JP2006175829A - Manufacturing method of composite material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a composite material which can have sound insulation properties (sound insulation, sound absorption), fire prevention and fire resistance, lightweight nature, outstanding compression and tensile strength (outstanding plastic deformation nature), moisture permeability or the like, and which can be used also as a structure proof strength surface material. <P>SOLUTION: In a manufacturing method of the composite material, a green body (II) is made by forming a raw material composition (II), which is rich in wood based fiber or synthetic polymer based fiber and is obtained by blending the wood based fiber or the synthetic polymer based fiber with a raw material composition (I) for obtaining an inorganic based plate or sheet, into a plate or sheet. A green body (I) which is a plate or sheet made by forming the raw material composition (I) is laminated with the green body (II). Subsequently, the hydrothermal or curing treatment of the laminate is carried out. In addition, even if a cross-head speed increases from 5 mm/minute to 50 mm/minute in a three-point bending test, the distortion plastic deformation amount of the composite material increases. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a composite material, and more particularly to a method for manufacturing a composite material including layers having different contents of wood-based fibers or synthetic polymer fibers.

  Conventionally, in order to obtain characteristics that cannot be obtained with a single plate material or sheet material, many studies have been made on laminating plate materials or sheet materials of different materials. However, in addition to excellent compressive and tensile strength, it has been difficult to obtain a composite material that can have excellent plastic deformability, moisture permeability, and the like and can also be used as a structural load bearing material.

  The present invention can have soundproofing (sound insulation / sound absorption), fireproofing / fireproofing, light weight, excellent compression and tensile strength (excellent plastic deformation), moisture permeability, etc., and can also be used as a structural load bearing material. The present invention provides a method for producing a composite material.

The present invention provides the following inventions in order to solve the above problems.
(1) Raw material rich in wood fiber or synthetic polymer fiber obtained by blending wood fiber or synthetic polymer fiber with raw material composition (I) for obtaining inorganic board or sheet material A green body (II) in which the composition (II) is formed into a plate or a sheet is obtained, and the green body (I) in which the raw material composition (I) is formed into a plate or a sheet and the green body (II) are obtained. Laminate, and then hydrothermal or curing curing treatment to obtain a composite material having the property of increasing the strain plastic deformation amount even if the crosshead speed is increased from 5 mm / min to 50 mm / min in the three-point bending test Manufacturing method of the characteristic composite material;
(2) The composite material according to (1), wherein the inorganic plate or sheet material has a characteristic that the amount of strain plastic deformation increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min in a three-point bending test. Manufacturing method;
(3) The method for producing a composite material according to (1) or (2), wherein the raw material composition (I) may contain a wood fiber or a synthetic polymer fiber;
(4) The method for producing a composite material according to any one of (1) to (3), wherein the wood fiber is pulp or plant fiber;
(5) The method for producing a composite material according to (1) or (2), wherein the content of the wood fiber or the synthetic polymer fiber in the green body (II) is 2 to 8 wt%;
(6) The method for producing a composite material according to (1) or (2), wherein the content of the wood fiber or the synthetic polymer fiber in the green body (II) is 3 to 6 wt%;
(7) The method for producing a composite material according to (1) or (2), which is pressure-bonded after lamination;
(8) The method for producing a composite material according to (7), wherein the pressure bonding is a dehydration press;
(9) The composite material has the characteristics that even when the crosshead speed is increased from 5 mm / min to 50 mm / min, the strain plastic deformation amount increases and the bending strength does not substantially change or slightly increases (1 ) A method for producing the composite material described;
(10) When the inorganic plate or sheet material increases the crosshead speed from 5 mm / min to 50 mm / min, the strain plastic deformation increases and the bending strength does not substantially change or slightly increases. A method for producing the composite material according to (2) having characteristics;
(11) The method for producing a composite material according to any one of (1) to (10), wherein at least one green body (I) and at least one green body (II) are alternately laminated;
(12) The raw material composition (I) is a composition in which unexpanded vermiculite is blended with a base material, and the blending amount is 3 to 70% by mass of the total composition (solid content). (11) The method for producing a composite material according to any one of
(13) The method for producing a composite material according to (12), wherein the substrate is selected from one or more of gypsum, cement, calcium silicate, and slag gypsum;
(14) The composite material according to (1) or (2), wherein the green body (I) or the green body (II) is obtained by papermaking molding, extrusion molding, press molding or casting molding; and (15) (1) to (15) 13) Bearing wall structure using a composite material obtained by the production method according to any one of
It is.

  According to the method of the present invention, it can have soundproofing (sound insulation / sound absorption), fireproofing / fireproofing, lightness, excellent compression and tensile strength (excellent plastic deformation), moisture permeability, etc. A composite material that can also be used can be obtained.

  In the method for producing a composite material of the present invention, a wood fiber or a fiber obtained by blending a wood fiber or a synthetic polymer fiber with a raw material composition (I) for obtaining an inorganic board or sheet material, A green body (II) in which a raw material composition (II) rich in synthetic polymer fibers is formed into a plate or a sheet is obtained, and a green body (I) in which the raw material composition (I) is formed into a plate or a sheet; The green body (II) is laminated, then hydrothermally or hardened, and the amount of strain plastic deformation increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min in a three-point bending test. To obtain a composite material having

  The raw material composition (I) according to the present invention is a composition for obtaining the following inorganic plate or sheet material. That is, the inorganic plate or sheet material of the present invention preferably has an increased amount of strain plastic deformation and a substantial change in bending strength even when the crosshead speed is increased from 5 mm / min to 50 mm / min. Or have slightly increasing properties. More preferably, the face material has a characteristic that the amount of strain plastic deformation increases and the bending strength does not substantially change or slightly increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min. Made of inorganic material. Measurement by this three-point bending test can be performed according to JIS A5430. In the present invention, the amount of strain plastic deformation increases and the bending strength does not substantially change even when the cross-head speed is increased from 5 mm / min to 50 mm / min. Even when it does not have the property to increase, the composite material obtained should just have such a characteristic.

  As described above, a suitable inorganic board or sheet material in the present invention has the same characteristics as wood, but differs from wood in that it is inorganic. Examples of such inorganic materials include those mainly composed of calcium silicate, cement, slag gypsum, and the like, and particularly preferably, an unexpanded vermiculite is blended in a base material, and the blending amount thereof is What is obtained by shape | molding the composition which is 3-70 mass% of all the compositions (solid content) is mentioned. The substrate is not particularly limited as long as it does not substantially deteriorate the properties of vermiculite described later, but is preferably hydrophilic. Examples of such hydrophilic substrates include gypsum, cement, calcium silicate, slag gypsum, or the like. These can be used together as appropriate. The gypsum may be either anhydrous or hydrated salt, and various cements including Portland cement can be used as the cement. In this case, aggregates and admixtures are used. The calcium silicate is not particularly limited, but calcium silicate (tobermorite or zonotolite) obtained by hydrothermal reaction of a siliceous raw material and lime in an autoclave is common. The slag gypsum generally contains 20 to 40% of granulated blast furnace slag powder and 60 to 80% of dihydrate gypsum (exhaust gypsum) and 1 to 5% of Portland cement.

On the other hand, vermiculite (hillstone) blended with the above base material is a flaky mineral similar to biotite mainly composed of SiO ₂ , MgO, and Al ₂ O ₃ , and is commonly used in biotite, green mud. It may be any stone type, and can be used even if there is a difference in composition etc. depending on the production area. The specific surface area (nitrogen adsorption method) is usually 10 m ² / g or less. The particle size is not particularly limited, but is usually 5 mm or less, preferably 3 mm or less, particularly preferably 0.5 mm or less.

  In the present invention, such vermiculite is used in a substantially unexpanded state. That is, vermiculite usually contains about 10 to 20% of water, dehydrated by rapid heating at a high temperature (about 320 ° C. to 1000 ° C. at which interlayer water begins to desorb), and remarkably expands in a direction perpendicular to the layer. Then, it stretches like a hill and becomes a porous body (mostly 1000 ° C., 1-2 seconds, 10-30 times the original thickness). Accordingly, in the present invention, a material that does not substantially obtain such expansion is used.

  Furthermore, in the present invention, it is preferable to use a product that has been activated prior to blending the vermiculite into the substrate. The purpose of the activation treatment is to remove organic or inorganic substances adsorbed by vermiculite, and to reconstitute and recover the inherent humidity conditioning, adsorption performance, and the like. For example, pressurized steaming, boiling with saline, and the like can be mentioned, but steaming at a saturated steam pressure of 105 ° C. to 200 ° C. is preferable.

  In particular, when the substrate is a calcium silicate system, even if vermiculite that has not been activated is blended before the hydrothermal reaction, it is then autoclaved at a saturated vapor pressure of, for example, about 150 ° C. to 200 ° C. As a result, activation processing is performed.

  In the raw material composition (I), the blending of vermiculite into the base material is carried out so that the blending amount is 3 to 70% by weight, preferably 10% to 50% by weight of the total composition (solid content). It is selected according to the type of base material and the performance of the intended building material, such as humidity control, etc., but to form sufficient channeling (network) of vermiculite to obtain a suitable amount and speed of moisture absorption and desorption. Is generally particularly preferably 15% by mass or more.

  In the raw material composition (I), in addition to the unexpanded vermiculite, various compounding materials that are uniquely used for each base material depending on the use such as building materials for other purposes, Others can be appropriately blended. The kind and amount of blending can be determined by conventional methods, and the following wood fibers or synthetic polymer fibers can also be blended. In addition, for example, aggregates, reinforcing materials, admixtures, weight-reducing materials, etc. More specifically, glass fiber, fumed silica, foamed glass, shirasu balloon, alumina balloon, perlite, wollastonite, sepiolite, gravel, sand, organic binder and the like are appropriately selected.

  In the present invention, the raw material composition (II) is obtained by blending such raw material composition (I) with wood fiber or synthetic polymer fiber. Pulp and vegetable fibers (hemp fiber, kefuna fiber, bamboo fiber, etc.) are suitable as the wood fiber. Examples of synthetic polymer fibers include fibers such as polypropylene and polyvinyl chloride. These fibers may be any of non-woven fabric, woven fabric, knitted fabric and the like. The content of the wood fiber or the synthetic polymer fiber in the green body (II) is preferably 2 to 8 wt%, and more preferably 3 to 6 wt%. Furthermore, this raw material composition (II) may contain a polymer adhesive such as a resorcinol resin or an aqueous emulsion resin. When the resorcinol resin is used, aldehyde contained in the wood fiber can be adsorbed, so that the amount of the aldehyde curing agent to be used can be reduced.

  The raw material compositions (I) and (II) are formed into a plate or a sheet by conventional methods such as papermaking, extrusion, press molding, cast molding, etc., and become green bodies (I) and (II). In general, papermaking using a so-called papermaking machine is generally selected industrially.

  Thus, the inorganic board or sheet material obtained by using unexpanded vermiculite has moisture permeability and appropriate moisture release characteristics, and therefore has an excellent humidity control function. For example, the balance, amount and speed of moisture absorption and moisture release are excellent. Therefore, it is possible to prevent condensation, warping, and the like, and to effectively suppress the growth of mold, mites, and the like. Even if dew condensation occurs on the inside, water absorption is excellent, and water can be absorbed and released to the outside. Furthermore, it has an excellent deodorizing function. For example, it can adsorb and decompose volatile chemicals such as formaldehyde, toluene and xylene or odorous gases.

  Furthermore, since the inorganic plate or sheet material of the present invention has the above-described plastic deformation properties, it is excellent in stress absorption even when subjected to abrupt deformation (strain) due to wind pressure, earthquake, etc., and cracks and breaks. Etc. are less likely to occur.

  In the present invention, at least one green body (I) and at least one green body (II) are laminated. For example, the number of green bodies (I) and the number of green bodies (II) may be the same or different, and may be any of 1 + 1, 1 + 2, 2 + 1, 2 + 2, etc. These are usually stacked alternately, but are not necessarily alternating. Both sides of the resulting composite material may be the same or different, and can be selected according to the purpose. The stacked green bodies are then pressure-bonded, and a dehydrating press is suitable for pressure bonding. Subsequently, the green body is hydrothermally treated (calcium silicate) or hardened and cured (cement, gypsum, slag gypsum) by a conventional method to obtain a desired composite material. The resulting composite material includes layers having different contents of wood fibers or synthetic polymer fibers, but can also be a graded material.

  The dimensions of the composite material of the present invention can be appropriately selected depending on the application.

  The composite material of the present invention can be processed into various product forms by a conventional method depending on the application. Examples of the product form include various interior members, decorative members, exterior members, and the like.

  The composite material according to the present invention uses a composite material including layers having different contents of wood-based fibers or synthetic polymer fibers, while taking advantage of the advantages of inorganic and wood-based fibers or synthetic polymer fibers. It is possible to compensate for this difficulty. For example, the compressive strength of wood can be improved and the tensile strength of inorganic can be improved; the weight of wood can be adjusted to reduce the weight; the wood can be made non-combustible; The stress concentration at the opening can be alleviated; the holding power of the fastener can be improved as compared with the inorganic system, and thus the repeated use of the fastener is facilitated. Furthermore, since the composite material of the present invention can be used as a structural load-bearing surface material, it can provide a load-bearing wall structure in which the fire resistance of the wood-based material is improved.

  The composite material obtained in the present invention can be used by being fastened with a fastener. As fasteners, nails, machine screws, bolts and nuts, bottles, staples or pins are preferably used.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited by these Examples. The part represents part by mass.
Example 1
30 parts of siliceous powder as a siliceous raw material, 27 parts of slaked lime as a calcareous raw material and 3 parts of pulp as a reinforcing fiber, and 40 parts of unexpanded vermiculite (from South Africa, particle size of 0.25 to 0.5 mm) as starting raw materials, Water was added to these and mixed to form a slurry having a solid content of about 12%, and a sheet-like green body (I) was formed by a papermaking machine. On the other hand, 3 parts of pulp was added to the same slurry as above, and a sheet-like green body (II) was formed in the same manner. Next, the sheet-like green body (II) was laminated on both sides of the sheet-like green body (I) and dehydrated and pressed. The obtained composite green body was subjected to pressure curing in an autoclave (160 to 180 ° C., about 10 hours), then dried to a predetermined moisture content at less than 80 ° C., and sandwich structure calcium silicate board (910 mm × 1820 mm × 9.0 mm (1.5 mm / 6.0 mm / 1.5 mm)). When the proof stress test of the obtained calcium silicate board composite material was conducted, the wall magnification (actual magnification) was 3.6 times on both sides. For comparison, when the yield strength test was performed on the board alone obtained in Reference Example 1, the wall magnification (actual magnification) was 2.6 times.

  In addition, the calcium silicate board (910 mm × 1820 mm × 6.0 mm) obtained by the sheet-like green body (I) alone, even if the crosshead speed is increased from 5 mm / min to 50 mm / min in the three-point bending test, The strain plastic deformation amount was increased.

  The present invention can have soundproofing (sound insulation / sound absorption), fireproofing / fireproofing, light weight, excellent compression and tensile strength (excellent plastic deformation), moisture permeability, etc., and can also be used as a structural load bearing material. Composite materials can be provided.

Claims (15)

  Raw material composition (I) for obtaining an inorganic board or sheet material, which is obtained by blending wood fiber or synthetic polymer fiber, and is rich in wood fiber or synthetic polymer fiber ( II) to obtain a green body (II) formed into a plate or a sheet, and laminate the green body (I) formed from the raw material composition (I) into a plate or a sheet and the green body (II), Next, a composite characterized by obtaining a composite material having a characteristic that the amount of strain plastic deformation increases even if the crosshead speed is increased from 5 mm / min to 50 mm / min in a three-point bending test by hydrothermal or curing curing treatment. Method of manufacturing the material.   The method for producing a composite material according to claim 1, wherein the inorganic plate or sheet material has a characteristic that the amount of strain plastic deformation increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min in a three-point bending test. .   The method for producing a composite material according to claim 1 or 2, wherein the raw material composition (I) may contain wood fibers or synthetic polymer fibers.   The method for producing a composite material according to any one of claims 1 to 3, wherein the wood fiber is pulp or plant fiber.   The method for producing a composite material according to claim 1 or 2, wherein the content of the wood fiber or the synthetic polymer fiber in the green body (II) is 2 to 8 wt%.   The method for producing a composite material according to claim 1 or 2, wherein the content of the wood fiber or the synthetic polymer fiber in the green body (II) is 3 to 6 wt%.   The method for producing a composite material according to claim 1 or 2, wherein the composite material is pressure-bonded after lamination.   The method for producing a composite material according to claim 7, wherein the pressure bonding is a dehydration press.   The composite material according to claim 1, wherein the composite has a characteristic that the amount of strain plastic deformation increases and the bending strength does not substantially change or slightly increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min. A method of manufacturing composite materials.   The inorganic plate or sheet material has the characteristics that the strain plastic deformation increases and the bending strength does not substantially change or slightly increases even when the crosshead speed is increased from 5 mm / min to 50 mm / min. A method for producing the composite material according to claim 2.   The method for producing a composite material according to any one of claims 1 to 10, wherein at least one green body (I) and at least one green body (II) are alternately laminated.   The raw material composition (I) is a composition obtained by blending unexpanded vermiculite with a base material, and the blending amount is 3 to 70% by mass of the total composition (solid content). A method for producing the composite material according to any one of the above.   The method for producing a composite material according to claim 12, wherein the substrate is selected from one or more of gypsum, cement, calcium silicate, and slag gypsum.   The method for producing a composite material according to claim 1 or 2, wherein the green body (I) or the green body (II) is obtained by papermaking, extrusion, press molding or casting.   A load-bearing wall structure using the composite material obtained by the production method according to claim 1.