JP2611886B2 - Calcium silicate-based interior / exterior plate and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a calcium silicate molded product and a method for producing the same, and more particularly, to a lightweight and nonflammable material used as interior and exterior materials for buildings.
The present invention relates to a calcium silicate molded article having excellent resistance to freezing damage and workability, and a method for producing the same.

[0002]

2. Description of the Related Art Calcium silicate hydrates or calcium silicate compacts comprising calcium silicate hydrate and reinforcing fibers are used as various industrial materials. In general, industrial thermal insulation, fireproof coatings for buildings, interiors for buildings,
It is divided into exterior materials, ceiling materials, ship bulkheads, and floor materials. And the specific gravity of the product of these industrial materials is 0.1 to 0.3 for the industrial heat insulating material, 0.2 to 0.5 for the building refractory coating material,
Building interior, exterior materials, ceiling materials, ship bulkheads 0.5 ~
1.1, 0.9 or more exterior materials for construction and 1.3 or more floor materials.

[0003] There are two important methods for producing a calcium silicate compact. The first is a method for producing tobermorite-based calcium silicate, in which a raw material slurry obtained by mixing a siliceous raw material, calcareous raw material, reinforcing fiber and water is formed, and then the formed product is cured in an autoclave at about 180 ° C. ,
Dry to a product. The second is a method for producing a zonotolite-based calcium silicate, in which a siliceous raw material, a calcareous raw material and water are mixed, supplied to a batch type or continuous autoclave in a slurry state, cured at a temperature of 200 ° C. or more, and calcium silicate hydrate. After manufacturing, mixing the reinforcing fiber, molding,
It will dry.

[0004] There are a papermaking method, an extrusion method, and a pressing method as a molding method in the manufacturing process of a calcium silicate molded body. In the papermaking method, the thickness of the molded body is limited to a maximum of about 15 mm. In the extrusion method, a molded product having a thickness of 15 mm or more can be produced, but usually, the bulk specific gravity of the product is 1.0 or more. When the pressing method is used, it is possible to form a compact having a small thickness and a large specific gravity with respect to the specific gravity.
Therefore, products requiring a molded product having a large thickness and a small specific gravity (a fire-resistant coating material for a building, an interior material for a building) are molded by a pressing method, and mainly a zonotrite-based calcium silicate molded product. However, a zonotolite-based calcium silicate molded body using such a pressing method is,
It has the disadvantage of low weather resistance, frost damage resistance and impact resistance, and is not suitable for exterior materials for buildings.

The present invention relates to an improvement in the above-mentioned tobermorite-based calcium silicate and a method for producing the same. Regarding the method for producing tobermorite-based calcium silicate, for example, JP-A-63-74949 discloses that fibrous wollastonite (wollastonite calcium silicate naturally produced in the form of needle-like crystals) is used as a raw material for production. 30% is added to produce a raw material slurry, and the obtained raw material slurry is 90 to 100 ° C.
To produce calcium silicate gel, pressure 1.2k
A method is disclosed in which press molding is performed at g / cm ² , a molded product is cured in an autoclave, and dried to obtain a product having a low specific gravity.

As a calcium silicate-based compact containing Portland cement, there is Keikalex AF-0.8 (trade name) manufactured by Nozawa Corporation. The raw material ratio (weight ratio) of this product is cement 6%, slaked lime 30%, silica sand 30%
%, Diatomaceous earth 20%, perlite 8%, alkali-resistant glass fiber 2%, and pulp 4% (Building Materials Report 198).
March 2008, page 8).

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to provide excellent non-combustibility, frost resistance, and processing as interior and exterior materials for construction having a thickness of 1.2 to 10 cm and a specific gravity of 0.7 to 1.1. An object of the present invention is to provide a high-strength calcium silicate molded article having a property and a method for producing the same.

[0008]

The gist of the present invention is as follows: (1) 20 to 27 parts by weight of Portland cement, 13 to 18 parts by weight of quick lime or slaked lime in terms of slaked lime,
3 to 50 parts by weight of diatomaceous earth, 4 to 9 parts by weight of perlite,
4 to 7 parts by weight of pulp, 0.2 to 1 part by weight of organic fibers, an appropriate amount of an admixture and water are mixed to form a slurry, and the slurry is then dewatered and formed by pressing to produce a formed body. , A calcium silicate-based interior and exterior plate obtained by autoclaving and drying the molded body,

(2) 20 to 27 parts by weight of Portland cement, 13 to 18 parts by weight of quicklime or slaked lime in terms of slaked lime, 43 to 50 parts by weight of diatomaceous earth, 4 to 9 parts by weight of pearlite, 4 to 7 parts by weight Parts of pulp, 0.2 to 1 parts by weight of organic fibers, an appropriate amount of an admixture and water are mixed to form a slurry, and then the slurry is dewatered by pressing to produce a molded article. Autoclave curing and drying the body, a method for producing a calcium silicate-based interior and exterior plate, and

(3) The pressure for the dehydration molding of the slurry by a press is 20 to 40 kg / cm ² , the autoclave curing conditions are a temperature of 150 to 180 ° C., and a pressure of 5 to 10 kg / c.
m ² , a time of 4 to 8 hours, and a method of producing a calcium silicate-based interior / exterior plate according to the above (2), wherein drying is performed at a temperature of 100 to 120 ° C. for 24 hours or more.

Hereinafter, the amount of the slurry raw material based on the slurry raw material of the present invention and the slurry raw material excluding the admixture and water will be described. In the present invention, it is preferable to use ordinary Portland cement as Portland cement. The used amount is 20 to 27% (% by weight, the same applies hereinafter). 20% Portland cement used
If the amount is smaller, the durability and bending strength of the product become smaller. If the used amount of Portland cement is more than 27%, the specific gravity of the product increases, and the workability of nailing, sawing, etc. deteriorates.

In the present invention, diatomaceous earth is used as a siliceous raw material. The use of silica powder or the like is not preferred because of the weight reduction of the product and the like. 13 quick lime or slaked lime converted to slaked lime
The amount of diatomaceous earth used when 18% is used is 43-50%. If the used amount is less than 43%, the silica source for developing the strength of the molded product becomes insufficient, and the bending strength of the product is lowered. If the used amount exceeds 50%, unreacted silica content becomes a defect in the molded body, and the bending strength of the product becomes small and the product becomes brittle.

The amount of quicklime or slaked lime used is 13 to 18% in terms of slaked lime. Quick lime or slaked lime makes up for the shortage of calcium hydroxide (stimulant) generated by Portland cement in the hydration reaction and contributes to the pozzolanic reaction with diatomaceous earth.

The amount of perlite used is 4 to 9%. Since pearlite plays a role of a filter aid in reducing the weight of the product and dehydrating the slurry, if the used amount is less than 4%, delamination is likely to occur during dehydration molding, and the specific product specific gravity is also required. Can not be obtained. If the used amount exceeds 9%, material separation easily occurs, and pearlite floats on the upper surface of the slurry,
If press molding is performed as it is, the aesthetic appearance of the product surface deteriorates, or a predetermined product specific gravity or bending strength cannot be obtained.

In the present invention, pulp and organic fibers other than pulp are used in combination for improving the strength and reducing the weight of the product. The pulp is prepared by mixing a previously defibrated fiber into water and using it as a pulp-water mixture. The type of pulp to be used is preferably hemp pulp or sisal pulp in view of strength characteristics and the like.
Pulp usage is 4-7%. If the amount used is less than 4%, the product will have poor nail pull-out resistance and workability such as nailing and sawing. If it exceeds 7%, the non-combustibility of the product becomes small.

As the organic fibers, commercially available ordinary fibers can be used. However, the following conditions are met by autocure curing in an alkaline atmosphere, which endures these conditions, has a large strength development in a matrix, and dispersibility of the fibers. It is preferable to use a fiber that satisfies the following conditions. Fibers satisfying this condition include polypropylene fibers and acrylic fibers. 0.2-1% of organic fiber used
It is. If the amount is less than 0.2%, the effect as a reinforcing fiber is small, and the toughness of the product is reduced. 1 usage
%, The nonflammability of the product decreases.

In order to achieve the object of the present invention, the above-mentioned raw materials must be used in a predetermined mixing ratio, and an admixture must be used. As used herein, the admixture is an AE agent, an AE water reducing agent and a high-performance water reducing agent which are generally known in the cement industry.

Examples of the AE agent include one having a natural resin salt as a main component (eg, Vinsol, manufactured by Yamamune Chemical Co., Ltd.) and a polyoxyethylene nonionic and special anion activator as a main component. (Eg, Takemoto Yushi Co., Ltd.
Examples of the AE water-reducing agent include lignin sulfonic acid derivative (eg, Sanyo Kokusaku Pulp Co., Ltd., Sunflow S, Nisso Master Builders Co., Ltd.) Product name Pozzolith No. 5L),
An example of a high-performance water reducing agent is one in which the main component is a salt of a highly condensed naphthalenesulfonic acid formalin (eg, Kao Corporation)
(Product name: Mighty 150), the main component being a naphthalenesulfonic acid-modified lignin condensate (eg, Sanflow PS manufactured by Sanyo Kokusaku Pulp Co., Ltd.), the main component being a highly condensed triazine compound (Eg, Pozoris NL-4000, manufactured by Nisso Master Builders Co., Ltd.).

The AE agent, the AE water reducing agent and the high performance water reducing agent are used alone or in combination. When used alone, the amount of the AE agent is 0.05 to 0.15%, the AE water reducing agent is 0.2 to 1%, and the high performance water reducing agent is based on the total weight of the slurry raw material excluding water and the admixture. The agent is 0.5-3%.

Hereinafter, a method for manufacturing the interior and exterior plate of the present invention will be described. First, an appropriate amount of pulp and water are mixed so as to have a predetermined pulp addition amount and a water powder ratio (weight of water / total weight of the slurry raw material excluding the admixture, expressed in percentage). In the case of 0.5% and a water powder ratio of 320%, the pulp is mixed so that the pulp concentration becomes about 2% to prepare a pulp-water mixture in advance. The pulp-water mixture is transferred to a mixing tank and a predetermined amount of Portland cement, quicklime or slaked lime, diatomaceous earth, perlite, and organic fibers are added. Further, a predetermined amount of the admixture is added and mixed for 3 to 5 minutes to produce a slurry. Next, the slurry is transferred to a press molding machine and press-molded at a molding pressure of 20 to 40 kg / cm ² for 90 to 180 seconds to produce a molded body. The molded body was taken out of the press molding machine, and allowed to stand for at least 20 hours.
Curing is performed by an autoclave at 0 ° C. under a pressure of 5 to 10 kg / cm ² for 4 to 8 hours. Further, at a temperature of 100 to 1
Dry at 20 ° C. for 24 hours or more. In this way, the calcium silicate-based interior / exterior plate of the present invention having a thickness of 1.2 to 10 cm and a specific gravity of 0.7 to 1.1 and having excellent nonflammability, frost damage resistance and workability and high strength is manufactured. . Next, the present invention will be described with reference to examples.

[0021]

Examples 1 to 5, Comparative Examples 1 and 2 Pulp-water mixtures were prepared by adding 2 to 4 kg of pulp to 170 liters of water. The pulp-water mixture was transferred to a mixing tank, where Portland cement, slaked lime, diatomaceous earth,
A slurry was produced by adding pearlite and organic fibers as polypropylene fibers or acrylic fibers. The mixing ratio of the slurry raw material excluding water and the admixture and the water powder ratio (the weight of water / the total weight of the slurry raw material excluding water and the admixture, expressed as a percentage) were as shown in Tables 1 and 2.

The admixtures in Examples 1 and 2 and Comparative Example 1 were AE agents (manufactured by Yamamune Chemical Co., Ltd., trade name Vinsol), and Examples 3, 4 and Comparative Example 2 were AE water reducing agents (Sanyo). Example 5 manufactured by Kokusaku Pulp Co., Ltd., trade name: Sunflow S)
Is a high performance water reducing agent (manufactured by Kao Corporation, trade name Mighty 15
0) was used. The amount of the admixture used is 0.1% of the AE agent, 0.8% of the AE water reducer, and 1.5% of the high-performance water reducer based on the total weight of the slurry raw material excluding the water and the admixture.

Next, the slurry was transferred to a press molding machine having a capacity of 1200 tons, and pressed at a molding pressure of 35 kg / cm ² for 100 seconds to produce a molded body. The molded body was taken out from the press molding machine, and allowed to stand at room temperature for 24 hours.
After curing with an autoclave for 5 hours at a temperature of 10 ° C. and a pressure of 10 kg / cm ² , drying was performed at a temperature of 105 ° C. for 24 hours, a specific gravity of 0.75 to 0.86, a thickness of about 3 cm, and a shape of 10
A calcium silicate-based inner / outer board of 0 × 200 cm was manufactured. The resulting calcium silicate-based interior and exterior panels were tested for nonflammability, freeze-thaw resistance, nail pull-out resistance, and workability.
Table 3 shows the results.

[0024]

[Table 1]

[0025]

[Table 2]

[0026]

[Table 3]

The following test methods were used for nonflammability and the like. (1) Non-flammability JIS A 1321-1975, interior materials of buildings and flame retardancy test method (2) Freeze-thaw resistance JIS A 6701-1983, magnesium carbonate plate (3) Nail pull-out resistance JIS Z 2121- 1979, Test method for nail pull-out resistance of wood (4) Regarding workability, the following four types of test standards were established, and comprehensive judgment was made to certify four levels from excellent to unacceptable. Cutting Cut with a circular saw for woodworking, and determine the aesthetic appearance of the cut surface, resistance to cutting, and damage to the blade. Plank planer Plane planer is used to check whether the plane can be cut without chipping. Wood screw holding force The wood screw held by the material is pulled upward and the holding force is examined. Notch of nail 1c each from the edge (thickness side) of the board and the length and width of the board
A nail is hit at the corner of m, and it is checked whether the nail can be driven without breaking the board.

Comparative Examples 3 and 4 Table 3 shows the characteristic values of a commercially available pulp-mixed lightweight cement extruded board (Comparative Example 3) and an asbestos cement board (Comparative Example 4) for comparison. The raw material mixing ratios of the two are as follows.

Lightweight cement extruded board mixed with pulp (Comparative Example 3) Cement 60, asbestos 3, silica sand 27, pulp 7, organic additive 1, organic foaming agent 2 weight% asbestos cement board (Comparative Example 4) Cement 60, asbestos 18, silica sand 12, shirasu balloon 9, methyl cellulose 0.5, polyvinyl chloride fiber 0.5% by weight

[0030]

The calcium silicate-based interior / exterior plate of the present invention comprises:
Although it is lightweight as a building interior and exterior material, it has excellent balance of nonflammability, frost resistance, workability and strength. The method for producing a calcium silicate-based interior / exterior plate of the present invention provides a method for suitably producing a building interior / exterior material which is lightweight, yet has excellent balance of nonflammability, frost resistance, workability and strength. .

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location C04B 16:02 16:06) 111: 12 111: 30 111: 40

Claims (3)

(57) [Claims] 1. 20 to 27 parts by weight of Portland cement, 13 to 18 parts by weight of quicklime or slaked lime in terms of slaked lime, 43 to 50 parts by weight of diatomaceous earth, 4 to 9 parts by weight of pearlite, 4 to 7 parts by weight Pulp, 0.2 to 1 part by weight of organic fiber, an appropriate amount of an admixture and water are mixed to form a slurry, and then the slurry is dewatered by pressing to produce a molded article. Calcium silicate-based interior and exterior panels obtained by curing and drying. 2. 20 to 27 parts by weight of Portland cement, 13 to 18 parts by weight of quicklime or slaked lime in terms of slaked lime, 43 to 50 parts by weight of diatomaceous earth, 4 to 9 parts by weight of pearlite, 4 to 7 parts by weight Pulp, 0.2 to 1 part by weight of organic fiber, an appropriate amount of an admixture and water are mixed to form a slurry, and then the slurry is dewatered by pressing to produce a molded article. A method for producing a calcium silicate-based interior / exterior panel, comprising curing and drying an autoclave. 3. The pressure for dewatering and forming the slurry by pressing is 20 to 40 kg / cm ² , the autoclave curing conditions are a temperature of 150 to 180 ° C., a pressure of 5 to 10 kg / cm ² , a time of 4 to 8 hours, and a temperature of 100 to 100 kg / cm ² . The method for producing a calcium silicate-based interior / exterior plate according to claim 2, wherein the interior and exterior plate is dried at 120 ° C for 24 hours or more.