JP2522626B2 - Inorganic surface material and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cement-based inorganic surface material mainly used as a building material for houses.

[0002]

2. Description of the Related Art Conventionally, in wooden prefabricated houses and the like, means for constructing walls, floors, roofs or the like by panels has been implemented. As such a panel, for example, a wooden panel as shown in FIG. 2 is known. The wooden panel P includes vertical frame members 1a and 1a and horizontal frame members 1b and 1b.
The reinforcing core members 2a and 2b extending vertically and horizontally are arranged inside the frame body 1 assembled in a rectangular frame shape to form the frame member 2. Further, the reinforcing core members 2a and 2b and the vertical and horizontal frame members 1a are arranged. The inside surrounded by 1b is filled with a heat insulating material 3 such as glass wool, and face materials 4 and 4 made of plywood are attached to both front and back surfaces of the frame body 1, respectively.

By the way, in such a panel, for example, in a wall requiring a fireproof structure, an inorganic face material is attached instead of the face material 4 made of the plywood or on the face material 4. Is used. As an inorganic surface material, for example, a material in which a raw material slurry obtained by adding fly ash, slag, fibers or the like to a main component of ordinary Portland cement and formed into a board shape by a papermaking method is known. In order to produce such an inorganic surface material, for example, as shown in FIG. 1, first, a predetermined amount of these raw materials are automatically weighed from a tank 10 for storing cement, fly ash, slag, etc. into a mixing pulper 11. Supply. In addition, from the tank 12 that stores various fibers separately,
The fibers are led out, adjusted to an appropriate length by a crusher 13, and then supplied to a tank 14. Further, from the tank 14, a predetermined amount of the fiber having the adjusted wire length is supplied to the mixing pulper 11. Further, a predetermined amount of a dispersion liquid obtained by adding an appropriate dispersing material to water is supplied from the tank 15 to the mixing pulper 11. And
After stirring and mixing with the mixing pulper 11, various raw materials are uniformly dispersed in water to prepare a raw material slurry, which is then supplied to the slurry container 16.

Next, the raw material slurry is supplied from the slurry container 16 to the papermaking apparatus 17, where a large number of sheet-like bodies are formed. The papermaking apparatus 17 includes a papermaking machine 20 including a slurry reservoir 18 for storing a raw material slurry provided with a heating unit (not shown), and a roller 19 disposed in the slurry reservoir 18 and immersing a majority of the slurry in the slurry. Multiple (4 in the example of FIG. 1)
The transfer machine 21 in the form of a belt conveyor is disposed on the papermaking machines 20 ... In such a papermaking apparatus 17, the raw material slurry temperature in the slurry reservoir 18, that is, the papermaking temperature is set to about 70 to 80 ° C., and the roller 19 of the papermaking machine 20 rotating in this state.
The slurry is transferred onto the belt portion 21a of the transfer machine 21. Then, since the papermaking temperature is about 70 to 80 ° C., the water in the slurry evaporates and the hardening of the cement further progresses as the belt portion 21a rotates after copying the slurry. Is in a semi-cured state. Further, the semi-cured slurry is transferred to the peeling roller 21b arranged on the side portion of the transfer machine 21 and is peeled by an operator in an appropriate size to form a planar body. Then, a plurality of such sheet-like bodies are laminated, and the respective layers are joined and integrated through a pressing process, a heating and curing process, etc., thereby forming an inorganic face material.

[0005]

By the way, in order to fabricate a panel using the inorganic surface material thus obtained and using this as a surface material instead of plywood, the front and back surfaces of the frame 1 shown in FIG. An inorganic face material that is formed slightly larger than the panel size is pasted on both sides, and then the side end faces of the obtained panel are cut by a sizer device to obtain a panel with a predetermined size to obtain a product. However, the inorganic surface material is not sufficient in the interlaminar strength because the plurality of laminated sheet materials are simply joined by pressing and heat curing as described above, and therefore, the sizer finish in the sizer device is not sufficient. At this time, there is a problem that delamination occurs in the inorganic face material, resulting in manufacturing defects. The present invention has been made in view of the above circumstances, and an object thereof is to provide an inorganic face material having an increased interlayer strength and a method for producing the same, in order to prevent delamination.

[0006]

[Means for Solving the Problems] Claim 1 in the present invention
In the described inorganic surface material, multiple planar materials containing cement are laminated.
Of the cement-based inorganic surface material,
In addition, the water-soluble resin that does not gel at the papermaking temperature solidifies
Remaining in the state of being left was used as a means for solving the above problems. The method for producing an inorganic face material according to claim 2, wherein when an inorganic face material is produced by stacking a plurality of cement-based inorganic sheet materials obtained by a papermaking method , an aqueous raw material slurry containing fibers is water-soluble and is used for papermaking. It is prepared by adding a resin that does not cure at a temperature, then the raw material slurry is formed into a plurality of planar bodies by a papermaking method, and then a plurality of these planar bodies are laminated and pressed, and the resin is melted. Heating and curing at a temperature, and then cooling this were the means for solving the above problems. In the method for producing an inorganic surface material according to claim 3, polyvinyl alcohol is used as the resin, and the papermaking temperature is 80%.
The heating and curing temperature of 120 ° C or lower and the heating and curing temperature of 120 ° C or higher were taken as means for solving the above problems.

[0007]

According to the inorganic surface material of claim 1, at least
In addition, since the water-soluble resin that does not gel at the papermaking temperature remains in a solid state in the planar body containing cement , the laminated planar body has a high interlayer strength. Becomes According to the method for producing an inorganic face material according to the second aspect, as described above, it is possible to produce an inorganic face material having a high interlaminar strength of a sheet. According to the method for producing an inorganic surface material of claim 3, since polyvinyl alcohol having excellent adhesiveness is used as the resin, the interlayer strength of the obtained inorganic surface material becomes sufficiently high.

[0008]

EXAMPLE The inorganic surface material of the present invention is different from the conventional inorganic surface material described above in that a resin is added to the raw material slurry. The resin to be added is a resin that is water-soluble and does not gel at the papermaking temperature described below, and specifically includes polyvinyl alcohol, polyvinylpyrrolidone, polyacrylamide, acrylic acid copolymer, and the like, but particularly polyvinyl alcohol. It is preferably used. As an example using such a resin, the present invention will be described based on the manufacturing method according to claim 2 with reference to FIG. 1.

To prepare the inorganic surface material of the present invention, cement, fly ash, slag, etc. are added to the tank 1 as in the conventional case.
0, various fibers are supplied to the mixing pulper 11 from the tank 12, and the dispersion liquid is supplied to the mixing pulper 11 from the tank 15. Separately from this, one kind or two or more kinds selected from the above resins are automatically weighed from a tank 22 for storing the resins and then supplied to a predetermined amount to the mixing pulper 11. Then, after stirring and mixing with the mixing pulper 11, various raw materials are uniformly dispersed in water to prepare a raw material slurry, which is then supplied to the slurry container 16. Here, since the resin is water-soluble, it dissolves in the slurry when it is stirred and mixed with the dispersion liquid or the like by the mixing pulper 11.

Next, the raw material slurry is supplied from the slurry container 16 to the papermaking apparatus 17, and the thickness is 1-2 in the same manner as in the prior art.
A large number of planar bodies of about mm are formed. Here, the thickness of the sheet is detected by the thickness detector 21c provided on the peeling roller 21b. In the formation of such a sheet, the temperature of the raw material slurry in the slurry reservoir 18
That is, the papermaking temperature is, for example, about 70 to 80 ° C. when polyvinyl alcohol is used as the resin. Since polyvinyl alcohol does not gel at this papermaking temperature, most of the polyvinyl alcohol is contained in the sheet in a state of being dissolved in water.

Next, a plurality of, for example, four sheet-like bodies thus obtained are stacked and pressed in the stacking direction. Then, each sheet is dehydrated by being pressed and hardened by the progress of the hydraulic reaction of cement. At this time, a part of the resin is solidified by water being used for the hydraulic reaction of cement and remains in the sheet.

Next, the laminated sheet body after pressing is placed in a heating curing cabinet, and is heated and cured at 120 to 150 ° C. for a predetermined time to bond and integrate the layers, and then cooled to room temperature. Then, the resin remaining in a solidified state in each sheet is melted by heating and leached into the sheet, and a part thereof reaches between the sheets. The molten resin is solidified by cooling after heating and curing, and the resin between the sheet-like bodies is also solidified to function as an adhesive between the sheet-like bodies and enhance the interlayer strength.

Thereafter, as finishing, the operations such as pressing, steam curing, and drying are performed again, and the product is further cut into desired dimensions to obtain an inorganic surface material as a product. In such a method for producing an inorganic face material, by adding a resin to the raw material slurry, it can be made to function as an adhesive between face-to-face bodies, and the interlayer strength of the inorganic face material thus obtained can be obtained. Can be increased.

(Experimental example) According to the above-mentioned process, an inorganic surface material was prepared with the following composition. Normal Portland cement 30.0% by weight Slag 21.7% by weight Pulp fiber 4.5% by weight Vinylon fiber 0.8% by weight Mineral cotton 2.0% by weight Fly ash 40.0% by weight Polyvinyl alcohol 1.0% by weight Total 100.0% by weight (trade name; Kuraray Poval MSH-916) In the production of this inorganic surface material, the papermaking temperature is 70%.
The temperature was set to -80 ° C, and the heat curing was performed at 150 ° C for 3 hours. Further, during papermaking, gelation of polyvinyl alcohol was not observed at the above temperature, and the inorganic face material could be normally produced as in the conventional case. Further, for comparison, an inorganic surface material was prepared with the conventional formulation shown below. Ordinary Portland cement 30.0% by weight Slag 22.0% by weight Pulp fiber 4.5% by weight Vinylon fiber 0.8% by weight Mineral cotton 2.0% by weight Fly ash 40.7% by weight Total 100.0% by weight

Various physical properties of the obtained inorganic surface material were investigated and the results are shown in Table 1.

[Table 1] From the results shown in Table 1, it was confirmed that the product of the present invention is superior in the plane tensile strength to the conventional product, so that the improvement of the interlaminar strength is recognized and the flexural strength is also excellent.

[0016]

As described above, the inorganic surface material according to claim 1 of the present invention has a plurality of planar materials containing cement.
At least the above-mentioned sheet material of a layered cement-based inorganic surface material
Resin that is water-soluble and does not gel at the papermaking temperature solidifies
Since it remains in the state of being laminated, the interlayer strength of the laminated sheet becomes high, so if a panel is formed using this, delamination of the inorganic face material during the sizer finishing should be prevented. You can In the method for manufacturing an inorganic surface material according to the second aspect, it is possible to manufacture the inorganic surface material having the increased interlayer strength, and thus it is possible to prevent the occurrence of defects due to the sizer finishing in manufacturing the panel. Since the method for producing an inorganic surface material according to claim 3 uses polyvinyl alcohol having excellent adhesiveness as the resin, the interlayer strength of the obtained inorganic surface material can be sufficiently high. Thus, it is possible to produce an inorganic face material having excellent plane tensile strength, bending strength and the like.

[Brief description of drawings]

FIG. 1 is a flowchart showing a manufacturing process of an inorganic surface material according to the present invention.

FIG. 2 is a schematic configuration diagram of a wooden panel.

[Explanation of symbols]

 17 Papermaking equipment 22 Tank

Claims (3)

(57) [Claims] 1. A <br/> cementitious inorganic surface material planar body formed by stacking a plurality including cement, at least the planar element in, is water soluble and resin does not gel at a papermaking temperature solidification It is special that it remains in the
Inorganic surface material to be collected. 2. When manufacturing an inorganic surface material by laminating a plurality of cement-based inorganic planar materials obtained by a papermaking method, fibers are
An aqueous raw material slurry containing the same is prepared by adding a resin that is water-soluble and does not gel at the papermaking temperature, and then a plurality of planar bodies are formed from the raw material slurry by a papermaking method, and then a plurality of these planar bodies are laminated. Then, the resin is heated and aged at a temperature at which the resin melts, and then the resin is cooled, followed by cooling. 3. The method for producing an inorganic surface material according to claim 2, wherein polyvinyl alcohol is used as the resin, and the papermaking temperature is 80 ° C. or lower and the heating and curing temperature is 120 ° C. or higher.