JP2002240006A - Mineral composite material and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mineral composite material having a strength as a structural material by alternatively disposing mineral plates and woody plates and compositely integrating the plates as the structural material used for a skeleton work of a building and having excellent dimensional stability, antiseptic and ant-repellent effects and a nail holding force, and to provide a method for manufacturing the same. SOLUTION: The mineral composite material comprises the woody plates (veneers or a laminate of the veneers) and the mineral plates of a three-layer constitution (volcanic vitreous multi-layer plates), obtained by alternatively laminating and integrating core layers each containing mineral foam and a binding agent as indispensable components on front and rear layers each containing mineral fiber, inorganic powder-like material and a binding agent as indispensable components and having a specific gravity of 0.6 to 0.9 alternatively laminated via an adhesive, and compositely integrated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic composite material obtained by laminating and integrating an inorganic plate and a wooden plate and having excellent fire resistance, durability, dimensional stability, workability, and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, wood materials such as lumber and glued laminated wood have been used as structural materials used in the construction of pillars, beams, girders, foundations, girders, joists and the like of buildings. It is used. The lumber is warped due to drying after running,
Since cracks and the like are apt to occur, it is necessary to dry sufficiently, and a wood material having a defect has a low strength and cannot be used as a structural material. Therefore, only a small amount of good quality lumber is obtained and it is expensive. Glued lumber can eliminate the disadvantages of lumber products, so that a relatively uniform product can be obtained. Since a sufficiently dry wood material is used, warping, distortion, cracking, etc. are less likely to occur after the operation. However, it is a wood material, which is the same as a lumber product, and is deteriorated by decay and termites. Further, the dimensional change at the time of water absorption is large, and it is difficult to prevent warping and twisting.

[0003] On the other hand, if an inorganic material such as calcium silicate or cement is used, the above-mentioned problems caused by the wood material can be solved, but the material is hard and brittle, so it is weak against impact and cannot maintain the strength as a structural material. Further, the nail holding force is small, and the nail is easily pulled out when fastened with nails or screws.

[0004] In view of the above problems, the present invention has strength as a structural material by alternately arranging inorganic boards and wood boards and integrally integrating them, and has antiseptic and termite resistance, dimensional stability, and nail holding power. An object of the present invention is to provide an inorganic composite material having excellent properties and the like and a method for producing the same.

[0005]

According to the first aspect of the present invention, an inorganic foam and a binder are essential for a wood board, a front and back layer containing mineral fibers, an inorganic powder and a binder as essential components. A three-layer inorganic plate having a specific gravity of 0.6 to 0.9, in which core layers as components are laminated and integrated, is alternately laminated and integrated via an adhesive.

According to this structure, the inorganic plate having a low nail holding force and being vulnerable to an impact and the wooden plate having a high toughness and a high nail holding force are alternately bonded and integrated to provide an impact strength,
It has strength as a structural material such as bending strength, and the nail holding force is improved. In addition, wood boards are inferior in water absorption dimensional stability and are likely to be warped or twisted. As a material, a material which is hardly warped or twisted and has good dimensional stability can be obtained. Of course, fire resistance is improved as compared with conventional lumber products and laminated wood, and rot and deterioration due to termites can be prevented.

Further, the inorganic plate has a specific gravity of 0.6 to 0.9, which is close to the specific gravity of the wooden material. Unlike the case where the wooden plate is combined with the calcium silicate plate or the cement plate, the inorganic plate is used for processing such as cutting. Cracking and fluffing are unlikely to occur because the cutting ability of the blade is similar to that of the blade. Further, since the front and back layers of the inorganic plate contain mineral fibers, the adhesiveness to the wooden plate is good due to the anchoring effect of the adhesive, and it is difficult to separate even a composite of different materials.

According to the second aspect of the present invention, the core layer containing the inorganic foam and the binder as an essential component is laminated and integrated with the front and back layers containing the mineral fiber, the inorganic powder and the binder as the essential components. It is characterized in that a laminated inorganic plate obtained by laminating two or more layers of three-layer inorganic plates having a specific gravity of 0.6 to 0.9 and a wooden plate are alternately laminated and integrated.

According to this configuration, the strength as a structural material such as impact strength and bending strength and the nail holding force are slightly reduced as compared with the effects of the first aspect, but the dimensional stability of water absorption and decay are reduced.
Since the durability to termites is improved, it is suitable for use as a base or the like.

According to the third aspect of the present invention, in the inorganic composite material according to the first or second aspect, the wooden board is a single veneer.
It is characterized by being composed of a laminate of at least two layers.

According to this configuration, in addition to the effects of the first and second aspects, the bending strength and the nail holding force are further improved. In particular, when the veneers are laminated with the fiber direction of the veneer arranged parallel to the elongate direction, the bending strength and dimensional stability in the elongate direction are improved, and columns, beams, girders, foundations, large pulls, joists, etc. It becomes more preferable as a structural material used for the frame construction.

[0012] According to the invention of claim 4, according to claim 1,
The present invention relates to a method for specifically producing the inorganic composite board as described in 2 or 3, wherein the wooden boards and the wooden board and the inorganic board are laminated via the same thermosetting adhesive, and subjected to one hot pressing. This is a manufacturing method in which the components are combined and integrated.
According to the present production method, the inorganic plate used in the present invention has a specific gravity similar to that of the wooden plate, and has good adhesion to the wooden plate due to the anchoring effect of the adhesive. Since it can be manufactured, it can be bonded simultaneously with one heat and pressure, and the productivity is increased.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment according to the present invention will be described with reference to FIG. The inorganic composite material (A) of the present invention has a configuration in which a wooden board (1) and an inorganic board (2) are alternately laminated. In FIG. 1, the wood board (1) is arranged on the front and back surfaces. However, the use conditions such as the case where the front and back faces are the inorganic board (2), the case where the front and back faces are different between the wood board (1) and the inorganic board (2), etc. Can be selected arbitrarily.

The wooden board (1) is made of a wooden veneer, and may be laminated two or more layers according to the performance application in addition to laminating the veneer as it is. If the veneers are laminated with the fiber direction of the veneer arranged parallel to the elongate direction, the bending strength and dimensional stability in the elongate direction are improved, and frames such as columns, beams, girders, foundations, large pulls, joists, etc. This is more preferable as a long structural material used for construction. By laminating the fiber directions orthogonal to each other, the strength is improved in both the short and long directions.

All wooden boards (1) of the inorganic composite material (A)
For example, a laminate of two or more layers may be used, or a single plate of two or more layers may be laminated only on the front and back surfaces, and the other portion may be a single plate of one layer. In addition, wood board (1)
May have two or more layers, and may have a configuration as shown in FIG. 4 (the front and back surfaces are inorganic plates and a single veneer is 31 layers in the middle). In addition to veneers, known wood boards such as MDF (medium fiber board), OSB (oriented board), and particle board can be used.

As shown in FIG. 2, the inorganic plate (2) comprises a front and back layer (2a) containing mineral fibers, an inorganic powder and a binder as essential components, an inorganic foam and a binder as essential components. It is composed of three layers in which the core layer (2b) is laminated and integrated, and has an overall specific gravity in the range of 0.6 to 0.9, and is specifically referred to as a volcanic glassy multilayer plate (JIS A 5440). Things.

Here, the composition and manufacturing method of the volcanic glassy multilayer plate will be described. Rock mineral, slag wool, glass wool, or the like can be used as the mineral fiber that forms the front and back layers (2a) and develops strength, and the amount of addition is 20 to 80% by weight. The inorganic powder is used to increase the surface hardness and smoothness, and aluminum hydroxide, calcium carbonate, silica sand and the like can be used, and the added amount is 10 to 65% by weight. Starch, polyvinyl alcohol or the like can be used as a binder for binding and integrating these. In addition, it is preferable to add a water-resistant binder such as a phenol resin and an acrylic resin in order to impart water resistance. The added amount of these binders is 5 to 30% by weight in total. Organic fibers such as pulp and polypropylene may be added in an amount of 2 to 15% by weight to increase the strength. These were poured into water and stirred to obtain a slurry, and a wet mat to be the front and back layers (2a) was obtained.

On the other hand, examples of the inorganic foam which becomes the main component of the core layer (2b) and is effective in reducing the weight of the plate material include pearlite,
Shirasu foam, glass foam and the like can be used, and the added amount is 30 to 80% by weight. The same binder as the front and back layers can be used as a binder for binding the inorganic foam, and the total amount of the binder is 5 to 30% by weight.
Organic fibers such as pulp and polypropylene may be added in an amount of 3 to 30% by weight to increase the strength. In addition, an inorganic powder such as aluminum hydroxide, calcium carbonate, silica sand or the like may be added as necessary.
It must be 0% by weight or less. These are mixed by atomization of water, spray-deposited on the wet mat of the back layer (2a), and the wet mat of the surface layer (2a) is disposed thereon,
After heat-pressing with a hot press, drying with a dryer, the specific gravity of the front and back layers (2a) is 0.8 to 1.2, the specific gravity of the core layer (2b) is 0.2 to 0.7, and the total specific gravity is 0. An inorganic plate (2) of 0.6 to 0.9 was obtained.

Next, a method for producing the inorganic composite plate (A) will be described. As shown in FIG. 1, a wooden board (1) and an inorganic board (2) are laminated. At this time, a thermosetting adhesive (melamine, urea melamine, etc.) is applied between the plates, and the adhesive is cured through a hot-pressing process to form a composite and integrated, then cured, sanding-adjusted thickness, desired dimensions And actual processing was performed as necessary.

[0020]

(Example 1) As shown in FIG. 1, 13 single plates (1) having a thickness of 3.4 mm in the longitudinal direction of the fiber direction and an inorganic plate having a thickness of 6.0 mm (trade name: 12 dielights) (2) were arranged alternately. A melamine adhesive was applied at 400 g / m ² to bond the inorganic plate and the veneer. Thereafter, the mixture was cold-pressed for 30 minutes by a press, hot-pressed at 150 ° C. for 30 seconds, cured for about half a day, and sanded on the front and back surfaces to obtain an inorganic composite material (A) having a thickness of 105 mm, a width of 105 mm and a length of 3600 mm.

The composition of the inorganic plate used in this embodiment is as follows. The front and back layers are 60% by weight of rock wool as a mineral fiber, 25% by weight of calcium carbonate as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as a binder, and 5% by weight of powdered phenol as a water-resistant binder. The core layer is composed of 60% by weight of pearlite as an inorganic foam, 25% by weight of calcium carbonate as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as a binder, and 5% as a water-resistant binder. Powdered phenol 5
An inorganic plate (volcanic glassy multi-layer plate (trade name: Dylite)) having a specific gravity of 0.7 by weight was obtained.

(Embodiment 2) As shown in FIG.
17 mm of a 0 mm inorganic plate (trade name: Dylite)
The thickness of the fiber direction is 3.4m in the long direction while the sheets are laminated.
m, two veneers (1) were arranged on the front and back. An inorganic composite material (A) having a thickness of 105 mm, a width of 105 mm, and a length of 3600 mm was obtained by the same manufacturing method as in Example 1.

(Embodiment 3) As shown in FIG.
2 mm of 0 mm inorganic plate (trade name: Dylite)
Single plate with a thickness of 3.4 mm in the lengthwise direction of the fiber (1)
And 31 inorganic plates were arranged on the front and back. An inorganic composite material (A) having a thickness of 105 mm, a width of 105 mm, and a length of 3600 mm was obtained by the same manufacturing method as in Example 1. Various variations other than the above embodiment are possible,
Hereinafter, only the configuration of the inorganic board and the wood board will be described as a part of the modified example.

(Modification 1) FIG. 5 shows the first embodiment in which two single plates having a long fiber direction are laminated and alternately arranged as a wooden plate (1). The number of veneers may be three or more, or only some may be plural and others may be only one veneer. The fiber direction can be freely selected as needed. In FIG. 5, the front and back surfaces are made of a wooden plate, but the inorganic plate (2) can be arranged on the front and back surfaces according to the application.

(Modification 2) FIG. 6 shows the structure of the first embodiment in which a laminated inorganic plate is obtained by laminating two inorganic plates (2), and the inorganic plates are arranged on the front and back surfaces. The number of inorganic plates may be three or more, or some may be plural, and others may be only one inorganic plate. Further, the wooden board (1) can be arranged on the front and back surfaces according to the use.

In the first embodiment, since the inorganic plate and the wooden plate are alternately arranged one by one, the advantages of the inorganic plate and the wooden plate are averagely combined, and the structural material such as impact strength and bending strength is used. It is excellent in strength and nail holding power, excellent in water absorption dimensional stability, hardly warps and twists, and excellent in fire resistance, decay and durability against termites.

In the second embodiment, since the wooden boards are arranged on the front and back surfaces of the plurality of inorganic boards, the strength as a structural material such as impact strength and bending strength and the nail holding force are slightly reduced, but especially the water absorption size. Its stability, decay and durability against termites are greatly improved, and it is suitable for use as a base.

In Example 3, since inorganic plates are arranged on the front and back surfaces of a plurality of wooden plates, the dimensional stability of water absorption, the decay, and the durability against termites are slightly reduced, but the strength is comparable to that of ordinary wood. Excellent nail holding power. By arranging the inorganic plate on the surface that easily absorbs water, the water absorption dimensional stability is also excellent.

[0029]

According to the present invention, an inorganic composite plate having excellent bending strength and nail holding force, excellent water absorption dimensional stability, and low warpage and twist is provided by alternately laminating and integrating a wooden plate and an inorganic plate. Is obtained. In addition, the specific gravity of the wood board and the inorganic board are similar, cracks and fuzzing are less likely to occur when cutting blades, and the anchoring effect of the front and back layers of the inorganic board has good adhesion to the wood board, and even composites of different materials Difficult to peel off.

According to the second aspect of the present invention, the dimensional stability of water absorption, decay, and durability against termites are improved.

According to the third aspect of the invention, the bending strength and the nail holding force are further improved.

According to the manufacturing method of the present invention, the wooden boards and the wooden board and the inorganic board are laminated via the same thermosetting adhesive, and are combined and integrated by one heat and pressure. Productivity can be increased.

[Brief description of the drawings]

FIG. 1 is a sectional view of an inorganic composite material according to Example 1 of the present invention.

FIG. 2 is a cross-sectional view of the inorganic plate of the present invention.

FIG. 3 is a sectional view of an inorganic composite material according to Example 2 of the present invention.

FIG. 4 is a sectional view of an inorganic composite material according to Example 3 of the present invention.

FIG. 5 is a sectional view of an inorganic composite material according to a first modification of the present invention.

FIG. 6 is a sectional view of an inorganic composite material according to a second modification of the present invention.

[Explanation of symbols]

 1: Wood board 2: Inorganic board A: Inorganic composite

Claims (4)

[Claims] 1. A specific gravity of 0.6 obtained by laminating and integrating a wood board, a mineral fiber, an inorganic powder, and a front and back layer containing a binder as an essential component and a core layer containing an inorganic foam and a binder as an essential component. ~ 0.
9. An inorganic composite plate, wherein the three-layer inorganic plate and the three-layer inorganic plate are alternately laminated and integrated via an adhesive. 2. A specific gravity of 0.6 to 0.9 wherein a core layer containing an inorganic foam and a binder as essential components is laminated and integrated on a front and back layer containing mineral fibers, an inorganic powder and a binder as essential components. An inorganic composite material, wherein a laminated inorganic plate obtained by laminating two or more layers of the inorganic plate having three layers and a wooden plate are alternately laminated and integrated. 3. The inorganic composite material according to claim 1, wherein the wooden board is formed by laminating two or more veneers. 4. The inorganic composite material according to claim 1, wherein the two wooden boards, the two inorganic boards, and the two wooden boards and the inorganic board are laminated with the same thermosetting adhesive.
A method for producing an inorganic composite material, wherein the composite material is integrated by thermal pressure.