JP2000301651A - Composite building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve a strength and nailing properties by incorporating an inorganic noncrystalline material in a core material, and providing a fibrous material in the noncrystalline material. SOLUTION: A core material as a composite curable material 1 contains an inorganic noncrystalline material 2, and a fibrous material 3 is mixed within the material 2. The noncrystalline material is desirably formed of a noncrystalline material made of two or more types of oxides. In the material 1, the material 2 becomes a strength developing substance, and the material 3 improves a bending strength value and impact resistance. Its strength does not have an anisotropy to obtain a homogeneous cured material, and obtains a strength in a low density. As the oxide, a metal and/or a nonmetallic oxide can be used, and Al2O3, SiO2, CaO, Na2O, MgO, P2O5, SO3, K2O, TiO2, MnO, Fe2O3 and ZnO are desired. As the composite material of the oxide, Al2O3-SiO2- CaO or Al2O3-SiO2-CaO oxide is used.

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 can realize cost reduction without lowering performance than conventional ones and is useful for environmental protection. It is.

[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 disclosed in Japanese Patent Application Laid-Open No. 7-329236 has a problem that the strength is not sufficient because a prepreg and a gypsum board made of a thermoplastic resin are used. There was a problem that a nail or the like could not be hit and a crack would occur if the nail was forcibly hit.

An object of the present invention is to overcome the above-mentioned problems and to propose a composite building material having excellent strength and nailability.

[0005]

The gist of the present invention is as follows.
It is as follows. (1) In a composite building material in which a composite layer comprising a fiber base material and a resin is formed on at least one surface of a core material, the core material includes an inorganic amorphous material, and the inorganic amorphous material A composite building material having a fibrous material inside. In addition, the fibrous material in the core material may be oriented in a specific direction. This is because the orientation in a specific direction can improve the bending strength.

(2) A composite building material in which a composite layer comprising a fiber base material and a resin is formed on at least one surface of a core material, wherein the core material is an inorganic amorphous powder comprising an inorganic amorphous material. A composite building material characterized in that a body is formed via a bonding material.

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

(4) In any one of the above (1) to (3), the composite layer has a resin content of 20 to 200 parts by weight based on 100 parts by weight of the fiber base material. And composite building materials.

(5) A composite building material according to any one of (1) to (3) above, wherein the thickness of the composite layer is 0.1 to 3.5 mm.

(6) A composite building material according to any one of (1) to (3), wherein the specific gravity of the composite layer is 0.5 to 3.9.

(7) The composite building material according to any one of the above (1) to (3), wherein the composite layer contains an elastic polymer.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The structure of a composite hardened material constituting a first embodiment of a core material in a composite building material of the present invention is as follows.
FIG. 1 schematically shows this. The composite cured body 1 includes an inorganic amorphous body 2 and a fibrous material 3 in the inorganic amorphous body 2.
Is basically mixed. The inorganic amorphous body is not particularly limited, but is preferably an amorphous body composed of two or more oxides. 2 here
An amorphous body composed of at least one kind of oxide is an oxide (1) -oxide (2).
Is a natural number, oxide (1), oxide (2),...
The oxide (n) is an amorphous body of different oxides).

Although it is difficult to accurately define such an inorganic amorphous substance, it is considered that the inorganic amorphous substance is an amorphous compound formed by a solid solution or hydration reaction of two or more oxides. Can be 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 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.

The composite cured product 1 is made of an inorganic amorphous material 2
Becomes a strength-expressing substance, and since the fibrous material 3 is dispersed in the inorganic amorphous material 2 to improve the fracture toughness value, the bending strength value and the impact resistance can be improved. 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.

The reason why the amorphous body 2 serves as a strength-expressing substance is not clear, but is presumed to be because the progress of cracks is inhibited as compared with the 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 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.

As the above-mentioned oxide, metal and / or nonmetal oxide can be used, and Al ₂ O ₃ , SiO ₂ , C
aO, Na ₂ O, MgO, P ₂ O ₅ , SO ₃ , K ₂ O,
Desirably, it is selected from TiO ₂ , MnO, Fe ₂ O ₃ and ZnO. As the composite system of the above oxides, Al ₂ O ₃ —SiO ₂ —CaO system or Al ₂ O ₃
Composite -SiO ₂ -CaO- oxide amorphous material consisting based (Al ₂ O _3, 1 or more metals and / or oxides of metallic except SiO ₂ and CaO), or these amorphous form The body is optimal.

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 causing a solid solution or hydration reaction with a 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.

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 composite cured product 1 is represented by A
In terms of l ₂ O ₃ , SiO ₂ and CaO, the following composition is desirable. Al ₂ O _3: composite cured 3-51% by weight relative to the total weight of the body SiO _2: six to fifty-three wt% CaO with respect to the total weight of the composite hardened product: 8 to 63 of the total weight of the composite cured body % By weight However, the total of them does not exceed 100% by weight.

The reason is that the content of Al ₂ O ₃ is 3% by weight.
Less than or exceeds 51 wt%, the strength of the core material of the composite building material of the composite cured body 1 thus the present invention is reduced, also, the content of SiO ₂ is also beyond the or 53 wt% less than 6 wt%, The strength of the composite cured body 1 decreases. Even if the content of CaO is less than 8% by weight or exceeds 63% by weight, the strength of the composite cured product 1 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 composite cured body having high strength.

The composite cured product 1 is made of Al ₂ O ₃ , Si
As oxides other than O ₂ and CaO, Na ₂ O, Mg
O, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, F
When one or more of e ₂ O ₃ and ZnO are 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 1.2% by weight based on the total weight of the composite cured body MgO: 0.3 to 11.0% by weight based on the total weight of the composite cured body P ₂ O ₅ : Composite cured body 0.1 to 7.3 wt% SO relative to the total weight of _3: 0.1-3.5 wt% K ₂ O with respect to the total weight of the composite hardened product: 0 relative to the total weight of the composite hardened product .1～1.2 wt% TiO _2: from 0.1 to 8.7 wt% MnO, relative to the total weight of the composite hardened product: 0.1 to 1.5 wt% Fe with respect to the total weight of the composite cured body ₂ O ₃ : 0.2 to 17.8% by weight based on the total weight of the composite cured body ZnO: 0.1 to 1.8% by weight based on the total weight of the composite cured body The reason for limiting the range is that if the ratio is outside the above range, the strength of the composite cured body is reduced.

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 0.1 to 5 with respect to the total weight of the composite cured product 1.
It is desirably 0% by weight. 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, in the composite building material of the present invention, the composite hardened body 1 constituting the core material may have halogen in the inorganic amorphous body 2. The halogen serves as a catalyst for a solid solution or hydrate formation reaction and also acts as a combustion suppressing substance. The content of halogen is 0.1 to 1.2% by weight.
Is desirable. 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. This halogen includes chlorine, bromine,
Fluorine is preferred.

Similarly, in the composite building material of the present invention, the inorganic amorphous body 2 may have calcium carbonate (Calcite). Calcium carbonate itself is not a strength-expressing substance, but it is thought that by surrounding an inorganic amorphous body around calcium carbonate, it contributes to the improvement of strength by an action such as inhibiting the progress of cracks. The content of the calcium carbonate is desirably 48% by weight or less based on the total weight of the composite cured product 1. The reason is 48% by weight
This is because if the ratio exceeds the above, the bending strength decreases. Also, 0.
1% by weight or more is desirable. If the content is less than 0.1% by weight, it does not contribute to the improvement in strength.

Further, in the composite building material of the present invention, a binder may be contained in the composite cured body 1 constituting the core material.
It is advantageous for improving water resistance, chemical resistance and fire resistance. 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 body 2 in the composite building material of the present invention 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 polysaccharides have an OH group and are easily bonded to various compounds such as Al ₂ O ₃ , SiO ₂ or CaO which have formed an inorganic amorphous substance by hydrogen bonding. 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. By the way, pulp contains 10-30 lignins in addition to cellulose.
It contains about weight%. On the other hand, as inorganic fibrous materials, alumina whiskers, SiC whiskers, silica-alumina-based ceramic fibers, glass fibers,
At least one selected from carbon fibers and metal fibers can be used.

The content of the fibrous material is 2 to 75.
% By weight. The reason is that if the content is less than 2% by weight, the strength of the composite cured product 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 desirably 10 to 3000 μm. 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 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
At least one selected from oxides such as n, Fe and Zn, sols which are hydroxides or precursors thereof, or composites thereof, halogen and calcium carbonate
It is common to include seeds, and water. 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, fracture at the grain boundaries of limescale or crack propagation cannot be prevented, and the bending strength and the 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-
No. 15923 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 51
No. -30088 is a technique for forming a baked ash of pulp waste and a lightweight inorganic material, but the calcination conditions and the like are not described, and an amorphous ash cannot be obtained. JP 49
No. -2880 is a technique that focuses only on fibers in pulp waste, 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-8-246
No. 400 is a technology using wastepaper 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.

The composite hardened material 1 constituting the core material of the composite building material according to the second embodiment of the present invention is particularly limited similarly to the inorganic amorphous material 2 according to the first embodiment. Although not a thing, an inorganic amorphous powder having an inorganic amorphous body composed of at least two or more types of oxides is formed via a binder similar to the binder in the first embodiment. May be done. In general, an inorganic amorphous body has higher strength and toughness than a crystalline body, and by solidifying a powder having such an inorganic amorphous body with a binder, a composite hardened body having excellent compressive strength and bending strength, and thus a core. Material can be obtained. Since the amorphous body has a lower density than the crystalline body, a light core material can be obtained by solidifying the amorphous body with a binder.

It is preferable that the inorganic amorphous powder has an average particle diameter of 1 to 100 μm. This is because if the average particle size is too large or too small, a composite cured product 1 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.

The water content in the papermaking sludge is desirably 20 to 80% by weight as described above. 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.

Further, the composite hardened material 1 constituting the third embodiment of the core material in the composite building material of the present invention is shown in FIG.
As shown in FIG. 1, the composition contains an organic fibrous material 3 made of a polysaccharide, and specifically, a composite cured product composed of an organic fibrous material 3 made of a polysaccharide and an inorganic powder 4, This is a composite cured product in which the organic fibrous material 3 composed of a saccharide is mixed in 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.

The above-mentioned inorganic amorphous material can be used. As the inorganic powder 4, it is desirable to use powder of inorganic industrial waste, and for example, the above-mentioned papermaking sludge (scum) can be used. Further, as the inorganic powder 4, polished swarf of polished glass, crushed swarf of silica sand, or 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. It is desirable that the inorganic powder 4 has an average particle diameter of 1 to 100 μm. This is because if the average particle size is too large or too small, a composite cured product 1 having sufficient strength and toughness cannot be obtained.

The content of the inorganic powder is desirably from 10 to 90% by weight based on the weight of the composite cured product 1 as the core material. 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 above polysaccharide is used in an amount of 10 to 90% by weight based on the weight of the composite cured product 1 as the core material.
It is desirable that 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. The average length of the organic fibrous material comprising the polysaccharide is preferably from 10 to 1000 μm. If the average length is too short, entanglement does not occur, and if it is too long, inorganic powder and inorganic amorphous material cannot be mixed uniformly,
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 composite cured product 1 constituting 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. good.
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. In the example shown in FIG. 2, the inorganic amorphous body 2 functions as a binder.

In the composite building material of the present invention, as shown in FIG. 3, a reinforcing layer 6 which is a composite layer composed of a resin 6a and a fiber base material 6b is formed on at least one side of the core material 5, in the illustrated example, on both sides. The composite building material is characterized in that the composite hardened body 1 of any of the above-described first to third embodiments is applied to the core material 5. That is, even when a tensile force is applied to this composite building material by using the core material 5 as one of the above-described composite hardened bodies 1, the core material 5 itself is excellent in bending strength and does not easily break. It has a configuration. Further, even when pressure is locally applied to the surface, no dent or dent occurs.

Further, since the reinforcing layer 6 which is a composite layer is provided on the surface of the core material 5, it is possible to suppress the breakage of the stress concentration portion, further increase the bending strength value, and further improve the compressive strength. be able to.

Further, in the use of the composite building material of the present invention, a decorative layer such as a coating, a decorative panel, a decorative veneer, or the like may be provided on the reinforcing layer 6. The impact resistance is improved, and scratches such as dents are less likely to occur, and the decorative surface is not distorted by the scratches and the design is not reduced.

Resin 6a constituting reinforcing layer 6 which is a composite layer
It is desirable to use a thermosetting resin. 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. When the core material 5 contains an organic fibrous material, the thermosetting resin forming the reinforcing layer 6 and the organic fibrous material forming the core material 5 are chemically bonded. In addition, 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 an inorganic substrate such as a gypsum board.

The thermosetting resin used for the resin 6a includes a phenol resin, a melamine resin, an epoxy resin,
Polyimide resin, urea resin and the like are suitable. The content of the thermosetting resin in the reinforcing layer 6 is determined based on the fiber base material 100
It is desirable that the amount be in the range of 20 parts by weight to 200 parts by weight with respect to parts by weight. 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 the fiber base material 10
It is more preferable that the amount be in the range of 40 parts by weight to 120 parts by weight with respect to 0 parts by weight. If the content is large, the reinforcing layer 6 becomes heavy, and if the content is small, the reinforcing effect is reduced.

On the other hand, it is desirable to use inorganic fibers for the fiber base material 6b constituting the reinforcing layer 6. This is because inorganic fibers can improve the strength of the reinforcing layer 6 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 6b may be formed by molding non-continuous fibers into a mat shape or by forming continuous long fibers from 3 to 7c.
Cut into m to form a mat (so-called chopped strand mat), or dispersed in water to form a sheet, continuous long fibers are spirally laminated and formed into a mat, or even continuous It may be a woven long fiber.

Further, the thickness of the reinforcing layer 6 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 6 may contain 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 6 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 the reinforcing layer 6, a resin composition for imparting nail strength, which is made of 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. By curing such a resin, the elastic polymer “islands” are dispersed in the “sea” of the thermosetting resin matrix, and it is possible to secure the strength of the resin and to impart toughness. You can.

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 5 is manufactured as follows. First Manufacturing Method This corresponds to the first embodiment, and manufactures a composite hardened body 1 as a core material 5 by coagulating and hardening unfired papermaking sludge (scum). This coagulation hardening
The formation may be at the same time as the formation of the reinforcing layer 6 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. The inorganic amorphous powder is formed into a sheet by solidifying it with a binder. The binder used for this is desirably made of a thermosetting resin and / or an inorganic binder. As the thermosetting resin, a phenol resin,
At least one resin selected from melamine resin, epoxy resin and 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. In the case where the inorganic hardened powder is solidified with the binder to form the composite cured body 1 as the core material 5, the formation may be performed simultaneously with the formation of the reinforcing layer 6.

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 dehydration press method, a round sheet forming method, a fourdrinier forming method, an extrusion forming method or the like, and then dried or pressed by a roll while being conveyed by a conveyor to form a sheet. The sheet-shaped formed body is heated, dried and pressed while being pressed to form the core material 5. Heating temperature is 80-160 ° C, pressure is 1-20kgf / c
m 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, the composite building material is manufactured, for example, as follows. First, as described in the manufacturing method of the core material 5, 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. Alternatively, the mixture is formed into a sheet by the third manufacturing method to obtain a sheet-like molded body. On the other hand, a fiber base material impregnated with a resin is subjected to a heat treatment at 25 to 70 ° C. and dried to obtain a reinforcing sheet. Then, the sheet-shaped molded body and the reinforcing sheet are laminated and pressed together while heating to form a composite building material including the core material 5 and the reinforcing layer 6. It is appropriate that the heating temperature is 80 to 200 ° C. and the pressure is 1 to 20 kgf / cm ² . 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 6. A method of attaching the layer 6 to the core material 5 which has been cured in advance with an adhesive may be used.

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, a rock wool or a ceramic fiber is used as a constituent material of the above-mentioned fiber base material, a silane coupling agent is preferably coated. The composite building material thus obtained can be coated on the front and back surfaces, or can be applied with a decorative plate or a veneer veneer with an adhesive or the like. The coating is performed by printing and spraying various pigments, inks, and the like. The decorative board has a three-layer decorative board consisting of a phenolic resin-impregnated core layer, a melamine resin-impregnated pattern layer, and a melamine resin-impregnated overlay layer, a melamine resin-impregnated backer layer, a phenolic resin-impregnated core layer, and a melamine resin-impregnated pattern. A decorative board 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 materials and the like. And high quality wood such as cedar and cypress can be used as the decorative veneer.

[0068]

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.

When the thus obtained composite cured product was analyzed using a fluorescent X-ray analyzer (RIX2100, manufactured by Rigaku), 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, 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 composite cured product, and dried at a temperature of 80 ° C. for 20 minutes. Finally, the reinforcing sheet is superimposed on the front and back surfaces of the composite cured body, and the laminate is
Pressed at a temperature of 10 ° C. under a pressure of 7 kgf / cm ² for 20 minutes, a reinforcing layer 6 having a thickness of 1 mm on both sides, and a
Thus, a composite building material composed of a core material 5 having a thickness of 5 mm was obtained.

(Example 2) Unfired papermaking sludge ("raw sludge" handled by Maruto Kiln Co., Ltd .: solid content 34% by weight,
1512 parts by weight of water (66% by weight). Then
The papermaking sludge was dried at 80 ° C. with stirring, and the obtained dried body was calcined 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 parts by weight of an 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 above-described unfired papermaking sludge 1
512 parts by weight and 248 parts by weight of a calcined product (inorganic amorphous powder) are kneaded, and the obtained kneaded product is heated at 100 ° C. while applying a pressure of 3 kgf / cm ² while being conveyed by a conveyor. And dried to obtain a plate-shaped composite cured product having a thickness of 10 mm. The crystal structure of the obtained composite cured product was confirmed by X-ray diffraction. FIG. 4 shows a chart of the X-ray diffraction. This X-ray diffraction was performed by Rigaku Min.
Cu was targeted using iFlex. 2θ: 22
A gentle undulation (halo) is observed around °, and a peak indicating a crystal structure is also observed, which indicates that the crystal structure is mixed in the amorphous structure. From the peaks, Gehlenite, syn, Melilite-synthetic, Gehlenite-
synthetic, Anorthite, ordered, CaCO ₃ (Calcit
e), Kaolinite and SiO ₂ were identified.

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.

Finally, the reinforcing sheet was superimposed on the front and back surfaces of the composite cured product, and the laminate was pressed at a temperature of 110 ° C. under a pressure of 7 kgf / cm ² for 20 minutes.
A composite building material comprising a reinforcing layer 6 having a thickness of 1 mm on both sides and a core material 5 having a thickness of 10 mm was obtained.

Example 3 Basically the same as Example 1, except that 1800 parts by weight of unfired papermaking sludge, 248 parts by weight of a fired product of the papermaking sludge, and 5500 parts by weight of water were kneaded. The obtained slurry is pressurized at a pressure of 50 kgf / cm ² (4.9 MPa) by a dehydration press method to form a 15 mm-thick sheet-shaped molded body, and the sheet-shaped molded body is heated at 100 ° C. It was dried to obtain a plate-shaped composite cured product.

(Example 4) Basically the same as Example 2, except that 1600 parts by weight of unfired papermaking sludge and a fired product of the papermaking sludge (including inorganic amorphous and inorganic crystalline) 248 Parts by weight and 5000 parts by weight of water are kneaded to prepare a slurry, and the obtained slurry is molded by pressurizing at a pressure of 75 kgf / cm ² (7.35 MPa) by a dehydration press method. By heating and drying at a temperature of ° C, a composite cured body having a thickness of 20 mm was obtained.

(Comparative Example 1) A reinforcing layer similar to that of Examples 1 and 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 composite cured body. .

The composite building materials obtained in the above Examples and Comparative Examples were tested for flexural strength, compressive strength, workability and nailability. Table 1 shows the results.
The test method was a method in which the flexural strength was specified in JIS A6901, and the compressive strength was in accordance with JIS A 5416.
The method was stipulated according to the method specified in the above. The nailing property was determined by hitting a nail having a diameter of 4 mm and a length of 50 mm to check for cracks.

[0081]

[Table 1]

[0082]

As described above, according to the composite building material of the present invention, the building material is excellent in productivity, bending strength and compressive strength, and is capable of driving nails without cracks. Can be provided at a low cost.

It should be noted that the present invention is not limited to the configuration of the above 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 composite cured product.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of an example of a composite cured body constituting a core material of a composite building material of the present invention.

FIG. 2 is a schematic cross-sectional view of another example of a composite cured body constituting a core material of the composite building material of the present invention.

FIG. 3 is a schematic sectional view of the composite building material of the present invention.

FIG. 4 is an X-ray diffraction chart of the composite cured product of Example 2.

[Explanation of symbols]

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

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C08L 3/00 C08L 3/00 5/00 5/00 97/02 97/02 101/00 101/00 D21J 1/00 D21J 1/00 E04B 1/94 E04B 1/94 U (72) Inventor Kenji Sato 1- 1 north of Ibigawa-cho, Ibi-gun, Gifu Prefecture Ibiden Ogaki-Kita Plant (72) Inventor Toshihiro Nomura Gifu Prefecture 1- 1 north of Ibigawa-machi, Ibi-gun Ibiden Ogaki-Kita factory

Claims (7)

[Claims] 1. A composite building material in which a composite layer composed of a fiber base material and a resin is formed on at least one surface of a core material, wherein the core material contains an inorganic amorphous material and an inorganic amorphous material. A composite building material comprising a fibrous material in a body. 2. A composite building material in which a composite layer composed of a fiber base material and a resin is formed on at least one surface of a core material, wherein the core material is an inorganic amorphous powder composed of an inorganic amorphous material. A composite building material characterized by being molded through a binder. 3. A composite building material in which a composite layer composed of a fiber base material and a resin is formed on at least one surface of the core material, wherein the core material contains an organic fibrous material composed of a polysaccharide. And composite building materials. 4. The composite layer according to claim 1, wherein the content of the resin is 20 to 200 parts by weight with respect to 100 parts by weight of the fiber base material. Or a composite building material as described. 5. The thickness of the composite layer is 0.1 to 3.5 m.
The composite building material according to any one of claims 1 to 3, wherein m is m. 6. The composite building material according to claim 1, wherein the specific gravity of the composite layer is 0.5 to 3.9. 7. The composite building material according to claim 1, wherein the composite layer contains an elastic polymer.