JP4198868B2 - Manufacturing method of fiber reinforced inorganic board - Google Patents
Manufacturing method of fiber reinforced inorganic board Download PDFInfo
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- JP4198868B2 JP4198868B2 JP2000193937A JP2000193937A JP4198868B2 JP 4198868 B2 JP4198868 B2 JP 4198868B2 JP 2000193937 A JP2000193937 A JP 2000193937A JP 2000193937 A JP2000193937 A JP 2000193937A JP 4198868 B2 JP4198868 B2 JP 4198868B2
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- JP
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- Prior art keywords
- fiber
- polyvinyl alcohol
- polypropylene
- polypropylene fiber
- inorganic board
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/29—Frost-thaw resistance
Description
【０００１】
【発明の属する技術分野】
本発明は建築板として有用な繊維補強無機質板の製造方法に関するものである。
【０００２】
【従来の技術】
従来、この種の繊維補強無機質板の補強繊維としては、アスベストが使用されていたが、アスベストの使用は環境汚染を惹き起す。したがって最近ではアスベストに代えて木質繊維が使用されている。しかし木質繊維は絡み合いが弱く補強効果に乏しく、アスベストを使用した無機質板と同等の強度を得ることが難しい。
そこで木質繊維に代えて絡み易いポリビニルアルコール系繊維（ビニロン繊維）を使用した繊維補強無機質板が提供されている（特許第２５３７５８１号公報）。該ビニロン繊維はセメント等の水硬性無機材料との親和性が大きく、かつ柔軟性があって絡み易いので無機質板の補強効果が大きく耐凍性も向上せしめる。
【０００３】
【発明が解決しようとする課題】
しかしながら上記ビニロン繊維は無機質板の耐衝撃性の向上には余り寄与しないと云う問題点があった。
【０００４】
【課題を解決するための手段】
本発明は上記従来の課題を解決するための手段として、水硬性無機材料と、ポリプロピレン繊維よりも低い融点を有するポリビニルアルコール系繊維と、ポリプロピレン繊維とを含む原料混合物を固形分濃度６〜１７重量％のスラリーとし、該スラリーを使用して湿式抄造法によって抄造マットをフォーミングし、該抄造マットを加熱養生硬化せしめる際に、該ポリビニルアルコール系繊維を選択的に溶融させる繊維補強無機質板の製造方法を提供するものである。該ポリビニルアルコール系繊維は、太さ１〜２０デニール、長さ４〜１０ mm で、該ポリプロピレン繊維よりも低い融点を有し、該ポリプロピレン繊維は、太さ１〜２０デニール、長さ４〜１０ mm である。該ポリビニルアルコール系繊維は原料混合物中に０．１〜１．５重量％、ポリプロピレン繊維は原料混合物中に０．１〜１．５重量％の範囲とするとともに、原料混合中における該ポリビニルアルコール系繊維と該ポリプロピレン繊維との重量比率を１：１〜２：１とする。
【０００５】
【作用】
ポリビニルアルコール系繊維は水硬性無機材料と親和性が高いので、該水硬性無機材料硬化物中に均一に分散する。一方ポリプロピレン繊維は無機質板の耐衝撃性の向上には寄与するが、水硬性無機材料との親和性に乏しくまた剛性があって相互絡み合いにくゝ、無機質板の強度向上には寄与しにくい。しかし本発明では柔軟性のあるポリビニルアルコール系繊維が無機質板中に均一に分散し、かつポリプロピレン繊維と絡み合った状態で溶融してポリプロピレン繊維と水硬性無機材料硬化物との間の接着剤として作用し、その結果得られる無機質板は高強度と高耐衝撃性とを兼ね備えたものとなる。
【０００６】
【発明の実施の形態】
本発明を以下に詳細に説明する。
〔水硬性無機材料〕
本発明に用いられる水硬性無機材料としては、ポルトランドセメント、高炉セメント、シリカセメント、フライアッシュセメント、アルミナセメント等のセメント類；シリカ粉、ケイ砂、ケイ石粉、水ガラス、シリカヒューム、シラスバルーン、パーライト、マイカ、ケイ藻土、ドロマイト等のケイ酸含有物質と上記セメント類とを混合した混合物；二水石膏、半水石膏、無水石膏、消石灰、生石灰等の活性石灰含有物質と上記ケイ酸含有物質との混合物等が例示される。
上記水硬性無機材料の中でも、セメント類とケイ酸含有物質との混合物が好ましく、セメント類とケイ酸含有物質との混合比（重量比）は１：２〜６：１であるのが好ましい。
【０００７】
〔ポリビニルアルコール系繊維〕本発明で使用されるポリビニルアルコール系繊維は、一般に太さ１〜２０デニール、長さ４〜１０mmのものであり、また該ポリビニルアルコール系繊維の融点はポリプロピレン繊維の融点よりも低く、例えば１３０℃以下のものが選択される。
【０００８】
〔ポリプロピレン繊維〕
本発明で使用されるポリプロピレン繊維は、一般に太さ１〜２０デニール、長さ４〜１０mmのものである。
【０００９】
〔その他の成分〕
本発明の繊維補強無機質板の成形材料には、上記以外の成分として、塩化カルシウム、塩化マグネシウム、硫酸カリウム、硫酸カルシウム、硫酸マグネシウム、硫酸アルミニウム、アルミン酸ナトリウム、アルミン酸カリウム、ギ酸カルシウム、酢酸カルシウム、アクリル酸カルシウム、水ガラス等のセメント硬化剤、バーミキュライト、ベントナイト等の鉱物粉末、ロウ、ワックス、パラフィン、シリコン、界面活性剤等の防水剤や撥水剤、発泡性熱可塑性プラスチックビーズ、プラスチック発泡体等が添加されてもよい。なお、これらの例示は本発明を限定するものではない。
【００１０】
〔原料配合〕本発明において、水硬性無機材料は通常４０〜６０重量％、ポリビニルアルコール系繊維は通常０．１〜１．５重量％、ポリプロピレン繊維は通常０．１〜１．５重量％配合される。上記配合において、ポリビニルアルコール系繊維とポリプロピレン繊維との重量比率を１：１〜２：１とする。この比率の範囲でポリビニルアルコール系繊維の強度、耐凍性の改良効果とポリプロピレン繊維の耐衝撃性改良効果とがバランスよく発現される。その他の成分は通常数重量％程度配合される。
【００１１】
〔無機質板の製造方法〕
本発明の無機質板は湿式抄造法によって製造される。湿式抄造法においては上記原料を水に分散してスラリーとするが、該スラリーの固形分濃度は通常６〜１７重量％に設定される。
上記スラリーはフローオン法、長網法、丸網法、ハチェック法等通常の方式で抄造されてマットとされ、該マットは通常ロールプレス、平板プレス等によってプレスされて搾水されかつ成形される。
【００１２】
このようにして成形された抄造マットは養生硬化せしめられるが、養生工程は通常常温下または６０〜９０℃の加熱常圧下で４時間以上の予備養生工程とポリビニルアルコール系繊維の融点以上でポリプロピレン繊維の融点以下の温度、通常１３０〜１８０℃のオートクレーブ中で、６〜１５時間の本養生工程からなる。
上記本養生工程中に抄造マット中のポリビニルアルコール系繊維が選択的に溶融してポリプロピレン繊維と水硬性無機材料との間の接着剤として作用する。
養生硬化後は所望なればトリミング、塗装等を施されて繊維補強無機質板が製造される。
【００１３】
〔実施例１〜５および比較例１〜２〕
表１に示す配合比率の原料を水に投入攪拌分散して固形分１２重量％のスラリーを調製する。該スラリーをフェルト上に流し出し、該フェルトの下側から吸引脱水してマットを抄造する。該マットは８０℃、６時間予備養生後、オートクレーブ中１７０℃、１０時間の本養生によって略完全に硬化される。
このようにして製造された無機質板試料の物性は表１の通りである。
【００１４】
【表１】
表１によれば本発明の実施例１〜４の試料は曲げ強度、耐クラック性（耐衝撃性）、たわみ、寸法安定性、耐凍性のいずれにも優れているが、ポリプロピレン繊維のみを使用した比較例１の試料は曲げ強度、寸法安定性、耐凍性において実施例の各試料よりも劣り、ビニロン繊維（ポリビニルアルコール系繊維）のみを使用した比較例２の試料は耐クラック性において実施例の各試料よりも劣る。
【００１６】
【発明の効果】
本発明では無機質板内でポリプロピレン繊維がポリビニルアルコール系繊維の溶融物によって水硬性無機材料硬化物に物理的に接着される結果、無機質板には高強度、高耐凍性、高耐衝撃性が付与される。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a fiber-reinforced inorganic board useful as a building board.
[0002]
[Prior art]
Conventionally, asbestos has been used as the reinforcing fiber of this type of fiber-reinforced inorganic board, but the use of asbestos causes environmental pollution. Therefore, recently, wood fibers have been used in place of asbestos. However, wood fibers are weakly entangled and have a poor reinforcing effect, and it is difficult to obtain the same strength as an inorganic board using asbestos.
Therefore, a fiber-reinforced inorganic board using polyvinyl alcohol fibers (vinylon fibers) that are easily entangled instead of wood fibers is provided (Japanese Patent No. 2537581). The vinylon fiber has a high affinity with hydraulic inorganic materials such as cement, and is flexible and easily entangled, so that the reinforcing effect of the inorganic board is great and the frost resistance is improved.
[0003]
[Problems to be solved by the invention]
However, the vinylon fiber has a problem that it does not contribute much to the impact resistance of the inorganic board.
[0004]
[Means for Solving the Problems]
As a means for solving the above conventional problems, the present invention provides a raw material mixture containing a hydraulic inorganic material, a polyvinyl alcohol fiber having a melting point lower than that of polypropylene fiber, and polypropylene fiber, and a solid content concentration of 6 to 17 weights. % , A paper mat is formed by wet papermaking using the slurry, and the polyvinyl alcohol fiber is selectively melted when the paper mat is cured by heating and curing. Is to provide. The polyvinyl alcohol fiber has a thickness of 1 to 20 denier and a length of 4 to 10 mm , and has a melting point lower than that of the polypropylene fiber. The polypropylene fiber has a thickness of 1 to 20 denier and a length of 4 to 10 mm. mm . The polyvinyl alcohol fiber is in the range of 0.1 to 1.5% by weight in the raw material mixture, and the polypropylene fiber is in the range of 0.1 to 1.5% by weight in the raw material mixture. The weight ratio of the fiber to the polypropylene fiber is 1: 1 to 2: 1.
[0005]
[Action]
Since the polyvinyl alcohol fiber has high affinity with the hydraulic inorganic material, it is uniformly dispersed in the cured hydraulic inorganic material. Polypropylene fibers, on the other hand, contribute to improving the impact resistance of the inorganic board, but have poor affinity with the hydraulic inorganic material and are rigid and difficult to intertwine, making it difficult to contribute to improving the strength of the inorganic board. However, in the present invention, the flexible polyvinyl alcohol fiber is uniformly dispersed in the inorganic plate and melted in an intertwined manner with the polypropylene fiber to act as an adhesive between the polypropylene fiber and the cured hydraulic inorganic material. The resulting inorganic board has both high strength and high impact resistance.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described in detail below.
[Hydraulic inorganic material]
Examples of the hydraulic inorganic material used in the present invention include cements such as Portland cement, blast furnace cement, silica cement, fly ash cement, and alumina cement; silica powder, silica sand, quartzite powder, water glass, silica fume, shirasu balloon, Mixture of silicate containing materials such as pearlite, mica, diatomaceous earth, dolomite and the above cements; active lime containing materials such as dihydrate gypsum, hemihydrate gypsum, anhydrous gypsum, slaked lime, quick lime Examples thereof include a mixture with a substance.
Among the above-mentioned hydraulic inorganic materials, a mixture of cements and silicic acid-containing substances is preferable, and a mixing ratio (weight ratio) of cements and silicic acid-containing substances is preferably 1: 2 to 6: 1.
[0007]
Lupo polyvinyl alcohol fiber used in [polyvinyl alcohol fiber The present invention is generally thickness 1-20 denier, are of length 4 to 10 mm, also the melting point of the polyvinyl alcohol fiber is a polypropylene fiber A material having a temperature lower than the melting point, for example, 130 ° C. or lower is selected.
[0008]
[Polypropylene fiber]
The polypropylene fibers used in the present invention are generally those having a thickness of 1 to 20 denier and a length of 4 to 10 mm.
[0009]
[Other ingredients]
In the molding material of the fiber-reinforced inorganic board of the present invention, as components other than the above, calcium chloride, magnesium chloride, potassium sulfate, calcium sulfate, magnesium sulfate, aluminum sulfate, sodium aluminate, potassium aluminate, calcium formate, calcium acetate , Cement hardeners such as calcium acrylate, water glass, mineral powders such as vermiculite, bentonite, waterproofing agents and water repellents such as wax, wax, paraffin, silicon, surfactants, foaming thermoplastic beads, foaming plastic Body or the like may be added. In addition, these illustrations do not limit the present invention.
[0010]
[Raw material formulation] In the present invention, the hydraulic inorganic material is usually 40 to 60% by weight, the polyvinyl alcohol fiber is usually 0.1 to 1.5% by weight, and the polypropylene fiber is usually 0.1 to 1.5% by weight. Is done. In the above formulation , the weight ratio of polyvinyl alcohol fiber to polypropylene fiber is 1: 1 to 2: 1 . Within this range, the strength and frost resistance improvement effect of the polyvinyl alcohol fiber and the impact resistance improvement effect of the polypropylene fiber are expressed in a well-balanced manner. The other components are usually blended in the order of several weight percent.
[0011]
[Production method of inorganic board]
The inorganic board of the present invention is manufactured by a wet papermaking method. In the wet papermaking method, the raw material is dispersed in water to form a slurry, and the solid content concentration of the slurry is usually set to 6 to 17% by weight.
The slurry is made into a mat by making a paper by a usual method such as a flow-on method, a long mesh method, a round mesh method, or a check method, and the mat is usually pressed by a roll press, a flat plate press, etc. The
[0012]
The paper-making mat formed in this way is cured and cured, but the curing process is usually a polypropylene fiber at a room temperature or a normal curing temperature of 60 to 90 ° C. for 4 hours or more and a melting point of the polyvinyl alcohol fiber or more. It consists of a main curing step of 6 to 15 hours in an autoclave at a temperature below the melting point, usually 130 to 180 ° C.
During the curing process, the polyvinyl alcohol fiber in the papermaking mat is selectively melted and acts as an adhesive between the polypropylene fiber and the hydraulic inorganic material.
After curing and curing, if desired, trimming, painting, etc. are applied to produce a fiber-reinforced inorganic board.
[0013]
[Examples 1-5 and Comparative Examples 1-2]
A raw material having a blending ratio shown in Table 1 is charged into water and stirred and dispersed to prepare a slurry having a solid content of 12% by weight. The slurry is poured onto a felt and sucked and dehydrated from the lower side of the felt to make a mat. The mat is preliminarily cured at 80 ° C. for 6 hours and then almost completely cured by main curing at 170 ° C. for 10 hours in an autoclave.
Table 1 shows the physical properties of the inorganic plate sample thus manufactured.
[0014]
[Table 1]
According to Table 1, the samples of Examples 1 to 4 of the present invention are excellent in bending strength, crack resistance (impact resistance), deflection, dimensional stability, and frost resistance, but use only polypropylene fibers. The sample of Comparative Example 1 was inferior to the samples of Examples in bending strength, dimensional stability, and frost resistance, and the sample of Comparative Example 2 using only vinylon fiber (polyvinyl alcohol fiber) was in Example in crack resistance. It is inferior to each sample.
[0016]
【The invention's effect】
In the present invention, the polypropylene fiber is physically bonded to the cured hydraulic inorganic material by a melt of polyvinyl alcohol fiber in the inorganic plate, so that the inorganic plate is given high strength, high freezing resistance, and high impact resistance. Is done.
Claims (1)
該ポリビニルアルコール系繊維は、太さ１〜２０デニール、長さ４〜１０ mm で、該ポリプロピレン繊維よりも低い融点を有するものを使用し、
該ポリプロピレン繊維は、太さ１〜２０デニール、長さ４〜１０ mm のものを使用し、
該ポリビニルアルコール系繊維を原料混合物中に０．１〜１．５重量％の範囲とし、該ポリプロピレン繊維を原料混合物中に０．１〜１．５重量％の範囲とするとともに、原料混合中における該ポリビニルアルコール系繊維と該ポリプロピレン繊維との重量比率を１：１〜２：１とし、
更に、該加熱養生として、１３０〜１８０℃であるとともに、ポリビニルアルコール系繊維の融点以上でポリプロピレン繊維の融点以下である温度でオートクレーブ養生し、該ポリビニルアルコール系繊維を選択的に溶融させる
ことを特徴とする繊維補強無機質板の製造方法。Forming a hydraulic inorganic material, and Po polyvinyl alcohol fiber, a raw material mixture containing a polypropylene fiber having a solid content concentration of 6 to 17 wt% of the slurry, a sheet-processed mat Ri by the wet papermaking method using the slurry And a method for producing a fiber-reinforced inorganic board that is cured by heating and curing the paper mat ,
The polyvinyl alcohol fiber uses a fiber having a thickness of 1 to 20 denier, a length of 4 to 10 mm , and a melting point lower than that of the polypropylene fiber.
The polypropylene fiber used is one having a thickness of 1 to 20 denier and a length of 4 to 10 mm .
The polyvinyl alcohol fiber is in the range of 0.1 to 1.5% by weight in the raw material mixture, and the polypropylene fiber is in the range of 0.1 to 1.5% by weight in the raw material mixture. The weight ratio of the polyvinyl alcohol fiber and the polypropylene fiber is 1: 1 to 2: 1,
Further, as the heat curing, the temperature is 130 to 180 ° C., and autoclave curing is performed at a temperature not lower than the melting point of the polyvinyl alcohol fiber and not higher than the melting point of the polypropylene fiber, so that the polyvinyl alcohol fiber is selectively melted. A method for producing a fiber-reinforced inorganic board.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000193937A JP4198868B2 (en) | 2000-06-28 | 2000-06-28 | Manufacturing method of fiber reinforced inorganic board |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000193937A JP4198868B2 (en) | 2000-06-28 | 2000-06-28 | Manufacturing method of fiber reinforced inorganic board |
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| Publication Number | Publication Date |
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| JP2002011715A JP2002011715A (en) | 2002-01-15 |
| JP4198868B2 true JP4198868B2 (en) | 2008-12-17 |
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| JP2000193937A Expired - Fee Related JP4198868B2 (en) | 2000-06-28 | 2000-06-28 | Manufacturing method of fiber reinforced inorganic board |
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| EP2172434B1 (en) * | 2008-10-02 | 2015-03-11 | Redco S.A. | Fibre-cement product compositions and shaped products obtained therefrom. |
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