JP2006161221A - Compression panel reclaimed from gypsum board, method for producing the same, fireproof panel, temporary housing and simple frame house - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a panel reclaimed from gypsum board base paper that has lighter weight and high strength and satisfies demands of nonflammability/water resistance so as to be used as a building material and is used in a wide range. <P>SOLUTION: The panel 1 reclaimed from gypsum board base paper has a structure in which open-cell lattices 2 constituted of a plurality of ribs 2a, a continuous flat plate 3 covering one open part of the open-cell lattices 2, flanges 4 covering a part (circumference) of the other open part are integrally formed by a dense compressed fiber material and the shapes of the open-cell lattices 2 are approximately regular hexagonal prism shapes. Since the compressed fiber material constituting the structure is mixed with a noncombustible inorganic material (rockwool) and a waterproof material besides gypsum board base paper selected from waste gypsum board, the compressed fiber material has nonflammability/water resistance besides properties of lightweight and high strength of compressed fiber panel and an application range is enlarged in uses of building materials such as an inside wall/a partition of building and an outer wall. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention is a compressed fiber panel manufactured using gypsum board base paper separated as waste material from gypsum board frequently used as a building material, and can greatly contribute to the recycling of gypsum board that has become waste material. The present invention relates to a gypsum board recycled compression panel that has both incombustibility and light weight and can be widely used for building materials and the like, a manufacturing method thereof, a fireproof panel to which the gypsum board recycled compression panel is applied, a temporary housing, and a simple house.

  Regardless of detached houses, apartments, condominiums, and buildings, plasterboard is widely used for ceilings and wallboards of buildings. As of 2004, approximately 550 million square meters are produced annually, the most used in Japan. It has become a building material. This gypsum board is produced by pouring gypsum between two strong gypsum board papers and curing them, and the gypsum board from construction pieces and demolished houses are discarded as waste. In the case of stacking, the gypsum generated heat and the base paper of the gypsum board burned, so it was not accepted in a stable disposal site with low processing costs, and it had to be processed in a controlled disposal site with high processing costs.

However, in recent years, an apparatus for separating gypsum from gypsum board and gypsum board base paper that has become waste has been developed and used. Of these, the separated gypsum can be recycled as a raw material for gypsum board, but the gypsum board paper is difficult to recycle, and when burned, sulfur oxide compounds (SO _x ) are generated and the trees die. There was a big problem that caused acid rain, so it had to be processed at a managed disposal site with high processing costs. However, as of 2004, the amount of waste gypsum board base paper reached approximately 220,000 tons per year, and landfill disposal has reached its limit.

  Further, even when the paper is passed through a separator, 20% to 50% of gypsum is usually attached to the gypsum board base paper. When paper is made as it is, the gypsum adheres to the papermaking net and causes trouble. Therefore, it has been studied to use as a raw material for recycled paper by washing with water, but the gypsum content cannot be completely removed, and 5% to 10% are adhered, and they become gypsum water dissolved in water. The papermaking net is soiled and is an obstacle to reuse. At the same time, wastewater treatment during washing is a major problem.

Therefore, as shown in Patent Document 1, a raw material in which an aqueous solution of a water-soluble flame retardant is added to a defibrated fiber (main raw material) obtained by dry-defining gypsum board base paper is pre-molded into a mat shape, heat-compressed, and thickened. Recycling technology has been developed to form a flame retardant board of 6 mm to 20 mm.
JP 2004-122722 A

  However, the conventional flame retardant board described in Patent Document 1 is difficult to use as a building material because it is heavy with a specific gravity of 0.8 to 1.2 and has no water resistance. However, there is a problem in that it does not become a structure constituting a panel by itself and is not on the market as a product because it has no use.

  Therefore, the present invention makes use of the caking property and flame retardancy of the gypsum board base paper, and demands flame retardant or non-flammable and water resistance for use as a building material at low cost, lighter weight and high strength. It is an object of the present invention to provide a plasterboard base paper recycled panel, a method for manufacturing the same, and a fireproof panel having a wide range of uses utilizing the plasterboard base paper that can be satisfied and is currently a major obstacle to recycling building materials.

  Another object of the present invention is to provide a temporary house and a simple house to which a cheap, lightweight and high strength gypsum board recycled panel is applied.

  The gypsum board recycled paper panel according to the invention of claim 1 is prepared by adjusting the slurry obtained by defibrating the gypsum board base paper separated from the gypsum board with a pulper to weak acidity, adding a flocculant, Is poured into a formwork composed of a porous carrier formed on the entire surface and a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier, and a vacuum is applied from below the porous carrier. An open cell grid composed of a plurality of ribs, a continuous flat plate that covers one opening of the grid, and one of the other openings, which are obtained by suction and dehydration, and further compression and heating. The flange that covers the part has a structure integrally formed of a dense compressed fiber material.

  The gypsum board recycled paper panel according to the invention of claim 2 is the structure of claim 1, after adding a low cationic flocculant as the flocculant to condense suspended particles and flocking to soft floc, A strong cationic flocculant is added to agglomerate the soft flocs to form hard flocs.

  According to a third aspect of the present invention, in the gypsum board recycled paper panel, the weak acidity is a hydrogen ion concentration (pH) of about 6, and the flocculant is a cationic flocculant or an anionic flocculant. An agent is added in an amount of 0.01% to 0.2% by weight based on the paper portion of the gypsum board base paper.

  A gypsum board recycled paper panel according to a fourth aspect of the present invention has a bulk specific gravity in the range of about 0.2 to about 0.5 in any one of the first to third aspects.

  A gypsum board recycled paper panel according to a fifth aspect of the present invention is the gypsum board recycled paper panel according to any one of the first to fourth aspects, wherein the slurry is blended with a waterproofing agent.

  A gypsum board recycled paper panel according to a sixth aspect of the present invention is the one in any one of the first to fourth aspects, wherein the surface is waterproofed.

  According to a seventh aspect of the present invention, there is provided a gypsum board recycled paper panel in which the waterproof film is attached to the surface in any one of the first to fourth aspects.

  A gypsum board recycled paper panel according to an eighth aspect of the invention is the one according to any one of the first to seventh aspects, wherein the slurry is blended with rock wool and / or glass fiber as a nonflammable inorganic material. .

  A gypsum board recycled paper panel according to the invention of claim 9 is the structure of any one of claims 1 to 8, wherein two flange-side surfaces covering a part of the other opening are bonded together. Is.

  The gypsum board recycled paper panel according to the invention of claim 10 is the structure of any one of claims 1 to 8, wherein a thin steel plate is attached to the entire surface of the flange side covering a part of the other opening. It is attached.

  The gypsum board recycled paper panel according to the invention of claim 11 is the same as any one of claims 1 to 10, wherein an inorganic coating agent is applied to the continuous flat plate surface.

  A gypsum board recycled paper panel according to a twelfth aspect of the present invention is the gypsum board recycling panel according to any one of the first to tenth aspects, which is entirely immersed in an inorganic impregnating agent.

  A fireproof panel according to a thirteenth aspect of the present invention is obtained by alternately stacking the gypsum board recycled paper panel and the gypsum board according to any one of the first to fourth aspects.

  A fireproof panel according to the invention of claim 14 is formed by adhering gypsum board on both sides of the gypsum board recycled paper panel according to any one of claims 1 to 4.

  A method for producing a gypsum board recycled paper panel according to the invention of claim 15 comprises a step of defibrating a gypsum board base paper separated from the gypsum board with a pulper to obtain a slurry; After adjusting to the region, adding a flocculant to obtain a coagulated paper material that is completely solid-liquid separated, and forming the coagulated paper material as a slurry having a concentration of 0.5 to 3% on the surface of the porous carrier Poured into a mold having a plurality of fixedly placed elastomer pads and vacuum dehydrated from below the porous carrier, and a pair from above and below while vacuum sucking from below the porous carrier and dehydrated The method further comprises a step of further dehydrating by a pre-press compressed by the press plate and a hot press step of heating and compressing from above and below by a pair of press plates incorporating a heater.

  A method for producing a gypsum board recycled paper panel according to the invention of claim 16 is a method of defibrating with a pulper a gypsum board base paper separated from a gypsum board and a raw material blended with rock wool and / or glass fiber as a non-combustible inorganic material A step of obtaining a slurry, a step of adding a reinforcing agent and a water-resistant agent and adjusting to a weakly acidic region, and then adding a flocculant to obtain a coagulated paper material that has been completely solid-liquid separated, and a concentration of the coagulated paper material of 0. As a 5 to 3% slurry, it is poured into a mold having a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier, and dehydrated by vacuum suction from under the porous carrier; A process of further dewatering by a prepress that compresses with a pair of press plates from above and below while dewatering by vacuum suction from below the porous carrier, and a pair of presses with a built-in heater Those having a hot pressing process of heating compressed from above and below by.

  According to a seventeenth aspect of the present invention, there is provided a method for producing a gypsum board recycled paper panel, wherein in the structure of the fifteenth or sixteenth aspect, a low cationic flocculant is added as the flocculant to agglomerate suspended particles and soften. After flocking to flocs, a strong cationic flocculant is added to agglomerate the soft flocs into hard flocs.

  A temporary house or a simple house according to the invention of claim 18 is assembled by using a plurality of the gypsum board recycled paper panels according to any one of claims 1 to 12.

  The gypsum board recycled paper panel according to the invention of claim 1 is prepared by adjusting the slurry obtained by defibrating the gypsum board base paper separated from the gypsum board with a pulper to weak acidity, adding a flocculant, Is poured into a formwork composed of a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier drilled on the entire surface, dehydrated by vacuum suction from below the porous carrier, and An open cell lattice composed of a plurality of ribs, a continuous flat plate covering one opening of the lattice, and a flange covering a part of the other opening, obtained by compressing and heating, are dense. It is composed of a structure integrally molded with a compressed fiber material.

  Here, the gypsum board base paper separated from the gypsum board contains about 5 wt% to about 50 wt% of gypsum. Furthermore, when gypsum board base paper is defibrated with a pulper, this gypsum dissolves in water by about 0.1% to 1%. Therefore, the obtained slurry contains some gypsum, which gives the gypsum board recycled paper panel caking and flame retardancy. The dissolved fine gypsum water and the gypsum suspended in the slurry clog the micropores formed on the entire surface of the porous carrier, making it impossible to manufacture a gypsum board recycled paper panel.

  Therefore, as a result of repeated extensive experimental research by the present inventors, by adjusting the slurry to weak acidity and adding a flocculant, the free powder of gypsum coagulates with the paper content of the base paper of the gypsum board, and the gypsum water is the paper. Because it is adsorbed by the cellulose (cellulose), the problem of clogging the micropores drilled in the entire surface of the porous carrier does not occur, and highly transparent water is dehydrated from the micropores of the porous carrier. Become. In this way, the present inventors have invented a completely new method for producing a gypsum board recycled paper panel.

  The plurality of geometrically arranged elastomer pads are crushed and stretched in the lateral direction by being compressed, and the dehydrated material slurry sandwiched between them is strongly compressed into ribs. An open-cell grid having a fixed shape determined by the shape and geometric arrangement is formed. And the side of the porous carrier becomes a plurality of openings that are partially (surrounded) by the flange, and a continuous flat plate made of recycled gypsum board base paper is formed on the opposite side surface. As a result, a light-weight (bulk specific gravity of less than 0.8), tough and flame-retardant panel can be obtained.

  As mentioned above, the binder is not added to the raw material of this panel, but the reason why it becomes a tough panel is that the plaster board base paper and the plaster board base paper still adhering to the gypsum board base paper separated from the gypsum board as described above This is probably because the adhesive contained therein acts as a binder.

  Such a panel is usually used by adhering two sides of a plurality of openings together and can be used by attaching a flame-retardant or non-combustible plate material to the surfaces of the plurality of openings. And since it is lightweight, tough and flame retardant, it can be easily transported and constructed if used on room walls and partitions, and it is a low cost panel because it is a recycled product.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be satisfied, which can satisfy the requirement of flame resistance for use as a building material with lighter weight and higher strength.

  The gypsum board recycled paper panel according to the invention of claim 2 is the structure of claim 1, after adding a low cationic flocculant as the flocculant to condense suspended particles and flocking to soft floc, A strong cationic flocculant is added to agglomerate the soft flocs to form hard flocs. By using a hard flock, the drainage in papermaking becomes rapid and the yield of the material can be improved. In this way, an aggregate paper stock separated into solid and liquid is obtained for the first time through two stages of coagulation with low cationic flocculant (Coagulation) and coagulation with strong cationic flocculant (Flocculation). Gypsum board recycled paper panel can be molded smoothly.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be satisfied, which can satisfy the requirement of flame resistance for use as a building material with lighter weight and higher strength.

  According to a third aspect of the present invention, in the gypsum board recycled paper panel, the weak acidity is a hydrogen ion concentration (pH) of about 6, and the flocculant is a cationic flocculant or an anionic flocculant. An agent is added in an amount of 0.01% to 0.2% by weight based on the paper portion of the gypsum board base paper.

  As a result of repeated extensive experimental studies by the present inventors, the weak acidity has a hydrogen ion concentration (pH) of about 6, and the flocculant has a cationic flocculant or an anionic flocculant of 0.01 wt. It has been found that it is most effective to add it in the range of from 0.2% to 0.2% by weight, and the present invention has been completed based on this finding. The addition amount of the flocculant was found to be optimally 0.015% by weight with respect to the paper portion.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be satisfied, which can satisfy the requirement of flame resistance for use as a building material with lighter weight and higher strength.

  The gypsum board recycled paper panel according to the invention of claim 4 has a bulk specific gravity in the range of about 0.2 to about 0.5. Thus, even if the bulk specific gravity is reduced, the gypsum board recycled paper panel according to the present invention can ensure sufficient strength, and the labor for transportation and construction can be remarkably reduced by using it as a building material. Can contribute to the ease and speed of construction. And because it is lightweight, tough and flame retardant, it can be easily transported and constructed if used on room walls and partitions, and it is a low cost panel because it is a recycled product.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be satisfied, which can satisfy the requirement of flame resistance for use as a building material with lighter weight and higher strength.

  In the gypsum board recycled paper panel according to the invention of claim 5, a waterproofing agent is blended in the raw slurry. As a result, the recycled gypsum board base paper panel has not only flame retardancy but also water resistance, water resistance and water repellency, and it can be used not only for interior walls and partitions, but also for outdoor applications such as exterior walls. It will be tolerable. In addition, since an operation of applying an inorganic water permeation preventive agent to the surface after molding the gypsum board recycled paper panel is unnecessary, the cost is further reduced.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be obtained that can satisfy the requirements of lighter weight, higher strength, flame resistance and water resistance for use as a building material.

  The gypsum board recycled paper panel according to the invention of claim 6 has a waterproof surface. Here, examples of the waterproofing method include a method of applying an inorganic water permeation preventive agent on the surface. Thus, the gypsum board recycled paper panel of the present invention has not only flame retardancy but also waterproof, water resistance and water repellency, and not only for applications such as internal walls and partitions, but also for outdoor applications such as external walls. Can withstand. Moreover, since the prevention treatment can be performed only on the necessary portions after the gypsum board base paper recycled panel is molded, the waterproof property can be more reliably imparted.

  In this way, a gypsum board recycled paper panel having a wide range of uses can be obtained that can satisfy the requirements of lighter weight, higher strength, flame resistance and water resistance for use as a building material.

  The gypsum board recycled paper panel according to the invention of claim 7 has a waterproof film attached to the surface. As a result, the gypsum board recycled paper panel of the present invention has stronger waterproofness, water resistance, and water repellency, and can withstand outdoor applications such as external walls as well as internal walls and partitions. It becomes. And since a waterproof film can be affixed on the surface after shape | molding a gypsum board base paper reproduction | regeneration panel and bonding two sheets at a time etc., waterproofness can be provided more reliably.

  In this way, a gypsum board recycled paper panel that can satisfy the requirement of water resistance for use as a building material with lighter weight and higher strength and has a wide range of uses.

  The gypsum board recycled paper panel according to the invention of claim 8 is obtained by blending rock wool and / or glass fiber as a nonflammable inorganic material in a raw slurry. As a result, the gypsum board recycled paper panel of the present invention becomes a non-flammable panel that is much better than flame retardancy, and also has waterproof, water resistance, and water repellency. It can withstand outdoor use such as.

  In this way, the gypsum board recycled paper panel can be used in a wide range of applications that can meet the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength.

  The recycled gypsum board base panel according to the invention of claim 9 is obtained by bonding two flange-side surfaces that cover a part of the other opening. As a result, both sides of the gypsum board recycled paper panel are formed into a continuous plate shape, making it easy to use as a panel.

  In this way, a gypsum board recycled paper panel that can satisfy the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength, has a wide range of uses, and can be used in various applications Become.

  The gypsum board recycled paper panel according to the invention of claim 10 is obtained by attaching a thin steel plate to the entire surface of the flange side covering a part of the other opening. Thus, the fire resistance can be given to the thin steel plate without impairing the light weight of the gypsum board recycled paper panel, and the use can be further expanded.

  In this way, a gypsum board recycled paper panel that can meet the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength, has a wide range of uses, and can be used in various applications Become.

  The gypsum board recycled paper panel according to the invention of claim 11 is the same as any one of claims 1 to 10, wherein an inorganic coating agent is applied to the continuous flat plate surface. Thereby, further flame retardancy and further non-flammability can be imparted to the surface of the gypsum board recycled paper panel, and the use can be further expanded.

  In this way, a gypsum board recycled paper panel that can meet the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength, has a wide range of uses, and can be used in various applications Become.

  A gypsum board recycled paper panel according to a twelfth aspect of the present invention is the gypsum board recycling panel according to any one of the first to tenth aspects, which is entirely immersed in an inorganic impregnating agent. Thereby, the inorganic impregnating agent is impregnated in the entire gypsum board recycled paper panel, so that further flame retardancy and further non-combustibility can be imparted, and the use can be further expanded.

  In this way, a gypsum board recycled paper panel that can satisfy the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength, has a wide range of uses, and can be used in various applications Become.

  A fireproof panel according to the invention of claim 13 is formed by alternately laminating gypsum board recycled paper panels and gypsum boards. In this way, by alternately laminating gypsum board recycled paper panels and gypsum board that can be manufactured at low cost by recycling, it is possible to make a panel with lower cost and superior fire resistance, and also reduce weight. Can do.

  In this way, a fire-resistant panel that is lower in cost and light in weight and excellent in fire resistance is obtained.

  The fireproof panel according to the invention of claim 14 is obtained by bonding a gypsum board on both sides of a gypsum board recycled paper panel. In this way, by sandwiching the gypsum board recycled paper panel that can be produced at low cost by recycling with the gypsum board, it is possible to obtain a panel with lower cost and excellent fire resistance, and also to reduce the weight.

  In this way, a fire-resistant panel that is lower in cost and light in weight and excellent in fire resistance is obtained.

  A method for producing a gypsum board recycled paper panel according to the invention of claim 15 comprises a step of defibrating a gypsum board base paper separated from the gypsum board with a pulper to obtain a slurry; After adjusting to the region, adding a flocculant to obtain a solid paper that is completely solid-liquid separated, and geometrically arranging this as a slurry with a concentration of 0.5 to 3% on the plate surface of the porous carrier A process of pouring into a mold having a plurality of fixed elastomer pads, vacuum suction from under the porous carrier and dehydrating, and a pair of press plates from above and below while vacuum suctioning from under the porous carrier and dewatering The method further comprises a step of further dehydrating by a pre-press compressed by the above and a hot press step of heating and compressing from above and below by a pair of press plates incorporating a heater.

  Here, the reason for adjusting to the weakly acidic region is to increase the yield of other additives and to improve the yield and drainage by fixing to an inorganic material because the paper stock is alkaline. And since the reinforcement | strengthening agent and the water-resistant agent are added to the slurry obtained by defibrating the gypsum board base paper with a pulper, the high-strength and excellent water-resistance gypsum board base paper recycled panel can be obtained.

  In this way, it is possible to meet the requirements of flame resistance and water resistance for use as a building material with lighter weight and higher strength, and a method for producing a gypsum board recycled paper panel having a wide range of uses.

  A method for producing a gypsum board recycled paper panel according to the invention of claim 16 is a method of defibrating with a pulper a gypsum board base paper separated from a gypsum board and a raw material blended with rock wool and / or glass fiber as a non-combustible inorganic material A step of obtaining a slurry, a step of adding a reinforcing agent and a water-resistant agent and adjusting to a weakly acidic region, and then adding a flocculant to obtain a coagulated paper material that is completely solid-liquid separated, and a concentration of the coagulated paper material of 0.5 As a slurry of ˜3%, it is poured into a mold having a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier, and dehydrated by vacuum suction from under the porous carrier; A process of further dewatering by a pre-press compressed by a pair of press plates from above and below while being vacuum-dehydrated and dehydrated from the bottom of the conductive carrier, and a pair of press plates with a built-in heater Ri is for and a hot pressing step of hot compression from above and below.

  Here, the reason for adjusting to the weakly acidic region is to increase the yield of other additives and to improve the yield and drainage by fixing to an inorganic material because the paper stock is alkaline. In addition, rock wool and / or glass fiber is blended into gypsum board paper as a raw material, and a reinforcing agent and a water-resistant agent are added to the slurry obtained by defibrating this raw material with a pulper. Thus, it is possible to obtain a gypsum board recycled paper panel having excellent water resistance.

  In this way, the gypsum board recycled paper manufacturing method can be used for a wide range of uses that can satisfy the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength.

  In the method for producing a gypsum board recycled paper panel according to the invention of claim 17, a low cationic flocculant is added as a flocculant to agglomerate suspended particles to form a soft floc, and then a strong cationic flocculant is added. It is added to agglomerate soft flocs to form hard flocs. By using a hard flock, the drainage in papermaking becomes rapid and the yield of the material can be improved. In this way, a coagulation paper stock that is completely solid-liquid separated is obtained for the first time through two stages of coagulation with a low cationic coagulant (Coagulation) and coagulation with a strong cationic coagulant (Flocculation). Therefore, it is possible to smoothly form a plasterboard base paper recycled panel.

  In this way, the gypsum board recycled paper manufacturing method can be used for a wide range of uses that can satisfy the requirements of non-flammability and water resistance for use as a building material with lighter weight and higher strength.

  A temporary house or a simple house according to the invention of claim 18 is assembled by using a plurality of the gypsum board recycled paper panels according to any one of claims 1 to 12. In particular, it is preferably non-flammable and water-resistant, and the two gypsum board recycled paper flange panels are bonded together.

  As seen in the Niigata Chuetsu earthquake that occurred in late October of this year (2004), people who lost their homes due to large earthquakes, typhoons, landslides, debris flows, fires, etc. are refuges such as school gymnasiums. Some people are forced to live temporarily for a long time in tents and tents, and their mental and physical distress is immeasurable. However, it takes nearly one month to build a temporary housing at the earliest, and the cost for that is huge. Therefore, by assembling a temporary housing using a plurality of cheap, lightweight and high-strength gypsum board recycled panels, if it is used as a temporary housing until the temporary housing is built, at least a shelter or tent It is thought that mental and physical stress is reduced rather than living for a long time.

  In addition, from a global perspective, there are currently insufficient housing in developing countries in poor regions such as Africa. Therefore, it is possible to solve the shortage of houses by building a simple house using a plurality of gypsum board recycled paper panels which are easy to assemble with a simple panel structure and are lightweight and flame retardant and water resistant. Especially in the desert area, the difference in temperature between day and night is severe and intense sandstorms blow, so tents are not enough. With a gypsum board recycled paper panel that has thermal insulation and can prevent sandstorms, a simple house that can surpass the weather can be built. Moreover, because of the light weight of the gypsum board recycled paper panel, it can be easily transported in large quantities overseas and is useful as part of development assistance such as ODA (Government Development Assistance).

  In this way, it becomes a temporary house or a simple house as one application of the gypsum board recycled paper panel that can satisfy the requirements of non-combustibility and water resistance for use as a building material at low cost, light weight and high strength.

  Embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
First, Embodiment 1 of the present invention will be described with reference to FIGS.

  FIG. 1A is a perspective view showing a part of a completed state of a gypsum board base paper recycled panel according to Embodiment 1 of the present invention, and FIG. 1B is a partially enlarged plan view thereof. Fig.2 (a) is a perspective view which shows the formwork for manufacturing the gypsum board base paper recycled panel concerning Embodiment 1 of this invention, (b) is the elements on larger scale. FIGS. 3A, 3B, and 3C are explanatory views showing the procedure of the method for manufacturing the gypsum board recycled paper panel according to the first embodiment of the present invention. FIG. 4 is an explanatory view showing a process of forming the flange of the gypsum board recycled paper panel according to the first embodiment of the present invention. FIG. 5 is a partially cutaway perspective view showing a state where two plasterboard base paper recycled panels according to the first embodiment of the present invention are bonded to each other on the flange side.

  As shown in FIGS. 1 (a) and 1 (b), a gypsum board recycled paper panel 1 according to the first exemplary embodiment includes an open cell grid 2 composed of a plurality of ribs 2a and one of the open cell grids 2. The continuous flat plate 3 covering the opening of the other and the flange 4 covering a part (periphery) of the other opening have a structure integrally formed of a dense compressed fiber material, and the open cell lattice 2 The shape is substantially a regular hexagonal column. And about 20 weight% of the compressed fiber material which comprises the gypsum board base paper recycled panel 1 consists of a nonflammable inorganic material (rock wool), and about 80 weight% consists of the gypsum board base paper isolate | separated from the waste gypsum board.

  And the waterproofing agent is also mix | blended with the raw material. As a result, the gypsum board recycled paper panel 1 also has water repellency, water resistance, and water resistance. The gypsum board recycled paper panel 1 is non-combustible in addition to the characteristics of the compressed fiber panel that is lightweight and high in strength.・ Because it also has water resistance, it can also be used for building materials such as inner walls / partitions of buildings and outer walls where combustible compressed fiber panels made of 100% recovered pulp could not be used. The range will be expanded.

  Next, a mold for producing the gypsum board recycled paper panel 1 according to the first embodiment will be described with reference to FIG. As shown in FIGS. 2 (a) and 2 (b), the mold 11 for producing the gypsum board recycled paper panel 1 according to the first embodiment has a large number of small holes 12a formed on the entire surface. A porous carrier 12 made of a metal plate, a number of elastomer pads 13 fixed to the porous carrier 12 with a predetermined geometrical arrangement and mutual spacing, and a stop plate 14 surrounding the porous carrier 12 are centered. It is configured as.

  As a method of fixing the elastomer pad 13 to the porous carrier 12, in the first embodiment, the metal porous carrier 12 coated with a primer is pressed against an unsolidified elastomer put into a mold, After the solidification, the porous carrier 12 and the elastomer pad 13 were integrated. The elastomeric pad 13 is usually arranged evenly on the surface of the porous carrier 12 by a geometric pattern. The elastomer pad 13 can be formed of any material as long as it has sufficient elastomer elasticity. For example, various synthetic rubbers including silicon rubber, chlorobrene rubber, etc. can be used. In the first embodiment, silicon rubber having particularly excellent characteristics in terms of durability and elasticity is used.

  Furthermore, in the first embodiment, as shown in the enlarged view of FIG. 2 (b), the open cross section of the plasterboard base paper recycled panel 1 is obtained by making the cross section of the elastomer pad 13 a substantially regular hexagon. 2 has a substantially regular hexagonal prism shape. When the elastomer pad 13 is not pressurized, the ratio of the diameter d of the top of the elastomer pad 13 to the diameter e of the bottom is preferably d / e ≦ 1.2. If d / e> 1.2, the flange portion may be broken during demolding. Further, by making the hardness of the elastomer pad 13 softer and flexible, when a pressure is applied to the porous carrier 12 in a vertical direction, the elastomer pad 13 is consolidated into a portion surrounding the base portion of each elastomer pad 13. The amount of deposited fibers can be increased and the area of the flange 4 protruding into the open cell grid 2 can be increased.

  In the first embodiment, the elastomer pad 13 has a sufficient height and flexibility, and when pressed perpendicular to the porous carrier 12, the fiber material around the base of the elastomer pad 13 Is pressed against the porous carrier 12 and compressed where it adheres to the porous carrier 12. This is because since the elastomer pad 13 is fixed to the porous carrier 12, it is impossible to locally extend the elastomer pad 13 in the direction parallel to the surface of the porous carrier 12 at the base of the elastomer pad 13. Occur. The resulting pressure captures a portion of the deposited fibers around the base of the elastomeric pad 13 and compresses to form a flange 4 that is integrally formed with the portion 2b that forms the walls or ribs of the open cell grid 2.

  Such a flange 4 can reinforce the grid 2 and increase the rigidity of the gypsum board recycled paper panel 1 by covering about 5% to about 15% of the area in the open cell grid 2. In addition, this gypsum board base paper recycled panel 1 can be used alone, but in the case of forming a multilayer gypsum board base paper recycled panel in which two or more gypsum board base paper recycled panels 1 are bonded together, The contact area for can be increased. As an application of building materials, etc., the two plasterboard base paper recycled panels 1 are usually bonded together by bonding the flanges 4 side and used as a board without an opening.

  Example 1 of a specific manufacturing method will be described with reference to FIGS. The raw materials are 100% by weight of gypsum board base paper separated from waste gypsum board, 2% by weight of anionic acrylic resin, 1.5% by weight of low cationic epoxy resin, and a paraffin emulsion as a neutral waterproofing agent. The mixture was 3% by weight, and wet defibrated with a laboratory pulper to obtain a slurry. The slurry concentration was adjusted to 3.0%, and further adjusted to pH 6 with aluminum sulfate. Considering the drainage of the slurry, a strong cationic flocculant was added to obtain an agglomerated paper material that was completely solid-liquid separated.

  The agglomerated paper stock thus produced is poured into a mold 11 as a slurry S1 having a concentration of 1.2%, and vacuumed by a vacuum pump 16 from below the porous carrier 12 of the mold 11 as shown in FIG. Molded by suction. In this case, the drain time was 45 to 50 seconds, and the water content after demolding was 75% by weight. Thereafter, a pre-press dehydration process shown in FIG. 3B was performed for 5 seconds, and a hot press process shown in FIG. 3C was performed for 13 minutes to obtain a gypsum board recycled paper panel 1 as a molded product.

  The obtained gypsum board recycled paper panel 1 has flame retardancy that is not easily ignited, and can further increase nonflammability by sticking a steel plate to the surface or applying an inorganic coating. In addition, it has moderate water resistance and is hardly affected by water.

  Here, in the compression dehydration step by the pre-press shown in FIG. 3B and the hot press step shown in FIG. 3C, the upper mold 15A is attached to the elastomer pad 13 fixed on the porous carrier 12. , 17A, pressure is applied to the porous carrier 12 in the vertical direction via the deposited fibers S2 and S3. Then, the elastomer pad 13 is deformed from the original trapezoidal cross-sectional shape to the cross-sectional shape as shown in FIG. Since the bottom portion of the elastomer pad 13 is fixed to the porous carrier 12, the size of the bottom portion hardly changes. However, the middle part of the elastomer pad 13 spreads horizontally due to the pressure applied from above. By this expansion action, the accumulated fibers are not only compressed and strengthened in the horizontal direction but also in the horizontal direction.

  When the pressure by the upper mold 17A is released, the elastomer pad 13 returns to its original shape by the elastic force of the elastomer pad 13 as shown in FIG. Then, as shown in FIGS. 4B and 4C, the flange 4 protrudes over the entire circumference at the opening of the finished gypsum board recycled paper panel 1.

  As shown in FIG. 5, the gypsum board recycled paper panel 1 manufactured in this way is bonded to the two flanges 4 side to form a single board 1A. It will be used for the purpose of. At this time, since the area of the flange 4 is large, the bonding area can be widened, and the flame-retardant gypsum board base paper recycled panel 1A for building materials that is firmly bonded is obtained.

  Next, Example 2 of a specific manufacturing method will be described with reference to FIG. As raw materials, 30% by weight of gypsum board base paper separated from waste gypsum board, 70% by weight of rock wool, 2% by weight of anionic acrylic resin, 1.5% by weight of low cationic epoxy resin, neutral waterproofing A paraffin emulsion as an agent was blended at 3% by weight, and wet defibrated and mixed with a laboratory pulper to obtain a slurry. The slurry concentration was adjusted to 3.0% and further adjusted to pH 6 with aluminum sulfate. Considering the drainage of the slurry, a strong cationic flocculant was added to obtain an agglomerated paper material that was completely solid-liquid separated. As the non-combustible inorganic material, glass fiber, hydrous magnesium silicate (sepiolite), attapulgite and the like can be used besides rock wool.

  The agglomerated paper stock thus produced is poured into a mold 11 as a slurry S1 having a concentration of 1.2%, and vacuumed by a vacuum pump 16 from below the porous carrier 12 of the mold 11 as shown in FIG. Molded by suction. In this case, the drain time was 45 to 50 seconds, and the water content after demolding was 75% by weight. Thereafter, a pre-press dehydration step shown in FIG. 3B and a hot press step 13 minutes shown in FIG. 3C were passed through to obtain a gypsum board recycled paper panel as a molded product.

As a result of testing the nonflammability of the obtained gypsum board base paper recycled panel, the total calorific value is 8 MJ / m ² or less, which is a measure of nonflammability, and it is found that it is nonflammable.

Embodiment 2
Next, Embodiment 2 of the present invention will be described with reference to FIG. FIG. 6 is a perspective view showing a completed state of the plasterboard base paper recycled panel according to the second embodiment of the present invention.

  As shown in FIG. 6, the gypsum board base paper recycled panel 20 according to the second embodiment has a thickness of about 0.5 mm on the flange 4 side of the gypsum board base paper recycled panel 1 according to the first embodiment. The steel plate 21 is bonded using an epoxy adhesive as an adhesive. The manufacturing method of the gypsum board base paper recycled panel 1 is the same as that described in the first embodiment, and an adhesive is applied to the entire surface of the flange 4 of the manufactured gypsum board base paper recycled panel 1 so that the A steel plate 21 having a thickness of 0.8 mm is placed and bonded under pressure.

  Since the gypsum board recycled paper panel 20 thus completed is covered on one side with the steel plate 21, this side is nonflammable and also has fire resistance. Therefore, it can be applied to the surface of buildings that require fireproof properties, and without loss of lightness. Furthermore, since it is thinner than the board on which two plasterboard baseboard recycled panels 1 are laminated, it is transported and constructed. Is easy, and it becomes an excellent fireproof panel for exterior walls of building materials. In the second embodiment, the thin steel plate 21 is attached to the flange 4 side of the gypsum board recycled paper panel 1 with an organic adhesive or an inorganic adhesive, but instead of the thin steel plate 21. A thin board made of an incombustible inorganic material (rock wool, glass fiber, sepiolite, attapulgite, etc.) may be attached with an organic adhesive or an inorganic adhesive.

Embodiment 3
Next, Embodiment 3 of the present invention will be described with reference to FIGS. FIG. 7: is a perspective view which shows the completion state of the fireproof panel concerning Embodiment 3 of this invention. FIG. 8: is a perspective view which shows the completion state of the fireproof panel concerning the modification of Embodiment 3 of this invention.

  As shown in FIG. 7, the fireproof panel 25 according to the third embodiment is formed by alternately stacking the gypsum board 26 and the gypsum board recycled paper panel 1 according to the first embodiment. As the gypsum board 26, a gypsum board having a thickness of 5 mm to 20 mm is usually manufactured and distributed. However, the fireproof panel 25 according to the third embodiment uses a thin gypsum board 26 having a thickness of 5 mm. ing. The gypsum board recycled paper panel 1 is also thin and has a thickness of 10 mm. The gypsum board 26 and the gypsum board recycled paper panel 1 are laminated by applying an inorganic foam adhesive to the entire surface, and a predetermined number of sheets are laminated.

  In the third embodiment, as shown in FIG. 7, the fireproof panel 25 is completed by alternately bonding four gypsum boards 26 and three plasterboard base paper recycled panels 1. Thus, since the nonflammable gypsum board 26 is arrange | positioned in both surfaces in the fireproof panel 25, it is not necessarily necessary to pinch | interpose the nonflammable gypsum board raw paper recycled panel 1, and it isolate | separates from a waste material gypsum board as a raw material. It is also possible to sandwich a flame-retardant gypsum board recycled paper panel manufactured by the same procedure as in the first embodiment using only the gypsum board raw paper.

  This eliminates the need for blending rock wool or glass fiber as a non-combustible inorganic material, so that raw material costs can be kept low, and the manufacturing process is simplified, thereby further reducing costs.

  Next, a fireproof panel according to a modification of the third embodiment will be described with reference to FIG. As shown in FIG. 8, the fireproof panel 27 according to the modification of the third embodiment is obtained by sandwiching both sides of the gypsum board recycled paper panel 1 according to the first embodiment with two gypsum boards 26. It is. As described above, a gypsum board having a thickness of 5 mm to 20 mm is usually manufactured and distributed. However, the fireproof panel 27 according to the modification of the third embodiment is thicker than the fireproof panel 25. A gypsum board 26 having a thickness of 10 mm is used. Further, as the gypsum board base paper recycled panel 1, a slightly thick one having a thickness of 15 mm is used. These gypsum boards 26 are bonded to both sides of the gypsum board recycled paper panel 1 by applying an inorganic foamed adhesive to form a fireproof panel 27.

  As described above, since the non-combustible gypsum board 26 is disposed on both sides of the fireproof panel 27, it is not always necessary to sandwich the non-combustible gypsum board recycled paper panel 1 between them and separated from the waste gypsum board as a raw material. The fire retardant gypsum board base paper recycled panel manufactured by the same procedure as in the first embodiment may be sandwiched using only the gypsum board base paper made. This eliminates the need for blending rock wool or glass fiber as a non-combustible inorganic material, so that raw material costs can be kept low, and the manufacturing process is simplified, thereby further reducing costs.

Embodiment 4
Next, a temporary house according to the fourth embodiment of the present invention will be described. The temporary house according to the fourth embodiment is assembled by using a plurality of plasterboard base paper recycled panels 1A in which the flange 4 sides of the plasterboard base paper recycled panel 1 shown in FIG. This plasterboard base paper recycled panel 1A has nonflammability and water resistance, has no opening, and is suitable for use on the ceiling and outer wall of a temporary house.

  As seen in the Niigata Chuetsu earthquake that occurred in late October of this year (2004), people who lost their homes due to large earthquakes, typhoons, landslides, debris flows, fires, etc. are refuges such as school gymnasiums. Some people are forced to live temporarily for a long time in tents and tents, and their mental and physical distress is immeasurable. However, it takes nearly one month to build a temporary housing at the earliest, and the cost for that is huge. Therefore, by assembling a temporary housing by using a plurality of cheap, lightweight and high strength gypsum board recycled panels 1A, if it is used as a temporary housing until the temporary housing is constructed, at least a shelter or Rather than living in a tent for a long time, it is thought that mental and physical stress is reduced.

  In addition, from a global perspective, there are currently insufficient housing in developing countries in poor regions such as Africa. Therefore, it is possible to solve the shortage of houses by building a simple house using a plurality of gypsum board recycled panels 1A that are easy to assemble with a simple panel structure and are lightweight, flame retardant and water resistant. . Especially in the desert area, the difference in temperature between day and night is severe and intense sandstorms blow, so tents are not enough. With a gypsum board recycled paper panel 1A that has heat insulation properties and can prevent sandstorms, a simple house that can surpass wind and rain can be built. Moreover, because of the light weight of the gypsum board recycled paper panel 1A, it can be easily transported in large quantities overseas, and is part of development assistance for ODA and the like.

  As described above, the temporary housing and the simple housing according to the fourth embodiment of the present invention are a gypsum board recycled paper panel that can satisfy the demand for non-combustibility and water resistance for use as a building material at low cost, light weight, and high strength. One of the uses.

  In each of the above embodiments, the case where the cross-sectional shape of the elastomer pad 13 is a substantially regular hexagon has been described. However, an elastomer pad having another cross-sectional shape may be used.

  In carrying out the present invention, the construction, shape, quantity, material, size, connection relationship, etc. of the other parts of the gypsum board base paper recycled panel and the fireproof panel, other steps of the method for manufacturing the gypsum board base paper recycled panel Is not limited to the above embodiments.

FIG. 1A is a perspective view showing a part of a completed state of a gypsum board base paper recycled panel according to Embodiment 1 of the present invention, and FIG. 1B is a partially enlarged plan view thereof. Fig.2 (a) is a perspective view which shows the formwork for manufacturing the gypsum board base paper recycled panel concerning Embodiment 1 of this invention, (b) is the elements on larger scale. FIGS. 3A, 3B, and 3C are explanatory views showing the procedure of the method for manufacturing the gypsum board recycled paper panel according to the first embodiment of the present invention. FIG. 4 is an explanatory view showing a process of forming the flange of the gypsum board recycled paper panel according to the first embodiment of the present invention. FIG. 5 is a partially cutaway perspective view showing a gypsum board base paper recycled panel in which two plasterboard base paper recycled panels according to Embodiment 1 of the present invention are bonded to each other on the flange side. FIG. 6 is a perspective view showing a completed state of the plasterboard base paper recycled panel according to the second embodiment of the present invention. FIG. 7: is a perspective view which shows the completion state of the fireproof panel concerning Embodiment 3 of this invention. FIG. 8: is a perspective view which shows the completion state of the fireproof panel concerning the modification of Embodiment 3 of this invention.

Explanation of symbols

1, 1A, 20 Gypsum board recycled paper panel 2 Open cell lattice 3 Continuous flat plate 4 Flange 11 Mold 12 Porous carrier 13 Elastomer pads 15A, 15B, 17A, 17B Press plates 18A, 18B Heating heater 21 Thin steel plates 25, 27 Fireproof panel 26 Gypsum board

Claims (18)

  The slurry obtained by defibrating the gypsum board base paper separated from the gypsum board with a pulper is adjusted to weak acidity, and after adding a flocculant, the porous carrier with fine pores formed on the entire surface and the porosity By pouring into a formwork composed of a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the carrier, vacuum suctioning from below the porous carrier, dehydrating, and further compressing and heating The obtained open cell lattice composed of a plurality of ribs, a continuous flat plate covering one opening of the lattice, and a flange covering a part of the other opening are integrated with a dense compressed fiber material. Gypsum board recycled paper panel with a molded structure.   A low cationic flocculant is added as the flocculant to condense suspended particles to form a soft floc, and then a strong cationic flocculant is added to aggregate the soft floc to form a hard floc. The gypsum board recycled paper panel according to claim 1 characterized by the above-mentioned.   The weak acidity has a hydrogen ion concentration (pH) of about 6, and the flocculant is added with 0.01% to 0.2% by weight of a cationic flocculant or an anionic flocculant with respect to the paper portion of the base paper of the gypsum board. The gypsum board base paper recycled panel according to claim 1 or 2, characterized by the above-mentioned.   The gypsum board recycled paper panel according to any one of claims 1 to 3, wherein the bulk specific gravity is in the range of about 0.2 to about 0.5.   The gypsum board recycled paper panel according to any one of claims 1 to 4, wherein a waterproofing agent is blended in the slurry.   The gypsum board recycled paper panel according to any one of claims 1 to 4, wherein the surface is waterproofed.   The gypsum board recycled paper panel according to any one of claims 1 to 4, wherein a waterproof film is attached to the surface.   The gypsum board recycled paper panel according to any one of claims 1 to 7, wherein rock wool and / or glass fiber is blended in the slurry as an incombustible inorganic material.   The plasterboard base paper recycling panel according to any one of claims 1 to 8, wherein two flange-side surfaces covering a part of the other opening are bonded to each other.   The gypsum board recycled paper panel according to any one of claims 1 to 8, wherein a thin steel plate is attached to the entire surface of the flange side that covers a part of the other opening.   The gypsum board recycled paper panel according to any one of claims 1 to 10, wherein an inorganic coating agent is applied to the continuous flat plate surface.   The gypsum board recycled paper panel according to any one of claims 1 to 10, wherein the whole is immersed in an inorganic impregnating agent.   5. A fireproof panel, wherein the gypsum board recycled paper panel and the gypsum board according to any one of claims 1 to 4 are alternately laminated.   A fireproof panel comprising a gypsum board laminated on both sides of the gypsum board recycled paper panel according to any one of claims 1 to 4. A step of defibrating the gypsum board base paper separated from the gypsum board with a pulper to obtain a slurry;
Adding a toughening agent and a water-resistant agent, adjusting to a weakly acidic region, and then adding a flocculant to obtain a solid paper that is completely solid-liquid separated;
The agglomerated paper stock is poured into a mold having a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier as a slurry having a concentration of 0.5 to 3%, and vacuumed from below the porous carrier. Sucking and dehydrating; and
A step of further dewatering by a pre-press compressed from above and below by a pair of press plates while dewatering by vacuum suction from under the porous carrier;
A method for producing a gypsum board recycled paper panel, comprising: a hot press process in which a pair of press plates incorporating a heater is heated and compressed from above and below. A process of obtaining a slurry by defibrating a gypsum board base paper separated from a gypsum board and a raw material containing rock wool and / or glass fiber as a non-combustible inorganic material with a pulper;
Adding a toughening agent and a water-resistant agent, adjusting to a weakly acidic region, and then adding a flocculant to obtain a solid paper that is completely solid-liquid separated;
The agglomerated paper stock is poured into a mold having a plurality of elastomer pads geometrically arranged and fixed on the plate surface of the porous carrier as a slurry having a concentration of 0.5 to 3%, and vacuumed from below the porous carrier. Sucking and dehydrating; and
A step of further dewatering by a pre-press compressed from above and below by a pair of press plates while dewatering by vacuum suction from under the porous carrier;
A method for producing a gypsum board recycled paper panel, comprising: a hot press process in which a pair of press plates incorporating a heater is heated and compressed from above and below.   A low cationic flocculant is added as the flocculant to condense suspended particles to form a soft floc, and then a strong cationic flocculant is added to aggregate the soft floc to form a hard floc. The method for producing a gypsum board recycled paper panel according to claim 15 or 16, characterized in that:   A temporary house or a simple house, which is assembled by using a plurality of the gypsum board recycled paper panels according to any one of claims 1 to 12.

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