JP2003146775A - Decorative building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative building material which can satisfy requirements for humidification balance of the amount and velocity of moisture absorption and release and is excellent in design characteristics as well by further effectively utilizing vermiculite as a natural resource. SOLUTION: This decorative building material is formed by subjecting a building material obtained by shaping the building material composition containing a hydrophilic base material selected from one or more kinds of gypsum, calcium silicate, cement, slag gypsum or basic magnesium carbonate/to a surface baking treatment.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a decorative building material.

[0002]

2. Description of the Related Art Conventionally, in the production of building materials, base materials are often selected for various purposes, and various materials are often mixed with these various base materials.

Among them, vermiculite is one of the mineral materials. This vermiculite (hill stone)
Is a clay mineral similar to biotite, which expands remarkably in the direction perpendicular to the layer due to dehydration at high temperature, and expands like a leech into a porous body. For this reason, it has excellent heat insulation and sound absorption properties, and it is intended to be used as a material for compounding into base materials (filling material, extender material), and as a base material for various building materials such as heat insulating materials and sound absorbing materials, in order to reduce its weight. Often used together. On the other hand, vermiculite is not highly regarded as a humidity conditioner because it does not have a high hygroscopic capacity.

Therefore, as described above, when blending vermiculite into a building material, it is usual to use expanded vermiculite for the purpose of weight reduction and the like. For example, it is used as a lightweight aggregate in cement products such as mortar and concrete. On the other hand, unexpanded vermiculite cannot obtain the above-mentioned advantages such as weight reduction, so even a small amount of up to several% can be used as a base material for a special purpose to utilize its properties such as acid resistance and alkali resistance. It is only included. Also, it has been attempted to fix a board made of substantially unexpanded vermiculite as a base material to the back side portion of the inner wall and the like so that the board expands when a fire occurs and fire spread is prevented. It is used as a specific base material used.

On the other hand, it has been proposed that the building material itself be provided with various functions in order to differentiate it from competing products. Among them, various studies have been made on building materials having humidity control (moisture absorption / release) and / or deodorization, and further, aesthetics, but none have been found to be satisfactory. That is, although these have obtained a certain result by utilizing those having a large specific surface area, in particular, there are many cases in which the moisture retention rate is too strong and the moisture release rate is difficult.

[0006] Therefore, the present inventor intends to further effectively utilize vermiculite as a natural resource to control humidity and / or
In addition, various studies were conducted to find a building material that is capable of satisfying demands of deodorization and also aesthetics, and that is particularly well balanced in the amount and rate of moisture absorption and desorption.

As a result, surprisingly, the moisture-releasing ability is remarkably improved by blending unexpanded vermiculite with a base material, particularly a hydraulic material having hygroscopicity but insufficient moisture-releasing property, and the above-mentioned problems are solved. It has been found that it is possible to solve the problem, and a building material obtained by molding a building material composition in which unexpanded vermiculite is compounded in a base material and the compounding amount thereof is 5 to 70% by mass of the total composition (solid content) is known. I found it.

[0008]

DISCLOSURE OF THE INVENTION As a part of the examination of the above-mentioned building materials, the present invention aims to obtain a building material excellent in designability by a simple method.

[0009]

Means for Solving the Problems The present inventors have surprisingly found that the building material itself containing a hydrophilic base material is baked, preferably the surface of the building material containing unexpanded vermiculite is baked. It was found that the task of can be achieved.

That is, the gist of the present invention is to surface a building material obtained by molding a building material composition containing a hydrophilic base material selected from one or more of gypsum, calcium silicate, cement, slag gypsum or basic magnesium carbonate. A decorative building material that has been baked, preferably an unexpanded / unpeeled expansive / exfoliating mineral is further added to the base material, and / or a color-changing substance whose color changes by redox or the like is added to the base material. It is a decorative building material prepared by blending with and surface-baked.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The hydrophilic substrate used in the present invention is selected from one or more of gypsum, cement, calcium silicate, slag gypsum, and basic magnesium carbonate, and the analogs thereof are also included. sell. The gypsum may be either anhydrous or hydrous salt, and various cements such as Portland cement may be used as the cement. In this case, aggregates and admixtures are used.
The calcium silicate is not particularly limited, but it is generally obtained by hydrothermally reacting a siliceous raw material and lime in an autoclave (tobermorite or xonotlite). The slag gypsum contains 20 to 40% of granulated blast furnace slag powder, and 60 to 2 gypsum dihydrate (exhausted gypsum).
A mixture of 80% and 1 to 5% Portland cement is general. Basic magnesium carbonate is XMgC
O ₃ · Mg (OH) ₂ · YH ₂ O (X = 3 to 5, Y = 3 to
It is a general term for compounds having the composition of 7), and X = 3, Y =
3 is the most common.

On the other hand, in the present invention, as the unexpanded / unexfoliated expansive / exfoliatable mineral which can be blended into the above-mentioned base material in an unexpanded manner, vermiculite, pearlite, obsidian, pinelite, mica or expanded shale (expanded clay) ) Selected from one or more. Vermiculite is SiO ₂ , MgO, Al ₂ O ₃
It is a flaky mineral containing as a main component, and may be a general biotite-based or chlorite-based mineral, and may be used even if there is a difference in composition or the like depending on the place of origin. The specific surface area (nitrogen adsorption method) is usually 10 m ² / g or less. The particle size is also not particularly limited,
Usually, it is 5 mm or less, preferably 3 mm or less, and particularly preferably 0.5 mm or less. For example, fine-grained products with a size of 0.25 mm or less are not suitable for use as expanded vermiculite and are therefore regarded as nonstandard products as tailing. Of the vermiculite is dehydrated and denatured (interlayer water 2
It was found that the number of molecular layers changed to one molecular layer was small, and it can be preferably used in the present invention. This is because the interlayer water having two molecules of water is more suitable for humidity control and deodorant properties.

In the present invention, such vermiculite is used in a substantially unexpanded state. That is,
Vermiculite usually contains about 10 to 20% of water, and is high temperature (about 320 ° C to
It is dehydrated by the rapid heating at 000 ° C and expands significantly (mostly at 1000 ° C for 1-2 seconds, the original thickness of 10
~ 30 times). Therefore, in the present invention, a material that does not substantially obtain such expansion is used.

Further, in the present invention, it is preferable to use the vermiculite which has been activated prior to blending with the substrate. The activation process releases organic or inorganic substances adsorbed by vermiculite,
The purpose is to reconstruct and restore the original humidity control and adsorption performance. For example, pressure steam treatment, boiling treatment with saline, and the like can be mentioned, but preferably 105 ° C to 2 ° C.
It can be by steam treatment at a saturated vapor pressure of 00 ° C.

Further, particularly when the base material is a calcium silicate type, even if unactivated vermiculite is blended before the hydrothermal reaction, the temperature is, for example, 150 ° C. after that.
Since the autoclave treatment is performed at a saturated vapor pressure of about 200 ° C., the activation treatment is eventually performed.

The blending of vermiculite into the substrate is carried out so that the blending amount thereof is 5 to 70% by mass, preferably 10% to 50% by mass of the total composition (solid content). It is selected according to the type of base material, the performance of the target building material such as humidity control, etc., but to form sufficient channeling (network) of vermiculite to obtain a suitable amount and rate of moisture absorption and desorption. Is generally preferably 15% by mass or more.

When pearlite, obsidian, pinelite, mica, or expanded shale is added as an expansive / exfoliating mineral in an unexpanded / unexpanded state, the amount of the composition (solid content) varies depending on the purpose. 1 to 40% by mass, preferably 1
It is selected from 0 to 20% by mass.

Further, in the present invention, a color-changing substance whose color is changed by redox, dehydration or the like by surface baking treatment may be added to the base material. Examples of such color-changing substances include substances containing one or more of Fe, Co, Ni, Cu, Cr, Mg, or Mn. For example,
Those hydroxides are most suitable, and the color can be changed to black, red, blue, brown or the like by forming an oxide by surface baking treatment. The blending amount can be appropriately selected depending on the type, the intended color tone and the like.

The building material composition of the present invention contains, in addition to the expansive and exfoliating minerals and / or color-changing substances described above, various compounding materials that are uniquely used in building materials for other purposes. In addition, other components may be appropriately mixed.
The type and blending amount can be determined by a conventional method. For example, aggregates, reinforcing materials, admixtures, lightening materials, and the like, more specifically pulp, cellulose fibers, glass fibers, fumed silica, foam glass, shirasu balloons, alumina balloons, wollastonite, sepiolite, gravel, Sand, organic binder, etc. are appropriately selected.

The obtained building material composition of the present invention can be made into a building material having a desired shape and size such as a board by a conventional method such as papermaking molding, extrusion molding, press molding and cast molding. Generally, in the case of a board, industrially, papermaking and molding using a so-called papermaking machine is selected.

In the building material of the present invention, when the unexpanded vermiculite content is 5 to 70% by mass of the total composition (solid content), in the moisture absorption and desorption test described in Reference Example 5 below, Suitably, when the relative humidity is changed to 60 to 90%, the moisture absorption / absorption rate is 90% or more of the equilibrium value in 30 minutes of moisture absorption,
Dehumidification: Equilibrium is shown in 25 minutes or less, more preferably 20 minutes or less.

The building material thus obtained is preferably used as an interior material such as a wall material, a ceiling material, and a partition material, but can also be used as an exterior material such as an eaves ceiling material.

When the unexpanded vermiculite is blended, the building material of the present invention can satisfy the requirements of humidity control and / or deodorization and further aesthetics. That is, 1. It has an appropriate moisture release property, so it has an excellent humidity control function.
For example, it has an excellent balance, amount and speed of moisture absorption and moisture release.

Therefore, it is possible to prevent dew condensation, warpage, etc., and effectively suppress the reproduction of mold, mite, etc. 2. Excellent deodorant function. For example, the building material of the present invention can adsorb volatile chemicals such as formaldehyde, toluene, xylene, or odorous gases. 3. Furthermore, unexpanded vermiculite particles can be raised by surface polishing or the like to form a granite-like surface,
A board material or the like having an aesthetic appearance can be easily provided. 4. A product that has been subjected to an autoclave treatment in the manufacturing process can be regenerated by recovering the used building material of the present invention and subjecting it to steam treatment at about 105 to 150 ° C in the autoclave as it is. This is because vermiculite does not react with the above substrate. 5. As a raw material for expanded vermiculite, a non-standard fine-grain product can be used more preferably, so that resources can be effectively used.

In the present invention, the building material thus obtained is surface-baked to obtain a decorative building material. This surface baking treatment differs depending on the intended design, the content of expansive and peelable minerals and / or the color changing substance, but is 500
-1500 ° C, preferably 800-1500 ° C. This surface baking treatment is preferably performed by flame treatment with a burner or a torch. The treatment time depends on the intended design, temperature conditions, etc., but is usually at least appropriately selected from the time required for the expansion of unexpanded vermiculite and the like, for example, about 0.1 to 30 seconds. The resulting decorative building material has unevenness due to the expansion of expansive and peelable minerals such as unexpanded vermiculite and / or coloring due to color-changing substances on the surface, and when it contains pulp etc., it also has a carbonized pattern. Have,
A variety of designs can be controlled by changing the baking conditions. Further, the baking conditions can be selected so that a part of the expansive and peelable mineral such as unexpanded vermiculite is vitrified on the surface if desired.

In a preferred embodiment of the present invention, the surface-baked building material can be wet-treated and, if necessary, embossed to correct warpage. Although the wet treatment is not particularly limited, for example, it is performed by spraying water on the surface or placing the building material in a high-humidity atmosphere. The embossing is performed by pressing at least one surface of the building material.

The decorative building material thus obtained does not need to have a finishing material such as cloth or wallpaper on the surface thereof, and thus has an additional advantage that the use of an adhesive therefor is unnecessary.

Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. Note that “parts” means “parts by mass”.

[0029]

EXAMPLES Reference Example 1 27 parts of silica stone powder as a siliceous raw material, 27 parts of slaked lime as a calcareous raw material, 6 parts of pulp as a reinforcing fiber, and unexpanded vermiculite (produced in South Africa, particle size 0.25 to 0.25).
(0.5 mm) 40 parts as a starting material, water was added to and mixed with them to form a slurry having a solid content of about 12%, and a raw sheet was formed by a paper making machine, and then in an autoclave (16
Pressure cure at 0-180 ° C for about 10 hours, then 8
The calcium silicate board (30 cm × 30 cm × 6 mm) was obtained by drying at a temperature of less than 0 ° C. until a predetermined water content was reached. Reference Example 2 A calcium silicate board was obtained in the same manner as in Example 1 using 42 parts of silica stone powder, 42 parts of slaked lime, 6 parts of pulp and 10 parts of unexpanded vermiculite. Reference Example 3 16 parts of slag powder, 38 parts of flue gas desulfurization gypsum powder, 6 pulp
And 40 parts of unexpanded vermiculite were added and mixed to form a slurry having a solid content of about 12%. Then, a raw sheet is formed on a paper making machine, and then at about 80 ° C. for about 12 hours,
It was steam-cured and further dried at less than 80 ° C. to obtain a slag gypsum board (30 cm × 30 cm × 6 mm). Reference Example 4 60 parts of hemihydrate gypsum, 40 parts of unexpanded vermiculite and 24 parts of water are mixed, and the resulting mixture is cast into a predetermined mold to form a plate, which is then cured at room temperature and further at 80 ° C.
Gypsum board (30cm × 30cm × 6m)
m) was obtained. Reference Example 5 (Moisture Absorption / Desorption Test) The moisture absorption rate and the moisture absorption / desorption rate of the present invention and commercially available building materials were measured by the following measuring methods. (1) Measuring method / apparatus Measuring apparatus: "IGA SOR" manufactured by Hiden Analylial Ltd.
P ”Measuring method: The powder sample is adjusted as it is, and the lump sample is adjusted to about 2 to 3 mm, and the measurement basket of about 1 cc is filled and measured.

Measurement item: Moisture absorption rate at relative humidity of 0 to 90% Moisture absorption rate at relative humidity of 60 to 90% Moisture absorption rate from 60% to 90% relative humidity Moisture absorption rate from 90% to 60% relative humidity Moisture absorption and release The wetting rate was repeated every 30 minutes. (2) Measurement sample Present invention: the following boards obtained in Reference Examples 1 to 4 Reference example 1 Calcium silicate board containing 40 wt% unexpanded vermiculite Reference example 2 Calcium silicate board containing 10 wt% unexpanded vermiculite Reference example 3 Unexpanded Vermiculite 40 wt% slag gypsum board Reference Example 4 Unexpanded vermiculite 40 wt% gypsum board Comparative product: A to HA Allophane firing board (commercial item) B Allophane (Tochigi) C Zeolite 30 wt% slag gypsum board (commercial item) ) D Zeolite (produced in Miyagi) E Calcium silicate board containing 40 wt% of diatomaceous earth (commercial product) F Diatomaceous earth (produced in Akita) G Calcium silicate board containing 40 wt% of expanded vermiculite (a method similar to that of Example 1 except that expanded vermiculite is used) H calcium silicate De (In Example 1, quartzite 47 parts, was obtained using a lime 47 parts and 6 parts of pulp.) (3) The measurement results are shown in Table 1.

[0031]

[Table 1]

These results show that the building material of the present invention is excellent in the balance between the amount and the rate of moisture absorption and desorption. As a result of the 30-minute cycle test of moisture absorption and desorption, the building material of the present invention had a good balance of moisture absorption and desorption, so that the baseline during moisture desorption was kept constant, while the comparative product released moisture. It was shown that the baseline increased to the right as time passed because it could not catch up. From the above, it can be seen that the building material of the present invention is less likely to cause dew condensation. Reference Example 6 Vermiculite was subjected to autoclave treatment at about 180 ° C. in order to examine the effect of steam treatment on moisture absorption / release characteristics. The results are shown in Table 2.

[0033]

[Table 2]

Reference Example 7 2 7 parts of silica powder, 33 parts of slaked lime and 40 parts of unexpanded vermiculite were mixed with water to obtain a slurry having a solid content of about 12%, which was autoclaved (190 to 200 ° C., about 1).
It was pressure-cured for 0 hours. Then, it was dried at a temperature of less than 80 ° C. until a predetermined water content was obtained to obtain a zonotolite-based calcium silicate board.

According to the moisture absorption / desorption test measured by the method described in Reference Example 1, the moisture absorption amount was slightly smaller and the moisture desorption rate was slightly larger than that of the calcium silicate of Example 1. Example 1 (burner baking) The calcium silicate boards obtained in Reference Examples 1 to 2 and 7 were surface baked by a burner at a surface temperature of about 1000 ° C for 2 seconds. As a result, a decorative building material having a pattern of carbonized pulp on the surface of which expanded vermiculite portions formed convex portions was obtained. Example 2 A calcium silicate board obtained in the same manner as in Reference Example 1 except that 3 parts of pearlite was added was treated with a burner at a surface temperature of about 1
The surface was baked at 100 ° C. for 2 seconds. as a result,
A decorative building material having a pattern of expanded vermiculite on the surface of which convex portions were formed, expanded pearlite was scattered, and a pattern of carbonized pulp was obtained. Example 3 The surface of the decorative building material obtained in Example 2 was moistened by spraying, and then both surfaces were embossed to obtain a decorative building material in which warpage was corrected. Example 4 In Reference Example 1, iron (III) oxide hydroxide (FeO (O
H)) (yellow) was further added to obtain a calcium silicate board with a burner, and the surface temperature was about 1000 ° C.
Then, the surface was baked for 2 seconds. As a result, a decorative building material was obtained in which the surface of the expanded vermiculite had convex portions, had a pattern of carbonized pulp, and was dehydrated and red was scattered.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) C04B 14/20 C04B 14/20 Z 28/00 28/00 E04B 1/64 E04B 1/64 D E04F 13 / 14 102 E04F 13/14 102A 15/08 15/08 A // (C04B 28/00 C04B 14:20 Z 14:20 14:18 14:18 16:02 Z 16:02) (72) Inventor Kazuo Ishihara 5 hills, 558, Shinano-cho, Totsuka-ku, Yokohama-shi, Kanagawa 5-302 (72) Inventor Hirofumi Shioji 2-F Term of 5-417-249 Makuhari-cho, Hanamigawa-ku, Chiba 2E001 DB03 DH21 HA01 HA03 HA21 HA23 HF18 JA12 JA13 JB01 2E110 AA16 AA57 AB04 AB05 AB23 BA12 BB04 GB13W GB16W GB23W 4G012 PA07 PA08 PC11 4G028 AA02 4G054 AA01 AA02 AB03 AC04 BD00

Claims (27)

[Claims] 1. A building material obtained by molding a building material composition containing a hydrophilic base material selected from one or more of gypsum, calcium silicate, cement, slag gypsum or basic magnesium carbonate, and surface-baking the building material. Makeup building material. 2. The decorative building material according to claim 1, wherein an unexpanded / unpeeled expansive / peeling mineral is blended with the base material. 3. An expansive / exfoliating mineral is vermiculite,
The decorative building material according to claim 2, which is selected from one or more of pearlite, obsidian, pine rock, mica, and expanded shale. 4. The decorative building material according to claim 1, wherein the base material is mixed with a color-changing substance whose color is changed by surface baking treatment. 5. The color-changing substance is Fe, Co, Ni, C.
The decorative building material according to claim 4, which is a substance containing at least one of u, Cr, Mg or Mn. 6. The color-changing substance is a hydroxide.
Alternatively, the decorative building material described in 5. 7. The decorative building material according to claim 3, wherein unexpanded vermiculite is mixed with the base material. 8. The surface baking treatment is performed at 500 to 1500 ° C.
The decorative building material according to claim 1, which is within the range of. 9. The decorative building material according to claim 1, wherein the surface baking treatment is flame treatment with a burner or a torch. 10. The decorative building material according to claim 2, wherein the building material has irregularities due to expansion of the expansive / peelable mineral on the surface. 11. The decorative building material according to claim 7, wherein the building material has irregularities on the surface due to expansion of unexpanded vermiculite. 12. The blending amount of unexpanded vermiculite is:
The decorative building material according to claim 7, which is 5 to 70 mass% of the total composition (solid content). 13. The decorative building material according to claim 1, further comprising pulp or cellulose fibers. 14. The decorative building material according to claim 1, wherein the molding is paper forming, extrusion molding, press molding or cast molding. 15. Gypsum, calcium silicate, cement,
Manufacture of a decorative building material characterized by producing a decorative building material by surface-baking a building material obtained by molding a building material composition containing a hydrophilic base material selected from one or more of slag gypsum or basic magnesium carbonate Method. 16. The method for producing a decorative building material according to claim 15, wherein an unexpanded / unpeeled expansive / peeling mineral is mixed with the base material. 17. The method for producing a decorative building material according to claim 16, wherein the expansive / peelable mineral is selected from one or more of vermiculite, pearlite, obsidian, pine rock, mica, and expansive shale. 18. The method for producing a decorative building material according to claim 17, wherein unexpanded vermiculite is mixed with the base material. 19. The surface baking treatment is performed in the range of 500 to 1500.
The method for producing a decorative building material according to claim 15, which is in the range of ° C. 20. The method for producing a decorative building material according to claim 15, wherein the surface baking treatment is flame treatment with a burner or a torch. 21. The method for producing a decorative building material according to claim 16, wherein the building material has irregularities on the surface due to the expansion of the expansive / peelable mineral. 22. The method for producing a decorative building material according to claim 18, wherein the building material has irregularities on the surface due to expansion of unexpanded vermiculite. 23. The blending amount of unexpanded vermiculite is
It is 5 to 70 mass% of the total composition (solid content).
A method for manufacturing the described decorative building material. 24. Gypsum, calcium silicate, cement,
To produce a decorative building material by subjecting a building material obtained by molding a building material composition containing a hydrophilic base material selected from one or more of slag gypsum or basic magnesium carbonate to surface baking, and then subjecting the building material to a wet treatment. A method for producing a decorative building material, comprising: 25. The method for producing a decorative building material according to claim 24, wherein after the wet treatment, an embossing treatment is further performed. 26. The method for producing a decorative building material according to claim 24, wherein the wet treatment is water spraying on the surface of the building material. 27. The method for producing a decorative building material according to claim 24, wherein the moistening treatment is to place the building material in an atmosphere of high humidity.