JP2007083668A - Manufacturing method of inorganic panel, inorganic decorative panel, and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the formation of a small projection on an inorganic panel surface by particles of fiber called "Dama" generated through scratching down of a slurry S to a cylinder 3 by a brush roll or the long stirring in a forming box 2, in a method in which the slurry S containing a mineral fiber, an inorganic powder and a bonding agent as a principal component is subjected to papermaking with a wet type cylinder paper machine 1, to form a wet mat W2, and an inorganic panel is manufactured from the wet mat W2. <P>SOLUTION: The slurry S is fed not only to an adverse current side S1 but also to a fair current side S2 to the paper making direction, by the spinning of a cylinder 3 of the wet type cylinder paper machine 1 and is subjected to papermaking to form the wet mat W2. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a production method for producing an inorganic board suitable for use as a decorative board for interior materials, building materials, opening members, furniture, etc. of a building such as a house, and a makeup using the inorganic board as a substrate. The present invention relates to an inorganic decorative board having good adhesion to a layer and excellent cosmetic properties, and a method for producing the inorganic decorative board.

Conventionally, for example, as shown in Patent Document 1, an inorganic board having good adhesion to a decorative layer, in particular, a thin inorganic board, comprising mineral fibers, an inorganic powder and a thermosetting resin binder as essential components Are known in the art, and a method for producing a product with good productivity and production yield, and an inorganic decorative board provided with a decorative layer on the surface of the inorganic board with good adhesion.
JP-A-2005-126646

  However, when an inorganic board is produced by a round net type paper machine by the above conventional method, the following problems occur and there is room for improvement. In other words, the round net type paper making machine rotates the round net in the forming box so that a part of the round net is immersed in the slurry inside, but the excess slurry adhering to the round net is scraped off and formed by the brush roll. Due to the agitation of the slurry for a long time due to the round net in the box, a granular material of fibers called lumps is generated in the slurry in the forming box, and the surface of the inorganic board after papermaking, drying, and heat compression by this granular material. A small convex part is made on the back side. And when this inorganic board is used as a substrate and a decorative layer is provided on one of the front and back surfaces to form an inorganic decorative board, even if the surface on which the decorative layer is provided is ground, the decorative layer In particular, in the case of a thin decorative layer such as a decorative sheet, the effect of convex portions appears on the decorative surface, resulting in poor cosmetic properties.

  The present invention has been made in view of such problems, and its purpose is to provide a slurry by improving a method for producing an inorganic plate containing mineral fibers, an inorganic powder, and a water-soluble polymer binder as essential components. It is to prevent a small convex part from being formed on one surface of the inorganic board due to lumps during paper making.

  In order to achieve the above object, according to the present invention, the forward flow is made by supplying slurry to each of the forward flow side as well as the reverse flow side with respect to the paper making direction by the rotation of the circular net of the wet round net making machine. One of the front and back layers of the wet mat was formed by a fresh slurry in which side lumps (fiber granules) had not yet occurred.

  Specifically, in the method for producing an inorganic board according to the first aspect of the present invention, a slurry containing mineral fibers, an inorganic powder, and a binder as main components flows backward with respect to the papermaking direction of the wet round netting machine. A wet mat is formed by feeding to the side and the forward flow side to form a wet mat, and then the wet mat is dried to form a dry mat, and the dry mat is heated and compressed.

  According to the above configuration, when the slurry is supplied from the forward flow side in addition to the supply from the reverse flow side of the round net making direction in the wet round net paper making machine, the fresh slurry is always close to the round net on the forward flow side. It will be supplied and will adhere to the round net. For this reason, even if there is a fiber entanglement due to brush roll scraping off or long-time stirring in the forming box, the stagnation first adheres to the round net during papermaking. Thus, a fresh and uniform slurry is first made on the forward flow side, that is, the contact surface with the round net. The slurry produced in this way is different between the reverse flow side and the forward flow side, so that a wet mat consisting of multiple layers is formed. The surface performance of the round net side and the opposite side of the round net is different, especially the round net. A wet mat that is made dense by the fresh slurry on the side is formed. And by heating and compressing the wet mat, an inorganic plate having a smooth surface at least on the round net side can be obtained. As a result, when a decorative layer is provided on the smooth surface to make an inorganic decorative plate, adhesion with the decorative layer is reliably obtained, and even with a thin decorative layer, the surface of the inorganic plate has an influence on the surface. It does not appear and can improve its makeup.

  In the invention of claim 2, a water-soluble polymer binder that gels upon drying is used as the binder.

  Thus, by using a water-soluble polymer binder that gels in the drying process as a slurry, a dry mat (dry board) having an appropriate adhesive strength is formed. For this reason, for example, handling is improved during transport to the next heat-compression step and in the step of reversing, and high productivity can be obtained.

  In the invention of claim 3, at least one of a thermosetting resin binder and a thermoplastic resin binder is used as the binder.

  By this, since at least 1 type of a thermosetting resin binder or a thermoplastic resin binder is contained in a raw material and each can be utilized effectively, the inorganic board excellent in water resistance can be manufactured. .

  In the invention of claim 4, the composition of the mineral fiber, the inorganic powder, and the binder of the slurry supplied to the reverse flow side and the forward flow side in the paper making direction of the wet round net paper making machine are made different from each other.

  By making the slurry composition different between the reverse flow side and the forward flow side in this way, the surface performance is matched to the performance (hardness, strength, fire resistance, etc.) required on the surface side and back side of the inorganic board. Alternatively, the back surface performance and the base material performance can be easily designed.

  In the invention of claim 5, the wet mat after the paper making is dried by preheating dehydration using a hot air dehydrator and subsequent hot air drying using a dryer.

  As described above, since the wet mat is heated and dehydrated in advance with a hot air dehydrator, the gelation of the water-soluble polymer is promoted, and the binder effect can be enhanced. It is possible to move to the drying process, and the heat load is suppressed, contributing to energy saving and improving productivity.

  The invention of claim 6 is an invention of an inorganic decorative board, and in the inorganic board obtained by the method for producing an inorganic board according to any one of claims 1 to 5, the surface on the round mesh contact side of the wet round net making machine. And a decorative layer is provided on the ground surface.

  The invention of claim 7 is an invention of a method for manufacturing an inorganic decorative board. In the inorganic board obtained by the method for manufacturing an inorganic board according to any one of claims 1 to 5, a round net of a wet round net making machine is provided. The contact-side surface is ground, and a decorative layer is provided on the ground surface.

  According to these inventions, the inorganic board, which is the substrate of the inorganic decorative board, has the effect of any one of the first to fifth aspects of the invention, and the surface on the side of the round net that is less affected by lumps. Since it grinds, a decorative layer will adhere more favorably to this surface after grinding, and an inorganic decorative board with high adhesion of the decorative layer can be obtained. Moreover, even when a thin decorative sheet that is easily affected by the surface of the substrate is attached as the decorative layer, the high decorativeness of the inorganic decorative board can be exhibited.

  As described above, according to the first aspect of the present invention, the slurry is supplied from the forward flow side in addition to the supply of the slurry from the reverse flow side in the paper making direction of the circular mesh, so that fresh slurry is always supplied to the round mesh on the forward flow side. Even if there is lumps of fibers in the reverse flow side slurry that can be supplied nearby, the dams are prevented from adhering during paper making, forming a wet mat whose round net side is dense with fresh slurry. An inorganic plate having a smooth surface can be obtained. Therefore, when a decorative layer is provided on the smooth surface to make an inorganic decorative board, good adhesion of the decorative layer can be secured, and the cosmetic properties of the inorganic decorative board can be improved even with a thin decorative layer.

  According to the invention of claim 2, by using a water-soluble polymer binder that gels at the time of drying as a binder of the slurry, a dry mat having an appropriate adhesive force can be formed, and the next heating and compression step can be performed. Productivity can be improved by improving the handleability during conveyance and in the reversing process.

  According to the invention of claim 3, by using at least one of a thermosetting resin binder or a thermoplastic resin binder as a binder, an inorganic material having excellent water resistance by taking advantage of the effects of these resin binders. A board can be manufactured.

  According to the invention of claim 4, the performance required for the surface side and the back side of the inorganic plate is made different by the composition of the slurry supplied to the reverse flow side and the forward flow side in the paper making direction of the wet round net paper making machine. It is possible to easily design the surface performance, the back surface performance, and the base material performance according to the above.

  According to the invention of claim 5, the wet mat after paper making is dried by preheating dehydration with a hot air dehydrator and subsequent hot air drying with a dryer, thereby promoting gelation of the water-soluble polymer. The effect can be enhanced, and the moisture content of the wet mat can be appropriately lowered before the hot air drying process can be performed. Thus, the productivity of the inorganic board can be improved by saving energy.

  According to invention of Claim 6 or 7, in the inorganic board obtained by the said manufacturing method, the round net side surface of a wet round net papermaking machine is ground, and the decorative layer is provided in the ground side, and the inorganic decorative board is provided. As a result, the substrate of the inorganic decorative board has the effect of any one of claims 1 to 5, and the decorative layer is in good contact with the surface of the round net side where there is little influence of lumps. In addition, the adhesiveness of the decorative layer of the inorganic decorative board can be further improved, and the cosmetic properties of the inorganic decorative board with a thin decorative sheet that is easily affected by the surface of the substrate as the decorative layer can be improved. it can.

  Hereinafter, the best embodiment of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.

(Inorganic board manufacturing equipment)
FIG. 1 shows an inorganic board manufacturing apparatus F used in an embodiment of the present invention. This manufacturing apparatus F includes a wet round net papermaking machine 1, a dryer 15 such as a hot air circulation drying apparatus, and a hot press apparatus such as a hot press apparatus. 16 The papermaking machine 1 includes a forming box 2 for storing slurry, and a round net 3 disposed in the forming box 2 and rotating clockwise in FIG. 1 about a horizontal rotation axis. The circular net 3 is, for example, a cylindrical drum having a net-like peripheral wall. By sucking the inside of the round net 3, the slurry S in the forming box 2 is attached to the outer peripheral surface of the peripheral wall and made into paper.

  The forming box 2 has two openings, a reverse flow side supply port 2 a and a forward flow side supply port 2 b for supplying the slurry S into the forming box 2. The reverse flow side supply port 2a supplies the slurry S to the reverse flow side S1 (downstream side, left side in FIG. 1) in the papermaking direction due to the rotation of the round net 3 in the slurry S stored in the forming box 2. The slurry S is opened at a position higher than the liquid level of the slurry S, and the slurry S is supplied by dropping from the reverse flow side supply port 2a. On the other hand, the forward flow side supply port 2b is for supplying the slurry S to the forward flow direction S2 (upstream side, right side in FIG. 1) in the papermaking direction by the rotation of the round net 3 in the slurry S stored in the forming box 2. It is opened at a position lower than the liquid level of the slurry S in the box 2, and the slurry S is supplied by being supplied from the forward flow side supply port 2b.

  The reverse flow side supply port 2 a is connected to the same head box 7 through the reverse flow side supply channel 4, and the forward flow side supply port 2 b is connected to the same head box 7 through the forward flow side supply channel 5. An in-line mixer 8 is connected in the middle of the forward-side supply path 5, and approximately 2/3 of the slurry S supplied to the head box 7 is fed into the forming box 2 from the reverse-flow side supply port 2 a by the reverse-flow side supply path 4. While supplying, the remainder is supplied into the forming box 2 from the forward flow side supply port 2b by the forward flow side supply path 5.

  Reference numeral 10 denotes a wet mat conveyor for transferring the wet mat W2 made from the slurry S by the round net 3 from the round net 3, and conveying the upstream end in the vicinity of the top (upper end) of the round net 3. The wet mat W2 on the round net 3 is peeled off from the round net 3 by a peeling means (not shown) and continuously transferred to the wet mat conveyor 10. In the middle of the wet mat conveyor 10, the dryer 15 and the hot press device 16 are provided in order from the upstream side.

  Although not shown, the paper making machine 1 scrapes off unnecessary portions of the paper making mat W1 made by the slurry S adhering to the round net 3 at a position protruding from the liquid surface in the forming box 2 to form the forming box 2. A brush roll to be returned and a forming press for forming the wet mat W2 while pressing the papermaking mat W1 after passing through the brush roll against the round net 3 to adjust the thickness and the like are provided.

(Inorganic board manufacturing method)
The manufacturing method of the inorganic board which concerns on embodiment of this invention is equipped with the slurry production | generation process, the papermaking process, the drying process, and the heat compression process.

(1) Slurry production process In this papermaking process, first, raw materials containing mineral fibers, inorganic powder and water-soluble polymer binder (compound) as essential components are mixed and dispersed in water to prepare slurry S. To do.

  Examples of the mineral fiber used here include rock wool, slag wool, and glass wool. Such mineral fibers are preferably added at a rate of 20 to 80% by weight with respect to the solid components in the slurry S. When the addition amount is less than 20% by weight, it is difficult to obtain desired strength properties such as bending strength and peel strength. On the other hand, when it exceeds 80% by weight, the addition ratio of the inorganic powder is reduced and the surface is dense. This is not preferable because the properties and smoothness are lowered, and the cosmetic properties when a decorative layer described later is provided are impaired.

  As the inorganic powder, calcium carbonate, microsilica, aluminum hydroxide, slag powder or the like can be used. Such an inorganic powder is preferably added to the solid component in the slurry S at a ratio of 10 to 70% by weight. When the amount added is less than 10% by weight, the density and smoothness of the surface of the formed inorganic plate are lowered. On the other hand, when it exceeds 70% by weight, strength properties such as bending strength and peel strength are deteriorated. .

  As the water-soluble polymer binder, powdered or liquid starch, oxidized starch, glue, casein, polyvinyl alcohol, polyacrylamide, maleic anhydride copolymer and the like can be used.

  In addition to this, examples of raw materials that can be added to the slurry S as necessary include synthetic resin fibers such as polypropylene, polyester, and vinylon, plant fibers such as hemp, pulp, and wood fibers, flocculants, sizing agents, An antifoaming agent etc. can be mentioned.

  By adding at least one of a thermosetting resin binder or a thermoplastic resin binder to the slurry S, the water resistance of the inorganic plate can be improved. As this thermosetting resin binder, a powdery or liquid phenol resin, melamine resin, epoxy resin, polyester resin, isocyanate, etc. can be used alone or in combination. On the other hand, as the thermoplastic resin binder, powdery or liquid polyvinyl resin, ethylene vinyl alcohol resin, polyvinyl alcohol resin, acrylic resin, polyamide resin, or the like can be used alone or in combination.

  The total amount of the water-soluble polymer binder or the thermosetting resin binder and the thermoplastic resin binder is preferably added in a ratio of 7 to 15% by weight with respect to the solid component in the slurry S. . If the total amount of the binder is less than 7% by weight, it is not preferable because strength properties such as bending strength and peel strength are lowered. On the other hand, if it exceeds 15% by weight, fire resistance is impaired.

(2) Papermaking process In the papermaking process, the slurry S adjusted in this way is supplied to the wet round netting machine 1 for papermaking to form a wet mat W2. That is, as shown in FIG. 1, the slurry S is supplied to the head box 7 and dropped from the head box 7 into the forming box 2 through the reverse flow side supply path 4 from the reverse flow side supply port 2a. The slurry S stored therein is supplied to the reverse flow side S1 in the paper making direction by the round net 3 (the side where the peripheral wall of the round net 3 exits from the liquid surface). At the same time, the slurry S in the head box 7 is also introduced into the forming box 2 from the forward flow side supply port 2b via the forward flow side supply path 5, and the round net of the slurry S stored in the forming box 2 is obtained. 3 is also supplied to the forward flow side S2 in the paper making direction (the side where the peripheral wall of the round net 3 enters the liquid surface).

  Then, by rotating the round net 3 in the clockwise direction in FIG. 1, the slurry S in the forming box 2 is attached to the round net 3 to make a mat, and the thickness is adjusted by forming press the forming mat W1. Thus, the wet mat W2 is formed. The moisture content of the wet mat W2 obtained in this way is usually about 80% by weight.

  At that time, since the slurry S is also supplied into the forming box 2 from the forward flow side S2 of the round net 3 in the paper making direction, the fresh slurry S is always near the paper flow direction forward flow side S2 of the round net 3, that is, the forming box 2 The inner slurry S is supplied to the position where it first adheres to the round net 3. In this way, a continuous fresh slurry S can first be attached to the round net 3 to make paper, and the slurry S in the forming box 2 can be scraped off by a brush roll or in the forming box 2 on the reverse flow side S1. Even if there is a fiber entanglement (granular fiber) generated due to agitation for a long time, it is possible to prevent the dama from adhering at the time of papermaking first, and the forward flow side S2, that is, the round net 3 A fresh and uniform slurry S is first made on the contact surface.

  Thus, although the slurry S of the backflow side S1 and the forward flow side S2 is different, it is not surely divided, but the two-layer wet mat in which the slurry S of the backflow side S1 and the forward flow side S2 is laminated respectively. W2 (paper making mat W1) is formed, and the surface performance of the round net 3 side (inner side) and the opposite side (outer side) of the round net 3 are different. The formed wet mat W2 is formed.

  The slurry S to be supplied to the forward flow side S2 is further added with at least one of the mineral fiber, the inorganic powder, and the water-soluble polymer binder, and is mixed and dispersed by the in-line mixer 8 so that the slurry on the reverse flow side. A slurry S having a component ratio different from that of the slurry S may be used. In this case, the composition of the slurry S on the reverse flow side S1 and the forward flow side S2 can be made different. For example, the difference in performance (hardness, strength, fire resistance, etc.) required on the surface layer side and the back surface side of the inorganic plate It is possible to easily adjust and design the surface or back surface performance and the base material performance according to the above.

(3) Drying process Next, the length of the wet mat W2 obtained in the paper making process is cut and transferred to the dryer 15 by the wet mat conveyor 10, and the water-soluble polymer binder in the wet mat W2 is cured. A dry board is formed by drying so that the moisture content is less than 10% by weight, preferably less than 7% by weight.

  Here, the state in which the water-soluble polymer binder is not cured is a state in which mineral fibers and inorganic powders are not fixed by the water-soluble polymer binder in the dry board, and more preferably The water-soluble polymer binder on the surface layer of the dry board is preferably dried so as not to be in a pre-cured state. Such drying can be performed by appropriately setting drying conditions such as the type of water-soluble polymer binder, drying temperature, drying time, and drying schedule. For example, the moisture content of the dryboard is less than 10% by weight, preferably 7% by setting the drying conditions such that the front and back surfaces of the wet mat W2 and the inner layer have a temperature range of 70 ° C to 200 ° C. Drying is performed so that the water-soluble polymer binder in the surface layer of the dry board is not in a pre-cured state so as to be less than wt%.

  The wet mat W2 may be heated and dehydrated with a hot air dehydrator (not shown) before being carried into the dryer 15 such as a hot air circulation dryer. That is, the wet mat W2 after papermaking is dried by preheating dehydration using a hot air dehydrator and subsequent hot air drying using a dryer 15. In this case, the gelation of the water-soluble polymer is promoted, the binder effect can be enhanced, and the moisture content of the wet mat W2 can be lowered to a moderately low temperature before moving to the hot air drying step, thereby suppressing the heat load. This contributes to energy saving and improves productivity.

  The dry board thus obtained is dried so that the water content is less than 10% by weight, preferably less than 7% by weight, and even if the water-soluble polymer binder is not cured, it is suitable. It has rigidity and can be transported or set to the next heating and compressing process without damaging the dry board with good handleability.

(4) Heat compression step Next, the dry board is inserted between the heating plates of the hot press device 16 and heated and compressed for a predetermined time at a temperature equal to or higher than the curing temperature of the water soluble polymer binder to thereby form a water soluble polymer. The binder is cured, and then cut into dimensional accuracy to form an inorganic plate.

  During this heat compression, the dry board is dried so that its moisture content is less than 10% by weight, preferably less than 7% by weight. The phenomenon can be prevented from occurring. In addition, since the dry board is reasonably rigid due to the drying, the inorganic material is uniformly compressed without causing the curved deformation of the side end that is likely to occur in this type of board during heat compression. A board can be obtained.

  In addition, as described above, the water-soluble polymer binder of the dry board is heated and compressed in a state where it is not cured, preferably at least in a state where the water-soluble polymer binder of the surface layer is not precured. The porous polymer binder is cured, and the mineral fiber and the inorganic powder in the surface layer and the inner layer are well bonded by the water-soluble polymer binder to form a compressed and integrated inorganic plate. For this reason, once the water-soluble polymer binder is hardened, the mineral fiber or inorganic powder is temporarily bonded, and then the heat-compressed state is not damaged and the temporary bonded state is not damaged. An inorganic plate having good strength properties can be obtained.

  In addition, before heat-compressing a dry board, water or resin aqueous solution can be apply | coated to front and back. In this case, the moisture content of the dryboard can be adjusted, and the warp and twisting of the dryboard can be prevented, so that an inorganic plate that is more uniformly surface-compressed and has less specific gravity variation during heat compression is obtained. Can do.

  The inorganic plate formed by heat compression has a thickness of 1.5 mm to 9.5 mm and a specific gravity of 0.4 to 1.8. If the thickness exceeds 9.5 mm, it becomes heavier and the workability becomes worse, and if it is less than 1.5 mm, the strength becomes unfavorable. More preferably, it is reasonably thin and light and has a thickness of 2.5 mm to 7. Omm and having a specific gravity in the range of 0.7 to 1.5.

  In addition, the inorganic plate obtained as described above has a smooth contact surface with the round net 3 without the influence of fibers entangled during papermaking, and the level of smoothness is higher than that of the conventional one. It has become.

(Inorganic decorative board and manufacturing method thereof)
The inorganic plate obtained as described above is used as a substrate, and the surface of the inorganic plate that is in contact with the round net 3 in the wet round net making machine 1 is ground to the surface (opposite to the round net 3). The surface on the side may be ground together), and an inorganic decorative board is formed by providing a decorative layer on the ground surface by painting, printing, applying a decorative sheet, or the like.

  Since the substrate of the inorganic decorative board is an inorganic board, the above effects of the inorganic board can be obtained. In addition, since the round net 3 side having a low level of influence and high smoothness is used as the surface and further ground, the decorative layer adheres well to the ground surface, and the adhesiveness of the decorative layer is further enhanced. be able to. Furthermore, since there are no protrusions on the surface of the substrate made of an inorganic plate, even if the decorative layer is thin, such as by sticking a thin decorative sheet that is susceptible to the influence of the substrate surface, the surface of the inorganic plate is convex on the surface. The part itself does not appear, and the cosmetic properties of the inorganic decorative board can be improved.

(Other embodiments)
In the case of manufacturing an inorganic decorative board, the inorganic board obtained as described above is used as a substrate, and makeup is applied by directly coating, printing, applying a decorative sheet, etc. on one surface that was in contact with the round net 3. An inorganic decorative board may be formed by providing a layer. In this case, since the surface of the substrate (inorganic plate) itself is a smooth surface that is not affected by dama, an inorganic decorative plate having good adhesion between the decorative layer and the substrate surface can be obtained.

  Next, specific examples will be described.

Example 1
50% by weight of slag wool, 39% by weight of aluminum hydroxide, 6% by weight of phenolic resin binder, 2% by weight of polyvinyl alcohol, 2% by weight of tapioca starch, 1% by weight of polyester fibers as heat-bonding fibers, and a flocculant A slurry prepared by stirring and mixing and dispersing the raw material in water into the head box of the round net type paper machine, and then supplying the slurry to the forming box from the reverse flow side in the round net rotating direction. It was branched and supplied to the forming box also from the forward flow side in the direction of rotation of the circular mesh, and wet matting was performed by rotating the circular mesh to form a wet mat. Further, the wet mat was dehydrated with a hot air dehydrator, and then the thickness was adjusted with a roll press to prepare a wet mat having a thickness of 10 mm and a moisture content of 60% by weight. The solid content concentration of the slurry was 3% by weight.

  This wet mat is carried into a hot air drying apparatus and dried at 170 ° C. for 5 minutes and then at 190 ° C. for 15 minutes so that the internal temperature of the wet mat becomes 71 ° C. or higher, and the moisture content is 2%. The dry board was prepared.

100 g / m ² of water is uniformly applied to the front and back surfaces of the dry board thus obtained, then transported to a multi-stage hot press device, inserted between the hot plates (heating plates), and heated and compressed. did. In the handling up to the insertion of the hot press device between the hot plates, the dry board was not damaged and the handling property was good. Heat compression was performed for 5 minutes under a temperature condition of 190 ° C., and an inorganic plate having a thickness of 3.5 mm and a specific gravity of 1.2 was obtained in which the phenol resin binder was sufficiently cured by the heat compression. This inorganic plate was not punctured or deformed at the side edges.

  Next, after sanding (grinding) the front and back surfaces of the inorganic plate by 0.3 mm each, a diallyl phthalate resin (DAP) decorative sheet is adhered to the surface which becomes the surface of the circular mesh side in the wet circular mesh paper making machine. When a decorative board was formed, the cosmetic properties were good. Moreover, as a result of performing a cross-cut test (peeling test) on this inorganic decorative board based on the test method of JIS K5400, the base material was not peeled off, and the adhesion between the inorganic board and the decorative sheet was good. .

(Example 2)
50% by weight of slag wool, 39% by weight of aluminum hydroxide, 6% by weight of phenolic resin binder, 2% by weight of polyvinyl alcohol, 2% by weight of tapioca starch, 1% by weight of polyester fibers as heat-bonding fibers, and a flocculant The first slurry prepared by stirring and mixing and dispersing the raw material consisting of the following materials into the head box of the round net type paper machine is supplied to the forming box from the reverse flow side in the circular net rotating direction, and the slurry is Branched from the head box, 0.5% by weight of polyvinyl alcohol, 1% by weight of a phenol resin binder, and 15% by weight of aluminum hydroxide were added to the branched slurry and mixed and dispersed with an in-line mixer to form a second slurry. The second slurry is supplied to the forming box from the forward flow side in the circular mesh rotation direction. To form a wet mat was wet papermaking by rotation round network. Further, the wet mat was dehydrated with a hot air dehydrator, and then the thickness was adjusted with a roll press to prepare a wet mat having a thickness of 10 mm and a moisture content of 60% by weight. The total solid content of the slurry was 3% by weight.

  This wet mat is carried into a hot air drying apparatus and dried at 170 ° C. for 5 minutes and then at 190 ° C. for 15 minutes so that the internal temperature of the wet mat becomes 71 ° C. or higher, and the moisture content is 2%. The dry board was prepared.

After uniformly applying 100 g / m ² of water on each side of the front and back surfaces of the dry board thus obtained, it was transported to a multistage hot press apparatus, inserted between the hot plates, and heated and compressed. . In the handling up to the insertion of the hot press device between the hot plates, the dry board was not damaged and the handling property was good. Heat compression was performed for 5 minutes under a temperature condition of 190 ° C., and an inorganic plate having a thickness of 3.5 mm and a specific gravity of 1.2 was obtained in which the phenol resin binder was sufficiently cured by the heat compression. This inorganic plate was not punctured or deformed at the side edges.

  Next, after sanding the front and back surfaces of the inorganic board by 0.3 mm each, a diallyl phthalate resin (DAP) decorative sheet is pasted on the surface of the round net side of the wet round net papermaking machine to form an inorganic decorative board. When formed, the cosmetic properties were good. Moreover, as a result of performing a cross-cut test (peeling test) on this inorganic decorative board based on the test method of JIS K5400, the base material was not peeled off, and the adhesion between the inorganic board and the decorative sheet was good. .

(Comparative Example 1)
50% by weight of slag wool, 39% by weight of aluminum hydroxide, 6% by weight of phenolic resin binder, 2% by weight of polyvinyl alcohol, 2% by weight of tapioca starch, 1% by weight of polyester fibers as heat-bonding fibers, and a flocculant Slurry prepared by stirring and mixing and dispersing the raw material consisting of water into the head box of the round net type paper machine and then supplying it to the forming box from the reverse flow side in the direction of the round net rotation. A wet mat was formed. Further, the wet mat was dehydrated with a hot air dehydrator, and then the thickness was adjusted with a roll press to prepare a wet mat having a thickness of 10 mm and a moisture content of 60% by weight. The solid content concentration of the slurry was 3% by weight.

  This wet mat is carried into a hot air drying apparatus and dried at 170 ° C. for 5 minutes and then at 190 ° C. for 15 minutes so that the internal temperature of the wet mat becomes 71 ° C. or higher, and the moisture content is 2%. The dry board was prepared.

100 g / m ² of water on one side was uniformly applied to each of the front and back surfaces of the dry board thus obtained, and then transported to a multi-stage hot press device, inserted between the hot plates, and compressed by heating. In the handling up to the insertion of the hot press device between the hot plates, the dry board was not damaged and the handling property was good. Heat compression was performed for 5 minutes under a temperature condition of 190 ° C., and an inorganic plate having a thickness of 3.5 mm and a specific gravity of 1.2 was obtained in which the phenol resin binder was sufficiently cured by the heat compression. This inorganic plate was not punctured or deformed at the side edges.

  Next, after sanding the front and back surfaces of the inorganic board by 0.3 mm each, a diallyl phthalate resin (DAP) decorative sheet is pasted on the surface of the round net side to form an inorganic decorative board, and this inorganic decorative board is formed according to JIS K5400. As a result of performing a cross-cut test (peeling test) based on this test method, base material peeling, which was considered to be an effect of lumps, occurred, and the adhesion between the inorganic board and the decorative sheet was insufficient. Moreover, a small convex part was also seen in the makeup | decoration surface of the surface of an inorganic decorative board, and the cosmetics became low.

(Comparative Example 2)
A wet mat similar to that obtained in Example 2 was dried with a dryer at 190 ° C. for 15 minutes to obtain a dry board having a moisture content of 13% by weight. This dry board was heated and compressed in the same manner as in Example 2 to obtain an inorganic plate having a thickness of 3.5 mm and a specific gravity of 1.2. A puncture phenomenon occurred in some of the obtained inorganic plates.

(Comparative Example 3)
A wet mat similar to that obtained in Example 2 above is carried into a hot air drying apparatus, and the wet mat has an internal temperature of 71 ° C or higher for 5 minutes at 180 ° C and then for 25 minutes at 190 ° C. It was dried for a total of 30 minutes to prepare a dry board having a moisture content of 0.2%.

100 g / m ² of water on one side was uniformly applied to each of the front and back surfaces of the dry board thus obtained, and then transported to a multi-stage hot press device, inserted between the hot plates, and compressed by heating. Heat compression was performed for 3 minutes under a temperature condition of 190 ° C. to obtain an inorganic plate having a thickness of 3.5 mm and a specific gravity of 1.2. Although no puncture phenomenon or side edge deformation occurred in this inorganic plate, the bending strength was about 30% lower than that of the inorganic plate of Example 2.

  Next, after sanding the front and back surfaces of the inorganic board by 0.3 mm each, a diallyl phthalate resin (DAP) decorative sheet is pasted on the surface of the round net side to form an inorganic decorative board, and this inorganic decorative board is formed according to JIS K5400. As a result of the cross-cut test (peeling test) based on the test method, the decorative sheet peeled off with the surface layer of the inorganic board adhered to the back surface, and the base material peeled off on the surface layer of the inorganic board .

  It can be seen that the present invention is effective from the difference between the above Examples and Comparative Examples.

  The present invention provides an inorganic board obtained by making a slurry containing mineral fibers, an inorganic powder and a binder as main components by a wet round net making machine, and a decorative layer using the inorganic board as a base material. It is extremely useful in the technical field of manufacturing an inorganic decorative board and has high industrial applicability.

FIG. 1 is a diagram schematically showing an inorganic plate manufacturing apparatus used in an embodiment of the present invention.

Explanation of symbols

F Inorganic plate manufacturing apparatus S Slurry S1 Backflow side of slurry in forming box S2 Forward flow side of slurry in forming box W1 Papermaking mat W2 Wet mat 1 Wet round net papermaking machine 2 Forming box 2a Backflow side supply port 2b Forward flow side supply port 3 Round net 4 Reverse flow side supply path 5 Forward flow side supply path 7 Head box 10 Wet mat conveyor 15 Dryer 16 Hot press

Claims (7)

After the slurry containing mineral fiber, inorganic powder and binder as the main components is supplied to the reverse flow side and the forward flow side, respectively, with respect to the paper making direction of the wet round net paper making machine, and after forming the wet mat ,
A method for producing an inorganic board, wherein the wet mat is dried to form a dry mat, and the dry mat is heated and compressed. In the manufacturing method of the inorganic board of Claim 1,
The manufacturing method of the inorganic board characterized by using the water-soluble polymer binder which gelatinizes at the time of drying as a binder. In the manufacturing method of the inorganic board of Claim 1,
The manufacturing method of the inorganic board characterized by using at least any one of a thermosetting resin binder or a thermoplastic resin binder as a binder. In the manufacturing method of the inorganic board of any one of Claim 1 thru | or 3,
A method for producing an inorganic board, characterized in that the composition of the mineral fiber, the inorganic powder and the binder in the slurry supplied to the reverse flow side and the forward flow side in the paper making direction of the wet round net paper making machine are different from each other. In the manufacturing method of the inorganic board of any one of Claim 1 thru | or 4,
A method for producing an inorganic board, comprising: drying a wet mat after paper making by preheating dehydration with a hot air dehydrator and subsequent hot air drying with a dryer.   In the inorganic board obtained by the manufacturing method of the inorganic board of any one of Claim 1 thru | or 5, the surface by the side of the round net | network contact side of a wet round net-making machine is ground, and a decorative layer is provided in this ground side. An inorganic decorative board characterized by comprising   In the inorganic board obtained by the manufacturing method of the inorganic board of any one of Claim 1 thru | or 5, the surface of the round net | network contact side of a wet round net papermaking machine is ground, and a decorative layer is provided in this ground surface. The manufacturing method of the inorganic decorative board characterized by these.

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