to obtain a fabric-reinforced foam.

An asphalt / styrene-butadiene rubber adhesive mixture was applied to the fabric-reinforced foam to form a flame-retardant face material layer of about 0.5 mm on both front and back surfaces.

Using this foam, a falling ball test was conducted using 540 g of stainless steel balls, and the height was 300 cm.
No destruction was observed in the falling ball test from. However, the conventional foam (without cloth / flame-retardant surface material) caused a total destruction at a height of only 30 cm, and the debris was scattered around.

Further, the reinforced foam of the present invention did not burn in the flame test of the lighter for 30 seconds, and did not deform at all. The one that did not have the flame-retardant surface material used as a comparative product (the one to which only the cloth is adhered) is
Within 10 seconds, the part in contact with the flame burned, and then the whole burned.

Example 2 As a cloth, a polymer array fiber having a sheath component of polystyrene and a core component of polyethylene terephthalate (fiber length: 51 mm, number of islands: 16, denier of composite fiber: 3d)
A non-woven fabric web was prepared by using the above method and a card and a cross wrapper, and then needle punched to prepare two non-woven fabrics.

Two non-woven webs and the same foam plate as in Example 1 were used, and a plain woven fabric (weight per unit area: 100 g / m ² ) made of 1000d-666f aramid fiber was inserted in the middle to form a three-layer sheet. Furthermore, needle punching was performed to produce a composite fabric in which the non-woven fabric and the woven fabric were entangled. Further, heat pressing was performed in the same manner as in Example 1 to obtain a fabric-reinforced foam in which the composite fabric was bonded and integrated on the front and back of the foam.

A cement / acrylic adhesive composition was applied to the fabric-reinforced foam to form a flame-retardant face material layer having a thickness of about 1 mm on both front and back surfaces.

No damage was observed in such a reinforced foam in a falling ball test from 700 cm with 700 g of stainless steel balls.

In addition, the reinforced foam of the present invention did not burn in the flame test of the lighter for 100 seconds, and did not deform at all.

Example 3 The same non-woven web as in Example 1 was used, and "Nisseki Conwed Net ON301" manufactured by Nisseki Goju Products Co., Ltd. was used as the tissue structure.
0 ", extruded foam sheet as foam (30 times foamed product)
, Non-woven fabric / tissue structure / foam / tissue structure / non-woven fabric, and 120 ° C. for 3 times with a large heat press.
A fabric-reinforced foam was prepared by heat pressing for ² seconds at 2 Kg / cm ² . The resulting foam was one in which the nonwoven fabric passed through the interstices of the tissue structure and strongly adhered to the foam to be firmly adhered and integrated as a whole.

Next, a plaster / acrylic adhesive composition was applied to the fabric-reinforced foam to give a thickness of about 1.5 on both front and back surfaces.
A mm flame-retardant face material layer was formed.

The reinforced foam of the present invention reduces the flame of a lighter.
In the indirect combustion test for 00 seconds, no combustion occurred and no deformation occurred. Furthermore, in a ball drop test from 300 cm with 1200 g of stainless steel balls, it did not break and no peeling of the flame-retardant face material layer was observed.

[0054]

As described above, the reinforced foam of the present invention is
A fabric made of specific fibers is adhered to the surface of a foam such as polystyrene, and further, an anchor portion in which the flame-retardant face material bites into the gap between the fibers of the fabric is used.
It has a structure in which the fabric / face material is firmly integrated. With such a constitution, the brittleness of the foam can be remarkably improved, and favorable mechanical performance and favorable flame retardancy can be simultaneously achieved. It is also possible to impart effective waterproofness to the foam.

[Brief description of drawings]

FIG. 1 is a schematic view showing a cross-sectional structure of an example of a reinforced foam of the present invention.

FIG. 2 is a schematic perspective view showing a model of one embodiment of a core / sheath type composite fiber that can be used in the present invention.

FIG. 3 is a schematic perspective view schematically showing another embodiment of the core / sheath type conjugate fiber that can be used in the present invention.

FIG. 4 is a schematic perspective view showing a model of another embodiment of the core / sheath type conjugate fiber that can be used in the present invention.

FIG. 5 is a schematic perspective view showing one model example of the bimetal type composite fiber that can be used in the present invention.

FIG. 6 is a schematic perspective view showing a model of one embodiment of the multi-layered conjugate fiber that can be used in the present invention.

FIG. 7 is a schematic perspective view showing another model example of the multi-layered conjugate fiber that can be used in the present invention.

FIG. 8 is a schematic perspective view showing a model of another embodiment of the multi-layered conjugate fiber that can be used in the present invention.

[Explanation of symbols]

 1: Foam 2: Fabric 3: Curing type surface material 4: Composite fiber 5, 5 ': Core component 6: Sheath component

Claims (9)

[Claims] 1. A fabric composed mainly of a composite fiber and / or a composite yarn mainly composed of an adhesive component and a reinforcing component is adhered to at least one surface of a foam, and a cured face material is attached to the fabric. Reinforced foam characterized by being integrated. 2. The reinforced foam according to claim 1, wherein the cloth is a non-woven fabric, a tissue structure or a non-woven / tissue structure. 3. The reinforced foam according to claim 1, wherein the foam is a polystyrene resin foam. 4. The reinforced foam according to claim 1, wherein the composite fiber or the composite yarn is a core / sheath type composite fiber or the composite yarn. 5. The reinforced foam according to claim 4, wherein the core / sheath type composite structure is a multi-core / sheath type composite fiber. 6. The reinforced foam according to claim 1, wherein the tissue structure is a geogrid. 7. The reinforced foam according to claim 1, wherein the tissue structure is Geonet. 8. The reinforced foam according to claim 1, wherein the face material is a non-combustible or flame-retardant material. 9. The surface material is cement, asphalt, coal tar, gypsum, asbestos cement, calcium silicate board,
The reinforced foam according to claim 1, which is composed of one or more of cement calcium silicate board, asbestos calcium silicate board, pulp cement, and asbestos calcium silicate board.