JP2003048765A - Unsintered molded panel and method for producing unsintered molded panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an unsintered molded panel which is not only provided with strength, thermal insulation properties, airtightness and lightness fundamentally required as a wall material, is but also provided with excellent humidity conditioning function, can securely be returned to the natural world when it becomes useless because of its production by using only natural materials as raw materials, is harmless for the environment, prevents the generation of sick-house symptoms, and is harmless for the living body as well, and to provide a method for producing the unsintered molded panel. SOLUTION: The panel at least contains, by weight, 5 to 65% pearlite and 25 to 94% diatom earth or diatom shale pulverized material having moisture adsorbing and desorbing properties as the main components, and 1 to 10% patato pulpe and natural paste are mixed therein while performing heating, and this mixture is molded without performing sintering.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an unsintered molded panel and a method for manufacturing an unsintered molded panel. In particular, not only aggregate but also binder can be made of natural material so that it can be returned to the natural world. The present invention relates to an unsintered molded panel suitable for a wall material and a method for manufacturing the unsintered molded panel, which is environmentally friendly to the human body, is lightweight, and has an excellent humidity control function.

[0002]

2. Description of the Related Art In recent years, formaldehyde generated from building materials and furniture of houses, toluene and xylene used in paints and adhesives, wood preservatives, preservatives, insect repellents, antibacterial agents, polyvinyl chloride resins, etc. The so-called sick house syndrome, such as allergies, atopy, tingling of eyes, headache and sore throat, nausea, dizziness, malaise, etc., is increasing due to added plasticizers, termites and the like. Such a symptom often occurs in a new house or a house after remodeling or remodeling, which uses a lot of volatile chemical substances. Further, since recent houses have become highly airtight and highly heat-insulating, the sick house symptoms are strongly appearing.

In order to deal with such a sick house syndrome, the inventor of the present application pays attention to the plastering technique which is an ancient Japanese technique, and forms a plastered wall using a wall material mainly made of a natural material. I have been creative.

However, plastering technology requires many years of experience and unique intuition. For example, there is a problem that it is difficult to disseminate it as a general construction technique because it requires advanced techniques such as compounding technology for preparing a coated wall material that is easy to judge iron and delicate coating condition using plastering iron. It was

On the other hand, gypsum boards and tiles are examples of wall materials that do not require craftsmanship such as plastering technology. It can be said that such a wall material is easily popularized in general because it does not require compounding and preparation and does not require many years of experience or unique intuition.

[0006]

However, the above-mentioned wall materials such as plasterboard and tiles cannot be returned to the natural world when they are no longer needed due to rebuilding or relining, and must be treated as waste materials. There was a problem that it had to be. This is not easily accepted from the aspect of environmental problems in recent years.

[0007] In addition, although recent building styles tend to improve heat insulation and airtightness, general interior materials such as tiles and gypsum boards do not have a humidity control function, and dew condensation, mold and mite are generated in the living environment. It has been pointed out that it has a negative effect on the.

As described above, the properties of the wall material required as a building material in recent years are not only strength, heat insulation and airtightness but also environmental friendly and human body friendly.
However, once sintered like a porcelain tile, it can no longer be returned to the natural world, so it is necessary to perform room temperature molding without sintering. However, it was more difficult than expected to form a product with strength, hardness, and impact strength that can be practically used by molding using only natural materials at room temperature.

The present invention has been made in view of the above problems, and is excellent not only in terms of strength, heat insulation, airtightness and lightness which are basically required as a wall material. It has a humidity control function, and because it is made entirely of natural materials in a non-sintered state, it can be reliably returned to the natural world when it is no longer needed, is environmentally friendly, prevents the occurrence of sick house symptoms, and is human-friendly. It is an object of the present invention to provide a method for manufacturing a consolidated molded panel and a non-sintered molded panel.

[0010]

Means for Solving the Problems As described above, the inventor of the present application has conducted repeated trial and error in order to develop a panel that can be practically used as a building material without sintering using only natural materials. As a result of devising, the inventors have found the following green molded panel and a method for manufacturing the green molded panel.

That is, the feature of the unsintered molded panel according to claim 1 of the present invention is that the main component is at least 5 to 65.
1% to 10% by weight of perlite and 25 to 94% by weight of diatomaceous earth or diatom shale crushed product having moisture absorption and desorption
The point is that wt% potato pulp and natural paste were mixed while heating and molded without sintering.

By adopting such a constitution, since it contains perlite and diatomaceous earth or diatomite shale crushed product, it has an excellent humidity control function, and by mixing potato pulp and natural paste while heating, the binding force is improved. It can be increased and secure practical strength. Moreover, the potato pulp can retain the binding force without losing the moisture absorptive and desorptive properties of the diatomaceous earth or diatom shale crushed product. Moreover, since all natural materials are used and they are molded in a non-sintered state, they can be completely reduced to the natural world.

A feature of the green molded panel according to claim 2 is that in claim 1, a natural substance containing calcium carbonate such as coral sand is mixed.

By adopting such a constitution, the product hardness can be increased while maintaining the moisture absorption and desorption property, and it is easy to dry, and the occurrence of mold etc. due to the antibacterial effect can be prevented.

Further, a feature of the unsintered molded panel according to claim 3 is that graphite silica is mixed in claim 1 or claim 2.

By adopting such a constitution, the far infrared ray effect and antibacterial effect of the graphite silica can be obtained.

A feature of the green molded panel according to claim 4 is that a fibrous material is mixed in any one of claims 1 to 3.

By adopting such a constitution, the strength of the fiber can be increased because the fibrous material is strong in the breaking.

A feature of the unsintered molded panel according to claim 5 is that, in claim 5, the fibrous material is formed in a net shape and is mixed at a substantially central position in the thickness direction.

By adopting such a structure, the strength can be maintained in a well-balanced manner.

The non-sintered molded panel according to claim 6 is characterized in that a material containing at least pearlite as a main component and diatomaceous earth or diatom shale crushed material having moisture absorbing / releasing properties,
The point is that potato pulp and natural paste are added while heating, mixed and stirred, molded at room temperature, and then dried.

By adopting such a method, since it contains perlite and diatomaceous earth or diatom shale pulverized product, it has an excellent humidity control function, and absorbs and absorbs by mixing potato pulp and natural paste while heating and mixing. Manufactures unsintered molded panels that can increase bonding strength while maintaining the wet function, secure practical strength, use all natural materials, and can be completely reduced to the natural world because they are molded in a non-sintered state. can do.

Further, the feature of the method for manufacturing a green molded panel according to claim 7 is that when heating is carried out according to claim 6,
The point is that hot water or steam of 0 ° C or higher is added.

By adopting such a method, the binding force between the potato pulp and the seaweed glue can be strengthened more reliably.

[0025]

BEST MODE FOR CARRYING OUT THE INVENTION An example of an embodiment of a green molded panel and a method for manufacturing a green molded panel according to the present invention will be described below with reference to the drawings.

The unfired panel of this embodiment contains at least perlite as a main component and a diatomaceous earth or diatom shale crushed product having a moisture absorbing / releasing property, to which potato pulp and natural paste are mixed as a binder. . In addition,
Since the potato pulp contains fibers, it also has the role of increasing the strength of the green molded panel.

Here, pearlite not only plays a role as an aggregate that secures the strength of the unsintered molded panel, but it is also extremely lightweight and excellent in heat insulation and moisture absorption and desorption. Suitable as a wall material.

The diatomaceous earth is a substance in which diatoms of phytoplankton are deposited on the lake bottom or the seabed and only the silicic acid portion (SiO ₂ ) is fossilized, and it is a superporous body in which micropores are regularly arranged on the surface. . The diatom shale is a solid of diatomaceous earth, and the crushed diatom shale is diatom shale crushed to an appropriate particle size. The diatomaceous earth and diatomite shale crushed product is white to off-white and highly pure
%, Specific gravity of dried product is 0.34, porosity is 60%
Is 90%, it is excellent in humidity control property and deodorant property and has a property of repelling mites and cockroaches.

[0029] The potato pulp is a squeezed residue of potato, which is a material having a suitable amount of starch and fibrous material. Therefore, it has the effect of a binder as starch paste, and also has the effect of increasing the strength due to the fiber material. There are various binders,
Petroleum-based adhesives and the like reduce the moisture absorption / release function of the diatomaceous earth or diatom shale crushed product, but potato pulp has the effect of increasing the strength without reducing the moisture absorption / release function.

Furthermore, the addition of potato pulp accelerates the drying and is suitable for weight reduction. In the molding test, although waste paper was added to potato pulp, it was possible to manufacture a harder unsintered molded panel. On the other hand, since potato pulp is squeezed waste and is disposed of in large quantities, if it can be effectively used, it will have excellent cost performance and contribute to environmental protection. However, in order to exert a sufficient effect as a wall material, a considerable amount of trial and error was required in combination with other materials.

As the natural paste, casein milk (manufactured by Auro Botanical Co., Ltd.) in which lime is mixed with seaweed paste produced by boiling seaweed such as ginkgo grass or sap, and plant-based resin such as methylcellulose are used. preferable. When these natural pastes are kneaded with potato pulp while being heated, they are in good harmony with starch and have the property of further increasing the adhesive strength. In particular, when ginkgo biloba is mixed while being heated with hot water or steam of 80 ° C. or higher, the binding force with potato pulp and other materials is increased, and a high quality unsintered molded panel is obtained.

Here, the binder also includes petroleum-based adhesives such as cement, rubber-based, acrylic-based, and cellulosic-based binders, but cement and petroleum-based adhesives cannot be returned to the natural world and have an environmental load. For this reason, the cement does not meet the purpose of the present invention, and cement is not suitable as an inner wall material and has low moisture absorption and desorption. Further, rubber-based, acrylic-based, and cellulosic-based adhesives are not suitable as wall materials because of insufficient adhesive effect and large deformation and shrinkage. Therefore, in this embodiment, natural pulp such as potato pulp and natural paste are used.

In addition, the unsintered molded panel of this embodiment,
Further, a substance containing calcium carbonate as a main component and various mineral components such as coral sand may be mixed. The calcium carbonate material is suitable for increasing the hardness of the green molded panel while maintaining the moisture absorption and desorption properties, and is light. Furthermore, it is considered that mineral components are slowly released into the air from walls and the like, which has a positive effect on the human body. In particular, coral sand has an antibacterial property in addition to those effects, and therefore effectively prevents the growth of mold.

Further, graphite silica (silica black: trade name) may be mixed in the unsintered molded panel of this embodiment. This graphite silica is produced in the fault crushed part of the third black hard mudstone, and its composition is 5.03% carbon, 81.35% silicon dioxide (silica SiO ₂ ), and ferric trioxide ( Fe ₂ O ₃ ) is 0.53%, alumina (Al
₂ O ₃ ) 6.35%, calcium oxide (CaO) 0.02%, magnesium oxide (MgO) 0.45
%, Titanium oxide (TiO ₂ ) 1.18%, sodium oxide (Na ₂ O) 0.08%, potassium oxide (K
₂ O) has a component ratio of 1.66% and water content of 0.31%. This graphite silica is said to generate a large amount of far infrared rays not only at high temperature but also at room temperature due to the ambient temperature. The characteristic is that when the ambient temperature is 39.9 ° C, the far infrared radiation amount of graphite silica is radiated in the wavelength range from 6.0 microns to 14.0 microns, and 100 in the wavelength range of 8.5 microns. Watt / steradian / c
The peak value exceeds m ² / μm, and the radiation amount approximates to an ideal black body with a peak value of about 120 watts / steradian / cm ² / μm. Furthermore, the far infrared emissivity of graphite silica exhibits an emissivity of about 93% over a wavelength range of 6.0 to 22.0 microns. Therefore, when the unsintered molded panel mixed with this graphite silica is used as the inner wall, it is possible to obtain the ambient temperature, emit far infrared rays, and warm the human body. Graphite silica is more suitable as a wall material because it has an antibacterial property in addition to the far infrared effect. In order to exert these effects, it is preferable to mix the graphite silica in a proportion of 3 to 10% by weight or more.

In addition, the unsintered molded panel of this embodiment,
A fibrous material may be mixed. For example, straw, hemp, and used paper. These are extremely lightweight, but are suitable for increasing the strength, and have an effect of preventing cracks and breaks in the unsintered molded panel. The fibrous material may be finely cut so as to be mixed uniformly throughout the fibrous material, or may be formed in a net shape and sandwiched by another material and arranged in the green molded panel. At this time, it is preferable that the net-shaped fibrous material is arranged at a substantially central position in the thickness direction of the unsintered molded panel. This is because if it is biased too much to either one, the strength will vary during drying.

In addition, zeolite or lime may be mixed in the unsintered molded panel of this embodiment. Zeolite is hard and easy to dry, so it has the effect of solidifying the entire panel. In addition, the particles of lime are about 90μ in size.
Since it is about m, it plays a role of filling the gap and is also excellent in moisture absorption and desorption.

The material composition of the above-mentioned unsintered molded panel is 5 to 65% by weight of perlite, 25 to 94% by weight of diatomaceous earth or diatomite shale crushed product, 1 to 10% by weight of potato pulp and binder of natural paste, In addition, 0 to 60% by weight of coral sand, graphite silica, zeolite, lime, dyes and the like are preferable.

Next, a method for manufacturing the green molded panel of this embodiment will be described.

In the method for manufacturing a green molded panel according to the present embodiment, first, perlite, diatomaceous earth or diatom shale crushed material, and if necessary, other materials are weighed and mixed. At this time, potato pulp and natural paste are added as a binder and heated. In this embodiment, warm water is added. The temperature of the hot water is preferably 40 to 100 ° C, and more preferably 80 to 100 ° C. When hot water is added, the potato pulp and the natural paste may be dissolved in the hot water and added together. Each material to which the binder has been added is stirred and mixed, and after thoroughly kneading, it is filled in an appropriate mold such as a mold and press-molded. The molding conditions are that the molding temperature is room temperature, the molding pressure is 30 to 200 kg / cm ² , and the molding time is 1 to 3 minutes. The higher the molding pressure, the better the surface condition, and more preferably 100 kg / cm ² or more.

Although hot water is added to heat the materials when they are kneaded, steam may be added to heat the materials. That is, when the materials are mixed, they may be mixed while injecting steam into the mixer.

The mixing of hot water or steam as described above is for strengthening the bond between the materials. In other words, it is known that some strength can be obtained by using synthetic adhesives, etc., but if you stick to natural materials, you can use a binder made of natural materials to strengthen the properties of the main materials. It was quite difficult to combine. Therefore, when the present inventor mixes potato pulp and ginkgo, which is a natural paste, with warm water or steam, the starch quality of the potato pulp and the paste component of ginkgo are in harmony, and more strongly shows a paste form and enhances the effect of the binder. I found a thing. Furthermore, by adding water, heat, which is a characteristic of zeolite, is added, and it combines with lime and other aggregates,
Present a new crystal. On the other hand, lime absorbs carbon dioxide gas in the air to form calcium carbonate, which is set and hardened. As a result, it has become possible to mold a non-sintered molded panel that can be practically used as a wall material without mixing with a chemical resin or cement.

Next, the green molded panel of the present embodiment was tested for each physical property such as density, bending strength, impact strength and moisture absorption / release property. Each physical property test was conducted under the guidance of the Chemical Technology Department and the Product Development Section of the Hokkaido Industrial Test Station.

The unsintered molded panel used in the test was about 28.0% by weight of crushed diatom shale and about 14.0% of perlite.
% By weight, coral sand by about 18.6% by weight, and graphite silica by about 3.
0% by weight, lime about 18.6% by weight, zeolite about 2.3% by weight, ginkgo herb about 1.5% by weight, potato pulp about 2.0% by weight, pigment 11.6% by weight, A fibrous material and other additives were molded with a compounding ratio of about 0.4% by weight.
Further, as comparative samples, commercially available sintered tiles for walls (porcelain tiles) and gypsum boards were prepared.

In the method of manufacturing the unsintered molded panel, the respective materials were weighed so as to have the above-mentioned composition, hot water of about 80 ° C. or higher was added, stirred and mixed, and then filled in a mold of a predetermined shape.
At this time, about half of the mixed material was put, then a net-shaped hemp thread was laid on it, and the remaining mixed material was filled from above. As a result, the net-shaped hemp thread is stretched around the center in the thickness direction. Then, at room temperature, it was pressed at a pressure of about 75 kg / cm ² for about 2 minutes and dried. The sample is about 14 cm in length and width and about 1 cm in thickness.

Among the physical property tests, the bending test was a three-point bending test and was determined by the following equation. Bending strength = 3 LW / 2bh ² where L is a supporting span (cm) and W is a breaking load (k
g) and b are the width (cm) of the test piece, and h is the thickness (cm).

Further, a falling ball impact test was conducted for impact strength. The falling ball impact test is a test in which a sample is placed under a vinyl chloride pipe with a length of 1 m, and a steel ball weighing 500 g is dropped from above the pipe through the pipe to observe the state of breakage and the presence of cracks. is there.

On the other hand, the moisture absorptive and desorptive test is to measure the rate of weight change by repeatedly using a constant temperature and constant humidity tester at a temperature of 25 ° C. and repeatedly exchanging in a tank having a humidity of 50% and 90%.
That is, first, in order to completely remove the water content of each sample, each sample is left to stand in a thermostat at 120 ° C. for 24 hours. After that, the weight is measured, and the temperature is 25 ° C and the humidity is 90%.
%, And after 24 hours, the weight is measured to calculate the weight change rate. Next, the temperature in the tester tank is set to 25 ° C,
Set the humidity to 50% and place each sample above
Leave for hours. Then, the weight is measured and the rate of change in weight is calculated.

The results of the above tests are shown in FIGS. 1 and 2. FIG. 1 shows the results of the density, bending strength, falling ball impact and moisture absorption / desorption test, and FIG. 2 shows the results of the moisture absorption / desorption test as a graph.

As shown in FIG. 1, the density of the sintered tile is
1.66 g / cm ³ , and the density of the gypsum board was 0.
It was 68 g / cm ³ , whereas the unsintered molded panel was 0.84 g / cm ³ . The non-sintered molded panel is lightweight and can be formed with a weight about half that of the sintered tile.

The bending strength of the sintered tile is also highest, 78.2 kg / cm ² , and that of the gypsum board is 2.
2.1 kg / cm ² , and the unsintered molded panel is 5.
It was 6 kg / cm ² . However, in consideration of the fact that ² kg / cm ² is sufficient for practical use as a wall material, the strength of the unsintered molded panel can withstand practical use. If it is desired to increase the bending strength, the amount of lime compounded may be increased to enhance the airtightness of the sample, or the amount of potato pulp compounded may be increased to increase the strength and fiber quality of the binder.

Further, the falling ball impact test results showed that the sintered tile was broken into pieces and exhibited brittleness, but the gypsum board and the unsintered molded panel were not broken or cracked. You can see that it is strong against shock.

On the other hand, in the moisture absorption / desorption test, a panel having a high moisture absorption rate in a high humidity environment and a high moisture removal rate in a low humidity environment is desirable. That is, the larger the rate of change in FIG. 2 is, the more excellent the moisture absorption / release property is. In particular, in repeated tests, it can be said that it is better to absorb and release a certain amount of water. Looking at the moisture absorption / desorption test results from this point of view, the sintered tile has a property of absorbing and releasing a certain amount of water, but the rate of change thereof is slightly low at about 2%. On the other hand, gypsum board is not preferable from the viewpoint of moisture absorption / desorption because it has a high moisture absorption rate in both environments of humidity 90% and 50% and its rate of change does not change. On the other hand, the unsintered molded panel shows 2.11% when the humidity is changed between 90% and 50%.
The rate of change is large at 3.02% and 2.49% and the moisture absorption / desorption property is excellent, and stable moisture absorption and dehumidification are repeated, and thus it can be said that a good humidity control function is provided.

Therefore, according to the above-described embodiment, not only the strength, heat insulation, airtightness and lightness which are basically required for the wall material are provided, but also from the main component to the binder. Since a natural material is used and the material is molded at room temperature without being sintered, it can be reliably returned to the natural world when it is disposed of, and it can contribute to environmental protection.

Further, since it is formed only from natural materials without using any volatile chemical substances, it prevents generation of sick house symptoms and is friendly to the human body. Moreover, it also has an excellent humidity control function, which is extremely effective for the housing situation in Japan which suffers from high humidity.

Further, the effect of far infrared rays can be obtained if graphite silica is used depending on the material to be mixed, and the antibacterial property and the effect of extracting mineral components can be obtained by mixing coral sand.

The configurations of the present embodiment of the present invention are not limited to those described above, but can be modified as appropriate.

[0057]

As described above, according to the invention of claim 1, the wall material is basically required to have the strength and the light weight, and the excellent humidity control function is provided.
Moreover, since all the components from the main component to the binder are made of natural materials, and they are molded at room temperature without sintering, they can be reliably returned to the natural world at the time of disposal, contributing to environmental protection and sick house symptoms. It is possible to provide a wall material that is also friendly to the human body by preventing the occurrence of

According to the second aspect of the invention, in addition to the effect of the first aspect of the invention, the altitude can be increased while maintaining the moisture absorption and desorption property, the moisture can be easily dried, and the occurrence of mold etc. due to the antibacterial effect. Can be prevented.

According to the invention of claim 3, in addition to the effects of the invention of claim 1 or 2, the far infrared ray effect and antibacterial effect of graphite silica can be obtained.

According to the invention of claim 4, in addition to the effect of the invention of any one of claims 1 to 3, the fiber is strong against shearing, so that the weight can be reduced. Strength can be increased.

According to the invention of claim 5, in addition to the effect of the invention of claim 5, it is possible to maintain strength in a well-balanced manner.

According to the sixth aspect of the present invention, the wall material is provided with the necessary strength and light weight, and all the components from the main component to the binder are made of natural materials and are not sintered. Since it is molded at room temperature, it can be reliably returned to the natural world at the time of disposal, contributing to environmental protection, preventing the occurrence of sick house symptoms, friendly to the human body, and has an excellent humidity control function. It is possible to obtain a panel for the provided building material.

According to the invention of claim 7, in addition to the effect of the invention of claim 6, the binding force between the potato pulp and the natural paste can be strengthened more reliably.

[Brief description of drawings]

FIG. 1 is a table showing the results of a physical property test performed on an example of an embodiment of a green molded panel according to the present invention.

FIG. 2 is a graph showing the results of a moisture absorption / desorption test in FIG.

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Claims (7)

[Claims] 1. At least 5 to 65% by weight as a main component
Perlite and diatomaceous earth or diatom shale crushed product having a moisture absorption / desorption property of 25 to 94% by weight, and 1 to 10% by weight
An unsintered molded panel characterized by being prepared by mixing the potato pulp and natural paste of 1) while heating and mixing without sintering. 2. The green molded panel according to claim 1, wherein a natural substance containing calcium carbonate such as coral sand is mixed. 3. The unsintered molded panel according to claim 1, wherein graphite silica is mixed. 4. The unsintered molded panel according to any one of claims 1 to 3, wherein a fibrous material is mixed therein. 5. The unsintered molded panel according to claim 5, wherein the fibrous material is formed in a net shape, and is mixed at a substantially central position in the thickness direction. 6. A material containing at least perlite as a main component and a diatomaceous earth or a diatomite shale crushed product having moisture absorbing / releasing properties, mixed with potato pulp and natural paste while being heated, mixed and stirred, and molded at room temperature and then dried. A method for manufacturing a non-sintered molded panel, comprising: 7. The method for producing a non-sintered molded panel according to claim 6, wherein hot water or steam at 80 ° C. or higher is added when the heating is performed.