JP2001019508A - Cement-based burned board-like construction material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain the subject construction material with improved impact resistance. SOLUTION: This cement-based burned board-like construction material is obtained by incorporating 0.5-5 wt.% of ceramic and/or mineral inorganic fibers in 100 wt.% of a compound comprising 5-40 wt.% of portland cement, 5-30 wt.% of glass powder and the rest of refractory aggregate based on silica- alumina refractory material followed by conducting a kneading and then extrusion molding into a continuous board form, which is then burned. Another version of this construction material is obtained by laminating the reverse face of such a construction material 1 as produced above with a glass fiber sheet 2 through a thermosetting phenolic resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cement-based fired plate-like building material having excellent weather resistance and durability.

[0002]

2. Description of the Related Art Plate-like building materials used for interior and exterior materials of buildings, exteriors, interior materials of tunnels, and the like are required to have appearance, weather resistance, impact resistance, fire resistance, simplification of construction, and the like.

[0003] The material of this kind of plate-like building material is a cement-based or metal plate. However, cement-based products generally have poor durability due to unfired products. Although the metal plate has excellent impact resistance due to its flexibility, it has a problem of oxidative deterioration. Also,
The surface coloring of both cement-based and metal plates is resin coating, and is inferior in weather resistance.

[0004] Therefore, the present applicant has previously proposed a cement-based calcined plate-like building material (Japanese Patent Laid-Open No. 8-133825). This material is a fired product and has excellent durability. The surface color has no problem in weather resistance due to the color tone of the material itself or coloring by glaze.

[0005]

When the cement-based fired plate-like building material is damaged by the impact of a flying object or the like, it scatters or falls off, causing a serious accident. The above-mentioned fired plate proposed by the present applicant is excellent in impact resistance as compared with a fired plate of a conventional material, but it is by no means satisfactory. An object of the present invention is to obtain a cement-based fired plate-like building material having improved impact resistance.

[0006]

The cement-based calcined plate-like building material of the present invention comprises a refractory aggregate mainly composed of portland cement 5 to 40 wt%, glass powder 5 to 30 wt%, and a balance of silica-alumina refractory raw material. The composition is characterized in that 0.5 to 5% of inorganic fibers of ceramic and / or mineral substances are added to 100% by weight of the mixture, kneaded, extruded into a long plate shape, and then fired.

[0007] It is a known technique to add an inorganic fiber for imparting strength to the inorganic molded article. The present invention further enhances the effect of imparting strength by the addition of the inorganic fibers, particularly the effect of improving the impact resistance required for a cement-based fired plate-like building material.

[0008] In the case of a fired plate-like building material, the volume of the inorganic fiber added to the material is reduced by melting or partial disappearance due to the high temperature during the firing of the building material, and the fiber sufficiently exerts the traction support force of the building material structure. It may not have been done.

[0009] The fired plate-like building material according to the present invention is characterized in that glass powder is 5 to 3 times.
0 wt%. The glass component softens or melts in a relatively low temperature range of about 1000 ° C. or lower, and forms a glass film around fibers inherent in the building material structure. Then, this glass film acts to prevent the fiber component from escaping and to support the fusion bonding of the fibers.

[0010] The fired plate-like building material obtained according to the present invention has remarkably improved impact resistance, which is presumed to be due to the above-mentioned action of the glass powder.

[0011] For example, clay, silica and the like chemically contain SiO ₂ which is a main component of glass. However, because the SiO ₂ here is stabilized as a mineral composition linked to other components, the effect of the present invention by the glass powder cannot be obtained.

[0012] When a glass fiber sheet is attached to the back surface of the fired plate-like building material with a synthetic resin adhesive, the effect of imparting strength such as impact resistance is further improved.

[0013] When a glass fiber sheet is attached to the back surface of a building material, when the building material having poor heat insulating properties receives a high temperature at the time of fire, the adhesive to which the glass fiber sheet is attached generates gas or ignites. In addition, when the function of the adhesive is reduced by the high temperature, the effect of imparting strength by the glass fiber sheet is impaired.

[0014] In the present invention, the addition of the inorganic fiber added during the production of the fired plate-like building material forms fine voids in the structure of the fired plate-like building material, and improves the heat insulating property of the building material itself. Also,
The use of a thermosetting phenolic resin as the adhesive for attaching the glass fiber sheet, in particular, produces less gas and has excellent heat resistance, and the heat resistance is more excellent, in combination with the heat insulating effect of the building material body by the addition of the inorganic fiber described above. It will be.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION Portland cement used in the production of the main body of fired slab-like building materials includes early-strength cement, ultra-high-strength cement, ordinary cement and the like. From the viewpoint of workability and economy, ordinary cement is preferred.

[0016] If the proportion of Portland cement in the composition of the main body of the fired plate-like building material is less than 5 wt%, the shrinkage during firing is large and the dimensional accuracy is poor. On the other hand, if it exceeds 40% by weight, the strength is poor and there is a problem in durability.

Specific examples of the glass powder include borate glass, borosilicate glass, silicate glass, phosphate glass, soda glass, and the like. In order to make the particle size more remarkable than fusion with inorganic fibers, the particle size is preferably 0.5 mm or less.
More preferably, it is 0.3 mm or less. Any particle size can be obtained from commercial products.

If the proportion of the glass powder is less than 5 wt%, the impact resistance of the present invention cannot be obtained, and if it exceeds 30 wt%, excessive sintering occurs and the impact resistance is also poor in this case.

Specific examples of the silica-alumina-based refractory raw material include chamotte, pyroxene or brick waste mainly composed of these.
Ceramic debris. The ratio of the silica-alumina-based refractory raw material is automatically determined according to the increase and decrease of the glass powder and the Portland cement, but is preferably 30 to 90% by weight.

As the refractory aggregate, besides the silica-alumina refractory raw material, clay, silica stone, silica sand, feldspar and the like can be used in combination as long as the effects of the present invention are not impaired.

The inorganic fibers are ceramic fibers such as siliceous, alumina, alumina-silica, and vitreous, or mineral fibers such as rock wool, asbestos, and sepiolite. The proportion of the inorganic fibers is an outer ratio to the blend of 100 wt%, and if it is less than 0.5 wt%, the effects of the present invention in the impact resistance and heat resistance cannot be obtained. If the content exceeds 5 wt%, the hardness of the kneaded material increases during kneading of the fired plate-like building material composition, and the workability during molding decreases.

[0022] The production of fired plate-like building materials is based on the above-mentioned compounds and additives, as well as CMC (carboxymethyl cellulose),
A synthetic or natural binder such as MC (methylcellulose), PVA (polyvinyl alcohol), dextrin, resin and the like is added, kneaded, and then extruded, cured, dried and calcined with a roller hearth kiln, etc. as usual. .

In the extrusion molding, it is preferable to provide continuous hollow holes in the length direction of the fired plate-like building material in order to reduce the weight and heat insulation of the fired plate-like building material. The firing temperature is 1000 ~
1200 ° C. is preferred.

[0024] The fired plate-like building material is generally glazed for aesthetics and weather resistance. The fired plate-like building material obtained in the present invention is also preferably glazed. For glazing,
A glaze is applied to the surface of the fired plate-like building material by a spray method, a flow coater method, or the like to the building material before firing. When the building material is fired, the above glaze is vitrified and glazed.

When the glass fiber sheet is attached to the back of the fired plate-like building material, the glass fiber sheet is a glass cloth such as a glass nonwoven fabric, a glass woven cloth, a glass braided cloth, or a glass roving.

FIG. 1 schematically shows a cross section perpendicular to the longitudinal direction of a fired plate-like building material according to the present invention. In the figure, a glass fiber sheet (2) is attached to the back surface of a fired plate-like building material (1) with an adhesive. The fired plate-shaped building material (1) is provided with continuous hollow holes (3) in the length direction.

[0027] The adhesive used for attaching the glass fiber sheet is preferably a thermosetting phenol resin having a small curing shrinkage and excellent heat resistance.

When a polyester resin or an epoxy resin is used as the adhesive, for example, the shrinkage at the time of bonding and curing is large, and the baked plate-like building material is warped to deteriorate the dimensional accuracy. A
Adhesives such as BS resin, silicone resin, urethane resin
Although the shrinkage at the time of bonding is relatively small, the elasticity (elongation) of the material itself is high, so strength cannot be imparted to the base material due to rigidity, which prevents scattering and falling off at the time of impact, but the safety of the product itself Insufficient for improvement.

Further, unlike the thermosetting phenol resin, this kind of resin generates gas at the time of heating and may cause a secondary disaster at the time of fire, and is therefore unsuitable from the viewpoint of fire protection.

[0030] The method of attaching the glass fiber sheet includes cloth,
The hand lay-up method is preferable for a mat, and the spray-up method is preferable for roving. Drying after pasting is passed through a drying oven using infrared rays, a hot air generator, etc. as a heat source for the required time,
The adhesive is thermally cured.

The coating amount of the adhesive, 200~650g / m ² in the configuration of the building material is semi-incombustible certification, in the case of configuration as a noncombustible certified 200~450g / m ² preferred.

[0032]

EXAMPLES Examples of the present invention and comparative examples will be described below. Table 1 shows the composition of the fired plate-like building material in each example and the test results. In each case, MC was added as a binder to the formulations in the same table at 2 wt% (outer coating for 100 wt% of refractory aggregate) and 15 wt% of water (outer coating for the entire formulation including the binder), and was then kneaded with a kneader-ruder. After kneading, it was formed into a hollow long plate having a length of 2,000 × a width of 300 × a thickness of 20 mm by a vacuum extrusion molding machine.

Next, after curing, heating and drying were performed at 120 ° C. × 12 hours, and further, rapid baking was performed at 1100 ° C. × 3 hours using a roller hearth kiln. The test method is as follows.

Bending strength: Measured in accordance with JIS-A1408 "Method of bending test for building boards". Impact resistance: Measured according to JIS-A1421 "Method of impact test for building boards". Dimensional accuracy: The firing shrinkage was measured.

[0035]

【table 1】

As shown in the test results in the table, the plate-like building materials obtained according to the examples of the present invention are excellent in both bending strength and impact resistance.

On the other hand, a comparative example in which no glass powder was added
1 is inferior in bending strength and impact resistance. Comparative Example 2 in which glass powder was added but the amount of addition exceeded the range of the present invention was inferior in dimensional accuracy and impact resistance. Comparative Example 3 was obtained by adding clay instead of glass powder, and was particularly poor in impact resistance. In Comparative Example 4, the proportion of Portland cement was large,
Poor bending strength and impact resistance.

[0038] In the examples, glass fibers and rock wool were used as the inorganic fibers to be added to the fired plate-like building material, but similar effects were obtained by using other inorganic fibers.

Table 2 shows a test in the case where a glass fiber sheet was attached to the back surface. A glass fiber sheet having a thickness of 1 mm made of a glass fiber non-woven fabric was adhered to the back surface of the fired plate-shaped building material by a hand lay-up method on the back surface of the fired plate-shaped building material obtained in Example 2 shown in Table 1, and the temperature was 100 ° C × A heat-curing treatment for one hour was performed.

In Test Example 1, a glass fiber sheet was attached with a thermosetting phenol resin as an adhesive. On the other hand, test examples
In 2, a glass fiber sheet was attached using a polyester resin as an adhesive. In Test Example 3, a glass fiber sheet was attached using a silicone resin as an adhesive.

Bending strength and impact resistance: The test was performed under the same conditions as in the test method shown in the above examples. Warpage: Measured with a warpage measuring device. Nonflammability test: In accordance with the test method specified in Ministry of Construction Notification No. 1828. 〇… Pass, ×… Fail

[0042]

[Table 2]

In Test Example 1, a glass fiber sheet was attached,
The fired plate-like building material is further improved in bending strength and impact strength, and has small warpage. In the evaluation test relating to noncombustibility, the glass fiber sheet was slightly changed in color, and no smoke, ignition or peeling was observed.

On the other hand, in Test Example 2, the fired plate-like building material was greatly warped due to shrinkage due to curing of the adhesive, and the dimensional accuracy was impaired. In addition, in the evaluation test relating to noncombustibility, ignition and smoking were observed in the adhesive, and the glass fiber sheet was peeled off.

In Test Example 3 in which a silicone resin was used as the adhesive, the impact resistance was insufficient, and the impact resistance test did not result in dropping, but no remarkable effect was obtained in the impact resistance. , Cracks occurred on the surface. In the evaluation test for nonflammability, heat generation was large, and smoke and peeling of the glass fiber sheet were observed.

[0046]

As described above, the calcined plate-like building material produced by the method of the present invention is excellent in dimensional accuracy and impact resistance required for a large calcined plate-like building material. Also,
When the glass fiber sheet is stuck on the back surface, the reinforcing effect of the glass fiber sheet can be further improved by selectively using a thermosetting phenol resin for the sticking.

[Brief description of the drawings]

FIG. 1 schematically shows a cross section perpendicular to the length direction of a fired plate-like building material according to the present invention.

[Explanation of symbols]

 1 Fired plate-like building material 2 Glass fiber sheet 3 Continuous hollow hole

Claims (4)

[Claims] [Claim 1] 5 to 40% by weight of Portland cement, 5 to 30% by weight of glass powder, and 100% by weight of a mixture of a refractory aggregate mainly composed of a silica-alumina refractory raw material and 100% by weight of a ceramic and / or mineral substance After adding 0.5 to 5% of inorganic fiber and kneading, it is extruded and formed into a long plate shape,
Next, a cement-based fired plate-like building material manufactured by firing. 2. The cement-based calcined plate-like building material according to claim 1, wherein the particle size of the glass powder is 0.5 mm or less. 3. The sintering temperature is 1000 to 1200 ° C.
Or a cement-based calcined plate-like building material according to 2. 4. A cement-based fired plate-like building material produced by sticking a glass fiber sheet to a back surface of the cement-based fired plate-shaped building material according to claim 1, 2 or 3 with a thermosetting phenol resin.