JP2001038847A - Inorganic plate and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inorg. plate having lightweight properties and non- combustibility and excellent in the holding force of a wood screw or nail. SOLUTION: As a core layer, 15 wt.% or more of wooden fibers are added to inorg. foam and, in such a state that the surface of the inorg. foam is covered with wooden fibers, the wooden fibers are mutually bonded by a binder. When a wood screw or nail is driven in the core layer having this structure, the material of the core layer is moved to absorb the driving force of the wood screw or nail and, therefore, an inorg. plate is hard to generate internal fracture and the holding force of the wood screw or nail by the inorg. plate is enhanced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic plate which is lightweight and non-combustible and has excellent holding power for wood screws and nails, and a method for producing the inorganic plate.

[0002]

2. Description of the Related Art As a lightweight noncombustible inorganic plate, a paper-forming mat is formed by forming a slurry containing mineral fibers, an inorganic powder and a binder, and an inorganic foam, a fibrous material is formed on the paper-forming mat. A core layer raw material mixture containing a substance and a binder to form a core layer mat, and a slurry containing mineral fibers, an inorganic powder and a binder to form a papermaking mat; Is laminated on the core layer mat,
A product manufactured by hot-pressing the obtained laminate is provided. (JP-A-5-50417) In the above inorganic plate, the core layer contains 5% by weight of pulp as a fibrous material for reinforcement.

[0003]

However, the above-mentioned inorganic plate has a problem in that the holding force against wood screws and nails is weak.

[0004]

According to the present invention, there is provided a core layer containing an inorganic foam, a wood fiber material and a binder, and one or both sides of the core layer. And a surface layer containing an inorganic filler, an inorganic filler and a binder.
An object of the present invention is to provide an inorganic plate containing 0% by weight or more. Step 1 of forming a papermaking mat by papermaking a slurry containing inorganic fibers, an inorganic filler and a binder, wherein the inorganic plate contains an inorganic foam, a wood fiber material and a binder on the papermaking mat Forming a core layer mat by spraying the core layer raw material mixture to be formed, forming a papermaking mat by forming a slurry containing inorganic fibers, an inorganic filler and a binder, Step 3 of laminating on a mat, Step 1,
Step 4 of hot-pressing the laminate produced by Steps 2 and 3, a method comprising the above steps 1, 2, 3, and 4, or a core layer raw material mixture containing an inorganic foam, a wood fiber material, and a binder Is dispersed on a substrate to form a core layer mat, a slurry containing inorganic fibers, an inorganic filler, and a binder is formed to form a paper-forming mat. Step 3 of laminating on one or both sides of the formed core layer mat, Step 4 of hot-pressing the laminate produced by Steps 1, 2, and 3, Steps 1, 2, 3, and 4 above
It is manufactured by a method consisting of

The present invention will be described in detail below. Examples of the inorganic foam used in the core layer of the present invention include perlite, shirasu balloon, silica flower, glass balloon, and the like, and two or more kinds of the inorganic foam may be mixed.
The inorganic foam is intended to reduce the weight of the product while maintaining the strength of the product, and usually contains 40 to 90% by weight in the core layer.

As the wood fiber material used in the core layer of the present invention, wood pulp, wood fiber bundles, wood chips, wood wool and the like are used, and the wood fiber material has an elongated shape such as wood pulp fiber. Things are desirable. The wood fiber materials may be used in combination of two or more. The wood fiber material imparts strength to the product and improves the holding force against wood screws, nails, and the like. Therefore, the wood fiber material is contained in the core layer in an amount of 10% by weight or more, preferably 10% by weight to 50% by weight. More preferably, it is contained in an amount of 15% by weight or more and 35% by weight or less.
If the amount of the wood fiber material is less than 10% by weight, the strength of the product and the holding force against wood screws, nails and the like become insufficient,
On the other hand, if it exceeds 50% by weight, the non-combustibility may not be sufficient and a springback phenomenon in which the shape returns after hot pressing may occur.

The binder used in the core layer of the present invention may be a synthetic resin such as urethane resin, melamine resin, thermosetting acrylic resin, urea resin, phenol resin, epoxy resin, thermosetting polyester, or urethane resin. Resin prepolymer, epoxy resin prepolymer, melamine resin prepolymer, urea resin prepolymer, phenol resin prepolymer, diallyl phthalate prepolymer, acrylic oligomer, polyvalent isocyanate, methacrylic ester monomer, diallyl phthalate monomer, prepolymer, oligomer, There are synthetic resin precursors such as monomers and carbohydrate resins such as starch, and two or more kinds of the binders may be mixed. A preferred binder is a powdered phenolic resin. The binder binds the inorganic foam and the wood fiber material to each other to maintain the formed shape, and usually contains 5 to 25% by weight in the core layer.

The inorganic fibers used in the surface layer of the present invention include rock wool, slag wool, glass fibers, ceramic fibers, metal fibers, and the like, and two or more of these inorganic fibers may be mixed. The inorganic fibers reinforce the surface layer without impairing the noncombustibility, and the preferred amount is usually 35 to 65% by weight in the surface layer.

The inorganic filler used in the surface layer of the present invention includes calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide. , Titanium oxide, iron oxide, zinc oxide, alumina, silica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos, mica, glass fiber, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder , Stone powder, blast furnace slag, fly ash, cement, zirconia powder, etc., and two or more kinds of the inorganic fillers may be mixed. The inorganic filler constitutes the main component of the surface layer and at the same time imparts hardness and noncombustibility to the surface layer. The inorganic filler is usually contained in the surface layer in an amount of 15 to 75% by weight. In the present invention, a water repellent, a preservative, a pigment, a dye and the like may be added to the core layer and / or the surface layer other than the above-mentioned raw materials.

In the inorganic plate of the present invention, the core layer is manufactured by a dry method in order to secure cushioning properties.
The surface layer is manufactured by a papermaking method in order to obtain compactness.

In the method for producing an inorganic plate of the present invention,
First, a surface layer raw material mixture mainly composed of the inorganic fibers, the inorganic filler, and the binder is dispersed in water to have a solid content of usually 2%.
A slurry of up to 5% by weight is adjusted, and the slurry is formed by a paper machine such as a fourdrinier machine, a round mesh machine, a Hasheck machine, etc. to form a paper mat. The thickness of the papermaking mat is usually about 3 to 5 mm. Next, a core layer raw material mixture containing the inorganic foam, the wood fiber material, and the binder is sprayed on the papermaking mat to form a core layer mat having a thickness of usually 15 to 20 mm. in this case,
If water is allowed to adhere to the surface of the inorganic foam prior to mixing, the wood fiber substance is likely to adhere to the surface of the inorganic foam, and the mixing is performed uniformly. Finally, a papermaking mat formed in the same manner as above is laminated on the core layer mat, and the laminate is hot-pressed. The condition of the heating press is usually 1 temperature.
70-200 ° C., press pressure 20-40 kgf / cm ² , press time 10-40 minutes.

[0012] Instead of the above-mentioned production method, the above-mentioned core layer raw material mixture is sprayed on a substrate such as a template or a transport plate to form a core layer mat, and the above-mentioned papermaking mat is laminated on one or both sides of the core layer mat. And hot pressing may be employed. The molded product produced by the above method is dried or trimmed if necessary to obtain an inorganic plate product. In the present invention, an inorganic plate having a two-layer structure including only a surface layer and a core layer is also a target.

[0013]

In the inorganic board of the present invention, since the core layer contains 10% by weight or more of wood fiber material, the surface of the inorganic foam is wrapped with wood fiber material, and the wood fiber material is connected to each other. The adhesive binds. Accordingly, the inorganic foam or wood fiber material can be slightly displaced in the core layer, and when a wood screw or nail is driven in, the inorganic foam or wood fiber material is displaced by the wood screw or nail, and the wood fiber is removed. It holds wood screws and nails driven in by the elastic restoring force of the fiber material. Further, when a pulling force is applied to the wood screw or nail, the inorganic foam or wood fiber material around the wood screw or nail slightly moves to absorb the pulling force. In this way, the inorganic plate of the present invention has a large holding force against wood screws and nails. If the amount of wood fiber material is less than 10% by weight,
The proportion of the inorganic foams directly bound by the binder increases, and when a wood screw or nail is driven into the core layer, structural damage occurs in the core layer, and a sufficient holding force for the wood screw or nail is secured. Disappears.

[0014]

[Examples 1 to 9] The raw material mixture of the front and back layers shown in Table 1 was dispersed in water to obtain a slurry having a solid content of 4% by weight, and the slurry was formed by a fourdrinier machine. A 3 mm thick papermaking mat is formed. In order to prepare the core layer raw material mixture shown in Table 1, first, water was adhered to the surface of a shirasu balloon, wood pulp fibers were added, and the mixture was mixed with a mixing device such as an Erich mixer, and then powdered. Add phenolic resin. The core layer raw material mixture is sprayed on a substrate to form a core layer mat having a thickness of 16 mm. The core layer mat is laminated on the papermaking mat, and the papermaking mat is further laminated on the core layer mat to form a laminate having a three-layer structure with a thickness ratio of the surface layer: the core layer: the back layer of 3: 16: 3. Form. The laminate was heated at a temperature of 185 ° C. and a pressure of 30 kgf / cm ² for 30 minutes.
Heat press for minutes. The thickness ratio of the surface layer: the core layer: the back layer of the inorganic plate thus obtained was 4: 10: 4. Table 1 shows the physical properties of the inorganic plate.

[0015]

[Table 1]

[0016]

Comparative Example Using the raw materials shown in Table 2, an inorganic plate was produced in the same manner as in the example. Table 2 shows the physical properties of the obtained inorganic plate.
Shown in

[0017]

[Table 2]

Referring to Tables 1 and 2, in Comparative Example 1 in which the core layer contains wood pulp fiber in an amount of 10% by weight or less, the screw retaining force is significantly reduced as compared with the inorganic plate of the example. . In Comparative Example 2 containing wood pulp fiber in an amount exceeding 50% by weight, a springback phenomenon occurs after hot pressing.

[0019]

According to the present invention, an inorganic plate which is lightweight and non-combustible and has excellent holding power for wood screws and nails can be obtained. The inorganic plate is very useful as an architectural base material for roofs, walls and the like.

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[Procedure amendment]

[Submission date] March 29, 2000 (2003.
9)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0004

[Correction method] Change

[Correction contents]

[0004]

According to the present invention, there is provided a core layer containing an inorganic foam, a wood fiber material and a binder, and one or both sides of the core layer. made from a surface layer containing an inorganic fiber and an inorganic filler and a binder and laminated on, the wood fiber material in said core layer 1
The present invention provides an inorganic plate containing 5 % by weight or more. Step 1 of forming a papermaking mat by papermaking a slurry containing inorganic fibers, an inorganic filler and a binder, wherein the inorganic plate is made of an inorganic foam and wood fiber material having water adhered to the surface of the papermaking mat Step 2 of forming a core layer mat by spraying a core layer raw material mixture containing a binder and a binder, forming a slurry containing inorganic fibers, an inorganic filler and a binder to form a papermaking mat, Step 3 of laminating the papermaking mat on the core layer mat, Step 4 of hot-pressing the laminate produced in Steps 1, 2, and 3, a method comprising the above steps 1, 2, 3, and 4, or water. Of forming a core layer mat by spraying a core layer raw material mixture containing an inorganic foam, a wood fiber substance, and a binder onto which a binder is attached , forming an inorganic fiber, an inorganic filler, and a binder. Forming a papermaking mat by papermaking a slurry containing Step 3 of laminating the papermaking mat on one or both sides of the core layer mat formed in Step 1, Step 4 of hot-pressing the laminate produced by Steps 1, 2, and 3, and Steps 1, 2, 3, and 4 above It is manufactured by a method consisting of

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0006

[Correction method] Change

[Correction contents]

As the wood fiber material used in the core layer of the present invention, wood pulp, wood fiber bundles, wood chips, wood wool and the like are used, and the wood fiber material has an elongated shape such as wood pulp fiber. Things are desirable. The wood fiber materials may be used in combination of two or more. The wood fiber material imparts strength to the product and improves the holding power against wood screws, nails and the like. For this purpose, the wood fiber material is contained in the core layer in an amount of 15 % by weight or more, preferably 15 % by weight or more and 50% by weight or less. More preferably, it is contained in an amount of 15% by weight or more and 35% by weight or less.
If the addition amount of the wood fiber material is less than 15 % by weight, the strength of the product and the holding force against wood screws, nails and the like become insufficient,
On the other hand, if it exceeds 50% by weight, the non-combustibility may not be sufficient and a springback phenomenon in which the shape returns after hot pressing may occur.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0013

[Correction method] Change

[Correction contents]

[0013]

In the inorganic board of the present invention, viewed it contains 15 wt% or more of wood fiber material in the core layer, and the water in the inorganic foam surface
Since allowed to adhere to, a state in which adhered to the inorganic foam surface is wood fiber material wrapped, the binder is deposited forming the the wood-fiber material together. Accordingly, the inorganic foam or wood fiber material can be slightly displaced in the core layer, and when a wood screw or nail is driven in, the inorganic foam or wood fiber material is displaced by the wood screw or nail, and the wood fiber is removed. It holds wood screws and nails driven in by the elastic restoring force of the fiber material.
Further, when a pulling force is applied to the wood screw or nail, the inorganic foam or wood fiber material around the wood screw or nail slightly moves to absorb the pulling force. In this way, the inorganic plate of the present invention has a large holding force against wood screws and nails. If the amount of the wood fiber material is less than 15 % by weight, the ratio of the inorganic foam to each other which is directly bound by the binder increases, and when a wood screw or a nail is driven in, a structural destruction occurs in the core layer. However, sufficient holding power for wood screws and nails cannot be secured.

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (Reference) E04F 13/16 E04F 13/16 A F term (Reference) 2E110 AA02 BA02 BA03 BA12 EA09 GA23Z GA24Z GA42W GA42Z GA43Z GB01W GB12W GB26W GB32W GB32Z GB33Z GB62Z 2E162 CA04 CA27 CA31 CA32 CA35 FC01 FC02 FC03 4F100 AA00A AA00B AA00C AC02 AK33 AP00A AS00A AS00B AS00C BA02 BA03 BA06 BA10B BA10C BA13 CA23B CA23C DG01A DG01B DG01C02 DJ07J02 EB01J07 EB01E07E02E02E02E02E02E04 LC02 LC03 LD02 4G052 EA07 EB01 EB28

Claims (3)

[Claims] 1. A core layer containing an inorganic foam, a wood fiber substance, and a binder, and a surface layer containing inorganic fibers, an inorganic filler, and a binder laminated on one or both sides of the core layer. Characterized in that the core layer contains at least 10% by weight of a wood fiber material. 2. A step 1 of forming a paper-making mat by paper-forming a slurry containing inorganic fibers, an inorganic filler and a binder, and forming an inorganic foam, a wood fiber material and a binder on the paper-forming mat. Step 2 of forming the core layer mat by spraying the core layer raw material mixture containing the core layer, forming a papermaking mat by forming a slurry containing inorganic fibers, an inorganic filler and a binder, A method of manufacturing an inorganic plate, comprising: a step 3 of laminating on a layer mat; a step 4 of hot-pressing the laminate manufactured by the steps 1, 2, and 3; and the above steps 1, 2, 3, and 4. 3. A process of spraying a core layer raw material mixture containing an inorganic foam, a wood fiber substance, and a binder on a substrate to form a core layer mat, the inorganic fiber, the inorganic filler, and the binder. 2, a step of laminating the sheet-forming mat on one or both sides of the core layer mat formed in the step 1, and laminating steps 1, 2, and 3. A method for producing an inorganic plate, comprising a step 4 of hot-pressing a body and the above steps 1, 2, 3, and 4.