JP3052964U - Building material panel - Google Patents

Abstract

(57) [Summary] [Object] To provide a building material panel which is made of natural stone-like tiles, has high fire resistance, is low in water absorption, is solid, lightweight, and has excellent physical strength. SOLUTION: Pumice and ceramic fine hollow particles are added to an inorganic or organic curable composition and pressure-molded to form a core material. On the front and back surfaces of the core material, laminated a plate material formed of a composition comprising ceramic fine hollow particles and glass fiber and an inorganic or organic curable composition, and further natural crushed stone particles and ceramic fine hollow particles on this surface. A tile made of an inorganic or organic curable composition is attached.

Description

[Detailed description of the invention]

[0001]

[Technical field to which the invention belongs]

 INDUSTRIAL APPLICABILITY The present invention provides a building material panel having high strength, light weight, and excellent heat insulation properties, and can be used as a wall material, a roof material, a floor material and the like of a building.

[0002]

[Prior art]

 Conventionally, there are panels for building materials that use inorganic or metallic materials. However, they have poor heat insulation, poor workability and heavy weight, which hinders handling. Lightweight building material panels using organic curable compositions as binders have also been developed, but in all cases, inorganic materials such as aluminum hydroxide, calcium silicate, or calcium carbonate are added as fillers to improve flame retardancy. In addition, inorganic fibers such as glass fibers were added as reinforcements, and surface materials were reinforced using surfacers to increase the strength. On the other hand, a foam made of an organic curable composition is foamed by adding a foaming agent, so that when the glass fiber is mixed, the fiber is entangled and it is difficult to uniformly disperse the glass fiber, and sufficient strength can be obtained. Did not. When the surfacer was used, it was attached to the front or back surface of the face material, so the impact strength on the front and back surfaces improved, but the strength as a plate material did not sufficiently increase.

[0003]

[Problems to be solved by the invention]

 An object of the present invention is to provide a building material panel having a tile-like surface with a smooth surface, a high degree of fire resistance, a low water absorption, a compact, lightweight, and excellent physical strength.

[0004]

[Means for Solving the Problems]

 The building material panel of the present invention uses an inorganic or organic curable composition as a binder, and adds a pumice stone and ceramic fine hollow particles to the inorganic or organic curable composition and press-molds the core material. An inorganic or organic curable composition is used as a binder on the front and back surfaces, and a plate formed of a composition comprising fine ceramic hollow particles and glass fibers is laminated thereon. A tile formed by press-molding the ceramic fine hollow particles and an inorganic or organic curable composition is adhered.

[0005]

[Embodiment of the invention]

In a building material panel, high-strength ceramic fine hollow particles are joined together, and this portion is fixed with an inorganic or organic curable composition. The core material is formed by adding a small amount of water to the high-strength ceramic fine hollow particles, pumice and the inorganic or organic curable composition, sufficiently kneading the mixture, and then press-molding the mixture under a pressure of 10 to 100 kgf / cm ² . The specific gravity of the core material is 0. 5 to 0.6.

[0006] On the front and back surfaces of the core material, ceramic fine hollow particles and a plate material formed of glass fiber and an inorganic or organic curable composition are laminated, and natural crushed stone particles, ceramic fine hollow particles and A tile formed by press-molding an inorganic or organic curable composition is adhered. The specific gravity of the front and back layers is 0.6 to 0.8.

The inorganic or organic curable composition according to the present invention includes an inorganic substance exhibiting curability when kneaded with water and an inorganic substance exhibiting curability by adding a curing agent. The former is, for example, ordinary Portland cement, alumina cement, gypsum, etc., and the latter is, for example, an aqueous solution of alkali metal silicate or a powder of SiO ₂ component and alkali metal M in the form of SiO ₂ / M ₂₀ (in terms of alkali metal oxide). It is contained at a molar ratio of 8 or less. In the case of an aqueous solution, the water content is 10 to 1000% by weight, and particularly preferably 10 to 400% by weight. As the alkali metal M here, K, Na or Li is preferable.

The curing agent used in the aqueous alkali metal silicate solution is, for example, an alkali metal salt of silicon polyphosphate, silicon polyphosphate, titanium phosphate, zirconium phosphate, aluminum phosphate, calcium phosphate, magnesium phosphate, zinc phosphate , Phosphate soda or the like is used alone or in combination of two or more.

The organic curable composition in the present invention is, for example, a resol type phenol resin, a synthetic resin emulsion, a polyester resin and the like.

The resol type phenolic resin used for the building material panel of the present invention includes phenols such as phenol, cresol, xylenol, paraalkylphenol, paraphenylphenol and resorcinol and modified products thereof, and formaldehyde, paraform aldehyde, furfural, acetaldehyde and the like. Aldehydes are reacted with an alkaline catalyst such as sodium hydroxide, potassium hydroxide, calcium hydroxide, hexamethylenetetramine, trimethylamine, triethylamine and the like.

[0011] Synthetic resin emulsions include acrylic resin emulsions, vinyl acetate emulsions, vinyl chloride resin emulsions, vinylidene chloride resin emulsions, styrene / butadiene resin emulsions, epoxy resin emulsions, acrylate esters, styrene , Ethylene, vinyl ester, vinyl acetate, copolymerized with synthetic rubber and the like.

For example, copolymers of these include acrylic / vinyl acetate copolymers, vinylidene chloride / butyl acrylate copolymers, ethylene / vinyl acetate copolymers, and the like.

In order to improve the properties of the synthetic resin emulsion, if necessary, various surfactants as a dispersant, an emulsifier for stabilizing the emulsion, an anti-wrinkling agent for the emulsion, a thickening agent, an anti-sagging agent, An anti-settling agent, anti-freezing agent, etc. may be added. For the purpose of further improving the performance, a stabilizer for preventing deterioration due to heat and light, a fungicide for preventing the generation of mold, and the like may be added.

The fine hollow ceramic particles used in the present invention have particularly high compressive strength as compared with conventional fine hollow foams, and can withstand high stress and shearing force. Further, by performing pressure molding, a dense building material panel can be obtained despite its light weight.

[0015] The compressive strength of ceramic fine hollow particles or fine hollow foam is synonymous with water pressure resistance. The measurement of compressive strength is based on the fact that the fine hollow foam is pressurized in water, The compressive strength is the pressure transmitted to the foam and broken by the fine hollow foam.

[0016] A building material panel that can exhibit excellent performance must have a sufficient stirring and kneading process, and is particularly important for producing a uniform and high-quality product. When the composition is sufficiently stirred and kneaded as in the present invention, the stress and shearing force applied to the ceramic fine hollow particles become 300 kgf / cm ² or more. None of the conventional fine hollow foams could withstand such high pressure, and none of them could be used as such a building material panel to obtain sufficient performance. That is, most of them are destroyed.

The melting point of the ceramic fine hollow particles used in the present invention is 1300 ° C. or higher. Naturally, the fine hollow ceramic particles are caused by their materials, but generally, the higher the melting point, the higher the compressive strength. If the compressive strength is 300 kgf / cm ² or more, its melting point becomes 1300 ° C. or more.

As described above, the ceramic fine hollow particles used in the present invention are formed by foaming a ceramic composition comprising 50 to 60% of silica, 40 to 45% of alumina, and 1.5 to 2.5% of others. Its physical properties are compressive strength of 300 kgf / cm ² or more, melting point of 1300 ° C. or more, bulk specific gravity of 0.3 to 0.5 g / cm ³ , thermal conductivity of 0.1 (kcal / mhr ° C.), and consisting only of completely hollow particles. Have been. The particle diameter of the ceramic fine hollow particles is in the range of 5 to 350 μm, and the fineness is adjusted to 20 parts by weight of fine particles, 20 parts by weight of fine particles, and 5 to 75 μm, 75 to 150 μm, and 150 to 350 μm. And 30 parts by weight of a coarse powder. The bulk specific gravity is heavy for fine particles and light for coarse ones. Although the scope of this for the bulk specific gravity is 0.3~0.5g / c ^{m 3,} which was the particle size adjustment is 0.36 g / cm ³ before and after.

The fine ceramic hollow particles are used in an amount of 100 to 900 parts by weight based on 100 parts by weight of the inorganic or organic curable composition. If the amount is less than 100 parts by weight, the fire resistance and the heat insulating property cannot be sufficiently exhibited, and if the amount is more than 900 parts by weight, the strength is greatly reduced. The amount of ceramic fine hollow particles will be adjusted according to the required physical strength and specific gravity of building material panels.

The pumice used as the core material of the building material panel is a natural lightweight aggregate or an artificial lightweight aggregate of 6 mm or less, but a particle size of 3 to 6 mm is more preferable. Pumice is used in an amount of 200 to 800 parts by weight based on 100 parts by weight of the inorganic or organic curable composition.

The glass fiber used in the present invention is a short fiber having a diameter of 13 μm or less and a length of 3 to 8 mm. This is because the smaller the diameter of the glass fiber is, the higher the tensile strength is, and if the diameter is 13 μm or less, the tensile strength of 100 kgf / mm ² or more can be obtained. The reason why the length of the short fibers is 3 to 8 mm is that the fibers can be uniformly dispersed without entanglement during stirring and kneading.

The natural stone used as a raw material of the natural crushed stone particles may be any of granite, andesite, marble, serpentine and the like, and is not limited. Natural crushed stone particles are fine, medium, and coarse. Fine particle diameter is adjusted to 0.1 to 0.5 mm, medium to 0.5 to 1.5 mm, and coarse to 1.5 to 3.4 mm. To use. In addition to natural crushed stone particles, silica sand, silica stone powder, fly ash, silica fume, clay, talc, kaolin, crushed ceramic, crushed blast furnace slag, siliceous dust, and pigments may be added. For the particle size adjustment of natural crushed stone, use 40 parts by weight of fine, 30 parts by weight of medium, and 10 parts by weight of coarse.

In addition to the above main constituent materials, admixtures such as dispersants, antibacterial and antifungal agents, stabilizers and the like, inorganic extender pigments and the like are used to improve properties. A thickener, titanium powder, alumina powder, or the like may be added to improve the fire resistance and physical properties in order to improve the press moldability.

[0024]

【Example】

 Hereinafter, embodiments of the present invention will be described in detail.

Example 1 100 parts by weight of a resole type phenol resin, 5 parts by weight of methylene chloride as a foaming agent, a compressive strength of 700 kgf / cm ² , a bulk density of 0.3 to 0.5 g / cm ³ , a melting point of 1600 ° C., and heat conduction 750 parts by weight of ceramic fine hollow particles composed of only completely hollow particles at a rate of 0.1 (kcal / mhr ° C.), 300 parts by weight of 3-6 mm artificial lightweight aggregate, 80 parts by weight of water, After sufficiently stirring and kneading the composition to which an appropriate amount of each of the other dispersants, stabilizers, and the like are added, 20 parts by weight of a phosphoric acid-based curing agent is added, and the mixture is further sufficiently stirred and kneaded, and is punched into a 600 mm x 900 mm formwork to a thickness of 10 mm. The surface was press-molded at 20 kgf / cm ² , cured at 125 ° C. for 70 minutes and cured to prepare a core material.

The plate material on the front and back sides is 100 parts by weight of resol type phenol resin, 400 parts by weight of the same ceramic fine hollow particles as used as the core material, 2 parts by weight of 13 μm-diameter 6 mm glass fiber and 50 parts by weight of water. Parts, and a composition to which an appropriate amount of each of a dispersing agent, a stabilizer and the like were added was sufficiently stirred and kneaded, and then 15 parts by weight of a phosphoric acid-based curing agent was added.

The tile to be adhered to the surface of the surface layer is composed of 100 parts by weight of resol type phenol resin, 100 parts by weight of the same ceramic fine hollow particles used as the core material, and 600 parts by weight of granite natural crushed stone particles and 50 parts by weight of water. Parts and other components each containing an appropriate amount of a dispersing agent, a stabilizer and the like were sufficiently stirred and pulverized, and then 15 parts by weight of a phosphoric acid-based curing agent was added thereto, followed by pressure molding.

A core material is laid on a back plate having a thickness of 3 mm in a form frame of 600 × 900 mm, a surface plate having a thickness of 3 mm is laminated on an upper surface of the core, and an uncured tile is placed thereon with a thickness of 4 mm. After being integrally molded at 20 kgf / cm ² , cured at 125 ° C. for 3 hours and cured to produce a building material panel.

The specific gravity of the building material panel manufactured in the example was 0.68 (g / cm ³ ), the bending strength was 111 kgf / cm ² , and the water absorption was 2.1%. As a result of a surface heating test based on the notification of the Ministry of Construction No. 1828, no melting crack was found by the surface heating test.

Example 2 100 parts by weight of Portland cement were mixed with 300 parts by weight of the ceramic fine hollow particles and artificial lightweight aggregate used in Example 1 and 300 parts by weight of water, 60 parts by weight of water, a dispersant, a stabilizing agent, etc., and sufficiently stirred.・ Kneaded.

The plate material on the front and back sides is the same ceramic fine hollow particles and glass fiber as used in Example 1 in 300 parts by weight and 2 parts by weight, water in 50 parts by weight, and other dispersants in 100 parts by weight of cement. An agent and the like were added, sufficiently stirred and kneaded, and molded under pressure.

The tile to be adhered to the surface of the surface layer is as follows. 150 parts by weight of the same ceramic fine hollow particles as used in Example 1 and 550 parts by weight of natural crushed stone particles are used for 100 parts by weight of cement and 45 parts by weight of water , A stabilizer and the like were added in appropriate amounts, respectively, and molded under pressure.

[0033] After pressure molding in the surface sheet of Da設further 3mm thick the core to a thickness of 10mm on the back plate of 600 × 3mm thick in a mold of 900mm stacked 10 kgf / cm ^2, the An uncured tile previously cast on a formwork was adhered to the surface, and cured and cured in this state.

[0034]

[Effect of the invention]

 As described above, the building material panel of the present invention uses an inorganic or organic curable composition as a binder, and the core material uses pumice and ceramic fine hollow particles as a filler. On the front and back of this core material, a front and back plate formed by using ceramic fine hollow particles and glass fiber as a binder is formed, and on one surface of the binder, a tile containing natural crushed stone particles and ceramic fine hollow particles as a filler is attached. I'm wearing

With such a configuration, a core material having a high heat insulating effect is used as a light-weight layer inside a tough front and back surface layer reinforced with a beautiful tile having a natural stone-like surface, and the surface is light and smooth. Thus, it was possible to obtain a building material panel having high fire resistance, low water absorption, and excellent physical strength.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a building material panel.

[Explanation of symbols]

 1. 1. Surface layer Back layer 3. Core material 4. Tile 5. Joint

Claims (1)

[Utility model registration claims] An inorganic or organic curable composition is pressure-molded on pumice and ceramic fine hollow particles, and the ceramic fine hollow particles, glass fibers, and an inorganic or organic curable composition are formed on the front and back surfaces of a core material. A panel for building materials, characterized by laminating plate materials molded in step (a) and laminating natural-crushed particles, ceramic fine hollow particles and an inorganic or organic curable composition under pressure on one surface thereof.