JP2005153297A - Manufacturing method for ceramic inorganic panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a ceramic inorganic panel excellent in weatherability without separately providing production equipment like a drying apparatus. <P>SOLUTION: A raw material slurry based on a hydraulic material is molded to obtain a base material and a color decorative material, which is prepared by mixing a cementitious material, a resin, a pigment and water, is subsequently applied to the surface of the base material. Next, the coated base material is allowed to stand at the normal temperature for 5 hr or above and subsequently aged in an autoclave. Alternatively, the raw material slurry based on the hydraulic material is molded to obtain the base material and the color decorative material composed of the cementitious material, the resin, the pigment and water is allowed to stand at the normal temperature for 5-20 hr after the start of mixing to be applied to the surface of the base material and the coated base material is subsequently aged in the autoclave. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a ceramic inorganic board used for an exterior material or interior material of a building such as a house.

  2. Description of the Related Art Conventionally, ceramic-based inorganic plates that are lightweight, have excellent heat insulation properties, and are nonflammable are widely used as exterior materials and interior materials for buildings such as houses.

  In the conventional method for producing a ceramic inorganic board, usually, a raw material slurry containing at least cement as a solid component is made, extruded or cast, and the obtained base material is shaped and patterned by a press machine, A ceramic-based inorganic board is obtained by loading the molded base material and curing it by curing in an autoclave. In addition, the obtained inorganic plate is overcoated to give a colored cosmetic finish to form a decorative film.

  In this method, a coating film is formed by applying a thin film of paint to a cured substrate in a separate process, but there is a risk that the colored makeup layer may be exposed due to weather resistance deterioration or film thickness reduction. It was.

A manufacturing method for coping with this problem is disclosed in Japanese Patent Laid-Open No. 10-000604 (Patent Document 1). In this manufacturing method, a colored cement layer made of colored cement containing cement, pigment, and water is provided on a base material containing cement, and then the surface of the colored cement layer is dried by a drying apparatus and then autoclaved. To get a cement board.
JP 10-000604 A

  However, in the method disclosed in Patent Document 1, it is necessary to separately provide a drying device for drying the colored cement layer.

  The present invention has been made in view of the above circumstances, and its object is to provide a method for manufacturing a ceramic inorganic board having excellent weather resistance without separately providing production equipment such as a drying apparatus. There is.

  In order to solve the above problems, in the present invention, a raw material slurry containing a hydraulic material as a main component is formed to obtain a base material, and then a cementitious material, a resin, a pigment, and water are mixed on the base material surface. The colored cosmetic material is applied, and then the base material is allowed to pass at room temperature for 5 hours or more, and then the base material is cured in an autoclave.

  In the method for manufacturing a ceramic inorganic board according to the present invention, before the substrate is autoclaved, a colored cosmetic material formed by mixing a cement-based material, a resin, a pigment and water is applied, and the energy during autoclaving is used. Since the colored decorative material is cured, a production facility such as a drying apparatus is unnecessary, and a ceramic inorganic board having excellent weather resistance can be manufactured.

(Embodiment 1)
In the present embodiment, the ceramic-based inorganic board manufacturing method includes making a raw material slurry containing a hydraulic material as a main component, making paper, extruding or casting, and forming the cement-based material, resin, pigment on the surface of the base material obtained by molding. And a colored cosmetic material made of water is applied, and then the base material is allowed to elapse for 5 hours or more at room temperature, and then the base material is cured in an autoclave.

  The composition of the raw material slurry, papermaking, extrusion or casting conditions, molding conditions, etc. are not particularly limited, and conditions usually used in the production of inorganic plates may be applied. Moreover, it is preferable to perform normal pressure curing after performing press molding etc. as needed.

  The colored cosmetic material is composed of a cement-based material, a resin, a pigment, and water, and cement, slaked lime, steel slag, coal ash, or the like is used as the cement-based material. As the resin, an acrylic emulsion resin or an epoxy emulsion resin is used from the viewpoints of efflux resistance and adhesion to the base substrate. Here, the resin particle size is preferably 4 μm or less, and more preferably 0.5 μm or less, in order to fill a void formed by cementitious materials. Moreover, about the mixing ratio of resin, it is 1-40 mass% with respect to solid content which a coloring cosmetic material contains. When it exceeds 40% by mass, blocking between the substrates occurs during autoclave curing.

  The colored cosmetic material is applied to a substrate using an air spray or the like, and then cured at room temperature for 5 hours or more. By doing so, the reaction of the colored cosmetic material proceeds and can be sufficiently cured. And a ceramics type inorganic board can be manufactured by accumulating the obtained base material and performing autoclave curing.

  Examples and comparative examples according to the first embodiment will be described below.

(Example 1)
A cement material composed of 40 parts by mass of cement, 40 parts by mass of silica, and 20 parts by mass of slag powder, a pigment, an epoxy emulsion resin for mixing cement, and water, a cement material: pigment: an epoxy emulsion for mixing cement. Resin: water = 4: 0.4: 0.4: 23 (mass ratio) was mixed with glass beads to prepare a colored cosmetic material.

Next, a colored cosmetic material was applied to the surface of the base material after normal pressure curing using an air spray so that the solid content was 220 g / m ² .

  Then, after curing the base material at room temperature for 8 hours, the base material was stacked, and autoclave curing was performed at 170 ° C. for 10 hours to obtain a ceramic inorganic board.

(Example 2)
In Example 1, instead of the cement-mixed epoxy emulsion resin, the cement-mixed acrylic emulsion resin was used, and the mixing ratio of the colored cosmetic material was determined as follows: cement-based material: pigment: cement-mixed acrylic emulsion resin: water = A ceramic inorganic board was obtained in the same manner as in Example 1 except that the ratio was 4: 0.4: 0.7: 23 (mass ratio).

(Example 3)
Example 2 except that the mixing ratio of the colored cosmetic material in Example 2 was changed to cement material: pigment: acrylic emulsion resin for mixing with cement: water = 4: 0.4: 1: 23 (mass ratio). In the same manner as above, a ceramic inorganic board was obtained.

Example 4
In Example 2, the mixing ratio of the colored cosmetic material was carried out except that cement material: pigment: cement mixing acrylic emulsion resin: water = 4: 0.4: 2.9: 23 (mass ratio). A ceramic inorganic board was obtained in the same manner as in Example 2.

(Comparative Example 1)
In Example 1, a ceramic inorganic board was applied in the same manner as in Example 1 except that a sealer was applied instead of the colored cosmetic material, and the enamel paint was applied so that the solid content was 50 g / m ² after curing the autoclave. Obtained.

(Comparative Example 2)
In Example 1, instead of the cement-mixed epoxy emulsion resin, the cement-mixed SBR emulsion resin was used, and the mixing ratio of the colored cosmetic material was determined as follows: cement-based material: pigment: cement-mixed SBR-based emulsion resin: water = 4 : 0.4: 1: 23 (mass ratio) Except having been set as the same as Example 1, the ceramics type inorganic board was obtained.

(Comparative Example 3)
Example 2 except that the mixing ratio of the colored cosmetic material in Example 2 was changed to cement material: pigment: acrylic emulsion resin for mixing with cement: water = 4: 0.4: 4: 23 (mass ratio). In the same manner as above, a ceramic inorganic board was obtained.

(Comparative Example 4)
In Example 3, the base material coated with the colored cosmetic material was cured at room temperature for 2 hours, and then the base material was stacked and subjected to autoclave curing to obtain a ceramic inorganic board in the same manner as in Example 3. .

  About the above Examples 1 to 4 and Comparative Examples 1 to 4, the presence or absence of efflux during autoclave curing, the presence or absence of blocking during autoclave curing, the efro deterrence after construction, the adhesion after the frost damage test, and weather resistance Evaluation was performed. Here, with respect to the Efro deterrence after construction, 125 cycles (test time 1000 hours) were tested with a Dew panel tester, with 4 hours of irradiation and 4 hours of wet condition as one cycle. About the frost damage test, the peeling test by a gum tape was done after 100 cycles by ASTM-A method. As for the weather resistance, the appearance was evaluated by irradiating 3000 hours in the super UV test.

Table 1 shows the results. Here, the presence or absence of the occurrence of ephro during autoclave curing is as follows.
○: No occurrence of ephro ×: Efro is generated The presence or absence of blocking during autoclave curing is as follows.
○: No blocking occurred ×: Blocking occurred Efro deterrence after construction is as follows.
○: No ephro is generated. △: Slight ephro is generated. ×: Severe efro is generated. Adhesion after the frost damage test is as follows.
○: 5% or less peeling Δ: More than 5 and 10% or less peeling ×: 10% or more peeling Weather resistance is as follows.
○: No discomfort compared to the initial state ×: Deteriorated from the initial state

  From the results in Table 1, using epoxy and acrylic emulsion resins, setting the resin ratio in the colored cosmetic material to 1 to 40% by mass, and setting the curing time after application to 5 hours or more, the ephro and blocking are A ceramic-based inorganic board excellent in adhesion and weather resistance after frost damage was obtained.

  In this embodiment, a colored cosmetic material obtained by mixing a cement-based material, a resin, a pigment, and water is applied to a base material, and autoclaving is performed after 5 hours at room temperature. The colored decorative layer can be thickened. As a result, the ceramic inorganic board excellent in weather resistance can be manufactured at low cost.

  Moreover, since the base material is cured under normal pressure before applying the colored cosmetic material, the base material can be sufficiently dehydrated, and as a result, the base materials can be prevented from sticking to each other.

  In addition, by using an acrylic emulsion resin or an epoxy emulsion resin as the resin in the colored cosmetic material, it is excellent in effluent resistance and can improve the adhesion to the substrate.

  In addition, since the maximum particle size of the resin is 4 μm or less, it is possible to fill a void formed by cement-based materials, and as a result, it is possible to improve the durability of the base material.

  Furthermore, by setting the mixing ratio of the resin to 1 to 40% by mass with respect to the solid content contained in the colored cosmetic material, coating properties are good and blocking can be prevented.

(Embodiment 2)
In the present embodiment, the ceramic-based inorganic board manufacturing method includes making a raw material slurry containing a hydraulic material as a main component, making paper, extruding or casting, and forming the cement-based material, resin, pigment on the surface of the base material obtained by molding. And after starting mixing of the coloring cosmetic material formed by mixing water and 5 to 20 hours at room temperature, it is applied to the surface of the base material, and then the base material is autoclaved.

  The composition of the raw material slurry, the molding method, the composition of the colored cosmetic material, and the like are the same as in the first embodiment, and detailed description thereof is omitted.

  In this embodiment, after mixing the coloring cosmetic material which mixes a cement-type material, resin, a pigment, and water, after making it pass for 5 to 20 hours at normal temperature, it apply | coats to a base material. This is because if the elapsed time from the start of mixing the colored cosmetic material is less than 5 hours, the colored cosmetic material will be insufficiently cured, resulting in poor adhesion between the colored cosmetic material and the substrate after the frost damage test. On the other hand, if the elapsed time exceeds 20 hours, the colored cosmetic material is too hard to be cured, so that the viscosity of the colored cosmetic material becomes high and it is difficult to apply to the substrate.

  The method for applying the colored cosmetic material to the substrate after 5 to 20 hours at room temperature after mixing is as follows. First, as shown in FIG. 1, the apparatus comprises a mixing tank 1, a first stock tank 2, a second stock tank 3, and a coating machine 4 for mixing cement-based materials, resins, pigments and water, and connecting them. The piping is provided with pumps 5 to 7 and valves 8 to 11. The colored cosmetic material 20 mixed in the mixing tank 1 is fed to the first stock tank 2 or the second stock tank 3 after at least 5 hours from the start of mixing, and further to the coating machine 4. The liquid is fed and applied to the substrate 30.

  Next, a method for controlling the apparatus will be described. As shown in FIG. 2, the colored cosmetic material 20 is not fed to the stock tank until 5 hours have passed since the colored cosmetic material was mixed in the mixing tank 1. While one of the first stock tank 2 and the second stock tank 3 is sending liquid to the coating machine, the other is in a state where the colored resin material 20 is stored. When one of the stock tanks becomes empty, the colored resin material 20 is fed from the mixing tank 1.

  A ceramic-based inorganic board can be manufactured by applying the colored cosmetic material 20 to the base material 30 using the coating machine 4 and performing the autoclave curing by overlapping the obtained base materials.

  In addition, it is preferable that the mixing tank 1, the 1st stock tank 2, and the 2nd stock tank 3 have the capacity | capacitance which can store only the part which can apply | coat a coloring cosmetic material for 5 hours or more. In this way, when one of the stock tanks becomes empty, a new colored cosmetic material can be supplied from the mixing tank, so that continuous production is possible. In addition, since it is not necessary to mix colored cosmetic materials having different mixing times in the stock tank, it is possible to apply colored cosmetic materials having a uniform mixing time.

  Hereinafter, examples and comparative examples according to the second embodiment will be described.

(Example 5)
Cement-based material consisting of 40 parts by weight of cement, 40 parts by weight of silica, and 20 parts by weight of slag powder, pigment, cement-based acrylic emulsion resin, and water, cement-based material: pigment: cement-based acrylic emulsion A colored cosmetic material was prepared by mixing with glass beads in a ratio of resin: water = 4: 0.4: 1: 23 (mass ratio). At this time, the colored cosmetic material was mixed at room temperature for 5 hours.

Next, a colored cosmetic material was applied to the surface of the base material after normal pressure curing that had been heated to 60 ° C. in advance so that the solid content would be 220 g / m ² using air spray. After application, the substrate was dried until the temperature of the substrate reached 80 ° C., and then the substrates were stacked, followed by autoclave curing at 170 ° C. for 10 hours to obtain a ceramic inorganic board.

(Example 6)
In Example 5, a ceramic inorganic board was obtained in the same manner as in Example 5 except that the mixing time of the colored cosmetic material was 12 hours.

(Example 7)
In Example 5, a ceramic inorganic board was obtained in the same manner as in Example 5 except that the mixing time of the colored cosmetic material was 20 hours.

(Comparative Example 5)
In Example 5, a ceramic inorganic board was obtained in the same manner as in Example 5 except that the mixing time of the colored cosmetic material was 2 hours.

(Comparative Example 6)
In Example 5, a ceramic inorganic board was obtained in the same manner as in Example 5 except that the mixing time of the colored cosmetic material was 24 hours.

  About the above Examples 5-7 and the comparative examples 5 and 6, the presence or absence of the generation | occurrence | production of the Efro at the time of autoclave curing, the presence or absence of the generation | occurrence | production of blocking at the time of an autoclave curing, applicability | paintability, and the adhesiveness after a frost damage test were evaluated.

Table 2 shows the results. Here, the coating properties are as follows.
○: Can be applied by spray ×: Can not be applied by spray or becomes dry spray In addition, among the evaluation items, the same items as in Examples 1 to 4 and Comparative Examples 1 to 4 were carried out in the same manner, and the result Since the symbols are the same, description thereof is omitted.

  From the results in Table 2, a ceramic inorganic board in which the coating property and the adhesion in the frost damage test did not decrease was obtained by setting the mixing time of the colored cosmetic material to 5 to 20 hours.

  In this embodiment, the surface of the base material is coated on the surface of the base material after 5 to 20 hours have passed since the start of mixing the colored cosmetic material obtained by mixing the cement-based material, resin, pigment and water. Then, since the substrate is autoclaved, the reaction of the colored cosmetic material can proceed, and the colored cosmetic material can be sufficiently cured.

  Further, by using the mixing tank system, it is possible to accurately control the mixing time of the colored cosmetic material, and furthermore, it can be continuously applied, so that the ceramic inorganic board can be efficiently manufactured.

It is a schematic diagram which shows the mixing tank system of a coloring cosmetic material. It is a flowchart which controls a mixing tank system.

Explanation of symbols

1 Mixing tank 2 First stock tank 3 Second stock tank 4 Painter 4
20 Colored cosmetic material 30 Base material

Claims (7)

Forming a raw material slurry mainly composed of hydraulic material to obtain a base material,
Next, a colored cosmetic material obtained by mixing a cement-based material, a resin, a pigment, and water is applied to the surface of the base material,
Then, after allowing the base material to pass for 5 hours or more at room temperature, the base material is subjected to autoclave curing. Forming a raw material slurry mainly composed of hydraulic material to obtain a base material,
Then, after starting mixing of the colored cosmetic material consisting of cement-based material, resin, pigment and water, after 5 to 20 hours have passed at room temperature, applied to the substrate surface,
Next, the substrate is subjected to autoclave curing. A mixing tank for mixing the colored cosmetic material;
Two or more stock tanks for storing the colored cosmetic material,
Manufacturing a ceramic-based inorganic board using a control system that controls so that the colored cosmetic material cannot be fed from the mixing tank to the stock tank unless more than 5 hours have elapsed since the mixing of the colored cosmetic material is started. The manufacturing method of the ceramics type inorganic board of Claim 2 characterized by these.   The method for producing a ceramic inorganic board according to any one of claims 1 to 3, wherein the base material is subjected to normal pressure curing before the coloring cosmetic material is applied.   The method for producing a ceramic inorganic board according to any one of claims 1 to 4, wherein the resin is an acrylic emulsion resin or an epoxy emulsion resin.   The method for producing a ceramic inorganic board according to any one of claims 1 to 5, wherein a maximum particle size of the resin is 4 µm or less. The method for producing a ceramic inorganic board according to any one of claims 1 to 6, wherein a ratio of the resin is 1 to 40% by mass in a solid content of the colored cosmetic material.

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