JP2018083393A - Ceramic-based building board and method for producing the same - Google Patents
Ceramic-based building board and method for producing the same Download PDFInfo
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
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Abstract
Description
本発明は、セメントを含有する組成物からなる成形体の養生硬化物である窯業系建築板及びその製造方法に関する。 The present invention relates to a ceramic building board, which is a cured cured product of a molded body made of a composition containing cement, and a method for producing the same.
従来、セメントを含有する組成物から作製された無機質セメント板は、建築板として広く用いられている（特許文献１参照）。 Conventionally, the inorganic cement board produced from the composition containing cement is widely used as a building board (refer patent document 1).
建築物の意匠性向上の要請により、建築板には種々の塗装が施されることが多いが、自然の風合いを有する模様を塗装で形成しようとすると、塗装に要する手間がかかり、更に人工的に形成された模様であることが観察者に容易に看破されてしまう。 In response to demands for improving the design of buildings, building boards are often painted in various ways. However, if a pattern with a natural texture is to be formed by painting, it takes time and effort to paint. It is easily observed by an observer that the pattern is formed on the screen.
本発明の目的は、塗装によらない模様であって、自然の風合いを有するとともに人工物であることが看破されにくい模様を有する窯業系建築板、及びその製造方法を提供することである。 An object of the present invention is to provide a ceramic building board having a pattern that does not depend on coating, has a natural texture, and is not easily detected as an artifact, and a method for manufacturing the same.
本発明に係る窯業系建築板は、セメントを含有する組成物からなる成形体の養生硬化物である窯業系建築板であり、前記窯業系建築板の外面は、エフロレッセンスで構成された模様を有する。 The ceramic building board according to the present invention is a ceramic building board which is a cured cured product of a molded body made of a composition containing cement, and the outer surface of the ceramic building board has a pattern composed of efflorescence. Have.
本発明に係る窯業系建築板において、前記外面全体に対する、前記エフロレッセンスが占める割合は、１０％以上９５％未満の範囲内であることが好ましい。 In the ceramic building board according to the present invention, the ratio of the efflorescence to the entire outer surface is preferably within a range of 10% or more and less than 95%.
本発明に係る窯業系建築板において、前記窯業系建築板中のＳｉのモル量に対する、前記窯業系建築板中のＣａのモル量の比の値は、０．５〜０．９の範囲内であることが好ましい。 In the ceramic building board according to the present invention, the ratio of the molar amount of Ca in the ceramic building board to the molar amount of Si in the ceramic building board is in the range of 0.5 to 0.9. It is preferable that
本発明に係る窯業系建築板において、前記エフロレッセンスは、前記組成物の養生硬化時に生成したものであることが好ましい。 In the ceramic building board according to the present invention, it is preferable that the efflorescence is generated at the time of curing and curing the composition.
本発明に係る窯業系建築板において、前記窯業系建築板は、前記模様の一部を構成する化粧材を含有することが好ましい。 In the ceramic building board according to the present invention, it is preferable that the ceramic building board contains a decorative material constituting a part of the pattern.
前記化粧材は、コーヒー豆かすとガラス破砕粉とのうち少なくとも一方を含有することが好ましい。 The cosmetic material preferably contains at least one of coffee grounds and crushed glass powder.
本発明に係る窯業系建築板の製造方法は、セメントを含有する組成物からなる成形体の養生硬化物である窯業系建築板の製造方法であり、前記成形体を養生硬化させる際に前記養生硬化物の外面にエフロレッセンスを生成させて前記エフロレッセンスから構成された模様を形成する養生工程を含む。 The method for manufacturing a ceramic building board according to the present invention is a method for manufacturing a ceramic building board, which is a cured cured product of a molded body made of a composition containing cement, and the curing is performed when the molded body is cured and cured. It includes a curing step of generating efflorescence on the outer surface of the cured product to form a pattern composed of the efflorescence.
本発明に係る窯業系建築板の製造方法において、前記養生工程において、前記成形体の外面上にシーラーが塗布されておらず、又は前記成形体の外面上におけるシーラーの塗布量が２５０ｇ／ｍ2未満であることが好ましい。 In the method for manufacturing a ceramic building board according to the present invention, in the curing step, no sealer is applied on the outer surface of the molded body, or the coating amount of the sealer on the outer surface of the molded body is 250 g / m 2. It is preferable that it is less than.
本発明に係る窯業系建築板の製造方法は、前記組成物に前記模様の一部を構成する化粧材を含有させることを含むことが好ましい。 The method for producing a ceramic building board according to the present invention preferably includes containing a decorative material constituting a part of the pattern in the composition.
本発明に係る窯業系建築板は、エフロレッセンスで構成される、塗装によらない模様を有することから、この模様は自然な風合いを有し、しかも観察者からはこの模様が人工的であるとは看破されにくい。 Since the ceramic building board according to the present invention has a pattern made of efflorescence and does not depend on painting, this pattern has a natural texture, and this pattern is artificial from the observer. Is hard to overlook.
本発明に係る窯業系建築板の製造方法では、エフロレッセンスで構成される、塗装によらない模様を有する窯業系建築板を容易に製造できる。 In the method for manufacturing a ceramic building board according to the present invention, it is possible to easily manufacture a ceramic building board having a pattern that does not depend on painting and is made of efflorescence.
以下、本発明の一実施形態について説明する。 Hereinafter, an embodiment of the present invention will be described.
本実施形態に係る窯業系建築板は、セメントを含有する組成物からなる成形体の養生硬化物である。窯業系建築板の外面は、エフロレッセンスで構成された模様を有する。 The ceramic building board according to the present embodiment is a cured cured product of a molded body made of a composition containing cement. The outer surface of the ceramic building board has a pattern composed of efflorescence.
この窯業系建築板は、塗装によらない、エフロレッセンスで構成された模様を有する。エフロレッセンスは、白っぽい外観を有し、窯業系建築板の外面に不規則に分布する。そのため、エフロレッセンスで構成された模様は自然な風合いを有し、観察者からはこの模様が人工的であるとは看破されにくい。 This ceramic building board has a pattern composed of efflorescence, which does not depend on painting. Eflorescence has a whitish appearance and is irregularly distributed on the outer surface of ceramic building boards. Therefore, the pattern composed of efflorescence has a natural texture, and it is difficult for an observer to perceive that this pattern is artificial.
なお、本実施形態において、窯業系建築板の外面とは、窯業系建築板が建築物に設置された場合に外部に露出する面である。また、後述する成形体の外面とは、成形体における、窯業系建築板の外面と対応する面である。 In the present embodiment, the outer surface of the ceramic building board is a surface exposed to the outside when the ceramic building board is installed in the building. Moreover, the outer surface of the molded object mentioned later is a surface corresponding to the outer surface of the ceramic industry building board in a molded object.
窯業系建築板の外面全体に対する、エフロレッセンスが占める割合は、１０％以上９５％未満の範囲内であることが好ましい。この割合が１０％以上であれば、エフロレッセンスは、観察者によって、染み、汚れなどの欠陥として認識されにくく、そのためエフロレッセンスが模様を構成する要素として認識されやすい。また、この割合が９５％未満であれば、外面がほぼ単一色に見えるようなことがなくなり、そのため、エフロレッセンスが模様を構成する要素として認識されやすい。 The ratio of efflorescence to the entire outer surface of the ceramic building board is preferably in the range of 10% to less than 95%. If this ratio is 10% or more, the efflorescence is not easily recognized by the observer as a defect such as a stain or a stain, and therefore the efflorescence is easily recognized as an element constituting the pattern. Further, if this ratio is less than 95%, the outer surface does not appear to be almost a single color, so that efflorescence is easily recognized as an element constituting the pattern.
窯業系建築板の構成及びその製造方法について、更に詳しく説明する。この製造方法は、セメントを含有する組成物からなる成形体の養生硬化物である窯業系建築板の製造方法であり、成形体を養生硬化させる際に養生硬化物の外面にエフロレッセンスを生成させてエフロレッセンスで構成された模様を形成する養生工程を含む。 The structure of the ceramic building board and the manufacturing method thereof will be described in more detail. This manufacturing method is a method for manufacturing a ceramic building board, which is a cured cured product of a molded body made of a composition containing cement. When curing the molded body, efflorescence is generated on the outer surface of the cured cured product. And a curing process for forming a pattern composed of efflorescence.
窯業系建築板の製造方法の第一の例について説明する。 A first example of a method for manufacturing a ceramic building board will be described.
まずセメントを含有する組成物（以下、セメント組成物という）を準備する。 First, a composition containing cement (hereinafter referred to as a cement composition) is prepared.
セメント組成物は、例えばセメント、シリカ質を含む混和材、補強繊維、軽量骨材、増量材、水等を含有できる。シリカ質を含む混和材は、例えばＳｉＯ2含有率が７０質量％以上であるとともにブレーン値が３０００ｃｍ2以上のケイ石粉、前記以外のケイ石粉、シリカパウダー、高炉水砕スラグ、フライアッシュ、パルプスラッジ焼却灰、及び汚泥焼却灰からなる群から選択される少なくとも一種の成分を含有する。補強繊維は、例えばパルプ、ビニロン繊維、ポリプロピレン繊維、及びロックウールからなる群から選択される少なくとも一種の成分を含有する。補強繊維は、使用済み紙コップなどの紙製廃材を解繊して得られる繊維を含んでもよい。軽量骨材は、パーライト、回収セメント製品の破砕物などを含有できる。増量材は、例えばマイカ、ワラストナイト、バーミキュライト、タルク、及び炭酸カルシウムからなる群から選択される少なくとも一種の成分を含有する。増量材はマイカを含有することが好ましい。マイカの平均粒径は５０μｍ以上１５０μｍ未満の範囲内であることが好ましく、マイカのアスペクト比は８０〜１５０の範囲内であることが好ましい。 The cement composition can contain, for example, cement, an admixture containing siliceous material, reinforcing fibers, lightweight aggregate, filler, water, and the like. The admixture containing siliceous material is, for example, silica powder having a SiO 2 content of 70% by mass or more and a brain value of 3000 cm 2 or more, silica stone powder other than the above, silica powder, granulated blast furnace slag, fly ash, pulp sludge It contains at least one component selected from the group consisting of incineration ash and sludge incineration ash. The reinforcing fiber contains at least one component selected from the group consisting of pulp, vinylon fiber, polypropylene fiber, and rock wool, for example. The reinforcing fibers may include fibers obtained by defibrating paper waste materials such as used paper cups. The lightweight aggregate can contain perlite, crushed recovered cement products, and the like. The extender contains at least one component selected from the group consisting of mica, wollastonite, vermiculite, talc, and calcium carbonate, for example. The extender preferably contains mica. The average particle diameter of mica is preferably in the range of 50 μm or more and less than 150 μm, and the aspect ratio of mica is preferably in the range of 80 to 150.
セメント組成物中の固形分１００質量部に対し、セメントの量は例えば２５〜４５質量部の範囲内、シリカ質を含む混和材の量は例えば１５〜６７質量部の範囲内、補強繊維の量は例えば４〜１０質量部の範囲内、軽量骨材の量は例えば０〜３０質量部の範囲内、増量材の量は例えば４〜１２質量部の範囲内である。 The amount of cement is within the range of, for example, 25 to 45 parts by mass, the amount of admixture containing siliceous is within the range of, for example, 15 to 67 parts by mass, and the amount of reinforcing fibers with respect to 100 parts by mass of the solid content in the cement composition. Is within the range of 4 to 10 parts by weight, the amount of the lightweight aggregate is within the range of 0 to 30 parts by weight, for example, and the amount of the filler is within the range of 4 to 12 parts by weight, for example.
セメント組成物中の固形分量に対する水の量の比の値（水の量／固形分量）は、５／９５〜３０／７０の範囲内であることが好ましい。 The value of the ratio of the amount of water to the amount of solids in the cement composition (the amount of water / the amount of solids) is preferably in the range of 5/95 to 30/70.
また、セメント組成物中のＳｉのモル量に対する、セメント組成物中のＣａのモル量の比の値（Ｃａのモル量／Ｓｉのモル量）は、０．５〜０．９の範囲内であることが好ましい。すなわち、Ｓｉのモル量に対するＣａのモル量の比の値が０．５〜０．９の範囲内となるように、セメント組成物中の成分の種類及び量が決定されることが好ましい。 The ratio of the molar amount of Ca in the cement composition to the molar amount of Si in the cement composition (Ca molar amount / Si molar amount) is in the range of 0.5 to 0.9. Preferably there is. That is, it is preferable to determine the types and amounts of components in the cement composition so that the ratio of the molar amount of Ca to the molar amount of Si is in the range of 0.5 to 0.9.
セメント組成物は、化粧材を含有してもよい。この場合、化粧材が、窯業系建築板の外面の模様の一部を構成できる。すなわち、エフロレッセンスと化粧材とが模様を構成できる。化粧材は、有機質の材料であっても、無機質の材料であってもよい。有機質の材料の例は、植物の実若しくは種子又はそれらを覆う殻、また、それらの形状をできるだけ保持して炭化させたものや前記炭化させたものを粉砕したものなどを含み、例えば、コーヒー豆かす、モミガラの炭化処理品などが挙げられる。無機質の材料の例はガラス破砕粉を含む。例えば化粧材は、コーヒー豆かすとガラス破砕粉とのうち少なくとも一方を含む。化粧材の量は、窯業系建築板の外面に付与する模様に応じて適宜決定される。セメント組成物が有機質の材料を含有する場合、セメント組成物は撥水剤を更に含有することが好ましい。この場合、有機質の材料の腐食及び変質を抑制することができ、これにより模様の変化を抑制できる。 The cement composition may contain a cosmetic material. In this case, the decorative material can constitute a part of the pattern on the outer surface of the ceramic building board. That is, the efflorescence and the decorative material can form a pattern. The decorative material may be an organic material or an inorganic material. Examples of organic materials include plant nuts or seeds, or shells that cover them, and those that have been carbonized while retaining their shape as much as possible, or those that have been pulverized, such as coffee beans. Examples include debris and carbonized products of chaff. Examples of inorganic materials include crushed glass powder. For example, the cosmetic material includes at least one of coffee bean residue and glass crushed powder. The amount of the decorative material is appropriately determined according to the pattern applied to the outer surface of the ceramic building board. When the cement composition contains an organic material, the cement composition preferably further contains a water repellent. In this case, the corrosion and alteration of the organic material can be suppressed, and thereby the change of the pattern can be suppressed.
セメント組成物を板状に成形して、成形体を作製する。そのための成形方法は、例えば抄造法であるが、これに限られず、例えば押出成形法又は注型成形法でもよい。 The cement composition is molded into a plate shape to produce a molded body. The molding method for this is, for example, a papermaking method, but is not limited thereto, and may be, for example, an extrusion molding method or a cast molding method.
養生工程の前に、成形体にプレス加工を施してもよい。プレス加工の条件は、例えばプレス圧２．９〜１１．８ＭＰａ（３０〜１２０ｋｇ／ｃｍ2）、時間３〜３０秒である。 Prior to the curing step, the molded body may be pressed. The press working conditions are, for example, a press pressure of 2.9 to 11.8 MPa (30 to 120 kg / cm 2 ) and a time of 3 to 30 seconds.
養生工程では、この成形体を養生することで硬化させる。養生の方法は、例えばオートクレーブ養生法、蒸気養生法、常温養生法、又はこれらのうちの二種以上の組み合わせである。特に養生の方法が蒸気養生法を含む場合には、析出物を生成させやすい。本実施形態における養生の方法の一具体例では、まず成形体を４０〜９０℃、９０〜１００％ＲＨ、４〜２４時間の条件で蒸気養生法により養生してから、１４０〜２００℃、２〜１２時間の条件でオートクレーブ養生法により養生する。 In the curing process, the molded body is cured by curing. The curing method is, for example, an autoclave curing method, a steam curing method, a room temperature curing method, or a combination of two or more of these. In particular, when the curing method includes a steam curing method, precipitates are easily generated. In one specific example of the curing method in this embodiment, the molded body is first cured by steam curing under conditions of 40 to 90 ° C., 90 to 100% RH, and 4 to 24 hours, and then 140 to 200 ° C., 2 Cured by autoclave curing method for ~ 12 hours.
このように成形体を養生して硬化させることで、窯業系建築板を作製できる。また、この養生時に、成形体の外面に、エフロレッセンスを生成させる。このエフロレッセンスは、セメント組成物中の成分に由来して生成する。このため、窯業系建築板の外面は、エフロレッセンスで構成された模様を有することができる。 Thus, a ceramic building board can be produced by curing and curing the molded body. In addition, during this curing, efflorescence is generated on the outer surface of the molded body. This efflorescence is generated from components in the cement composition. For this reason, the outer surface of the ceramic building board can have a pattern made of efflorescence.
養生工程において、成形体の外面上にシーラーが塗布されておらず、又は成形体の外面上におけるシーラーの塗布量が２５０ｇ／ｍ2未満であることが好ましく、２００ｇ／ｍ2以下であればより好ましい。この場合、成形体におけるエフロレッセンスの生成を促進することができる。 More in curing process, sealer not coated on the outer surface of the shaped body, or it is preferable that the coating amount of sealer on the outer surface of the shaped body is less than 250 g / m 2, if 200 g / m 2 or less preferable. In this case, generation of efflorescence in the molded body can be promoted.
一般に、無機質セメント板の製造時には、シーラーを用いる。シーラーは、例えばアクリル樹脂、酢酸ビニル樹脂、エポキシ樹脂、塩化ゴム、ウレタン樹脂、シリコン樹脂、フッ素樹脂などの樹脂を含有する。シーラーは、例えば水性エマルションであり、あるいは有機溶剤を含有する溶液又は分散液である。シーラーは、必要により重質炭酸カルシウム、沈降性炭酸カルシウム、カオリン、ベントナイト、セリサイト、ドロマイト、タルク、クレー、酸化アルミニウム、酸化マグネシウム、珪藻土などの無機粒子を含有する。このようなシーラーは、エフロレッセンスの生成を抑制してしまう。 Generally, a sealer is used when manufacturing an inorganic cement board. The sealer contains, for example, a resin such as an acrylic resin, a vinyl acetate resin, an epoxy resin, a chlorinated rubber, a urethane resin, a silicon resin, or a fluorine resin. The sealer is, for example, an aqueous emulsion, or a solution or dispersion containing an organic solvent. The sealer contains inorganic particles such as heavy calcium carbonate, precipitated calcium carbonate, kaolin, bentonite, sericite, dolomite, talc, clay, aluminum oxide, magnesium oxide, diatomaceous earth as necessary. Such a sealer suppresses generation of efflorescence.
しかし、上記のように成形体の養生硬化時に、成形体の外面上にシーラーが塗布されておらず、又は成形体の外面上におけるシーラーの塗布量が２５０ｇ／ｍ2未満、より好ましくは２００ｇ／ｍ2以下であれば、エフロレッセンスの生成が抑制されず、すなわちエフロレッセンスが生成される。また、成形体の外面上にシーラーが塗布される場合は、シーラーの量を調整することで、エフロレッセンスの生成量を制御することができる。例えば、シーラーの量を調整することで、窯業系建築板の外面全体に対する、エフロレッセンスが占める割合を、１０％以上９５％未満の範囲内で制御することができる。このため、エフロレッセンスの量を所望の量に制御できる。 However, when the molded body is cured and cured as described above, no sealer is applied on the outer surface of the molded body, or the amount of the sealer applied on the outer surface of the molded body is less than 250 g / m 2 , more preferably 200 g / If m 2 or less, generation of efflorescence is not suppressed, that is, efflorescence is generated. In addition, when a sealer is applied on the outer surface of the molded body, the amount of efflorescence generated can be controlled by adjusting the amount of the sealer. For example, by adjusting the amount of the sealer, the ratio of efflorescence to the entire outer surface of the ceramic building board can be controlled within a range of 10% or more and less than 95%. For this reason, the amount of efflorescence can be controlled to a desired amount.
また、上記のようにセメント組成物中のＳｉのモル量に対するセメント組成物中のＣａのモル量の比の値（Ｃａのモル量／Ｓｉのモル量）が０．５〜０．９の範囲内であると、すなわち窯業系建築板中のＳｉのモル量に対する窯業系建築板中のＣａのモル量の比の値が０．５〜０．９の範囲内であると、窯業系建築板の外面上に適度な量のエフロレッセンスを容易に生成させることができる。詳しくは、上記比の値が０．５以上であると、養生時の析出物の生成を十分に促進することができる。更に、窯業系建築板が十分に高い強度を有することもできる。また、上記比の値が０．９以下であると、エフロレッセンスの過度な生成を抑制でき、窯業系建築板の外面にエフロレッセンスが部分的に存在するようにできる。また上記比の値を０．５〜０．９の範囲内で調整することで、窯業系建築板の外面全体に対する、エフロレッセンスが占める割合を、１０％以上９５％未満の範囲内で制御することができる。 Further, as described above, the ratio of the molar amount of Ca in the cement composition to the molar amount of Si in the cement composition (Ca molar amount / Si molar amount) is in the range of 0.5 to 0.9. In other words, when the ratio of the molar amount of Ca in the ceramic building board to the molar amount of Si in the ceramic building board is within the range of 0.5 to 0.9, the ceramic building board An appropriate amount of efflorescence can be easily generated on the outer surface of the substrate. Specifically, when the value of the ratio is 0.5 or more, the generation of precipitates during curing can be sufficiently promoted. Furthermore, the ceramic building board can have a sufficiently high strength. Moreover, when the value of the ratio is 0.9 or less, excessive generation of efflorescence can be suppressed, and efflorescence can partially exist on the outer surface of the ceramic building board. Moreover, by adjusting the value of the above ratio within a range of 0.5 to 0.9, the ratio of efflorescence to the entire outer surface of the ceramic building board is controlled within a range of 10% or more and less than 95%. be able to.
窯業系建築板の製造方法の第二の例について説明する。 A second example of the method for manufacturing a ceramic building board will be described.
まずセメント組成物を準備する。第二の例では、セメント組成物は、第一の組成物と第二の組成物とを含む。 First, a cement composition is prepared. In a second example, the cement composition includes a first composition and a second composition.
第一の組成物は、第一の例におけるセメント組成物と同じ組成を有してよい。なお、第一の組成物は、化粧材を含有する必要はないが、化粧材を含有してもよい。 The first composition may have the same composition as the cement composition in the first example. The first composition need not contain a cosmetic material, but may contain a cosmetic material.
第二の組成物は、例えばセメント、シリカ質を含む混和材、補強繊維、軽量骨材、増量材、水等を含有できる。シリカ質を含む混和材は、例えばＳｉＯ2含有率が７０質量％以上であるとともにブレーン値が３０００ｃｍ2以上のケイ石粉、前記以外のケイ石粉、シリカパウダー、高炉水砕スラグ、フライアッシュ、パルプスラッジ焼却灰、及び汚泥焼却灰からなる群から選択される少なくとも一種の成分を含有する。補強繊維は、例えばパルプ、ビニロン繊維、ポリプロピレン繊維、及びロックウールからなる群から選択される少なくとも一種の成分を含有する。補強繊維は、使用済み紙コップなどの紙製廃材を解繊して得られる繊維を含んでもよい。軽量骨材は、パーライト、回収セメント製品の破砕物などを含有できる。増量材は、例えばマイカ、ワラストナイト、バーミキュライト、タルク、及び炭酸カルシウムからなる群から選択される少なくとも一種の成分を含有する。増量材はマイカを含有することが好ましい。マイカの平均粒径は５０μｍ以上１５０μｍ未満の範囲内であることが好ましく、マイカのアスペクト比は８０〜１５０の範囲内であることが好ましい。 The second composition can contain, for example, cement, an admixture containing siliceous materials, reinforcing fibers, lightweight aggregates, fillers, water, and the like. The admixture containing siliceous material is, for example, silica powder having a SiO 2 content of 70% by mass or more and a brain value of 3000 cm 2 or more, silica stone powder other than the above, silica powder, granulated blast furnace slag, fly ash, pulp sludge It contains at least one component selected from the group consisting of incineration ash and sludge incineration ash. The reinforcing fiber contains at least one component selected from the group consisting of pulp, vinylon fiber, polypropylene fiber, and rock wool, for example. The reinforcing fibers may include fibers obtained by defibrating paper waste materials such as used paper cups. The lightweight aggregate can contain perlite, crushed recovered cement products, and the like. The extender contains at least one component selected from the group consisting of mica, wollastonite, vermiculite, talc, and calcium carbonate, for example. The extender preferably contains mica. The average particle diameter of mica is preferably in the range of 50 μm or more and less than 150 μm, and the aspect ratio of mica is preferably in the range of 80 to 150.
第二の組成物中の固形分１００質量部に対し、セメントの量は例えば２５〜４５質量部の範囲内、シリカ質を含む混和材の量は例えば１５〜６７質量部の範囲内、補強繊維の量は例えば４〜１０質量部の範囲内、軽量骨材の量は例えば０〜３０質量部の範囲内、増量材の量は例えば４〜１２質量部の範囲内である。 The amount of cement is within a range of, for example, 25 to 45 parts by mass, and the amount of admixture containing siliceous is within a range of, for example, 15 to 67 parts by mass with respect to 100 parts by mass of the solid content in the second composition. For example, the amount of lightweight aggregate is in the range of 0 to 30 parts by mass, and the amount of the extender is in the range of 4 to 12 parts by mass, for example.
第二の組成物中の固形分量に対する水の量の比の値（水の量／固形分量）は、０〜１／２の範囲内であることが好ましい。 The value of the ratio of the amount of water to the amount of solid content in the second composition (the amount of water / the amount of solid content) is preferably in the range of 0 to 1/2.
第二の組成物は、化粧材を含有してもよい。この場合、化粧材が、窯業系建築板の外面の模様の一部を構成できる。すなわち、エフロレッセンスと化粧材とが模様を構成できる。化粧材は、有機質の材料であっても、無機質の材料であってもよい。有機質の材料の例は、コーヒー豆かす及びモミガラを含む。無機質の材料の例はガラス破砕粉を含む。例えば柄材は、コーヒー豆かすとガラス破砕粉とのうち少なくとも一方を含む。このような化粧材は、窯業系建築板の外面の模様における自然な風合いを更に高めることができる。柄材の量は、窯業系建築板の外面に付与する模様に応じて適宜決定される。第二の組成物が有機質の材料を含有する場合、セメント組成物は撥水剤を更に含有することが好ましい。この場合、有機質の材料の腐食及び変質を抑制することができ、これにより模様の変化を抑制できる。 The second composition may contain a cosmetic material. In this case, the decorative material can constitute a part of the pattern on the outer surface of the ceramic building board. That is, the efflorescence and the decorative material can form a pattern. The decorative material may be an organic material or an inorganic material. Examples of organic materials include coffee grounds and chaff. Examples of inorganic materials include crushed glass powder. For example, the pattern material includes at least one of coffee bean residue and glass crushed powder. Such a decorative material can further enhance the natural texture of the pattern on the outer surface of the ceramic building board. The amount of the pattern material is appropriately determined according to the pattern applied to the outer surface of the ceramic building board. When the second composition contains an organic material, the cement composition preferably further contains a water repellent. In this case, the corrosion and alteration of the organic material can be suppressed, and thereby the change of the pattern can be suppressed.
第一の組成物と第二の組成物とを併せたセメント組成物全体中のＳｉのモル量に対する、セメント組成物全体中のＣａのモル量の比の値（Ｃａのモル量／Ｓｉのモル量）は、０．５〜０．９の範囲内であることが好ましい。すなわち、Ｓｉのモル量に対するＣａのモル量の比の値が０．５〜０．９の範囲内となるように、セメント組成物中の成分の種類及び量が決定されることが好ましい。 The value of the ratio of the molar amount of Ca in the entire cement composition to the molar amount of Si in the entire cement composition including the first composition and the second composition (the molar amount of Ca / the molar amount of Si) The amount is preferably in the range of 0.5 to 0.9. That is, it is preferable to determine the types and amounts of components in the cement composition so that the ratio of the molar amount of Ca to the molar amount of Si is in the range of 0.5 to 0.9.
第一の組成物を板状に成形して、中間成形体を作製する。そのための成形方法は、例えば抄造法であるが、これに限られず、例えば押出成形法又は注型成形法でもよい。 The first composition is molded into a plate shape to produce an intermediate molded body. The molding method for this is, for example, a papermaking method, but is not limited thereto, and may be, for example, an extrusion molding method or a cast molding method.
中間成形体上に第二の組成物を撒布することで、成形体を作製する。 A molded body is produced by spreading the second composition on the intermediate molded body.
養生工程の前に、成形体にプレス加工を施してもよい。プレス加工の条件は、例えばプレス圧２．９〜１１．８ＭＰａ（３０〜１２０ｋｇ／ｃｍ2）、時間３〜３０秒である。 Prior to the curing step, the molded body may be pressed. The press working conditions are, for example, a press pressure of 2.9 to 11.8 MPa (30 to 120 kg / cm 2 ) and a time of 3 to 30 seconds.
養生工程では、この成形体を養生することで硬化させる。養生の方法は、第一の例の場合と同じでよい。このように成形体を養生して硬化させることで、窯業系建築板を作製できる。 In the curing process, the molded body is cured by curing. The curing method may be the same as in the first example. Thus, a ceramic building board can be produced by curing and curing the molded body.
窯業系建築板は、第一の組成物に由来する第一層と、第二の組成物に由来する第二層とを備える。第二層は、第一層を覆っている。窯業系建築板の外面は、第二層における外部に露出する面である。 The ceramic building board includes a first layer derived from the first composition and a second layer derived from the second composition. The second layer covers the first layer. The outer surface of the ceramic building board is a surface exposed to the outside in the second layer.
第二の例でも、第一の例と同様に、養生工程において、成形体の外面に、エフロレッセンスを生成させる。このエフロレッセンスは、セメント組成物中の成分に由来して生成する。このため、窯業系建築板の外面は、エフロレッセンスで構成される模様を有することができる。 In the second example, as in the first example, efflorescence is generated on the outer surface of the molded body in the curing process. This efflorescence is generated from components in the cement composition. For this reason, the outer surface of the ceramic building board can have a pattern composed of efflorescence.
第二の例でも、第一の例と同様に、成形体の養生硬化時には、成形体の外面上にシーラーが塗布されておらず、又は成形体の外面上におけるシーラーの塗布量が２５０ｇ／ｍ2未満であることが好ましく、２００ｇ／ｍ2以下であることがより好ましい。この場合、成形体におけるエフロレッセンスの生成を促進することができる。また、成形体の外面上にシーラーが塗布される場合は、シーラーの量を調整することで、エフロレッセンスの生成量を制御することができる。例えば、シーラーの量を調整することで、窯業系建築板の外面全体に対する、エフロレッセンスが占める割合を、１０％以上９５％未満の範囲内で制御することができる。このため、エフロレッセンスの量を所望の量に制御できる。 Also in the second example, as in the first example, when the molded body is cured and cured, no sealer is applied on the outer surface of the molded body, or the amount of the sealer applied on the outer surface of the molded body is 250 g / m. preferably less than 2, and more preferably 200 g / m 2 or less. In this case, generation of efflorescence in the molded body can be promoted. In addition, when a sealer is applied on the outer surface of the molded body, the amount of efflorescence generated can be controlled by adjusting the amount of the sealer. For example, by adjusting the amount of the sealer, the ratio of efflorescence to the entire outer surface of the ceramic building board can be controlled within a range of 10% or more and less than 95%. For this reason, the amount of efflorescence can be controlled to a desired amount.
第二の例でも、第一の例と同様に、上記のようにセメント組成物中のＳｉのモル量に対するセメント組成物中のＣａのモル量の比の値（Ｃａのモル量／Ｓｉのモル量）が０．５〜０．９の範囲内であると、すなわち窯業系建築板中のＳｉのモル量に対する窯業系建築板中のＣａのモル量の比の値が０．５〜０．９の範囲内であると、窯業系建築板の外面上に適度な量のエフロレッセンスを容易に生成させることができる。また比の値を０．５〜０．９の範囲内で調整することで、窯業系建築板の外面全体に対する、エフロレッセンスが占める割合を、１０％以上９５％未満の範囲内で制御することができる。 In the second example, as in the first example, as described above, the ratio of the molar amount of Ca in the cement composition to the molar amount of Si in the cement composition (the molar amount of Ca / the molar amount of Si). Amount) in the range of 0.5 to 0.9, that is, the value of the ratio of the molar amount of Ca in the ceramic building board to the molar amount of Si in the ceramic building board is 0.5 to 0.00. When it is within the range of 9, it is possible to easily generate an appropriate amount of efflorescence on the outer surface of the ceramic building board. Moreover, by adjusting the value of the ratio within a range of 0.5 to 0.9, the ratio of efflorescence to the entire outer surface of the ceramic building board is controlled within a range of 10% or more and less than 95%. Can do.
本実施形態による窯業系建築板の外面には塗装が施されていないことが好ましい。この場合、エフロレッセンスで構成されあるいはエフロレッセンスと柄材とで構成される、自然の風合いを有する模様を、有効に利用することができる。また、塗装が不要であることで、塗装のための労力及び資源の削減が可能である。また、セメント組成物が補強繊維として紙製廃材を解繊して得られる繊維を含有する場合には、更なる資源の削減が可能である。 It is preferable that the outer surface of the ceramic building board according to the present embodiment is not coated. In this case, a pattern having a natural texture that is composed of efflorescence or composed of efflorescence and a pattern material can be used effectively. Further, since painting is unnecessary, labor and resources for painting can be reduced. Further, when the cement composition contains fibers obtained by defibrating paper waste as reinforcing fibers, further resource reduction is possible.
なお、窯業系建築板の外面にはクリアー塗装が施されていてもよい。窯業系建築板の外面にクリアー塗装が施されていると、窯業系建築板の模様を有効に利用しながら、窯業系建築板の外面を保護することができる。このため、例えば窯業系建築板の外面が摩耗することによる破損及び粉落ちの発生、並びに窯業系建築板の外面の汚れを、抑制できる。 In addition, the clear coating may be given to the outer surface of the ceramic industry building board. If the outer surface of the ceramic building board is clear, the outer surface of the ceramic building board can be protected while effectively using the pattern of the ceramic building board. For this reason, the generation | occurrence | production of the failure | damage and powder fall by the outer surface of a ceramics-type building board, for example, and the stain | pollution | contamination of the outer surface of a ceramic-type building board can be suppressed.
以下、本発明の具体的な実施例を提示する。 Hereinafter, specific examples of the present invention will be presented.
表１に示す成分と水を混合することで、セメント組成物を調製した。 A cement composition was prepared by mixing the components shown in Table 1 and water.
なお、表に示す成分の詳細は次の通りである。
・セメント：普通ポルトランドセメント。
・シリカ質を含む混和材：珪石粉（７０００ブレーン）及びＪＩＳフライアッシュ。
・軽量骨材：回収セメント製品の破砕物。
・増量材：マイカ。
・補強繊維：バージンパルプ。
・化粧材：コーヒー豆かす。
The details of the components shown in the table are as follows.
・ Cement: Ordinary Portland cement.
-Admixture containing siliceous materials: silica powder (7000 branes) and JIS fly ash.
-Lightweight aggregate: Crushed material of recovered cement products.
-Bulk material: Mica.
-Reinforcing fiber: Virgin pulp.
・ Cosmetics: Coffee bean grounds.
また、セメント組成物中のＳｉのモル量に対するＣａのモル量の比の値を、表１中の「Ｃａ／Ｓｉモル比」の欄に示す。 Further, the value of the ratio of the molar amount of Ca to the molar amount of Si in the cement composition is shown in the column of “Ca / Si molar ratio” in Table 1.
セメント組成物を押出成形法で成形することで、成形体を作製した。 A molded body was produced by molding the cement composition by an extrusion molding method.
この成形体を、まず４０℃、９５％ＲＨ、１０時間の条件で一次（前置）養生し、続いて８０℃、９５％ＲＨ、１０時間の条件で二次（蒸気）養生してから、１７０℃、７気圧、４時間の条件でオートクレーブ養生法により養生した。 First, the molded body was firstly cured at 40 ° C. and 95% RH for 10 hours, followed by secondary (steam) curing at 80 ° C. and 95% RH for 10 hours. It was cured by an autoclave curing method under the conditions of 170 ° C., 7 atm and 4 hours.
これにより、５２５ｍｍ×５２５ｍｍ×１５ｍｍの寸法を有する窯業系建築板を作製した。 As a result, a ceramic building board having a size of 525 mm × 525 mm × 15 mm was produced.
この窯業系建築板の曲げ強度を、ＪＩＳ Ａ５９０８に準拠して測定した。その結果を、表１中の「曲げ強度」の欄に示す。なお、曲げ強度が１０ＭＰａ以上であれば、曲げ強度が特に高いと評価できる。 The bending strength of this ceramic building board was measured according to JIS A5908. The results are shown in the column “Bending strength” in Table 1. In addition, if bending strength is 10 Mpa or more, it can be evaluated that bending strength is especially high.
また、窯業系建築板の外面を観察し、この外面全体に対する、エフロレッセンスが占める割合を調査した。その結果を、表中の「外面におけるエフロレッセンスの占める割合（％）」の欄に示す。なお、この割合が１０％以上９５％未満であれば、外観が特に良好であると評価できる。 In addition, the outer surface of the ceramic building board was observed, and the ratio of efflorescence to the entire outer surface was investigated. The result is shown in the column of “percentage of efflorescence on the outer surface (%)” in the table. In addition, if this ratio is 10% or more and less than 95%, it can be evaluated that the appearance is particularly good.
また、図１Ａに実施例１０の窯業系建築板の外面を撮影した写真を示し、図１Ｂに実施例１３の窯業系建築板の外面を撮影した写真を示す。この図１Ａ及び図１Ｂに示すように、窯業系建築板の外面には化粧材及びエフロレッセンスで構成される模様が生じており、特に図１Ａに示すように実施例１０では自然の風合いが強い模様が得られた。 Moreover, the photograph which image | photographed the outer surface of the ceramic building board of Example 10 is shown in FIG. 1A, and the photograph which image | photographed the outer surface of the ceramic building board of Example 13 is shown in FIG. 1B. As shown in FIGS. 1A and 1B, a pattern composed of a decorative material and efflorescence is generated on the outer surface of the ceramic building board. In particular, in Example 10, the natural texture is strong as shown in FIG. 1A. A pattern was obtained.
Claims (8)
前記窯業系建築板の外面は、エフロレッセンスで構成された模様を有する
窯業系建築板。 It is a ceramic building board that is a cured cured product of a molded body made of a composition containing cement,
The outer surface of the ceramic building board is a ceramic building board having a pattern made of efflorescence.
請求項１に記載の窯業系建築板。 The ceramic building board according to claim 1, wherein a ratio of the efflorescence to the entire outer surface is within a range of 10% or more and less than 95%.
請求項１又は２に記載の窯業系建築板。 The value of the ratio of the molar amount of Ca in the ceramic building board to the molar amount of Si in the ceramic building board is in the range of 0.5 to 0.9. Ceramic building board.
請求項１から３のいずれか一項に記載の窯業系建築板。 The ceramic building board according to any one of claims 1 to 3, wherein the ceramic building board contains a decorative material that constitutes a part of the pattern.
請求項４に記載の窯業系建築板。 The ceramics building board according to claim 4, wherein the decorative material contains at least one of coffee bean residue and crushed glass powder.
前記成形体を養生硬化させる際に前記養生硬化物の外面にエフロレッセンスを生成させて前記エフロレッセンスで構成された模様を形成する養生工程を含む
窯業系建築板の製造方法。 It is a method for producing a ceramic building board that is a cured cured product of a molded body comprising a composition containing cement,
A method for producing a ceramic building board comprising a curing step of forming a pattern composed of the efflorescence by generating efflorescence on an outer surface of the cured cured product when the molded body is cured and cured.
請求項６に記載の窯業系建築板の製造方法。 7. The ceramic building board according to claim 6, wherein, in the curing step, a sealer is not applied on the outer surface of the molded body, or a coating amount of the sealer on the outer surface of the molded body is less than 250 g / m 2. Manufacturing method.
請求項６又は７に記載の窯業系建築板の製造方法。 Including a cosmetic material constituting a part of the pattern in the composition,
A method for manufacturing a ceramic building board according to claim 6 or 7.
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