JP2000141546A - Production of veneer laminated inorganic panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a veneer laminated inorg. panel producing method capable of laminating veneer smoothly, also preventing the generation of delamination and high in productivity. SOLUTION: A veneer laminated inorg. panel A is produced by heating an inorg. panel 1 of three-layered constitution, which is obtained by laminating and integrating surface and rear layers containing a mineral fiber, an inorg. powder and a re-activatable binder such as starch or the like as essential components and a core layer containing an inorg. foam and the re-activatable binder as essential components, by a hot press to apply flexibility thereto and applying a thermosetting adhesive 2 such as urea/melamine to the single surface of the inorg. panel 1 to arrange veneer 3 on the panel 1 and inserting the whole into a curved form to press the same in a heated state not only to mold the pressed object into a curved shape but also to cure the thermosetting adhesive 2 and subsequently cooling the same to cure the re-activatable binder.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a veneer-coated inorganic plate formed into a curved surface so as to be applied to a curved surface portion.

[0002]

2. Description of the Related Art
When applying a wood decorative finish to a curved surface that requires fire protection, sprinkle water on an inorganic plate such as a calcium silicate plate or fiber reinforced gypsum plate, leave it for a few minutes and let the entire plate absorb water, and then use a mold etc. After forming a curved surface to the desired curvature and drying to an appropriate moisture content, after fixing it to the curved surface with screws or adhesive, the veneer lined with a nonwoven fabric etc. Generally, a method of bonding with a strong adhesive has been used.

[0003] In this method, water is sprayed on an inorganic plate at a construction site, formed into a curved surface, dried, and then a veneer is attached. Therefore, it takes a great deal of time and time. In this case, it is difficult to apply the adhesive uniformly, and there is a possibility that unevenness may occur on the surface of the veneer plate, or peeling may occur partially.

SUMMARY OF THE INVENTION In view of the above problems, an object of the present invention is to provide a method of manufacturing a veneer-attached inorganic plate with high productivity, which can prevent the occurrence of peeling because the veneer is applied smoothly.

[0005]

Means for Solving the Problems In order to solve the above-mentioned problems, a method for producing a veneer-attached inorganic plate according to the present invention comprises mineral fibers, an inorganic powder, and a reactivating binder as essential components. After heating and imparting flexibility to the three-layer inorganic plate obtained by laminating the front and back layers and the core layer containing the inorganic foam and the reactivating binder as essential components, at least one surface of the inorganic plate A veneer is arranged via a thermosetting adhesive, pressed in a heated state to form a curved surface and the thermosetting adhesive is cured, and then the inorganic plate is cooled to cure the reactivating binder. It consists of having

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment according to the present invention will be described with reference to FIG. The veneer-attached inorganic plate A shown in FIG. 1 includes front and back layers 1a and 1c containing mineral fibers, an inorganic powder, and a reactivating binder as essential components, and an inorganic foam and a reactivating binder. An inorganic plate 1 having a three-layer structure in which a core layer 1b as a component is laminated and integrated is formed into a curved surface, and a projecting plate 3 is adhered via a thermosetting adhesive 2.

[0007] The production method of the present invention will be specifically described.
First, the inorganic plate 1 is heated in advance by a hot press or a drier to impart flexibility. The heating conditions vary depending on the thickness of the plate and the type of the reactivating binder, but are usually 100 to 100.
A temperature of 150 ° C. may be within a few minutes. Next, the thermosetting adhesive 2 is applied on the inorganic plate 1 and the protruding plate 3 is arranged. As the thermosetting adhesive, urea, melamine, urea / melamine, phenol, epoxy and the like can be used. Next, as shown in FIG. 2, the sheet is inserted into a mold 11 having a curved surface, pressed with a press machine 10 to form the inorganic plate 1 and the projecting plate 3 integrally into a curved surface, and the thermosetting adhesive 2 is cured. After the activatable binder has hardened, it is removed from the mold 11 and
As shown in the figure, a curved veneer-attached inorganic plate A was obtained.

Next, a specific composition and a manufacturing method of the inorganic plate 1 will be described. Rock mineral, slag wool, glass wool, or the like can be used as the mineral fiber that mainly forms the front and back layers 1a and 1b and develops strength, and the addition amount is 20 to 80% by weight. The inorganic powder is used to increase the surface hardness and smoothness, and aluminum hydroxide, calcium carbonate, silica sand and the like can be used, and the added amount is 10 to 65% by weight. The reactivating binder that binds and integrates these is a binder that softens when heated in the presence of moisture and hardens again when cooled,
Starch, polyvinyl alcohol and the like can be used. Usually, flexibility is exhibited by heating with water contained in the plate material, but it is preferable to further add water. In addition, phenolic resin to impart water resistance,
It is preferable to add a water-resistant binder such as an acrylic resin. The total amount of these binders is 5 to 30% by weight.
It is. Organic fibers such as pulp and polypropylene can be added in an amount of 3 to 15% by weight to increase the strength. These were poured into water and stirred to obtain a slurry, and a wet mat to be the front and back layers was obtained.

On the other hand, as the inorganic foam which becomes the main component of the core layer 2 and is effective in reducing the weight of the plate material, pearlite, shirasu foam, glass foam and the like can be used.
0 to 80% by weight. As the binder for binding the inorganic foam, the same binder as that used for the front and back layers can be used, and the added amount is 5 to 30% by weight in total of the reactivating binder and other water-resistant binders. . Organic fibers such as pulp and polypropylene can be added in an amount of 5 to 30% by weight to increase the strength. Moreover, you may add an inorganic powdery material as needed. These are mixed by atomization of water, dispersed and deposited on the wet mat of the back layer, a wet mat of the surface layer is disposed thereon, heated and pressed by a continuous press, and then dried by a dryer, and a specific gravity of the front and back layers is obtained. Was 0.8 to 1.2, the specific gravity of the core layer was 0.4 to 0.7, and the overall specific gravity was 0.6 to 0.9.

[0010] Since the front and back layers of the inorganic plate 1 are mainly composed of mineral fibers, they are easily deformed along the curved surface at the time of forming the curved surface. Since the reactivating binder is mainly used as a binder, the plate material is heated. It is softened and easily deformed, enabling curved surface processing. Further, since the veneer plate 3 is disposed via the thermosetting adhesive 2 immediately after the heating of the inorganic plate 1 and the curved surface is formed, the thermosetting adhesive 2 is cured at the same time as the curved surface forming, and the veneer plate can be smoothly adhered and peeled. Occurrence can also be prevented. Also,
Curved surface forming and veneer bonding can be performed simultaneously, and productivity can be increased.

[0011]

EXAMPLES 65% by weight of rock wool as mineral fiber;
20% by weight of aluminum hydroxide as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as a reactivating binder, and powdered phenol 5 as a water-resistant binder
About 2% of the slurry obtained by throwing the weight% into water and stirring was subjected to paper making with a fourdrinier paper machine to obtain a wet mat of a surface layer portion and a back layer portion. On the other hand, as the core layer, 65% by weight of pearlite as an inorganic foam, 20% by weight of aluminum hydroxide as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as a reactivating binder, and water resistance 5% by weight of powdered phenol as a water-soluble binder is formed from a mixture obtained by mixing by atomization with water, and is scattered and deposited on the wet mat to be the back layer, and the wet mat to be the surface layer is formed on the upper surface thereof. Lamination was performed to obtain a laminate. This laminate is
After pressing with a hot press at 0 ° C. for 5 minutes, drying with a drier at 200 ° C. for 60 minutes, cooling to room temperature, an inorganic plate 1 having a specific gravity of 0.7 and a thickness of 6 mm (manufactured by Daiken Kogyo Co., Ltd.
(Product name: Dylite).

Then, the inorganic plate 1 is heated in a hot press at 130 ° C. for about one minute, and while being flexible, a urea-melamine adhesive 2 is quickly applied to one surface of the plate and a veneer plate is placed thereon. 2 was placed on a lower frame 11a attached to a press machine 10 as shown in FIG. 2 and pressed with an upper frame 11b to form a curved surface. Cooling was performed while sandwiching the mold frame 11, and the reactivating binder of the inorganic plate was cured to obtain a veneer-attached inorganic plate A formed into a desired curved surface as shown in FIG. As the veneer plate 3, a plate conventionally attached to plywood or MDF (medium fiber board) can be used as it is, and there is no particular limitation. The flexibility is further enhanced by spraying water on the inorganic plate 1 or adding water by a press or the like that generates steam. Further, the heating means of the inorganic plate 1 is not limited to the hot press, but may be a drier. If the curved surface forming means can bend the plate and hold it in that state, only the mold 11 as shown in this embodiment can be used. Not limited.

The heating temperature and time for providing flexibility are appropriately selected depending on the thickness of the inorganic plate 1 and the type of the reactivating binder used. In addition, the temperature of the hot press at the time of forming the curved surface is appropriately selected depending on the type of the thermosetting adhesive to which the veneer is attached, and if the inorganic plate 1 holds sufficient heat to cure the thermosetting adhesive, the temperature of the normal temperature is maintained. Curved surface forming by pressing may be used.

Since the obtained veneer-attached inorganic plate A is formed into a curved surface with a desired curvature, it can be fixed to the curved surface as it is with an adhesive or nails, and has excellent workability. In addition, as for the veneer-attached inorganic plate of the flat plate to be applied to the flat portion, it is only necessary to attach the veneer 3 via an adhesive in the same manner as attaching the veneer to the plywood or the MDF to the inorganic plate 1 used in the present invention, At this time, it is not necessary to use a thermosetting adhesive as the adhesive.

[0015]

As described above, according to the present invention,
Immediately after heating the inorganic plate formed using the reactivating binder to impart flexibility, the veneer is arranged via a thermosetting adhesive and molded into a curved surface, so at the same time as curved surface molding The veneer plate can be adhered and integrated with the inorganic plate, and the veneer plate can be smoothly affixed to prevent peeling, and the productivity can be increased.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a veneer-attached inorganic plate showing an embodiment of the present invention.

FIG. 2 is a diagram illustrating the production of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Inorganic board 2 ... Thermosetting adhesive 3 ... Veneer 11 ... Formwork A ... Veneer attached inorganic plate

 ──────────────────────────────────────────────────の Continued on the front page F term (reference) 4F100 AA00A AA00B AA00C AA19 AC00A AC00C AC10 AJ07 AJ07H AK36G AP00D AP00E BA04 BA06 BA07 BA10A BA10D BA13 CA30A CA30B CA30C CB00 DE01A DE01C DG01 EDG42 EJ01 DG01 EJ01 DG01 DG01E JB13G JK06 JL02

Claims (1)

[Claims] 1. A lamination and integration of a front and back layer containing mineral fiber, an inorganic powder and a reactivating binder as essential components, and a core layer containing an inorganic foam and a reactivating binder as essential components. After heating the three-layered inorganic plate to impart flexibility, at least one surface of the inorganic plate is provided with a veneer via a thermosetting adhesive, and pressed to form a curved surface in a heated state. A method for manufacturing a veneered inorganic plate, comprising: curing a thermosetting adhesive; and then cooling the inorganic plate to cure a reactivating binder.