JP3365189B2 - Manufacturing method of inorganic plate - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an inorganic plate, and more particularly to a method for manufacturing an inorganic plate useful for building boards and the like.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing an inorganic plate, a method of manufacturing by a papermaking method, or an extrusion molding method or a cast molding method has been known. Among these, the method for producing an inorganic plate by the papermaking method has been generally performed because it is excellent in productivity. Then, after forming the aqueous slurry to obtain a green sheet, the powder material is sprayed to form a powder layer on the surface of the green sheet, and the surface of the inorganic plate obtained by press molding is used. It was designed to give a deep pattern.

[0003]

However, in such a method for producing an inorganic plate, since the adhesion strength between the green sheet and the powder layer is weak, there is a problem between the green sheet and the powder layer. However, there is a problem that peeling easily occurs.

Therefore, in order to increase the adhesion strength between the green sheet and the powder layer, the surface of the green sheet is roughly formed by, for example, a flow coater after it is formed into a green sheet and before the powder material is sprayed. A method of covering the entire surface with the resin emulsion was considered.

However, even with such a method, although the adhesion strength between the green sheet and the powder layer can be surely increased by the anchor effect through the resin emulsion, it can be applied to an aqueous slurry or powder material. A new problem has arisen in that hydraulic materials such as cement contained are not sufficiently bonded to each other. That is, there is a problem that the close contact between the green sheet and the powder layer is not sufficiently performed.

The present invention has been made to eliminate the above-mentioned drawbacks, and an object of the present invention is to provide an inorganic plate capable of sufficiently adhering at a boundary portion between a green sheet and a powder layer. It is to provide a manufacturing method.

[0007]

In the method for producing an inorganic plate according to claim 1 of the present invention, an aqueous slurry (3) is formed into a green sheet (7), and the green sheet (7) is obtained.
The powder material (4) is sprayed on the surface (1) of the
In the method for producing an inorganic plate for forming 1), a resin emulsion (8) having adhesiveness is applied to the green sheet (7) after the paper has been formed as the green sheet (7) and before the powder material (4) is sprayed. It is characterized in that it is scattered so as to be scattered on the surface (1) of (7).

In the method for producing an inorganic plate according to claim 2 of the present invention, the resin emulsion (8) is sprayed on the surface (1) of the green sheet (7) by a brush coater (2). It is characterized by doing.

In the method for producing an inorganic plate according to claim 3 of the present invention, the amount of the resin emulsion (8) sprayed is
The solid content is 5 to 100 g / m ² .

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is described in detail below.

FIG. 1 is a schematic view showing a method for manufacturing an inorganic plate according to an embodiment of the present invention.

In the method for producing an inorganic plate of the present invention, as shown in FIG. 1, an aqueous slurry (3) is formed into a green sheet (7), and a surface (1) of this green sheet (7) is obtained.
In the method for producing an inorganic plate, in which the powder material (4) is sprayed on to form the powder layer (11), before the green material (7) is made into paper and before the powder material (4) is sprayed. Then, the resin emulsion (8) having adhesiveness is sprinkled so as to be scattered on the surface (1) of the green sheet (7).

The above-mentioned aqueous slurry (3) contains, for example, cement and aggregate as main components, and can contain a fiber component, if necessary, such as a reinforcing material. It contains auxiliary components.

As the above-mentioned fiber component, that is, an auxiliary component such as a reinforcing material, for example, pulp powder or the like is usually used, but it is not limited to this, and other cellulose-based pulp fibers are also used. , Mineral fibers such as asbestos, organic resin fibers such as polypropylene and vinylon, glass fibers, carbon fibers, metal fibers and the like can be used.

As the above-mentioned cement, for example, Portland cement, fly ash cement, blast furnace cement and the like are used. Further, as the aggregate, granite, crushed stone such as serpentine, silica stone powder, shirasu balloon, glass balloon, silica, pearlite, sand,
Also, beads and the like are used.

The green sheet (7) is obtained by making the aqueous slurry (3) into paper. As shown in FIG. 1, a papermaking machine (10) is used for papermaking. This papermaking machine (10) is, for example, a Hatschek system,
Examples include a long-net system.

In particular, when the paper making machine (10) is a fourdrinier type, it is possible to more effectively dewater unnecessary water from the green sheet (7) by reducing the pressure using a suction box or the like. Is. The suction box can be placed under a reduced pressure of about 10 to 30 cmHg.

The papermaking machine (10) has a conveyor (5).
The conveyor (5) is wound around a roll (6) as shown in FIG. 1, for example. That is, the aqueous slurry (3) is placed on this conveyor (5).
And the aqueous slurry (3) is formed into a green sheet (7).

The powder layer (11) is formed by spraying the powder material (4) on the surface (1) of the green sheet (7). As the powder layer (11), the amount of the powder material (4) to be sprayed can be determined according to the desired thickness at which the powder layer (11) is formed. As the powder material (4), for example, a material containing cement and an aggregate as main components, and a material containing a reinforcing material and fibers as an auxiliary component are used, but the powder material (4) is not limited to this. Various formulations can be used without being processed. The powder material (4) is generally a semi-dry material, and contains less water than the aqueous slurry (3).

The above-mentioned powder material (4) is specifically, as a main component cement, for example, Portland cement,
Fly ash cement, blast furnace cement, etc. are used, and the main components of the aggregate are crushed stone such as granite, serpentine, silica stone powder, shirasu balloon, glass balloon, silica, pearlite, sand, and beads. Is used. Further, as a reinforcing material or fiber as an auxiliary component, pulp powder, vermiculite, cellulosic pulp fiber, mineral fiber such as asbestos, polypropylene, organic resin fiber such as vinylon, glass fiber, carbon fiber, Metal fibers or the like can be used.

As shown in FIG. 1, the resin emulsion (8) has adhesiveness, and is produced as the green sheet (7) before the powder material (4) is sprayed. The green sheet (7) is scattered so as to be scattered on the surface (1).

There are various possible methods for spraying the resin emulsion (8) so as to be scattered on the surface (1) of the green sheet (7). For example, a brush roll is used for spraying. There is a method of spraying with a brush coater (2) or a spray.

Particularly, when the resin emulsion (8) is sprinkled by the brush coater (2) so as to be scattered on the surface (1) of the green sheet (7), the green sheet (7) can be more reliably discharged. The resin emulsion (8) can be scattered so as to be scattered on the surface (1) of (1), and the anchor effect by the reliable resin emulsion (8) and a hydraulic material such as cement contained in the aqueous slurry (3). The coupling between them is more fully performed. Moreover, even if the brush coater (2) is once stopped, the spraying of the resin emulsion (8) can be started easily and immediately, and moreover, it is useful for long-term use, resulting in production. It will be highly responsive.

As the resin emulsion (8), for example, acrylic emulsion, epoxy emulsion and the like are used, but not limited thereto.
Various materials can be used as long as they have adhesiveness.

If the solid content of the resin emulsion (8) is 5 to 100 g / m ² , the resin emulsion (8) can be effectively applied to the green sheet (7).
Can be scattered so as to be scattered on the surface (1) of the powder, and as a result, more green sheets (7) and powder layers (1)
It is possible to achieve sufficient adhesion at the boundary with 1).

If the amount of the resin emulsion (8) to be applied is less than 5 g / m ² in terms of solid content, the resin emulsion (8) should be applied so as to be scattered on the surface (1) of the green sheet (7). Even if it is possible, it is not enough to improve the adhesion at the boundary between the green sheet (7) and the powder layer (11), and the amount of the resin emulsion (8) sprayed is solid. If it exceeds 100 g / m ² ,
The resin emulsion (8) is likely to be layered and is less likely to be scattered on the surface (1) of the green sheet (7). As a result, it is almost the same as the one covered over the entire surface and is non-uniform. As in the conventional case, it becomes difficult to sufficiently bond hydraulic materials such as cement contained in the aqueous slurry (3) and the powder material (4), respectively, as in the conventional case, and the green sheet (7) It is difficult to sufficiently enhance the adhesion strength with the powder layer (11).

Further, as shown in FIG. 1, when press molding is performed after suction suction dehydration is appropriately performed using a suction box or the like, the green sheet (7) is placed between the lower mold and the upper mold. The lower mold may be provided with a dehydration hole if necessary, and a felt may be laid on the upper surface of the lower mold.

Further, curing is carried out to obtain an inorganic plate. The curing method is carried out in an autoclave, and is cured in the autoclave at a temperature of 150 to 200 ° C. for 7 to 15 hours to obtain an inorganic plate.

Before the autoclave curing, the green sheet (7) may be used at room temperature for 2 to 5 hours, if necessary.
It is also possible to adopt a method such as leaving it to stand, and then performing heat and moisture curing for 10 to 100 hours at a temperature of 50 to 90 ° C. filled with steam.

As shown in FIG. 1, if necessary,
An overflow box (9) and the like can be installed so that the aqueous slurry (3) can be efficiently recycled.

According to the present invention, the green sheet (7) made from the aqueous slurry (3) and the powder layer (11) formed from the powder material (4) are obtained by using such a manufacturing method. However, the hydraulic materials such as cement contained in the aqueous slurry (3) and the powder material (4) are sufficiently bonded to each other, and the resin emulsion (on the surface (1) of the green sheet (7) ( By scattering 8) in a scattered manner, it is possible to obtain an anchor effect through the resin emulsion (8), and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) is increased. It is possible to surely increase the height and to sufficiently adhere the boundary portion between the green sheet (7) and the powder layer (11).

[0032]

EXAMPLES Examples of the present invention will be given below.

Example 1 Portland cement 100 parts by weight, silica stone powder 40 parts by weight, pulp powder (UKP, unbleached sulfate pulp) 15 parts by weight, fly ash 100 parts by weight, concentration 6 wt.
As shown in FIG. 1, the aqueous% slurry was made into paper by a Fourdrinier paper making machine (10) to obtain a green sheet (7) having a thickness of 12 mm.

Immediately after the green sheet (7) thus produced, a brush coater (2) was coated with a resin emulsion (8) of acrylic emulsion (produced by Yuka Birdish Co., Ltd.) on the surface (1) of the green sheet (7). At 5 g / solid
m ² (However, since the concentration was 50 wt%, the total amount was 10 g / m ^2. ) After that, put the green sheet (7) with the resin emulsion (8) in the width 20c.
on a conveyor (5) of m, 10.0 m / min
Portland cement 100 while being shed at the speed of
A powder material (4) containing parts by weight, 40 parts by weight of silica stone, 100 parts by weight of fly ash, 40 parts by weight of water, and 30 parts by weight of vermiculite is sprayed to form a powder layer (11) having a thickness of 3 mm. ) Was formed.

Thereafter, the green sheet (7) having the powder layer (11) formed thereon has a pressure of 4 MPa and a time of 1.0 sec.
Press molding of c was made. The state of the green sheet (7) at this time was good. And the temperature 60 ℃,
After steam curing for 10 hours, autoclave curing at 165 ° C. for 10 hours was performed, and an inorganic plate having a thickness of 15 mm could be obtained.

Then, the inorganic plate was heated at a temperature of 60 ° C. for 10
After leaving for an hour, the same inorganic plate is 40 mm x 40 m
It cut into m and prepared 20 samples. Then, a jig is attached to both sides of this sample, and the pulling speed is 1
A tensile test of pulling at a speed of mm / min was performed on each sample, and the green sheet (7) and the powder layer (1
The number of boundary fractures, which is the number of sheets destroyed at the boundary with 1), was examined. As a result, only one of the 20 samples broke at the boundary.

Example 2 The resin emulsion (8) was applied at a solid content of 25 g / m 2.
² (However, since the concentration was 50 wt%, the total amount was 5
It becomes 0 g / m ² . Other than the above, a 15 mm-thick inorganic plate could be obtained in the same manner as in Example 1.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Example 3 The resin emulsion (8) was applied at a solid content of 50 g / m 2.
² (However, since the concentration was 50 wt%, the total amount was 1
It becomes 00 g / m ² . Other than the above, a 15 mm-thick inorganic plate could be obtained in the same manner as in Example 1.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, only one of the 20 samples broke at the boundary.

Example 4 The resin emulsion (8) was applied at a solid content of 100 g /
m ² (However, since there was a concentration 50 wt%, the total amount becomes 200g / m ^2.) other than a, the same procedure as in Example 1, it was possible to obtain the inorganic board having a thickness of 15 mm.

Further, the number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Example 5 An epoxy emulsion (manufactured by Hoechst Synthetic Co., Ltd.) was used as the resin emulsion (8), and the amount of the resin emulsion (8) sprayed was 25 g / m ^{2 in} solid content (however, the concentration was 50 wt%. Therefore, the total amount becomes 50 g / m ^2, and the thickness is 15 in the same manner as in Example 1.
It was possible to obtain an inorganic plate of mm.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Example 6 An epoxy emulsion (manufactured by Hoechst Synthetic Co., Ltd.) was used as the resin emulsion (8), and the amount of the resin emulsion (8) sprayed was 75 g / m ^{2 in} solid content (however, the concentration was 50 wt%. Therefore, the total amount is 150 g / m ^2, and the thickness is 15 in the same manner as in Example 1 except that it is 150 g / m ² .
It was possible to obtain an inorganic plate of mm.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Comparative Example 1 The resin emulsion (8) was sprayed with a flow coater, and the spray amount of the resin emulsion (8) was 25 in terms of solid content.
g / m ² (However, since there was a concentration 50 wt%, the total amount becomes 50g / m ^2.) other than a, the same procedure as in Example 1, it was possible to obtain an inorganic sheet having a thickness of 15mm .

The number of boundary fractures was examined in the same manner as in Example 1. As a result, of the 20 samples, 6 broke at the boundary.

Comparative Example 2 A resin emulsion (8) was sprayed with a flow coater, and an epoxy emulsion (manufactured by Hoechst Synthetic Co., Ltd.) was used as the resin emulsion (8). Of 50 g / m ² (however, since the concentration was 50 wt%, the total amount is 100 g / m ² ), the thickness was 1
A 5 mm inorganic plate could be obtained.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, 4 of 20 samples were broken at the boundary.

Comparative Example 3 An inorganic plate having a thickness of 15 mm could be obtained in the same manner as in Example 1 except that the resin emulsion (8) was not sprayed.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, 12 of the 20 samples broke at the boundary.

Comparative Example 4 The resin emulsion (8) was applied at a solid content of 2.5 g /
m ² (However, since there was a concentration 50 wt%, the total amount becomes 5g / m ^2.) other than a, the same procedure as in Example 1, it was possible to obtain the inorganic board having a thickness of 15 mm.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, 5 of the 20 samples broke at the boundary.

Tables 1 below show Examples 1-6 and Comparative Examples 1-4.
Each of the spray emulsion, spray method, and spray amount was summarized, including the number of boundary fractures of the inorganic plate obtained in step.

[0056]

[Table 1]

As can be seen by comparing Table 1 with those of Examples 1 to 6 and Comparative Examples 1 to 4 together with the above description, the number of boundary fractures was found to be Examples 1 to 6. Is much less than Comparative Examples 1 to 4, and the green sheet (7) made from the aqueous slurry (3) and the powder layer (11) formed from the powder material (4) are water-based. The hydraulic materials such as cement contained in the slurry (3) and the powder material (4) are sufficiently bonded to each other, and the resin emulsion (8) is applied to the surface (1) of the green sheet (7). By scattering in a scattered manner, an anchor effect can be obtained through the resin emulsion (8), and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) is surely increased. Along with the green sheet 7) and it can be said that those powder layer (11) contact at the boundary portion between the can sufficiently perform.

[0058]

According to the method for producing an inorganic plate according to claim 1 of the present invention, a powder layer formed from the green sheet (7) made from the aqueous slurry (3) and the powder material (4). (11) is an aqueous slurry (3) and powder material (4)
When the hydraulic materials such as cement contained in each of the and are sufficiently bonded to each other and the resin emulsion (8) is scattered on the surface (1) of the green sheet (7), the resin is dispersed. An anchor effect can be obtained through the emulsion (8), and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) can be surely increased, and at the same time, the green sheet (7) and It is possible to achieve sufficient adhesion at the boundary with the powder layer (11).

According to the method for producing an inorganic plate according to claim 2 of the present invention, in addition to the case of claim 1, the surface (1) of the green sheet (7) is more reliably coated with the resin emulsion (8). As a result, the resin emulsion (8) can be dispersed as it is, and a reliable anchoring effect of the resin emulsion (8) is achieved, and the hydraulic materials such as cement contained in the aqueous slurry (3) are bonded more sufficiently. Moreover, even if you stop the brush coater (2) once,
Moreover, the application of the resin emulsion (8) can be started immediately, and it is useful for a long period of time, resulting in high productivity.

According to the method for producing an inorganic plate according to claim 3 of the present invention, in addition to the case of claim 1 or 2, the resin emulsion (8) is effectively added to the surface of the green sheet (7) ( As a result, they can be scattered so as to be scattered in 1), and as a result, the close contact between the green sheet (7) and the powder layer (11) can be more sufficiently achieved.

[Brief description of drawings]

FIG. 1 is a schematic view showing a method for manufacturing an inorganic plate according to an embodiment of the present invention.

[Explanation of symbols]

1 surface 2 brush coater 3 Aqueous slurry 4 Powder material 7 green sheets 8 resin emulsion 11 powder layer

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI B28B 11/06 B28B 11/06 C04B 41/63 C04B 41/63 41/65 41/65

Claims (3)

(57) [Claims] 1. A method for producing an inorganic plate, wherein an aqueous slurry is formed into a green sheet, and a powder material is sprinkled on the surface of the green sheet to form a powder layer. A method for producing an inorganic plate, which comprises spraying a resin emulsion having adhesiveness so as to be scattered on the surface of the green sheet before spraying the powder material. 2. The method for producing an inorganic plate according to claim 1, wherein the resin emulsion is dispersed by a brush coater so as to be scattered on the surface of the green sheet. 3. The method for producing an inorganic plate according to claim 1, wherein the amount of the resin emulsion sprayed is 5 to 100 g / m ² in terms of solid content.