JP2000297496A - Composite building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the strength of a building material and to achieve advantageous application of an electromagnetic wave shielding layer by allowing a core member constituting a composite building material having the shielding layer formed at least on one surface thereof to contain an inorganic amorphous body internally having fibrous materials. SOLUTION: A core member 3 containing an inorganic amorphous body 1 and fibrous materials 2 mixed therein, has reinforcing layers 5 on front and rear surfaces thereof, and an electromagnetic wave shielding layer 4 is arranged on the reinforcing layer 5. The inorganic amorphous body 1 is an amorphous compound obtained by solution treatment or hydration of at least two oxides. In the core member 3, the inorganic amorphous body 1 serves as a strength manifestation material and the fibrous materials 2 are dispersed in the inorganic amorphous body 1 to improve a fracture toughness value, whereby a bending strength value and impact resistance can be improved. Further, since the core member 3 is of the amorphous body, sufficient strength can be obtained in low density. Therefore, the shielding layer 4 can be prevented from being broken due to an impact, whereby the composite building material is rendered applicable to a wall member and a floor member of a room in which office automation equipment is set or of an intensive care unit in a hospital.

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 having high performance and low cost, and also useful for environmental protection.

[0002] The floor material of a so-called OA floor on which a computer or the like is installed bears the weight of the computer.
Even if a computer falls over during an earthquake, it is required not to be damaged by the impact, and since the wiring will be installed under the floor, it must also have excellent fire resistance so that it can withstand cable fires etc. is necessary.

Here, as a building material which is lightweight and excellent in fire resistance and workability, Japanese Unexamined Patent Publication No. 7-329236 proposes a non-combustible material in which a prepreg made of a thermoplastic resin is adhered to a gypsum board. However, this building material is used for walls and partitions, and does not have sufficient strength as a floor material.

In a room where an OA device such as a computer is installed, or in an intensive care unit of a hospital, a wall material and a floor material having an electromagnetic wave shielding layer are used so that the device in the room is not affected by electromagnetic wave noise. Preferably it is covered. This electromagnetic wave shielding layer is formed by using the above-described Japanese Patent Application Laid-Open No. 7-32.
When applied to the building material of No. 9236, its strength is low, so that it is not possible to sufficiently protect the shield layer when an impact such as impact is applied, and the shield layer is damaged, for example, due to electromagnetic wave noise. This may cause the computer to malfunction. In particular, since flooring materials are easily broken, a material having excellent impact resistance is required.

[0005]

SUMMARY OF THE INVENTION Therefore, the present invention
An object of the present invention is to propose a composite building material that enables advantageous application of an electromagnetic wave shielding layer by sufficiently increasing the strength of a lightweight building material having excellent fire resistance and workability.

[0006]

The gist of the present invention is as follows.
It is as follows. (1) A composite building material in which an electromagnetic wave shielding layer is formed on at least one surface of a core material, wherein the core material includes an inorganic amorphous material, and a fibrous material is contained in the inorganic amorphous material. A composite building material characterized by being mixed.

(2) A composite building material in which an electromagnetic wave shielding layer is formed on at least one surface of a core material, wherein the core material is formed by molding a powder made of an inorganic amorphous material via a binder. A composite building material characterized by being made.

(3) A composite building material having an electromagnetic wave shielding layer formed on at least one surface of a core material, wherein the core material contains a polysaccharide organic fibrous material. .

(4) The composite building material according to (1) or (3), wherein the fibrous material is oriented. In addition, that the fibrous material is oriented means that the longitudinal direction of each fiber is aligned in a specific direction.

(5) The composite building material according to any one of the above (1) to (4), wherein the electromagnetic wave shielding layer is a metal foil.

(6) A composite building material according to any one of the above (1) to (4), wherein the electromagnetic wave shielding layer is a composite sheet comprising a conductive filler and a resin.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of the composite building material of the present invention is schematically shown in FIG. The composite building material includes an inorganic amorphous body 1 and at least one surface of a core material 3 in which a fibrous material 2 is mixed in the amorphous body 1.
Is a plate-like member, and is provided with an electromagnetic wave shielding layer 4 on one of its front and back surfaces. Although the illustrated example has a structure in which the reinforcing layer 5 is provided on the front and back surfaces of the core material 3 and the electromagnetic wave shielding layer 4 is provided on the reinforcing layer 5, the reinforcing layer 5 may be omitted. .

As the inorganic amorphous material, an inorganic amorphous material comprising two or more oxides is desirable. Here, the inorganic amorphous body composed of two or more oxides refers to an oxide (1) -oxide (2)... -Oxide (n) (where n is a natural number, Oxide (1), oxide (2), ...
-The oxide (n) is an amorphous body of different oxides). Such an inorganic amorphous substance is difficult to define accurately, but is considered to be an amorphous compound formed by solid solution or hydration reaction of two or more oxides. . Such inorganic amorphous compounds are analyzed by fluorescent X-ray analysis to determine the elements (Al, Si,
Ca, Na, Mg, P, S, K, Ti, Mn, Fe, Z
at least one selected from n), and a halo is observed in the range of 2θ: 15 ° to 40 ° in the analysis chart by X-ray diffraction. This halo is a gradual 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.

The core material 3 has an inorganic amorphous material 1 as a strength developing material and a fibrous material 2 dispersed in the amorphous material 2 to improve the fracture toughness. Impact resistance can be improved. Further, a homogeneous core material 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, it is considered that the fracture toughness value is also improved because the fibrous material is more easily dispersed in the inorganic amorphous material than in the crystalline material. As a result, cracking does not occur even if a nail is driven or a through hole is provided, so that the material is optimal for a material requiring processing such as a building material.

Here, as the oxide, a metal and / or nonmetal oxide can be used, and Al ₂ O ₃ , SiO _{2
2, CaO, Na 2 O,} MgO, P 2 O 5, SO 3, K
It is desirable to be selected from ₂ O, TiO ₂ , MnO, Fe ₂ O ₃ and ZnO. In particular, Al ₂ O ₃ —Si
O ₂ —CaO-based or Al ₂ O ₃ —SiO ₂ —CaO—
An inorganic amorphous body composed of an oxide or a composite of these inorganic amorphous bodies is optimal. The oxides in the latter inorganic amorphous material are Al ₂ O ₃ , SiO ₂ and Ca
At least one of metal and / or nonmetal oxides except O.

Firstly, inorganic amorphous body composed of Al ₂ O ₃ -SiO ₂ -CaO system, Al ₂ O _3, SiO ₂ and C
All or a part of each component of aO is a compound having an amorphous structure formed by solid solution or hydration reaction with each other. That is, Al ₂ O ₃ and SiO ₂ , SiO ₂ and C
aO, Al ₂ O ₃ and CaO, Al ₂ O ₃ , SiO
_It is considered to include any of the compounds formed by solid solution or hydration reaction with each combination of 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. This halo is a gradual 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.

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. Material, CaO and oxide, Al ₂ O ₃ and SiO ₂ and oxide,
SiO ₂ and CaO and oxides, Al ₂ O ₃ and CaO and oxides, and compounds formed by solid solution or hydration reaction of each combination of Al ₂ O ₃ and SiO ₂ and CaO and oxides It is considered to include either.

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), if it is an amorphous substance (n is a natural number of 2 or more), these oxides, for example, oxide ( 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), and a compound formed by performing a solid solution or hydration reaction in a combination of two or more selected from the group consisting of Al ₂ O ₃ , SiO ₂ and CaO. Compounds formed by a solid solution or hydration reaction or the like in combination of two or more kinds, and oxides (1) and (2)
... At least one selected from oxides (n) (n is a natural number of 2 or more), Al ₂ O ₃ , SiO <sub>2
2. It</sub> is considered to include any of the compounds formed by solid solution or hydration reaction 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.
In the analysis chart by the line diffraction, 2θ: 15 ° to 40 °
Halo can be seen in the range. This halo is a gradual 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.

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 choice can be made on the basis of the properties expected of the core, and thus the building material.

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 of the core material to be plated becomes rough and can act as an anchor for plating. Can be. MgO is
It 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
Is advantageous in the case where the metal layer is directly adhered to the core material because the adhesion to metal can be improved. SO ₃ has a bactericidal action and is suitable for antibacterial building materials. Since TiO ₂ is a white coloring material and also acts as a photo-oxidation catalyst, it is a self-cleaning building material that can forcibly oxidize attached organic pollutants and can be washed only by irradiating light. 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. Note that each of these oxides may be present alone in the amorphous body.

The composition of the above amorphous material is Al ₂ O
₃ , in terms of SiO ₂ and CaO, Al ₂ O ₃ : ₃ to 51% by weight based on the total weight of the core material, SiO ₂ : 5 to 53% by weight based on the total weight of the core material, and CaO: the core 6 to 63% by weight based on the total weight of the material, and their sum is 1
It is preferable to contain it in a range not exceeding 00% by weight.

The reason is that the content of Al ₂ O ₃ is 3% by weight.
If it is less than 50% by weight or more than 51% by weight, the strength of the core material is reduced, and the content of SiO ₂ is less than 5% by weight or 5% by weight.
Even if it exceeds 3% by weight, the strength of the core material is reduced. Also, C
Even if the content of aO is less than 6% by weight or exceeds 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, Al ₂ O ₃ , SiO ₂ and CaO
Oxides other than Na ₂ O, MgO, P ₂ O ₅ , S
O ₃ , K ₂ O, TiO ₂ , MnO, Fe ₂ O ₃ and Z
When one or more of nO is contained, the preferred content of each component is as follows. It goes without saying that the total amount of these oxides does not exceed 100% by weight. Na ₂ O: 0.1 to 2.4% by weight based on the total weight of the core material MgO: 0.3 to 22.0% 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 14.6 wt% SO _3: 0.1 to 7.0 wt% K ₂ O with respect to the total weight of the core material: 0.1 to 2 relative to the total weight of the core material. 4 wt% TiO _2: .1-17.4 wt% MnO, relative to the total weight of the core material: 0.1 to 3.0% by weight relative to the total weight of the core material Fe ₂ O _3: the core material 0.2 to 35.6% by weight with respect to the total weight ZnO: 0.1 to 3.6% 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.

It should be noted that whether or not the material 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 can be confirmed that it has an amorphous structure. In the present invention, in addition to those having a completely amorphous structure, Hydrogen Aluminum Silicate, Kaolinite, Zeolit
e, Gehlenite, syn, Anorthite, Melitite, Gehlenit
e-synthetic, tobermorite, xonotlite, ettringite
Or SiO ₂ , Al ₂ O ₃ , CaO, Na ₂ O, Mg
O, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, F
oxides such as e ₂ O ₃ and ZnO, and CaCO ₃
Crystals such as (Calcite) may be mixed. These crystals are not considered to be the strength-expressing substances themselves, but are considered to have, for example, effects such as increasing the hardness and density to improve the compressive strength and suppressing the progress of cracks. The content of the crystal is desirably 0.1 to 50% by weight based on the total weight of the core material. This is because if the number of crystals is too small, the above effect cannot be obtained, and if the number is too large, the strength is reduced.

Incidentally, the above Al_Two O_Three -SiO_Two Ancestry
Crystalline compounds are Hydrogen AluminumSilicate, Kaolini
te, Zeolite, Al_Two O_Three -CaO-based crystalline compound
Is Calcium Aluminate, CaO-SiO_Two Crystallization of the system
Compound is Calcium Silicate, Al_Two O_Three -SiO_Two -Ca
O-type crystalline compounds are Gehlenite, syn and Anorthite.
And Al_Two O_Three -SiO_Two -CaO-MgO system
The crystalline compounds are Melitite and Gehlenite-synthetic.
Further, those containing Ca as a crystal are desirable, and Gehl
enite, syn (Ca_Two Al_Two O₇ ), Melitite-synthetic
(Ca_Two (Mg_0.5 Al_0.5 ) (Si_1.5 Al _0.5 O
₇ )), Gehlenite-synthetic (Ca_Two (Mg_0.25Al
_0.75) (Si_1.25Al_0.75O_0.7 ), Anorthite.ordere
d (Ca_Two Al_Two Si_Two O₈ ), Calcium carbonate (Calc
ite).

In the core material according to the present invention, halogen may be added to an amorphous body composed of two or more oxides. The halogen serves as a catalyst for a solid solution or hydrate formation reaction and also acts as a combustion suppressing substance. Its 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, calcium carbonate (Calcite) may be added. Calcium carbonate itself is not a strength-expressing substance, but it is thought that by surrounding the calcium carbonate with an amorphous body, it contributes to strength improvement by actions such as inhibiting the progress of cracks. The content of the calcium carbonate is 48% by weight based on the total weight of the core material.
The following is desirable. The reason for this is that if it exceeds 48% by weight, the bending strength is reduced. Further, the content is desirably 0.1% by weight or more. If the content is less than 0.1% by weight, it does not contribute to the improvement in strength.

Further, the addition of a binder is advantageous for further improving the strength and for improving the water resistance, chemical resistance and fire resistance. The binder desirably comprises one or both of a thermosetting resin and an inorganic binder. As thermosetting resins, phenolic resins,
At least one resin selected from melamine resin, epoxy resin and urea resin is desirable. As the inorganic binder, at least one selected from the group consisting of sodium silicate, silica gel and alumina sol is desirable. Note that a thermosetting resin, for example, at least one thermosetting resin selected from a phenol resin, a melamine resin, an epoxy resin, a urea resin, and a urethane resin may be applied to the surface.

Next, the fibrous material mixed in the amorphous material may be either organic or inorganic. As the organic fibrous material, at least one selected from chemical fibers such as vinylon, polypropylene, and polyethylene, and an organic fibrous material composed of polysaccharides can be used, and an organic fibrous material composed of polysaccharides is preferable. . This is because polysaccharides have an OH group, and A
This is because they are easily bonded to various compounds of l 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. Organic fibrous materials composed of these polysaccharides include:
Pulps, pulp residues, ground papers such as newspapers and magazines are advantageously suitable. The pulp contains about 10 to 30% by weight of lignin in addition to cellulose.

As the inorganic fibrous material, at least one selected from alumina whiskers, SiC whiskers, silica-alumina-based ceramic fibers, glass fibers, carbon fibers, and metal fibers can be used.

The content of the fibrous material is 2 to 75.
% By weight. The reason for this is that if the content 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 inorganic cured product tends to decrease.

It is recommended that the above-mentioned core material is obtained by drying and coagulating and hardening industrial waste, and particularly, the one obtained by drying and coagulating and hardening papermaking sludge (scum) is optimal. That is, the papermaking sludge is a pulp residue containing an inorganic substance, is low in cost because industrial waste is used as a raw material, and contributes to solving environmental problems. Moreover, the papermaking sludge itself has a function as a binder, and has an advantage that it can be formed into a desired shape by kneading with other industrial waste. In particular, waste paper of high quality paper contains a large amount of calcium-based crystals such as kaolin and calcium carbonate. Therefore, paper sludge containing a large amount of waste paper is suitable.

In the papermaking sludge (scum), in addition to pulp, Al, Si, Ca, Na, Mg, P, S, K,
It contains oxides and hydroxides such as Ti, Mn, Fe, and Zn, or sols that are precursors thereof, or composites thereof, and at least one selected from halogen and calcium carbonate and water. As the halogen, chlorine, bromine, and fluorine are desirable.

The water content of 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.

In the present invention, the specific gravity of the composite cured product is
0.2 to 2.2 is desirable. If the specific gravity is less than 0.2, the number of pores is so large that the strength of the composite cured body is reduced. Conversely, if the specific gravity exceeds 2.2, the effect of the inorganic amorphous material itself on the strength becomes too large, resulting in a fibrous material. The effect of reinforcing the object relatively decreases, and the strength also decreases. That is, practical compressive strength and bending strength can be obtained when the specific gravity is in the range of 0.2 to 2.2, and this range can be said to be a specific range for obtaining strength.

In the composite building material of the present invention, it is also possible to solidify the powder containing the inorganic amorphous material with a binder to form a core material. Here, the amorphous body has the same definition as described above, and a powder having an average particle size of 1 to 100 μm is advantageously suitable. That is,
This is because if the average particle diameter is too small or too large, sufficient strength as a core material cannot be obtained.

The inorganic amorphous powder is not particularly limited, but is preferably an inorganic amorphous material composed of two or more kinds of oxides, particularly one obtained by firing industrial waste. It is recommended that, especially, calcined papermaking sludge (scum) be optimal. That is, the papermaking sludge is a pulp residue containing an inorganic substance, is low in cost because industrial waste is used as a raw material, and contributes to solving environmental problems.

The papermaking sludge is desirably fired at 300 ° C. or higher and lower than 800 ° C. That is, when the temperature is 800 ° C. or more, the material tends to be crystalline, and when the temperature is less than 300 ° C., the pulp is only carbonized and powder cannot be obtained. An amorphous powder can also be obtained by subjecting papermaking sludge to heat treatment at 300 to 1500 ° C. and then quenching.

Although various techniques using papermaking sludge can be found, all of them have different technical contents from the present invention. That is, Japanese Patent Application Laid-Open No. 49-84638 discloses a hot-pressed mixture of pulp grounds (cellulose component) and lime ground, but the pulp grounds mean cellulol. It does not utilize inorganic components in papermaking sludge as described above, nor does it disperse fibers in inorganic amorphous. For this reason, fracture at the grain boundaries of limescale or crack propagation cannot be prevented, and problems remain in bending strength and compressive strength. Moreover, limescale is a crystalline material (calcium oxide) obtained by burning paper pulp liquor, and is clearly distinguished from the amorphous material of the present invention.

In addition, JP-A-7-47537 and JP-A-7-6
9701, 6-293546 and 5-270
No. 872 discloses a technique of combining cement and inorganic reinforcing fibers, and JP-A-10-15923 discloses a technique of mixing pulp sludge with crystalline gypsum.
Japanese Patent Application Laid-Open No. 9-2880 discloses a technique which focuses only on the fiber in pulp waste, and Japanese Patent Application Laid-Open No. 53-81388 discloses a fiber in pulp waste (fiber 15%, earth and sand 0.01%).
Each of the techniques described above is different from a technique in which a fibrous substance is dispersed in an inorganic amorphous material as in the present invention.

Furthermore, Japanese Patent Application Laid-Open No. 51-30088 describes a technique for forming a burnt ash of pulp waste and a lightweight inorganic material, but does not describe firing conditions and the like. Cannot be obtained. JP-A-8-2
No. 46400 discloses a technique in which waste paper pulp itself is used instead of papermaking sludge. JP-A-48-443
No. 49 discloses 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. And two or more metal oxides as in the present invention are different from those constituting a complex amorphous system. And, JP
JP-A-99524 discloses a ceramic (polycrystalline) base material, which is different from an amorphous base material as in the present invention.

On the other hand, a binder composed of one or both of the above-mentioned thermosetting resin and inorganic binder can be used. That is, 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. As the inorganic binder, at least one selected from the group consisting of sodium silicate, silica gel, and alumina sol
Seeds are preferred.

Further, in the composite building material of the present invention, it is possible to use a core material containing an organic fibrous material of a polysaccharide. That is, an organic fibrous material composed of a polysaccharide is dispersed in an inorganic material. The inorganic substance is desirably an inorganic powder or an inorganic amorphous substance. Since OH groups are present on the surface of the inorganic powder, in the inorganic amorphous material, or in the polysaccharide, the inorganic powder and / or the inorganic amorphous material and the organic fibrous material, or between the organic fibrous materials, By forming hydrogen bonds with each other, the inorganic powder and / or the inorganic amorphous material and the organic fibrous material are intricately entangled and integrated. For this reason, the strength can be secured without using cement or a reinforcing plate such as an iron plate, and a composite building material excellent in workability and productivity can be obtained.

Here, as the inorganic powder, powder of industrial waste is desirable. Again, papermaking sludge (scum)
Can be used. This papermaking sludge is a pulp residue containing an inorganic substance,
By performing the heat treatment at ° C, an inorganic powder can be obtained. Further, polishing powder of polished glass, crushed powder of silica sand, or the like can be used as the inorganic powder.

The inorganic substance contained in the inorganic powder is desirably at least one selected from silica, alumina, iron oxide, calcium oxide, magnesium oxide, potassium oxide, sodium oxide and phosphorus pentoxide. These are chemically stable, have excellent weather resistance, and have desirable properties as building materials.

In addition, if the inorganic powder is too small or too large, sufficient strength cannot be obtained.
It is preferable to use one having a thickness of 100 μm. And the content of the inorganic powder is 10 to the total weight of the core material.
Desirably, it is 90% by weight. If it is more than this range, it becomes brittle, and if it is too small, the strength decreases, and in any case, the strength decreases. The above-mentioned inorganic amorphous material can be used.

On the other hand, the polysaccharides constituting the organic fibrous material include at least one selected from amino sugars, uronic acids, starch, glycogen, inulin, lichenin, cellulose, chitin, chitosan, hemicellulose and pectin.
It is desirable that the compound be a species compound. This is because an organic fibrous material composed of these compounds has an OH group, easily forms a hydrogen bond with an inorganic powder, and is easy to obtain a fibrous material.

It is desirable that the content of the organic fibrous material comprising the polysaccharide is 10 to 90% by weight based on the total weight of the core material. If the amount of the organic fibrous material is too large, the strength is reduced, and if the amount is too small, the organic material becomes brittle and the strength is reduced. Further, the average length of the organic fibrous material composed of polysaccharide is preferably 10 to 1000 μm. This is because if the average length is too short, no entanglement of the fibrous material occurs, and if the average length is too long, the inorganic industrial waste cannot be uniformly mixed and sufficient strength cannot be obtained.

As the organic fibrous material composed of polysaccharides, pulp or pulp waste, especially industrial waste, contributes to low cost and solving environmental problems.
It is advantageous. As such an industrial waste, there is an unfired papermaking sludge (scum). Since the unfired papermaking sludge itself has a function as a binder, it is kneaded with inorganic powder. Thereby, it can be formed into a desired shape. The content of the organic fibrous material in the unsintered papermaking sludge can be adjusted within a range of 5 to 85% by weight based on the total solid content.

Further, a binder may be added in addition to the inorganic powder and the organic fibrous material composed of polysaccharide. This is because the binder can improve water resistance and fracture toughness. As the binder, the above-mentioned thermosetting resin or inorganic binder can be used.

In the present invention, it is essential to form an electromagnetic wave shielding layer on at least one surface of the above core material. A metal foil is advantageously used as the electromagnetic wave shielding layer. The metal foil not only efficiently absorbs electromagnetic waves, but also has high strength, light weight, and good workability. Specifically, one or more kinds selected from aluminum foil, copper foil, zinc foil, stainless steel foil, gold foil, and silver foil may be used. These have a property of effectively absorbing electromagnetic waves. The thickness of the metal foil is 10-500μ
It is preferable to be about m for the shielding property.

As the electromagnetic wave shielding layer, a composite sheet made of a conductive filler and a resin can be used. Such a composite sheet is excellent not only in that it efficiently absorbs electromagnetic waves, but also in that it is lightweight, has high workability, and absorbs sound and vibration. The conductive filler contained in the composite sheet is, for example, a powder of one or more selected from iron, copper, aluminum, stainless steel, brass, zinc, carbon, and the like. On the other hand, as the resin, for example, each resin of phenol, epoxy, polyurethane, urea, polyester, polypropylene, and polyethylene can be used. The thickness of the composite sheet
It is preferable for the shielding property to be about 0.5 to 5.0 mm. Furthermore, the electromagnetic wave shielding layer may be a conductive sheet-like material such as a composite sheet made of a metal foil, a conductive filler and a resin, or a material coated with a conductive paint or the like.

The electromagnetic wave shielding layer can be provided on at least one of the core materials, and when the core material is a plate, at least one of the front and back surfaces. Since building materials generally have a decorative layer on the front surface, it is preferable to provide an electromagnetic wave shielding layer on the back surface.

Further, as shown in FIG. 2, the electromagnetic wave shielding layer 4 may be embedded inside the core material 3. In particular,
What is necessary is just to sandwich the electromagnetic wave shielding layer 4 between the two core members 3. Also in this case, the reinforcing layer 5 provided on the front surface and the back surface of the core 3
It can be omitted.

The surface of the electromagnetic wave shielding layer which comes into contact with the core material (or the reinforcing layer) may be subjected to a roughening treatment in order to improve the adhesion with the core material (or the reinforcing layer). This roughening process is performed, for example, in an arithmetic average roughness (Ra) of 0.1 to 10
It is desirable that the thickness be about 0 μm.

When the reinforcing layer 5 is provided, the reinforcing layer is preferably made of a fiber base material and a resin. And, the resin constituting the reinforcing layer is preferably a thermosetting resin. This is because, 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 impaired. As the thermosetting resin, a phenol resin, a melamine resin, an epoxy resin, a polyimide resin, a urea resin, or the like can be used.

Incidentally, the thermosetting resin constituting the reinforcing layer is strongly chemically bonded to the core material, especially the organic fibrous material, and therefore, compared with the case where the reinforcing layer is provided on the surface of an inorganic substrate such as a gypsum board. Further, the adhesion between the reinforcing layer and the core material can be improved.

On the other hand, the use of inorganic fibers as the constituent material of the fiber base material is advantageous in that the strength is excellent and the coefficient of thermal expansion of the reinforcing layer is reduced. As the inorganic fiber, it is preferable to use glass fiber, rock wool, ceramic fiber glass fiber chopped strand mat, glass fiber roving cloth, glass fiber continuous strand mat, glass fiber paper and the like. This is because these are inexpensive and have excellent heat resistance and strength.

The fibrous base material may be a non-continuous fiber formed into a mat shape.
Cut into a mat (chopped strand mat), dispersed in water and combed into a sheet,
A continuous long fiber may be spirally laminated to form a mat, or a continuous long fiber may be woven.

The content of the thermosetting resin contained in the reinforcing layer is 20 to 150 parts by weight, more preferably 40 to 120 parts by weight, based on 100 parts by weight of the fiber base material. This is because if the content is too large, the weight becomes too heavy, and if the content is too small, there is no reinforcing effect, and by adjusting to the above range, sufficient rigidity and impact resistance can be obtained, and high fire resistance can be maintained. is there. Further, the thickness of the reinforcing layer is desirably 0.1 mm to 3.5 mm. By limiting to this range, sufficient rigidity and impact resistance can be obtained, and high workability can be maintained.

Further, 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 may be added to the reinforcing layer.

Further, when the reinforcing layer contains an elastic polymer, cracks do not occur from the nail as a starting point even when the nail is hit, and the elastic polymer secures a frictional force with the nail surface and holds the nail. Strength can be improved. As such a resin, a resin composition made of a thermosetting resin and an elastic polymer for imparting nail strength is desirable. For example, an elastic polymer emulsion is dispersed in an uncured thermosetting resin liquid. When such a resin is cured, the elastic polymer “sea” in the thermosetting resin matrix “sea”
Since the islands are dispersed, the strength of the resin is ensured and the toughness can be imparted.

The elastic polymer is a rubber-based latex,
Acrylic latex, acrylate latex or urethane latex is desirable. This is because these are dispersed in a liquid state in the uncured thermosetting resin liquid.Since both the thermosetting resin and the elastic polymer are liquid, it is easy to impregnate the porous substrate or the fibrous substrate. There are advantages. The rubber-based latex is preferably a nitrile-butadiene rubber (NBR) or a styrene-butadiene rubber (SBR). A phenol resin, a melamine resin, an epoxy resin, a polyimide resin, or the like is suitable for the thermosetting resin.

The weight ratio of the solid content of the thermosetting resin to 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, the holding power of the nail is reduced, and if the elastic polymer is too large, the resin strength is reduced,
This is because the holding power of the nail decreases.

Next, a method for producing the composite building material of the present invention will be described. First, the core material is manufactured as follows. Manufacturing Method 1 A core material is manufactured by drying and coagulating and hardening papermaking sludge (scum). When the reinforcing layer is provided, it may be formed simultaneously with the formation of the reinforcing layer.

Manufacturing Method 2 Papermaking sludge is fired at 300 ° C. or higher and lower than 800 ° C., or fired at 300 to 1500 ° C. and then rapidly cooled to produce an inorganic amorphous powder having an amorphous structure. This inorganic amorphous powder is hardened with a binder. As the binder, one composed of a thermosetting resin and / or an inorganic binder is used. As thermosetting resins, phenolic resins, melamine resins,
At least one resin selected from an epoxy resin and a urea resin is desirable. As the inorganic binder, at least one selected from the group consisting of sodium silicate, silica gel, and sirluminazole is desirable. Also, unfired papermaking sludge can be used as a binder. In the case where the amorphous powder is solidified with a binder and molded and a reinforcing layer is provided, the formation may be performed simultaneously with the formation of the reinforcing layer.

Production Method 3 An inorganic powder and an organic fibrous material comprising a polysaccharide are mixed by a dry method or a wet method. At the time of this mixing, a binder may be added as necessary. In addition, as explained earlier,
The use of unsintered papermaking sludge has the advantage of being easily wet-mixed because it itself acts as a binder and is water-containing. This mixture was conventionally formed into a sheet by a method known in the art, such as circular net making, fourdrinier forming, dewatering press molding, and extrusion molding, and then heated and dried.
Alternatively, the mixture is pressed by a roll while being conveyed by a conveyor to form a sheet-like molded body. Then, the sheet-shaped formed body is pressed while being heated, and formed into a plate-shaped building material. The heating temperature here is 80 to 160 ° C, and the pressure is 1 to 20 kgf.
/ Cm ² is recommended.

Incidentally, the term "pressing" means to maintain the pressure applied. Then, the fibrous material is oriented in a direction crossing the pressing direction by the pressure applied at the time of pressing, so that the bending strength of the core material can be improved. In addition, the pressurization removes moisture and suppresses the progress of crystallization, which is advantageous for forming an amorphous body.

The core material manufactured according to the above becomes a composite building material through the following steps. That is, in the case where a reinforcing layer is provided on the core material obtained above, a fiber reinforced material is impregnated with a resin, a heat treatment is performed at 25 to 70 ° C. and dried, and a reinforcing sheet is prepared. After laminating the core material molded into a piece, the body is pressed while heating. The heating temperature here is 80 to 150 ° C, and the pressure is 1 to 15 kgf / c.
and m ^2.

As a reinforcing sheet, a sheet obtained by impregnating a mat of inorganic fibers with a resin composition, drying and then curing a thermosetting resin by a hot press to form an adhesive is used. May be attached to a core material that has been formed in advance.

Further, the surface of glass fiber, rock wool or ceramic fiber is coated with a thermosetting resin such as phenol resin at another stage.
It is also possible to adopt a method in which a fiber base made of these fibers is laminated on a core material formed into a sheet shape and heated and pressed. In this method of coating the fiber surface with a thermosetting resin at another stage, the adhesion with the impregnated resin is improved,
Further, it is advantageous because the fibers can be easily bonded to each other and the impregnation ratio of the resin can be improved. As a method of such coating, a raw material melt of glass fiber, rock wool or ceramic fiber is discharged from a nozzle and fiberized by a blowing method or a centrifugal method. Simultaneously with the fiberization, a thermosetting resin such as a phenol resin is used. There is a technique of spraying a solution of When glass fiber, rock wool, or ceramic fiber is used as the constituent material of the fiber base material, it is preferable to coat a silane coupling agent.

Finally, an electromagnetic wave shielding layer is provided on at least one of the front and back surfaces of the thus obtained laminated material or the core material alone. The formation of the electromagnetic wave shielding layer varies depending on the material thereof. For example, one or two or more adhesives selected from phenol resin, epoxy resin, sisolcinol resin, melamine resin, urethane resin and vinyl acetate resin are applied to the electromagnetic wave shielding layer. A method of applying to a sheet (metal foil or composite sheet) and / or a surface on which an electromagnetic shielding layer is to be provided, and bonding the two to each other and curing the adhesive, or applying a mixture of a conductive filler and a resin. Method, and so on.

Incidentally, as a building material, it is also possible to apply a coating on the surface or to attach a decorative plate or a decorative veneer with an adhesive or the like. That is, the coating is performed by printing and spraying various pigments and inks. The decorative board has a three-layer decorative board consisting of a phenol resin-impregnated core layer, a melamine resin-impregnated pattern layer, and a melamine resin-impregnated overlay layer, a melamine resin-impregnated backer layer, a phenol resin-impregnated core layer, and a melanin resin-impregnated pattern. A decorative plate having a four-layer structure consisting of a layer and a melamine resin-impregnated overlay layer can be used. In particular, in the case of a decorative board having a phenolic resin-impregnated core layer as the core layer, the surface strength is significantly increased, so that it can be applied to flooring and the like. Furthermore, high quality wood such as cedar and cypress can be used as the decorative veneer.

[0078]

EXAMPLES (Example 1) Unfired papermaking sludge ("raw sludge" handled by Maruto Kiln Co., Ltd .: solid content 34% by weight, moisture 6)
(6% by weight) 3k while transporting 1512 g by conveyor
By applying a pressure of gf / cm ² , a sheet-shaped molded body having a thickness of 10 mm was obtained. The sheet-shaped molded body was dried by heating at 100 ° C. to obtain a plate-shaped cured body.

The cured product thus obtained was analyzed using an X-ray fluorescence spectrometer (RIX2100, manufactured by Rigaku), and it was found that it had the following composition in terms of oxide. In addition,
The pulp was calcined at 1100 ° C. and measured from the weight loss. Serial Pulp: 51.4 wt%, TiO _2: 1.0 wt% SiO _2: 24.2 wt%, SO _3: 0.5 wt% Al ₂ O _3: 14.0 wt%, P ₂ O _5: 0.2% by weight CaO: 8.0% by weight, Cl: 0.2% by weight MgO: 1.4% by weight, ZnO: 0.1% by weight Other: trace amount

Further, the side surface of the composite cured product was examined with an optical microscope (5
(0x), the fibers were oriented in a direction perpendicular to the pressing direction.

Next, 80% by weight of a commercially available phenol resin solution and 15% by weight of an elastic polymer latex emulsion solution (SBR latex solid content of 49%) were mixed at room temperature to give a liquid nail resistance. A resin composition was prepared. In addition, Nipol LX-436 manufactured by Zeon Corporation was used as the SBR latex. Then, a sheet-like glass fiber impregnated with a curing agent added to this resin composition (impregnation amount: 45% in terms of solid content) is dried at a temperature of 80 ° C. for 15 minutes to obtain a reinforcing sheet. Was.

On the other hand, a phenol resin was applied to the front and back surfaces of the cured product and dried at a temperature of 80 ° C. for 20 minutes. Then, after placing the reinforcing sheet on the front surface and the back surface of the cured body, a pressure of 7 kgf is applied at a temperature of 110 ° C.
/ Cm ² for 20 minutes to form a 10 mm thick core material having a 1 mm thick reinforcing layer on both sides.

Further, a thickness of 2 m was formed on the reinforcing layer on one side of the core material.
m were bonded with a vinyl acetate adhesive to produce a composite building material. The composite sheet was prepared by applying a composition obtained by kneading 20 parts by weight of a phenol resin and 300 parts by weight of copper powder to a polyethylene terephthalate (PET) film and heating it at 120 ° C. for 1 hour.
It was prepared by peeling the film.

Example 2 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 dried at 80 ° C. while stirring to obtain a paper sludge. The dried product was calcined at 780 ° C. for 5 hours and immediately exposed to room temperature to be rapidly cooled. Thereafter, the fired body was pulverized with a ball mill to obtain 248 g of an inorganic amorphous powder.

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

Next, the unfired papermaking sludge 15
12 g and the above-mentioned inorganic amorphous powder 248 g were kneaded, and a pressure of 3 kgf / cm ² was applied to the kneaded product while conveying the kneaded product to form a 10 mm thick sheet-like molded body. After laminating an aluminum foil having a thickness of 1 mm on the sheet-like molded body, the pressure was 40 kgf / cm ² and the temperature was 150 ° C.
After heating for one minute to integrate, a composite building material in which an aluminum layer was formed on both sides of the core material was manufactured.

The crystal structure of the core material was confirmed by X-ray diffraction. FIG. 3 shows a chart of the X-ray diffraction. For X-ray diffraction, use Rigaku MiniFlex,
Cu was targeted. A gentle undulation (halo) is observed around 2θ: 22 °, and a peak indicating a crystal structure is also observed, indicating that the crystal structure is mixed in the amorphous structure. From the peak, Gehlenite, M
CaCo ₃ (Calcite) besides elilite and Anorthite crystals
Crystals of Kaolinite and SiO ₂ were fixed. Ca
The content of Co ₃ was 9.8 in terms of the total weight of the core material.
% By weight.

Example 3 Basically the same as in Example 1 except that papermaking sludge (solid content 48% by weight, moisture 52
Water) to obtain a slurry having a solid content of 15% by weight, and 9000 kg of this slurry was formed into a sheet by a known sheeting method to obtain a sheet-shaped formed body having a thickness of 10 mm. Next, this sheet-shaped molded body was dried by heating at 100 ° C.
mm of a sheet-like molded body.

Example 4 Basically the same as in Example 2, except that 1800 parts by weight of unsintered papermaking sludge, 200 parts by weight of the above inorganic amorphous powder and 2300 parts by weight of water were mixed. 30 kgf by the dewatering press method
/ Cm ² (2.94MPa) pressure and 25m thickness
m plate-like body.

Comparative Example 1 A building material having the same structure as that of the composite building material of Example 1 was prepared except that a gypsum board having a thickness of 12 mm was used as a core material.

The composite building materials obtained in the above Examples and Comparative Examples were tested for bending strength, compressive strength, workability, and nailability. Table 1 shows the results. In the test method, the bending strength was measured in accordance with JIS A6901, and the compressive strength was measured in accordance with JIS A 5416. In the impact test, the depth of a dent formed by dropping a 530 g iron ball from a height of 1 m onto a composite building material was measured.

[0092]

[Table 1]

[0093]

As described above, the composite building material of the present invention is not only excellent in fire resistance and bending workability, but also has particularly high compressive strength and excellent impact resistance. The shield layer is not destroyed. Therefore, it is possible to provide a composite building material suitable for a wall material and a floor material such as a room where an OA device is installed or an intensive care unit of a hospital.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a cross section of a composite building material according to the present invention.

FIG. 2 is a schematic view showing a cross section of another composite building material of the present invention.

FIG. 3 is an X-ray diffraction chart of the inorganic amorphous powder of Example 2.

[Explanation of symbols]

 Reference Signs List 1 amorphous body 2 fibrous material 3 core material 4 electromagnetic wave shielding layer 5 reinforcing layer

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification FI FI Theme Court ゛ (Reference) // B32B 13/00 B32B 13/00 (72) Inventor Kenji Sato 1-1-1 Kita Ibigawa-cho, Ibi-gun, Gifu Prefecture In the Ogaki-Kita factory of Ibiden Co., Ltd. (72) Inventor Toshihiro Nomura 1-1, north of Ibigawa-cho, Ibi-gun, Gifu F-term in the Ogaki-Kita factory (reference) 2E162 CA31 CA35 CB22 CB23 CB24 CB25 CD09 EA11 EA18 FA14 FA19 FA20 FB02 FB03 FB07 FC00 FC01 FC02 FD04 FD06 FD08 4F100 AA01A AA18 AA19 AA20 AB17 AB33B AG00C AG00D AJ03A AK01B AK22G AK33 AK73 AR00B BA02 BA04 BA07 BA10C BA10D BA22A CA30B CB01 DE01A DG01A DG01C DG01D DG02 DH00C DH00D GB07 JA12A JD08 JD08B JG01B JJ07 JK01 JL01 JL03 4L055 AJ01 BE14 BG10 GA21 GA38

Claims (6)

[Claims] 1. A composite building material having an electromagnetic wave shielding layer formed on at least one surface of a core material, wherein the core material is
A composite building material comprising an inorganic amorphous body, wherein a fibrous material is mixed in the inorganic amorphous body. 2. A composite building material having an electromagnetic wave shielding layer formed on at least one surface of a core material, wherein the core material is
A composite building material obtained by molding a powder comprising an inorganic amorphous material via a binder. 3. A composite building material having an electromagnetic wave shielding layer formed on at least one surface of a core material, wherein the core material comprises:
A composite building material comprising a polysaccharide organic fibrous material. 4. The composite building material according to claim 1, wherein the fibrous material is oriented. 5. The method according to claim 1, wherein
A composite building material, wherein the electromagnetic wave shielding layer is a metal foil. 6. The method according to claim 1, wherein
A composite building material, wherein the electromagnetic wave shielding layer is a composite sheet comprising a conductive filler and a resin.