JP2000297495A - Composite building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve impact resistance and to prevent the design of a surface decorative layer of a composite building material, from being distorted even if the decorative layer is impacted, by allowing a core member constituting the composite building material having the decorative layer with a specific thickness formed at least on one surface thereof to contain an inorganic amorphous body internally having fibrous materials. SOLUTION: Decorative layers 5 each formed of a decorative veneer are arranged on both front and rear surfaces of a core member 1, and a reinforcing layer 6 is interposed between the core member 1 and each decorative layer 5 having a thickness of 0.1-10 mm, to thereby form a composite building material. The core member 1 contains an amorphous body 2 which internally contains organic fibrous materials 3 and inorganic fine particles 4, and the reinforcing layer 6 is constituted of a fibrous backing 6b impregnated with a resin 6a. The amorphous body 2 is an inorganic amorphous compound generated by solution treatment or hydration of two or more kinds of oxides, which compound serves as a strength manifestation material. In addition, the fibrous materials 3 are dispersed in the amorphous body 2 to improve a fracture toughness value, leading to improved bending strength value and impact resistance. Therefore, even if an impact acts, a gouge is rarely formed, whereby the design of the decorative layer 5 is not distorted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite building material, and more particularly to a composite building material which has excellent impact resistance and does not distort the design of the decorative layer even when the decorative layer on the surface receives an impact. Things.

[0002]

2. Description of the Related Art A so-called OA in which a computer or the like is installed.
The floor material of the floor is required to withstand the weight of the computer and not be damaged by the impact even if the computer etc. falls over during an earthquake.In addition, since the wiring will be installed under the floor, even if the cable fire etc. It is required to have excellent fire resistance so that it can withstand. For this reason,
For example, a non-combustible building material in which a prepreg made of a thermoplastic resin is pasted on a gypsum board is disclosed in Japanese Unexamined Patent Publication No. 7-3292.
No. 36.

[0003]

However, the technique described in Japanese Patent Application Laid-Open No. 7-329236 is inferior in impact resistance because it uses a prepreg and a gypsum board made of a thermoplastic resin. Even if a decorative layer is provided on the surface, there is a problem that the design of the decorative layer is distorted by dents or the like.

An object of the present invention is to propose a composite building material which overcomes the above problems, has excellent strength, and does not distort the design of the decorative layer due to dents or the like even when the decorative layer is provided.

[0005]

The gist of the present invention is as follows.
It is as follows. (1) In a composite building material in which a decorative layer is formed on at least one surface of a core material, the core material includes an inorganic amorphous material, and has a fibrous material in the inorganic amorphous material. A composite building material characterized by the fact that:

(2) In a composite building material in which a decorative layer is formed on at least one surface of a core material, the core material is made of an inorganic amorphous powder having an inorganic amorphous material via a binder. A composite building material characterized by being molded.

(3) A composite building material in which a decorative layer is formed on at least one surface of a core material, wherein the core material contains an organic fibrous material comprising a polysaccharide.

(4) A composite building material according to any one of (1) to (3), wherein a reinforcing layer is formed between the core material and the decorative layer.

(5) The composite building material according to any one of the above (1) to (3), wherein the thickness of the decorative layer is 0.1 to 10 mm.

(6) The composite building material according to any one of (1) to (3), wherein the reinforcing layer contains an elastic polymer. (7) The composite building material according to (1) or (3), wherein the fibrous material is oriented in a specific direction.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A first embodiment of a composite building material according to the present invention is a composite building material having a decorative layer formed on at least one surface of a core material, wherein the core material is an inorganic amorphous material. And a fibrous material in the inorganic amorphous body. The inorganic amorphous body is not particularly limited, but is preferably an amorphous body composed of two or more oxides.

Here, the inorganic amorphous body composed of two or more kinds of oxides means oxide (1) -oxide (2).
An oxide (n) -based (where n is a natural number and oxide (1), oxide (2),... Oxide (n) are different oxides) amorphous body;

Although it is difficult to accurately define such an inorganic amorphous substance, it is an inorganic amorphous compound that is formed by a solid solution or hydration reaction of two or more oxides. Conceivable. Such an inorganic amorphous compound,
By the X-ray fluorescence analysis, the elements (Al, S
i, Ca, Na, Mg, P, S, K, Ti, Mn, F
e, Zn, at least two types selected from the group consisting of e and Zn).
Halos can be seen in the range of 40 °. This halo is a gentle undulation of the intensity of the X-ray, and is observed as a broad swell on the X-ray chart. The halo has a half width of 2θ: 2 ° or more.

According to the present invention, an amorphous material composed of a composite system of at least two or more metal and / or nonmetal oxides serves as a strength-expressing material, and a fibrous material is dispersed in the amorphous material. In order to improve the fracture toughness value, the bending strength value and the impact resistance can be improved. For this reason, even when an impact is applied, dents are unlikely to occur, and the design of the decorative layer does not deteriorate. In addition, a homogeneous cured product having no anisotropy in strength can be obtained. Furthermore, since it is an amorphous body, there is an advantage that sufficient strength can be obtained at a low density.

[0015] The reason why the inorganic amorphous material serves as a strength-expressing substance is not clear, but it is presumed that the inorganic amorphous body inhibits the progress of cracks as compared with a crystalline structure.
Further, since the fibrous material is more easily dispersed uniformly in the amorphous state than in the crystalline state, it is considered that the fracture toughness value is also improved.

As the above oxide, Al_Two O_Three , SiO
_Two , CaO, Na_Two O, MgO, P _Two O_Five , SO_Three , K
_Two O, TiO_Two , MnO, Fe_Two O_Three And from ZnO
It is desirable to be selected. And the above oxide
As an amorphous body composed of a composite system of_Two O_Three -Si
O_Two -CaO-based or Al_Two O_Three -SiO_Two -CaO-
Oxide (Al_Two O_Three , SiO_Two Metals except Ca and CaO
And / or one or more non-metallic oxides)
An inorganic amorphous body or a composite of these inorganic amorphous bodies
Optimal. That is, the first of the composite building materials of the present invention
The core material in the embodiment is at least Al_Two O_Three , Si
O_Two , All or part of CaO is dissolved in each other or
A compound is formed by a hydration reaction or the like to exhibit an amorphous structure,
It consists of fibrous material dispersed in its amorphous structure.
You. In the above core material, Al_Two O_Three , SiO_Two , All of CaO
Alternatively, some form compounds such as solid solutions and hydrates to form inorganic
Amorphous structure, these compounds exhibit strength
And the fibrous material dispersed in the inorganic amorphous material breaks.
To improve the toughness value, the bending strength value and impact resistance are improved.
Up. In addition, nails are driven because of high fracture toughness
Even if a through hole is provided, cracks will not occur,
Processing building materials without reducing the design of the decorative layer
It is possible to

The inorganic amorphous body composed of the above system will be further described. First, the inorganic amorphous body composed of the Al ₂ O ₃ —SiO ₂ —CaO system is composed of each component of Al ₂ O ₃ , SiO ₂ and CaO. Are compounds having an amorphous structure in which all or a part of the compounds are formed by solid solution or hydration. That is, Al ₂ O ₃ and SiO ₂ , SiO ₂ and CaO, Al ₂ O ₃ and CaO, and Al ₂ O ₃ , Si
It is considered to include any of the compounds formed by solid solution or hydration reaction with a combination of O ₂ and CaO. In such an inorganic amorphous compound, Al, Si, and Ca are confirmed by fluorescent X-ray analysis, and a halo is seen in the range of 2θ: 15 ° to 40 ° in an analysis chart by X-ray diffraction.

Further, Al ₂ O ₃ , SiO ₂ and CaO
Other than at least one oxide, ie, Al
Inorganic amorphous bodies composed of ₂ O ₃ —SiO ₂ —CaO—oxide system include Al ₂ O ₃ and oxides, and SiO ₂ and oxides other than the above-mentioned combination of Al ₂ O ₃ —SiO ₂ —CaO systems. Substance, CaO and oxide, Al ₂ O ₃ , SiO ₂ and oxide, SiO ₂ , CaO and oxide, Al ₂ O ₃ , Ca
O and oxides, and Al ₂ O ₃ , SiO ₂ , CaO
And a compound formed by causing a solid solution or hydration reaction or the like with a combination of oxides and oxides.

It should be noted that the number of the oxides is two or more, that is, Al
₂ O ₃ —SiO ₂ —CaO—Oxide (1)... Oxide (n) -based (n is a natural number of 2 or more) inorganic amorphous materials, these oxides, for example, oxides (1), oxide (2) ... oxide (n) (n is a natural number of 2 or more, and oxide (n) means different oxides if the value of n is different, and Al ₂ O ₃ , SiO ₂ , and CaO are excluded). A compound formed by performing a solid solution or hydration reaction with at least two or more combinations selected from the group consisting of Al ₂ O ₃ , SiO ₂ , and CaO. Compounds formed by causing a solid solution or hydration reaction in at least two or more selected combinations, oxides (1), oxides (2) ... oxides (n) (n is a natural number of 2 or more) at least one or more selected from each), Al ₂ O _3, S O _2, is considered to include any compound that produces by such solid solution or hydration in combination with at least one selected from CaO.

Such an inorganic amorphous compound has a fluorescent X
According to the line analysis, in addition to Al, Si and Ca, the elements (Na, Mg, P, S, K, Ti, Mn, F
e, at least one selected from Zn) is confirmed. According to the analysis chart by X-ray diffraction, 2θ: 15 ° to
Halos can be seen in the range of 40 °.

Here, Al ₂ O ₃ , SiO ₂ and Ca
Oxides to be combined with O are one kind or two or more kinds, and are metals other than Al ₂ O ₃ , SiO ₂ and CaO and / or
Alternatively, non-metal oxides can be used, such as Na ₂ O, M
gO, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO,
It can be selected from Fe ₂ O ₃ and ZnO. This selection can be made based on the characteristics expected of the composite cured product.

For example, since Na ₂ O or K ₂ O can be removed with an alkali or the like, if the removal treatment is performed prior to the plating treatment, the surface to be plated on the surface of the composite hardened body becomes rough and acts as an anchor for plating. be able to. Mg
O forms a solid solution with Al ₂ O ₃ , SiO ₂ , and CaO to contribute to strength development, and greatly improves bending strength and impact resistance. P
₂ O ₅ improves the adhesion to metal. SO ₃ has a bactericidal action and is suitable for antibacterial building materials. TiO ₂ is a white colorant and also acts as a photo-oxidation catalyst, so it can forcibly oxidize organic contaminants attached and can be cleaned only by irradiating light. It has a unique effect that it can be used as a filter or a reaction catalyst. MnO is useful as a dark colorant, Fe ₂ O ₃ is useful as a light colorant, and ZnO is useful as a white colorant. These oxides may be present alone in the amorphous body.

Each component of the core material is Al ₂ O
₃ , It is desirable that the composition is as follows in terms of SiO ₂ and CaO. Al ₂ O _3: 3~51% by weight relative to the total weight of the core material SiO _2: six to fifty-three% by weight relative to the total weight of the core material CaO: 8 to 63 wt%, however, relative to the total weight of the core material , The sum of them does not exceed 100% by weight.

The reason is that the content of Al ₂ O ₃ is 3% by weight.
If the content is less than 51% by weight or more than 51% by weight, the strength of the core material is reduced, and if the content of SiO ₂ is less than 6% by weight or more than 53% by weight, the strength of the core material is reduced. Even if the content of CaO is less than 8% by weight or more than 63% by weight, the strength of the core material also decreases.

Further, in terms of oxide, CaO / SiO
Adjusting the ratio of ₂ to 0.2 to 7.9 and the ratio of CaO / Al ₂ O ₃ to 0.2 to 12.5 is advantageous for obtaining a core material having high strength.

Further, the core material is made of Al ₂ O ₃ , SiO ₂
And oxides other than CaO, such as Na ₂ O, MgO,
P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, Fe ₂
When one or more of O ₃ and ZnO are contained, the preferred content of each component is as follows. In addition,
It goes without saying that the total amount of these oxides does not exceed 100% by weight. Na ₂ O: 0.1 to 1.2% by weight based on the total weight of the core material MgO: 0.3 to 11.0% by weight based on the total weight of the core material P ₂ O ₅ : Total weight of the core material against 0.1 to 7.3 wt% SO _3: 0.1 to 3.5 wt% K ₂ O with respect to the total weight of the core material: 0.1 to 1 with respect to the total weight of the core material. 2 wt% TiO _2: from .1 to 8.7 wt% MnO, relative to the total weight of the core material: 0.1 to 1.5% by weight relative to the total weight of the core material Fe ₂ O _3: the core material 0.2 to 17.8% by weight with respect to the total weight ZnO: 0.1 to 1.8% by weight with respect to the total weight of the core material The reason for limiting the content of these oxides to the above range is as follows. This is because if the ratio deviates from the above range, the strength of the core material decreases.

Whether or not it has an amorphous structure can be confirmed by X-ray diffraction. That is, 2θ: 15 ° by X-ray diffraction
If a halo is observed in the region of ４０40 °, it has an amorphous structure. In the present invention, in addition to those having a completely amorphous structure, Hydror
ogen Aluminum Silicate, Kaolinite, Zeolite, Ge
hlenite, syn, Anorthite, Melitite, Gehlenite-synt
hetic, tobermorite, xonotlite, ettringite, and S
iO ₂ , Al ₂ O ₃ , CaO, Na ₂ O, MgO, P ₂
O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, Fe ₂ O
₃ , oxides such as ZnO, and CaCO ₃ (Calcite
)) May be mixed.

[0028] These crystals are not considered to be strength-generating substances themselves, but have effects such as improving the compressive strength by increasing the hardness and density, and suppressing the progress of cracks. it is conceivable that. The content of the crystal is desirably 0.1 to 50% by weight based on the total weight of the core material. If the amount is less than 0.1% by weight, effects such as increasing the hardness and density to improve the compressive strength and suppressing the progress of cracks cannot be sufficiently obtained. Conversely, if the amount exceeds 50% by weight, This is because bending strength is reduced.

Incidentally, the Al ₂ O ₃ —SiO ₂ based crystalline compound is selected from the group consisting of Hydrogen Aluminum Silicate and Kaolini.
te, Zeolite, Al ₂ O ₃ —CaO based crystalline compounds are Calcium Aluminate, CaO—SiO ₂ based crystalline compounds are Calcium Silicate, Al ₂ O ₃ —SiO ₂ —Ca
O-type crystalline compounds are Gehlenite, syn and Anorthite, and Al ₂ O ₃ —SiO ₂ —CaO—MgO-type crystalline compounds are Melitite and Gehlenite-synthetic.
Further, it is desirable that the above-mentioned crystal contains Ca, and Gehlenite, syn (Ca ₂ Al ₂ O ₇ ), Melitite-s
_{ynthetic (Ca 2 (Mg 0.5 Al} 0.5) (Si 1. 5 Al
_0.5 O ₇ )), Gehlenite-synthetic (Ca ₂ (Mg
_0.25 Al _0.75 ) (Si _1.25 Al _0.75 O ₇ )), Anorthit
e, ordered (Ca ₂ Al ₂ Si ₂ O ₈ ) and calcium carbonate (Calcite) may be contained.

Further, the above-mentioned core material may have halogen in the inorganic amorphous material. This halogen is a solid solution,
It acts as a catalyst for the hydrate formation reaction and acts as a combustion inhibitor. The halogen content is desirably 0.1 to 1.2% by weight. This is because if it is less than 0.1% by weight, the strength is low, and if it exceeds 1.2% by weight, harmful substances are generated by combustion. As the halogen, chlorine, bromine and fluorine are desirable.

Similarly, the above-mentioned core material contains, in its amorphous body,
It may have calcium carbonate (Calcite). Calcium carbonate itself is not a strength-expressing substance, but by surrounding the calcium carbonate with an inorganic amorphous body,
It is considered that the effect of preventing the propagation of cracks contributes to the improvement of the strength. The content of the calcium carbonate is desirably 48% by weight or less based on the total weight of the core material.
The reason is that if it exceeds 48% by weight, the bending strength decreases. Further, it is desirably 0.1% by weight or more. 0.1
If the content is less than% by weight, it does not contribute to strength improvement.

Further, the above-mentioned core material may have a binder therein, and the presence of the binder is advantageous for further improving strength, water resistance, chemical resistance and fire resistance. is there. This binder desirably comprises one or both of a thermosetting resin and an inorganic binder. As the thermosetting resin, at least one resin selected from a phenol resin, a melamine resin, an epoxy resin, and a urea resin is desirable. The inorganic binder is preferably at least one selected from the group consisting of sodium silicate, silica gel, and alumina sol.

The fibrous material mixed in the inorganic amorphous material in the core material may be either organic or inorganic. As the organic fibrous material, at least one selected from synthetic fibers such as vinylon, polypropylene, and polyethylene, and organic fibrous materials composed of polysaccharides can be used. desirable. This is because the polysaccharide has an OH group, and the hydrogen bond forms an inorganic amorphous substance.
_This is because they are easily bonded to various compounds such as ₂ O ₃ , SiO ₂ or CaO. The polysaccharide is desirably at least one compound selected from amino sugars, uronic acids, starch, glycogen, inulin, lichenin, cellulose, chitin, chitosan, hemicellulose and pectin. As the organic fibrous material composed of these polysaccharides, pulp, pulp grounds, and crushed waste paper such as newspapers and magazines are advantageously suited. Incidentally, pulp contains about 10 to 30% by weight of lignin in addition to cellulose. On the other hand, as inorganic fibrous materials, alumina whiskers, SiC whiskers, silica-alumina-based ceramic fibers, glass fibers, carbon fibers,
At least one selected from metal fibers can be used.

The content of the fibrous material is 2 to 75.
% By weight. The reason is that if it is less than 2% by weight, the strength of the core material is reduced, while if it exceeds 75% by weight, the fire protection performance, water resistance, dimensional stability and the like may be reduced. Further, the average length of the fibrous material is 10
〜3000 μm is desirable. If the average length is too short, no entanglement occurs, and if the average length is too long, voids are formed, and the strength of the core material tends to decrease.

It is recommended that the above composite cured product 1 is obtained by drying and coagulating and hardening industrial waste, and in particular, the one obtained by drying and coagulating and hardening papermaking sludge (scum) is optimal. That is, since papermaking sludge is a pulp residue containing an inorganic substance, industrial waste is used as a raw material, which is low in cost and contributes to solving environmental problems. Moreover, since the papermaking sludge itself has a function as a binder, it has an advantage that it can be formed into a desired shape by kneading with other industrial waste.

In this papermaking sludge, besides pulp,
Al, Si, Ca, Na, Mg, P, S, K, Ti, M
Sols containing oxides, hydroxides or precursors thereof, such as n, Fe and Zn, or composites thereof, and further include at least one selected from halogen, calcium carbonate, and water. General. In particular, waste paper of high quality paper contains a large amount of calcium-based crystals such as kaolin and calcium carbonate. Therefore, as the papermaking sludge, one containing a large amount of waste paper is suitable. The water content in the papermaking sludge is desirably 20 to 80% by weight. This is because molding is easy in such a range.
In addition, although the technique regarding the hardened | cured material using papermaking sludge is seen sporadically, all differ from this invention. For example, Japanese Patent Application Laid-Open No. 49-84638 discloses a method in which pulp residue (cellulose component) and lime residue (calcium carbonate) are mixed and hot-pressed. Pulp residue refers to cellulol, as in the present invention. It does not utilize inorganic components in papermaking sludge, and does not disperse fibers in inorganic amorphous. For this reason, it breaks at the grain boundaries of limescale,
Crack propagation cannot be prevented and bending strength and compressive strength are poor. In addition, limescale is crystalline and not an amorphous body as in the present invention. JP-A-5-270872, JP-A-6-293546, JP-A-7-47537 and JP-A-7-69701 relate to a composite technique of cement and inorganic reinforcing fibers, and are disclosed in Japanese Patent Application Laid-Open No. H11-163,979. It is different from the one in which the fibrous substance is dispersed in the matrix. JP-A-10-1
No. 5923 is a technique for mixing pulp sludge and crystalline gypsum, which is different from a technique in which a fibrous substance is dispersed in an inorganic amorphous material as in the present invention. JP-A-51-
No. 30088 is a technique for molding baked ash of pulp waste and a lightweight inorganic material, but does not describe calcination conditions and the like, and cannot produce amorphous ash. JP-A-49-
No. 2880 is a technique that focuses on fibers in pulp waste only, and does not disperse fibers in an inorganic amorphous material as in the present invention. JP-A-53-81388 discloses a method in which fibers (20% of fibers, 0.01% of earth and sand) in pulp waste are mixed with wood chips, and the fibers are dispersed in an inorganic amorphous material as in the present invention. It was not done. JP-A-8-2464
No. 00 is a technology that uses waste paper pulp itself (only cellulose) instead of papermaking sludge. JP 48
No. 44449 is a technique in which a pulp waste containing an organic substance and an inorganic substance is mixed with a polymer emulsion or the like. The term “inorganic” refers to silicon oxide, aluminum oxide, and iron oxide. Metal oxide alone, which is different from the one in which two or more metal oxides are combined to form a complex amorphous system as in the present invention. JP 4
No. 9-99524 is a ceramic (polycrystalline) base material, which is different from an amorphous type material as in the present invention.

In a second embodiment of the composite building material according to the present invention, there is provided a composite building material having a decorative layer formed on at least one surface of a core material, wherein the core material is an inorganic amorphous powder, Desirably, an inorganic amorphous powder composed of an inorganic amorphous body composed of at least two or more oxides is formed via a binder. The inorganic amorphous powder may be made of an inorganic amorphous material composed of at least two or more oxides, similar to the inorganic amorphous material in the first embodiment. The binder may be the same as the binder in the first embodiment. In general, an amorphous body has higher strength and toughness than a crystalline body, and a powder having such an amorphous body is hardened with a binder to form a core material having excellent compressive strength, bending strength and impact resistance. The composite building material using such a core material does not deteriorate the design of the decorative layer on the surface due to dents or the like. Further, since the density of the inorganic amorphous body is smaller than that of the crystalline body, a light core material can be obtained by solidifying the inorganic amorphous powder made of the inorganic amorphous body with a binder. For places where design is important, such as walls and ceilings, on the other hand, building materials are to be raised or lifted. Therefore, light building materials are desired. Can also be satisfied.

It is preferable that the inorganic amorphous powder has an average particle diameter of 1 to 100 μm. If the average particle size is too large or too small, a core material having sufficient strength and toughness cannot be obtained. Optimally, the inorganic amorphous powder is obtained by firing papermaking sludge (scum). That is, since papermaking sludge is a pulp residue containing an inorganic substance, industrial waste is used as a raw material, which is low in cost and contributes to solving environmental problems.

The inorganic amorphous powder obtained by firing papermaking sludge can be obtained by subjecting papermaking sludge to heat treatment at 300 to 1500 ° C. The inorganic powder thus obtained is
Since it is amorphous, has excellent strength and toughness, and has a low density, it can be reduced in weight by being dispersed in a composite cured product. In addition, the papermaking sludge is kept at 300 ° C or more and 800 ° C or more.
Inorganic powders obtained by firing at less than or less than 300 ° C. and rapidly cooling after heat treatment at 300 ° C. to 1500 ° C. are advantageous because they surely contain an amorphous body.

In papermaking sludge, in addition to pulp, A
1, Si, Ca, Na, Mg, P, S, K, Ti, M
Sols such as oxides, hydroxides or precursors thereof, such as n, Fe, and Zn, or composites thereof, and at least one selected from halogen and calcium carbonate, and water are contained. , In general.
As the halogen, chlorine, bromine and fluorine are desirable.

The water content in the papermaking sludge is from 20 to
Desirably, it is 80% by weight. This is because if the water content is less than 20% by weight, it becomes too hard and molding becomes difficult, while if it exceeds 80% by weight, it becomes a slurry and molding becomes difficult.

A third embodiment of the composite building material according to the present invention is a composite building material in which a decorative layer is formed on at least one surface of a core material, wherein the core material is an organic fibrous material comprising a polysaccharide. The core material is, specifically, a complex cured product composed of an organic fibrous material 3 composed of a polysaccharide and an inorganic powder 4, or an organic fibrous material composed of a polysaccharide. No. 3 is a composite cured product mixed with an inorganic amorphous material. Since OH groups are present in the surface of the inorganic powder, in the inorganic amorphous material, and in the polysaccharide, the inorganic powder and the organic fibrous material, the inorganic amorphous material and the organic fibrous material, or the organic fiber This is because the fibrous materials form hydrogen bonds with each other, and the inorganic powder and the like and the organic fibrous materials are complicatedly entangled and integrated. For this reason, the strength can be secured without using cement or using a reinforcing plate such as an iron plate, and a core material having excellent workability and productivity can be obtained. Further, since the impact resistance is improved, the design of the decorative layer is not degraded by the impact dent. Further, in the case where a decorative layer made of resin-impregnated paper is provided, there is an advantage that the resin and the organic fibers in the core material are easily bonded, so that problems such as peeling are less likely to occur.

The above-mentioned inorganic amorphous material can be used. In addition, as the inorganic powder, it is desirable to use powder of inorganic industrial waste, and for example, the above-mentioned fired papermaking sludge (scum) can be used. In addition, as the inorganic powder, polishing dust of polished glass, crushed dust of silica sand, and the like can be used.

In the above inorganic powder, silica, alumina,
It is preferable that at least one inorganic substance selected from iron oxide, calcium oxide, magnesium oxide, potassium oxide, sodium oxide, and phosphorus pentoxide is contained.
These are chemically stable and excellent in weather resistance, and have desirable characteristics as a building material. The inorganic powder preferably has an average particle size of 1 to 100 μm. If the average particle size is too large or too small, a core material having sufficient strength and toughness cannot be obtained.

The content of the inorganic powder is 1 to the core material.
It is desirably 0 to 90% by weight. If the amount is too large, the material becomes brittle, and if the amount is too small, the strength decreases, and in any case, the strength is insufficient.

The polysaccharide is at least one compound selected from amino sugars, uronic acids, starch, glycogen, inulin, lichenin, cellulose, chitin, chitosan, hemicellulose and pectin, as in the first embodiment. It is desirable that This is because an organic fibrous material composed of these compounds has an OH group and thus easily forms a hydrogen bond with an inorganic powder or the like, and a fibrous material is easily obtained. As the organic fibrous material comprising such a polysaccharide, chips, pulp or pulp residue, which are pulverized conifers or hardwoods, are desirable.

The organic fibrous material comprising the polysaccharide is desirably 10 to 90% by weight based on the core material. If the amount is too large, the strength decreases, and if the amount is too small, it becomes brittle, and in any case, the strength is insufficient. And the average length of the organic fibrous material comprising the polysaccharide is
It is desirable that the thickness be 10 to 1000 μm. If the average length is too short, no entanglement occurs. If the average length is too long, the inorganic powder and the inorganic amorphous material cannot be mixed uniformly, and in any case, sufficient strength cannot be obtained.

As the organic fibrous material, industrial waste is desirable. This is because it is low cost and contributes to solving environmental problems. As such industrial waste, unsintered papermaking sludge (scum) is desirable. Since the unsintered papermaking sludge itself has a function as a binder, it can be formed into a desired shape by kneading with the inorganic powder. Further, the unsintered papermaking sludge can be dried and cured to obtain the above-mentioned inorganic amorphous material. In addition, the content of the organic fibrous material in the unfired product of the papermaking sludge can be adjusted in the range of 5 to 85% by weight based on the total solid content.

Further, the core material in the third embodiment may have a binder in addition to the inorganic powder, the inorganic amorphous material, and the organic fibrous material composed of polysaccharide. This is because the binder can improve the water resistance and the fracture toughness value. The binder is preferably the same as the binder in the first embodiment, and the content of the binder is preferably 3 to 20% by weight.

The decorative layer used in the first to third embodiments of the present invention includes melamine resin paint, melamine resin impregnated paper, polyester resin paint, diallyl phthalate resin impregnated paper, ultraviolet curable resin paint, vinyl chloride resin Film, urethane resin paint, polyacryl urethane, vinyl fluoride resin film and at least one resin-based decorative layer selected from decorative boards, natural wood veneer (rose,
Teak, pine, ash, oak, cedar), natural stone, artificial stone,
Carpet, vinyl chloride tile, cloth carpet, decorative plywood, tatami, and the like can be used. The decorative panel has a three-layer decorative panel including a phenol resin-impregnated core layer, a melamine resin-impregnated pattern layer, and a melamine resin-impregnated overlay layer, and a melamine resin-impregnated backer layer.
A decorative board having a four-layer structure composed of a phenol resin-impregnated core layer, a melamine resin-impregnated pattern layer, and a melamine resin-impregnated overlay layer can be used. Particularly, in the case of a decorative board having a phenol resin-impregnated core layer as a core layer, ,
Since the surface strength is significantly increased, it can be applied to floor materials and the like.

The thickness of the decorative layer is 0.1 mm to
Desirably, it is 10 mm. The reason is 0.1m
This is because if it is less than m, the decorative layer is likely to be damaged, and if it exceeds 10 mm, it becomes heavy.

[0052] In the composite building material of the present invention, it is desirable that a reinforcing layer is formed between the core material and the decorative layer. In particular, it is preferable that the reinforcing layer made of a resin and a fiber base material is formed. desirable. By providing a reinforcing layer, the impact resistance of the composite building material can be further improved,
This is because it can be applied to floor materials requiring severe durability.

It is desirable to use a thermosetting resin as the resin constituting the reinforcing layer. That is, unlike a thermoplastic resin, a thermosetting resin has excellent fire resistance and does not soften even at a high temperature, so that the function as a reinforcing layer is not lost. If the core material contains an organic fibrous material, the thermosetting resin constituting the reinforcing layer and the organic fibrous material constituting the core material are chemically bonded to each other. The adhesion between the composite layer and the core material is superior to the case where the composite layer is provided on the surface of the inorganic substrate as described above. As the thermosetting resin, phenol resin, memelamine resin, epoxy resin, polyimide resin, urea resin and the like are suitable.

When the reinforcing layer is made of a resin and a fiber base material, the content of the thermosetting resin in the reinforcing layer is from 20 parts by weight to 200 parts by weight based on 100 parts by weight of the fiber base material. It is desirable to set the range of parts. With this range, sufficient rigidity and impact resistance can be obtained, and high fire resistance can be maintained. In addition, the content of the thermosetting resin is 40 parts by weight with respect to 100 parts by weight of the fiber base material.
It is more preferable that the amount be in the range of from 120 parts by weight to 120 parts by weight. When the content is large, the reinforcing layer becomes heavy, and when the content is small, the reinforcing effect is reduced.

When the reinforcing layer is made of a resin and a fiber base, it is desirable to use inorganic fibers as a constituent material of the fiber base. This is because inorganic fibers can improve the strength of the reinforcing layer and reduce the coefficient of thermal expansion. For this inorganic fiber, it is possible to use at least one of glass fiber, rock wool, ceramic fiber, glass fiber chopped strand mat, glass fiber roving cloth, glass fiber continuous strand mat, and glass fiber paper at a low price and It is preferable because it has excellent heat resistance and strength.

The fibrous base material may be a non-continuous fiber formed into a mat shape, a continuous long fiber cut into a mat shape by cutting into 3 to 7 cm (a so-called chopped strand mat), or dispersed in water. It may be made into a sheet-like shape, made into a mat by laminating continuous long fibers in a spiral shape, or may be woven from continuous long fibers.

The thickness of the reinforcing layer is 0.1 mm to
It is desirable to be 3.5 mm. This is because, if it is set in this range, sufficient rigidity and impact resistance can be obtained, and high workability can be maintained. The reinforcing layer may include a flame retardant such as aluminum hydroxide and magnesium hydroxide, and a commonly used inorganic binder such as silica sol, alumina sol, and water glass.

The reinforcing layer desirably contains an elastic polymer. If it contains an elastic polymer, cracks starting from the nail will not occur even if the nail is driven, and the elastic polymer can secure the frictional force with the nail surface and improve the holding power of the nail. Because you can. As a resin for forming such a reinforcing layer, a resin composition for imparting nail strength, comprising a thermosetting resin and an elastic polymer, is desirable.
That is, the emulsion of the elastic polymer is dispersed in the uncured thermosetting resin liquid. When such a resin is cured, the "sea" of the thermosetting resin matrix
The structure is such that the “islands” of the elastic polymer are dispersed in the resin, thereby ensuring the strength of the resin and imparting toughness. As the thermosetting resin in the above case, a phenol resin, a memelamine resin, an epoxy resin, a polyimide resin, a urea resin, or the like is suitable.

The elastic polymer is preferably a rubber latex, an acrylic latex, an acrylate latex, or a urethane latex. These can be dispersed in a liquid state in the uncured thermosetting resin liquid, and both the thermosetting resin and the elastic polymer are liquid,
This is because the fiber base material is easily impregnated. The rubber-based latex includes nitrile-butadiene rubber (NBR)
And styrene-butadiene rubber (SBR) are suitable.

The weight ratio of the thermosetting resin to the solid content of the elastic polymer is desirably 95/5 to 65/35. The reason is that if the amount of the thermosetting resin is too large, the toughness is reduced, cracks are easily generated and the holding power of the nail is reduced, and if the amount of the elastic polymer is too large, the resin strength is reduced, This is because the holding power of the nail decreases. In order to make the holding power of the nail sufficient, the weight ratio of the thermosetting resin to the solid content of the elastic polymer should be 95/5 to 65/3.
The optimal value is 5.

Next, a method for producing the composite building material of the present invention will be described. First, the core material is manufactured as follows. First Manufacturing Method This corresponds to the first embodiment, and a core material is manufactured by drying and coagulating and hardening unfired papermaking sludge (scum). This coagulation hardening may be performed simultaneously with the formation of the reinforcing layer composed of the fiber base material and the resin. Examples of the papermaking sludge include papermaking sludge that is discharged when making printing / information paper, kraft paper, titanium paper, tissue paper, dust paper, toilet paper, sanitary products, towel paper, industrial hybrid paper, and household hybrid paper. It is desirable to use As the commercially available papermaking sludge, "cyclone ash", "raw sludge", etc., which are handled by Maruto Kiln Co., Ltd. can be used.

The second production method corresponds to the second embodiment described above, and the papermaking sludge is fired at 300 ° C. or more and 800 ° C. or less, or fired at 300 to 1500 ° C. and then rapidly cooled. Thus, an inorganic amorphous powder having an amorphous structure is obtained. And, while hardening this inorganic amorphous powder with a binder,
Form into a sheet. The binder used for this is desirably made of a thermosetting resin and / or an inorganic binder. As the thermosetting resin, at least one resin selected from a phenol resin, a melamine resin, an epoxy resin, and a urea resin is desirable. The inorganic binder is preferably at least one selected from the group consisting of sodium silicate, silica gel, and alumina sol. Furthermore, unfired papermaking sludge can also be used as the binder. When the inorganic amorphous powder is solidified with the binder to form the core material, the core material may be formed simultaneously with the formation of the reinforcing layer.

Third Production Method A third production method according to the third embodiment, wherein an inorganic powder and an organic fibrous material comprising a polysaccharide are dry- or wet-mixed. At the time of this mixing, the above-mentioned binder may be added as necessary. In addition, when an unfired papermaking sludge is used as an organic fibrous material comprising a polysaccharide,
It has the advantage that it itself acts as a binder and that it is hydrated and easy to wet mix. The mixture is formed into a sheet by a conventionally known method such as a dewatering press method, a round sheet forming method, a fourdrinier forming method, an extrusion forming method, and then dried, or pressed by a roll while being conveyed by a conveyor to form a sheet. Then, the sheet-shaped molded body is pressed and pressed while heating and drying to form a core material 5. Heating temperature is 80-160 ° C, pressure is 1-20kgf / cm
^{A value of 2} is appropriate. By pressing, the fibrous material is oriented in a direction perpendicular to the pressing direction. Since water can be removed by applying pressure, it is possible to prevent crystallization from proceeding excessively by taking in water, and to form an amorphous body appropriately. In addition, the bending strength can be increased by the orientation.

Next, a decorative layer is provided on the core material. There are the following methods for forming the decorative layer. Coating Coating is performed by printing or spraying various pigments, inks, resins, and the like. Lamination A resin impregnated paper obtained by impregnating kraft paper or the like with an uncured resin and setting it to the B stage is laminated on a core material or the following sheet-like molded body, and is laminated by heating and pressing. Adhesion Carpets, tatami mats, decorative plywood, etc. are adhered to the core with an adhesive. As an adhesive used for this, a thermosetting resin such as an epoxy resin or a phenol resin, or vinyl acetate is preferable.

Further, when a reinforcing layer is provided between the core material and the decorative layer, it is manufactured as follows. First, as described in the manufacturing method of the core material, the papermaking sludge is formed into a sheet by the first manufacturing method, and the inorganic amorphous powder is solidified by a binder in the second manufacturing method and formed into a sheet shape, or By forming the mixture into a sheet by the third production method, a sheet-shaped molded body is obtained. On the other hand, for example, a fiber base material impregnated with a resin is heated at 25 to 70 ° C. and dried to obtain a reinforcing sheet. Then, the sheet-like molded body and the reinforcing sheet are laminated and pressed together while heating to form a composite building material including a core material and a reinforcing layer. The heating temperature is 80 to 200 ° C., and the pressure is 1 to 20 kgf / cm ^2.
The degree is appropriate. Here, the term “pressing” refers to maintaining the pressure applied.

Instead of the above method, a mat of inorganic fibers is impregnated with a resin composition, dried, and then heated and pressed, and the thermosetting resin is cured to form a reinforcing layer. May be attached to a core material that has been cured in advance with an adhesive.

Further, the surface of glass fiber, rock wool or ceramic fiber is coated with a thermosetting resin such as phenol resin in a separate step, and a fiber base made of these fibers is laminated on a sheet-like molded body. And hot pressing. This method of coating the fiber surface with a thermosetting resin in a separate step is advantageous because the adhesion to the impregnated resin is improved, the fibers are easily bonded to each other, and the resin impregnation rate can be further improved. . Examples of such a coating method include a method in which the fiber base material is impregnated with an uncured thermosetting resin and dried, or a method in which a raw material melt of glass fiber, rock wool or ceramic fiber is caused to flow out of a nozzle and a blowing method. And centrifugal method, and at the same time, a solution of a thermosetting resin such as a phenol resin is sprayed to collect cotton.

When a glass fiber, rock wool or ceramic fiber is used as a constituent material of the fiber base material, it is preferable to coat a silane coupling agent. On the front and / or back surface of the composite building material obtained in this way, as described above, painting is performed, or a decorative plate or veneer is adhered with an adhesive or the like.

[0069]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The following is a description of the embodiments. (Example 1) 1512 g of unfired papermaking sludge ("raw sludge" handled by Maruto Kiln Co., Ltd .: solid content 34% by weight, water content 66% by weight) was prepared. Next, the papermaking sludge was heated and dried at 100 ° C. while applying a pressure of 3 kgf / cm ² while being conveyed by a conveyor, to obtain a plate-shaped composite cured body having a thickness of 10 mm.

The cured product thus obtained was analyzed using a fluorescent X-ray analyzer (Rigaku RIX2100).
It was found that the composition was as follows in terms of oxide. The pulp was calcined at 1100 ° C. and measured from the weight loss. Serial Pulp: 51.4 wt%, SO _3: 0.5 wt% SiO _2: 24.2 wt%, P ₂ O _5: 0.2 wt% Al ₂ O _3: 14.0 wt%, Cl: 0 .2 wt% CaO: 8.0 wt%, ZnO: 0.1 wt% MgO: 1.4 wt%, others: traces TiO _2: 1.0 wt%,

On the other hand, a commercially available phenol resin solution 80
(% SBR latex solid content: 49% by weight)
Were mixed at room temperature to obtain a liquid resin composition for imparting nail strength. In addition, Nipol LX-436 manufactured by Zeon Corporation was used as the SBR latex. Next, the sheet-like glass fiber is impregnated with the above-described resin composition to which a curing agent is added (impregnation amount is 45% in terms of solid content), and then dried at a temperature of 80 ° C. for 20 minutes to obtain a reinforcing sheet. Was.

Further, the phenol resin solution was applied to the front and back surfaces of the cured product,
Dried for minutes. Then, the reinforcing sheet is superimposed on the front and back surfaces of the cured body, and the laminated body is pressed at a temperature of 110 ° C. and a pressure of 7 kgf / cm ² for 20 minutes,
A composite of a reinforcing layer having a thickness of 1 mm on both front and back surfaces and a core material having a thickness of 10 mm was obtained. Finally, on both sides of the composite,
A decorative veneer (cedar board) having a thickness of 1 mm was bonded with a vinyl acetate adhesive to obtain a composite building material.

As shown in the cross section in FIG. 1, the composite building material of Example 1 has a core 1, a decorative layer 5 composed of decorative veneers provided on both front and back surfaces of the core 1, and It comprises a reinforcing layer 6 interposed between the core material 1 and the decorative layer 5. Here, the core material 1 includes the amorphous body 2 and
The amorphous body 2 contains the organic fibrous material 3 and the inorganic powder 4, and the reinforcing layer 6 is made of a fiber base material 6b impregnated with a resin 6a.

(Example 2) Unfired papermaking sludge ("raw sludge" handled by Maruto Kiln Co., Ltd .: solid content 34% by weight,
1512 g of water (66% by weight) was prepared. Next, the papermaking sludge was dried at 80 ° C. with stirring, and the obtained dried body was immediately fired at 780 ° C. for 5 hours, immediately exposed to room temperature and rapidly cooled. The fired product was crushed by a ball mill to obtain 248 g of inorganic amorphous powder.

When the obtained inorganic amorphous powder was analyzed using a fluorescent X-ray analyzer (RIX2100, manufactured by Rigaku), it was found that the powder had the following composition in terms of oxide. SiO ₂ : 34.1% by weight, TiO ₂ : 1.0% by weight CaO: 21.3% by weight, SO ₃ : 0.5% by weight Al ₂ O ₃ : 20.7% by weight, Cl: 0.2 % By weight Fe ₂ O ₃ : 12.4% by weight, ZnO: 0.1% by weight MgO: 5.9% by weight, others: trace amount P ₂ O ₅ : 2.8% by weight,

Next, the unsintered papermaking sludge 151
2 g and 248 g of the above calcined product (inorganic amorphous powder) are kneaded, and the resulting kneaded material is dried by heating at 100 ° C. while applying a pressure of 3 kgf / cm ² while conveying it on a conveyor. By doing so, a plate-shaped composite cured product having a thickness of 10 mm was obtained.

The crystal structure of the obtained composite cured product was confirmed by X-ray diffraction. The X-ray diffraction chart is shown in FIG. In addition, this X-ray diffraction was performed by Rigaku MiniF
lex was used and Cu was targeted. 2θ: 22 °
And a peak indicating a crystal structure is also observed, which indicates that the crystal structure is mixed in the amorphous structure. From the peak,
Gehlenite, syn, Melilite-synthetic, Gehlenite-synt
hetic, Anorthite, and ordered were identified.

On the other hand, an overlay printed with a grain pattern
Bleached kraft paper for layer A (basis weight 25g / m^Two ), Patterns and colors
Bleached kraft paper for pattern layer printed with color (80 g basis weight)
/ M ^Two ), Bleached kraft paper for backer layer (basis weight 80g /
m^Two ) And bleached kraft paper for the core layer (basis weight 120g /
m^Two ) And bleached kraft paper and paper for the overlay layer.
Bleached kraft paper for the turn layer and bleached kraft for the backer layer
Melamine resin impregnation rate of 250% for paper and 80% respectively
%, 80%, and bleaching for the core layer.
Raft paper impregnated with phenolic resin at 100% content
You. The impregnation ratio is defined as (weight of impregnated resin / weight of kraft paper).
Amount (%) × 100 (%).

Finally, the bleached kraft paper for the backer layer, the bleached kraft paper for the core layer, the bleached kraft paper for the pattern layer, and the Place bleached kraft paper sequentially,
These are heated to a temperature of 15 kg while applying a pressure of 40 kgf / cm ^2.
By heating and integrating at 0 ° C. for 5 minutes, a composite building material having decorative panels formed on both sides of the core material was obtained.

The composite building material of Example 2 includes a core 1 and decorative layers 5 provided on the front and back surfaces of the core 1 as shown in FIG. Here, the core material 1 includes the amorphous body 2, the organic fiber 3 and the inorganic powder 4 in the amorphous body 2, and the decorative layer 5 includes the backer layer 5a, Core layer 5b, pattern layer 5c
And an overlay layer 5d.

Example 3 Basically the same as in Example 1, except that water was added to unfired papermaking sludge (solid content 34% by weight, water content 66% by weight) to form a slurry having a solid content of 10%. Then, 5000 kg of this slurry is formed into a sheet by a fourdrinier method, and then heated and dried at 100 ° C. to form a sheet-shaped formed body (cured body) having a thickness of 10 mm.
And Further, a phenol resin solution was applied to the front and back surfaces of the cured product and dried at a temperature of 80 ° C. for 20 minutes to obtain a composite cured product in the same manner as in Example 1.

Example 4 Basically the same as in Example 2, except that 1512 kg of unfired papermaking sludge (solid content 34% by weight, water content 66% by weight) was dried at 80 ° C. with stirring to obtain The obtained dried body was calcined at 780 ° C. for 5 hours and immediately exposed to room temperature to be rapidly cooled. The fired product was pulverized with a ball mill to obtain 248 kg of an inorganic amorphous powder. Next, 2300 parts by weight of unsintered papermaking sludge and 200 parts by weight of the inorganic amorphous powder are kneaded, and the obtained kneaded material is conveyed by a conveyor at 15 kgf / kg.
100 ° C. while applying a pressure of cm ² (1.47 MPa).
And dried to obtain a plate-shaped composite cured product having a thickness of 10 mm.

(Comparative Example 1) A decorative layer similar to that of Example 2 was provided on both sides of a core material, but a gypsum board having a thickness of 12 mm was used as the core material instead of the sheet-like molded body. .

For the composite building materials obtained in the above Examples and Comparative Examples, the measurement of bending strength and compressive strength and the impact test were carried out. Table 1 shows the results. The test method was based on the method defined by JIS A6901 for flexural strength and the method defined by JIS A 5416 for compressive strength. In the impact test, the depth of a dent formed by dropping a 530 kg iron ball from a height of 1 m was measured.

[0085]

[Table 1]

[0086]

As described above, according to the composite building material of the present invention, it is possible to provide inexpensively a building material which is excellent in productivity, excellent in bending strength and compressive strength, and does not deteriorate in design even when subjected to impact. can do.

The present invention is not limited to the configuration of the above-described embodiment, but includes a range that can be appropriately changed by those skilled in the art within the scope of the claims.
The core material of the composite building material of the present invention may further contain a material other than the above-mentioned cured product.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of Embodiment 1 of a composite building material according to the present invention.

FIG. 2 is a schematic cross-sectional view of Embodiment 2 of the composite building material of the present invention.

FIG. 3 is an X-ray diffraction chart of the composite cured product of Example 2;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Core material 2 Amorphous body 3 Fibrous material 4 Inorganic powder 5 Decorative layer 6 Reinforcement layer

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification FI FI Theme Court ゛ (Reference) D21J 1/00 D21J 1/00 (72) Inventor Kenji Sato 1-1-1 Ibiden, Ibigawa-cho, Ibi-gun, Gifu Prefecture In the Ogaki-Kita factory (72) Inventor Toshihiro Nomura 1-1-1 north of Ibigawa-cho, Ibi-gun, Gifu F-term in the Ogaki-kita factory (reference) FA16 FA19 FA20 FB07 FC00 FC01 FC02 FD04 FD06 FD08 4F100 AA01A AA18 AA19 AA20 AG00 AJ03A AK01C AK22G AK33 AK73 AP01 BA02 BA03 BA07 BA10A BA10B BA22A CB01 DE01A DG01A DG02 J07B04J07 J00B07A

Claims (7)

[Claims] 1. A composite building material having a decorative layer formed on at least one surface of a core material, wherein the core material contains an inorganic amorphous material, and a fibrous material is contained in the inorganic amorphous material. Composite building material characterized by having. 2. A composite building material in which a decorative layer is formed on at least one surface of a core material, wherein the core material is obtained by molding an inorganic amorphous powder having an inorganic amorphous material via a binder. A composite building material characterized in that: 3. A composite building material in which a decorative layer is formed on at least one surface of a core material, wherein the core material contains an organic fibrous material made of a polysaccharide. 4. The composite building material according to claim 1, wherein a reinforcing layer is formed between said core material and said decorative layer. 5. The thickness of the decorative layer is 0.1 to 10 mm
The composite building material according to any one of claims 1 to 3, wherein: 6. The composite building material according to claim 1, wherein the reinforcing layer contains an elastic polymer. 7. The composite building material according to claim 1, wherein the fibrous material is oriented in a specific direction.