JP2009030288A - Building board and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a plaster-based building board which achieves drastic improvement of a nail holding force or a nail pull-out resisting force. <P>SOLUTION: In manufacturing the building board, a natural polymer-based paste component and water are added to and mixed with calcined plaster as a base material to thereby obtain plaster slurry. Then the plaster slurry is applied to both front and rear surfaces of a glass fiber mat 2 as a core sheet, and the resultant glass fiber mat is dried and hardened, to thereby obtain the building board 1 of a three-layered composite structure consisting of the glass fiber mat 2 and plaster layers 3a, 3b on both the surfaces of the same. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a plaster-based building board suitable for use as an interior material of various buildings, in particular, a wall material, a ceiling material, a floor material, and the like, and a method for manufacturing the same.

  As this type of plaster-based building board, for example, as described in Patent Documents 1 to 3, so-called a combination of a plaster layer and a plate material such as a rubber plate, a resin plate, or a wooden plate as a reinforcing material in addition to a fiber mat. Various composites in the form of sandwiches have been proposed.

And this kind of conventional gypsum-based building board is generally lightweight, nonflammable, earthquake-resistant, although its own strength etc. will depend on the material of the reinforcing material used. It is said that it is excellent in property or soundproofing.
Japanese Patent Laid-Open No. 10-138219 Japanese Patent Laid-Open No. 10-259309 Japanese Patent Laid-Open No. 10-315378

  However, in a conventional gypsum-based building board, even if it is combined with a reinforcing material, the gypsum layer itself forms a single rigid layer. Therefore, the holding force is not sufficient particularly when using a nail, a screw, a thumbtack or the like, and there is a drawback that the nail or the like easily falls off.

  The degree of holding force when a nail, screw, or thumbtack is used is referred to herein as nail holding force or nail pulling strength as will be described later.

  As mentioned above, the nail holding power is poor, and the nails are easily pulled off because the gypsum material itself is poor in toughness and is brittle. This is based on the fact that the nail holding force or the nail pulling strength due to the self-elasticity or friction of the material cannot be obtained.

  The present invention has been made by paying attention to such a problem, and in particular, it is intended to provide a gypsum-based building board and a method for manufacturing the same, in which a nail holding force or a nail pulling strength is greatly improved. .

  According to the first aspect of the present invention, as a gypsum-based building board, at least one surface of a sheet-like core material is coated with a gypsum slurry obtained by adding a paste component and water to a gypsum material as a base material and mixing it. It is characterized by having a composite structure by drying and curing.

  In this case, as described in claim 2, it is of course possible to form a composite structure by coating gypsum slurry on both surfaces of a sheet-like core material.

Here, as the gypsum material to be used, so-called calcined gypsum obtained by heating the pulverized dihydrate gypsum to remove a part of the water of crystallization to make hemihydrate gypsum (CaSO ₄ .1 / 2H ₂ O) is used. This hemihydrate gypsum has the property that it reacts with water to take in crystal water and returns to stable dihydrate gypsum, and it solidifies with expansion and heat generation by an appropriate amount of water.

  As the paste component mixed in the gypsum material, for example, any one of natural polymer, inorganic and synthetic resin is selectively used. Natural polymer pastes include protein-based and hydrous carbon-based pastes. Typical examples of the former include glue, gelatin, casein, albumin, etc., and examples of the latter include starch, Examples include cellulose derivatives and gum arabic. On the other hand, there is sodium silicate as the inorganic paste, and vinyl acetate, polyvinyl alcohol, and the like as synthetic resin pastes, which are also called chemical pastes.

  In the present invention, it is premised on the use of a powdery paste component to uniformly mix with a gypsum material such as dihydrate gypsum as a base material, and any one of those exemplified above alone or in a plurality of Things shall be used together at a predetermined ratio. However, the purpose of mixing the glue component into the gypsum material is to give the gypsum layer with appropriate elasticity and toughness after solidification, and it does not cause secondary problems such as a decrease in strength or discoloration of the gypsum layer. In order to achieve this, it is desirable to use natural polymers.

  The sheet-like core material functions as a reinforcing material for the gypsum layer as in the past. For example, in addition to rubber plates, resin plates such as urethane and styrene foam, wood plates including plywood, calcium silicate plates, cement plates, pearlite plates Any material such as foam concrete board and particle board can be used.

  However, from the viewpoint of complete integration with the gypsum layer, and from the point of being lightweight and excellent in tensile and bending strength, the core material is a non-woven fabric or fibrous material having a slurry impregnation property, for example, according to claim 3. As described above, a continuous fiber glass fiber (continuous strand) such as a chopped strand mat or the like having a glass fiber as a main element, or a non-woven fabric, more specifically, as described in claim 4 It is possible to use a glass fiber mat that is laminated to a uniform thickness in a non-direction and formed into a mat shape using a binder, or a nonwoven fabric mat that is laminated in a uniform thickness into a mat shape by needle processing. desirable.

  In addition, when it is assumed that a fibrous material, a glass fiber mat, or a non-woven mat is used as the core material as described above, a core impregnated with gypsum slurry in advance as described in claim 5 It is of course possible to form a composite structure by coating the material with gypsum slurry and drying and curing.

  According to the present invention, a gypsum slurry obtained by adding a paste component and water to a gypsum material as a base material and mixing the mixture is coated on at least one surface of a sheet-like core material, and then dried and cured, so that the composite structure is used. Because it is a board, moderate elasticity and toughness are imparted to the plaster layer after setting and solidification, and even when nails, screws, thumbtacks, etc. are used in particular, those nails do not easily fall off. Holding power or nail pulling strength is greatly improved.

  FIG. 1 is a sectional view showing a more specific embodiment of a building board according to the present invention.

  As shown in the figure, this building board 1 has a so-called sandwich-like composite structure in which a glass fiber mat 2 is used as a sheet-like core material and gypsum layers 3a and 3b are arranged on both front and back surfaces to be integrated. It is.

  Here, in FIG. 1, the boundary between the glass fiber mat 2 as the core and the respective gypsum layers 3a and 3b appears relatively clearly, but in the present embodiment, the glass fiber mat 2 and the respective gypsum layers 3a. , 3b is not simply laminated and bonded, but the glass fiber mat 2 is coated with a gypsum slurry in which a paste component and water are added to a base gypsum material and mixed as described later, and then dried. Each gypsum layer 3a, 3b is formed integrally with the glass fiber mat 2 by being cured. Therefore, since the glass fiber mat 2 as the core material is impregnated with gypsum slurry, the boundary between the glass fiber mat 2 and the gypsum layers 3a and 3b is unclear in the actual cross section as compared to FIG. It has become.

  An example of the manufacturing method of the building board 1 having such a composite structure will be described with reference to FIG.

  First, by preparing a glass fiber mat 2 cut to a predetermined size as a sheet-like core material, and heating a dihydrate gypsum crushed as a gypsum material as a base material to remove a part of crystal water In addition to the so-called calcined gypsum made of hemihydrate gypsum, natural polymer powder paste (starch glue) and water are prepared, and the mixing ratio of these three is determined to be, for example, 5: 1: 4. .

  In addition, the said mixing ratio is only an example, and it cannot be overemphasized that it can change suitably according to the mechanical strength requested | required of the kind of calcined gypsum and paste to be used, or the board 1 for construction.

  Then, calcined gypsum and powdery paste are put in a predetermined mixer and mixed. If both are mixed uniformly, water is finally added and kneaded to form a gypsum slurry (step S1 in FIG. 2). .

  Further, the glass fiber mat 2 prepared as the sheet-like core material is formed into a mat shape using a binder by laminating long-fiber glass fibers (continuous strands) in a non-directional and uniform thickness as is well known. This is dipped in a gypsum slurry similar to the above and previously impregnated. Here, “Unifilo U-816-300 × 127” (trade name) manufactured by Nippon Electric Glass Co., Ltd. was used as the glass fiber mat 2.

  Separately, for example, prepare a platen plate (not shown) with a sense of rigidity, such as plywood, and apply a gel agent that also serves as a mold release agent to the surface to smooth the platen. deep.

  On the surface plate, the above gypsum slurry is uniformly coated with a predetermined thickness using, for example, a spray gun or an impregnation roller to form either one of the gypsum layers 3a or 3b (step S2 in FIG. 2), and is left for a predetermined time. It is allowed to stand to accelerate its solidification, that is, drying / curing (step S3 in FIG. 2).

  While one coated gypsum layer 3a or 3b is in a semi-cured state, the glass fiber mat 2 previously impregnated with gypsum slurry is overlaid on the one gypsum layer 3a or 3b (step S4 in FIG. 2). .

  In this case, a uniform pressing process is performed from above the laminated glass fiber mat 2 using a roller or the like, thereby smoothing the surface while defoaming the bubble components contained in the glass fiber mat 2. And complete laying of the glass fiber mat 2.

  Then, in this state, the glass fiber mat 2 impregnated with gypsum slurry is allowed to stand for a predetermined time to accelerate the solidification, that is, the drying and curing as a two-layer laminate (step S5 in FIG. 2).

  While the glass fiber mat 2 impregnated with the gypsum slurry is in a semi-cured state, the gypsum slurry is uniformly coated with a predetermined thickness from above the glass fiber mat 2 by using a spray gun, an impregnation roller or the like. The other gypsum layer 3b or 3a is used (step S6 in FIG. 2).

  In this state, it is allowed to stand for a predetermined time to promote further solidification, that is, drying / curing of the three-layered laminate composed of the glass fiber mat 2 and the gypsum layers 3a and 3b on both the front and back surfaces (see FIG. 2 step S7).

  Then, after waiting for complete drying and curing, the three-layer laminate is peeled off from the surface plate, appropriately subjected to surface adjustment treatment, etc., and then cut into standard dimensions (step S8 in FIG. 2) to construct as a product. The board 1 is finished (step S9 in FIG. 2).

  The building board 1 having a three-layer composite structure thus formed has a tensile or bending strength, weight reduction, incombustibility, and earthquake resistance since the glass fiber mat 2 as a sheet-like core material functions as a reinforcing material. Of course, the gypsum layers 3a and 3b on both the front and back sides of the building board 1 are preliminarily incorporated with a paste component at the slurry stage, so that the respective gypsum layers 3a and 3b are solidified. At this stage, moderate elasticity and toughness are imparted compared to the conventional one.

  Therefore, even if a nail, screw, or thumbtack is driven, the crack does not occur as in the conventional case, the nail does not easily fall off, and the self-elasticity of the gypsum layers 3a and 3b itself Necessary and sufficient nail holding force is obtained by the frictional force, and as a result, the resistance to pulling out the nail is greatly improved.

  When the inventor conducted a nail strength performance test on the building board 1 obtained in the above-described embodiment in accordance with the “nail extraction test” defined in the Japanese Agricultural Standard, etc., necessary and sufficient performance is obtained. I was able to confirm.

  Here, the manufacturing method of the building board 1 shown in FIG. 2 is only an example, and in particular, when the building board 1 is mass-produced, it may be appropriately changed so as to be suitable for a manufacturing method in an automated manufacturing facility. Is possible. For example, the coating of one of the gypsum layers 3a or 3b, the subsequent laying of the glass fiber mat 2 impregnated with the gypsum slurry, and the coating of the other gypsum layer 3b or 3a are sequentially performed on a conveyor that runs continuously. Of course, the three layers can be dried and cured after being pressed or in a pressed state, and the final cutting can be performed.

  Moreover, in the said embodiment, although the case where the gypsum layers 3a and 3b were provided in the front and back both surfaces of the glass fiber mat 2 which is a sheet-like core material was shown, a nonwoven fabric mat other than a glass fiber mat as a sheet-like core material was shown. As described above, any resin plate such as urethane or styrene foam, wood plate, calcium silicate plate, cement plate, pearlite plate, foamed concrete plate, or particle board can be used as necessary. . It is of course possible to provide the gypsum layer 3a or 3b only on one side of the core material represented by the glass fiber mat 2 as required.

  Furthermore, as the gypsum layers 3a and 3b, it is also possible to form a hard gypsum layer and a soft gypsum layer so as to overlap each other.

Cross-sectional explanatory drawing which shows an example of the building board which concerns on this invention. Process explanatory drawing which shows an example of the manufacture procedure of the building board shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Building board 2 ... Glass fiber mat as a sheet-like core material 3a, 3b ... Gypsum layer

Claims (6)

  For construction, characterized in that a gypsum slurry, which is a base material gypsum component and water added and mixed, is coated on at least one side of a sheet-like core material and then dried and cured to form a composite structure board.   The building board according to claim 1, wherein gypsum slurry is coated on both sides of a sheet-like core material to form a composite structure.   The building board according to claim 1 or 2, wherein the core material is a fibrous material mainly composed of glass fiber, or a non-woven fabric.   The core material can be obtained by laminating continuous long glass fibers in a non-directional uniform thickness and using a binder to form a mat or a non-woven fabric in a uniform thickness. The building board according to claim 3, wherein the building board is a non-woven mat formed into a mat shape.   5. The building board according to claim 3 or 4, wherein the core material previously impregnated with gypsum slurry is further coated with gypsum slurry and then dried and cured to form a composite structure. Add a paste component and water to the gypsum material that is the base material and mix to make a gypsum slurry.
A method for producing a building board, wherein the gypsum slurry is coated on at least one side of a sheet-like core material and then dried and cured to integrate both to form a composite structure.

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