JP4343617B2 - Lightweight inorganic board and method for producing the inorganic board - Google Patents

Lightweight inorganic board and method for producing the inorganic board Download PDF

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JP4343617B2
JP4343617B2 JP2003291909A JP2003291909A JP4343617B2 JP 4343617 B2 JP4343617 B2 JP 4343617B2 JP 2003291909 A JP2003291909 A JP 2003291909A JP 2003291909 A JP2003291909 A JP 2003291909A JP 4343617 B2 JP4343617 B2 JP 4343617B2
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JP2005060163A (en
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忠史 杉田
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Nichiha Corp
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
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    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Description

本発明は、例えば外壁材、内装材等の建築板に使用される軽量無機質板および該無機質板の製造方法に関するものである。   The present invention relates to a lightweight inorganic board used for building boards such as outer wall materials and interior materials, and a method for producing the inorganic board.

〔発明の背景〕
シリカ、アルミナ等のセラミック粉体を板状に成形し焼成した無機質板は耐久性に優れ、また美感や質感を有し高級感のある意匠を有する建築板として多用されている。
上記無機質板はセラミック粉体にバインダーと水とを添加して混練し、該混練物を押出成形あるいは鋳込み成形によって板状に成形し、該板状成形物を焼成することによって製造されるが、高硬度であり切削加工性が悪く、現場で簡単に所定寸法に切断することが困難である。また大板の場合は、重量が大きく運搬、構築作業に労力を要するし、壁躯体等に取付けた場合、壁躯体にかゝる重量負荷が大きくなる。
BACKGROUND OF THE INVENTION
An inorganic plate obtained by molding and firing ceramic powders such as silica and alumina into a plate shape is excellent in durability, and is frequently used as a building plate having a high-quality design with a sense of beauty and texture.
The inorganic plate is manufactured by adding a binder and water to a ceramic powder and kneading, forming the kneaded product into a plate shape by extrusion molding or casting, and firing the plate-shaped product, It has high hardness and poor machinability, and it is difficult to easily cut to a predetermined size on site. In the case of a large plate, the weight is large and labor is required for transportation and construction work, and when it is attached to a wall frame or the like, the weight load on the wall frame becomes large.

〔従来の技術〕
そこで上記無機質板の問題点を解決するための手段として、木質セメント板の廃材粉砕物等の可燃有機成分を含む材料を無機原料に添加し、水を加えて混練し、該混練物を押出成形等によって板状に成形し、該板状成形物を焼成することによって製造された無機質板が提供されている。
該無機質板にあっては、焼成時無機原料に混合されている木質セメント板廃材中に含まれる木質補強材等の有機成分が焼滅し、多孔質構造を形成する結果軽量になり、切削加工性も改良される(例えば特許文献1,2,3参照)。
[Conventional technology]
Therefore, as means for solving the problems of the above-mentioned inorganic board, a material containing a combustible organic component such as a pulverized waste material of a wood cement board is added to an inorganic raw material, water is added and kneaded, and the kneaded product is extruded. An inorganic plate produced by molding into a plate shape and the like and firing the plate-like molded product is provided.
In the inorganic board, the organic components such as the wood reinforcing material contained in the wood cement board waste mixed with the inorganic raw material at the time of firing are burned down, and as a result of forming a porous structure, the weight becomes light, and the machinability (See, for example, Patent Documents 1, 2, and 3).

特開2002−321966号公報(〔0014〕)JP 2002-321966 A ([0014]) 特開2003−206186号公報(〔請求項1〕)Japanese Patent Laying-Open No. 2003-206186 (Claim 1) 特開平6−191964号公報(〔請求項1〕)JP-A-6-191964 (Claim 1)

しかしながら上記軽量無機質板にあっては、表面が多孔になり粗面を呈するために意匠的に劣ったものとなるし、表面の凹部にごみが入り込み汚れが付着し易い。更に表面にエンボス加工によって明確な凹凸模様を付すことが困難である。また吸水し易く吸水による内部構造の劣化、更には耐凍結融解性能の劣化の問題もある。   However, the lightweight inorganic plate is inferior in design because the surface becomes porous and exhibits a rough surface, and dust enters the concave portions on the surface, and dirt tends to adhere. Furthermore, it is difficult to give a clear uneven pattern to the surface by embossing. There is also a problem that the internal structure is easily deteriorated due to water absorption, and further the freeze-thaw resistance is deteriorated.

本発明は上記従来の課題を解決するための手段として、芯層に可燃有機成分を含む無機原料層を配し、表裏層に可燃有機成分を含まない無機原料層を配した3層構造の無機質板生板を焼成し、該芯層の可燃有機成分を焼滅させることによって該芯層を多孔質にした軽量無機質板を提供するものである。
上記可燃有機成分として、木質セメント板廃材に含まれる木質分を使用することが望ましく、また該無機原料は水硬性無機材料とガラス質材料と骨材とを含むことが望ましい。そして該芯層の有機成分含有量は5〜35質量%であることが望ましい。
更に該表裏層の比重は1.5〜1.8、該芯層の比重は0.8〜1.3であることが望ましい。
本発明の軽量無機質板の望ましい製造方法は、型板上に表裏層用無機原料を撒布して表層または裏層マットをフォーミングし、該表層または裏層マット上に芯層用無機原料を撒布して芯層マットをフォーミングし、該芯層マット上に表裏層用無機原料を撒布して裏層または表層マットをフォーミングし、このようにして得られた3層構造のマットを水分存在下で圧締養生硬化せしめ、得られた無機質板生板を焼成する乾式法あるいは半乾式法である。
As a means for solving the above-mentioned conventional problems, the present invention provides an inorganic material having a three-layer structure in which an inorganic raw material layer containing a combustible organic component is arranged on the core layer, and an inorganic raw material layer containing no combustible organic component is arranged on the front and back layers. It is intended to provide a lightweight inorganic board in which the core layer is made porous by firing the green plate and burning the combustible organic component of the core layer.
As the combustible organic component, it is desirable to use a wood component contained in the wood cement board waste material, and it is desirable that the inorganic raw material includes a hydraulic inorganic material, a glassy material, and an aggregate. The organic layer content of the core layer is preferably 5 to 35% by mass.
Further, the specific gravity of the front and back layers is preferably 1.5 to 1.8, and the specific gravity of the core layer is preferably 0.8 to 1.3.
A desirable method for producing the lightweight inorganic board of the present invention is to spread an inorganic raw material for the front and back layers on the template, form a surface layer or a back layer mat, and spread an inorganic raw material for the core layer on the front layer or the back layer mat. The core layer mat is formed, the inorganic material for the front and back layers is spread on the core layer mat, the back layer or the surface layer mat is formed, and the mat having the three-layer structure thus obtained is pressed in the presence of moisture. It is a dry method or semi-dry method in which the cured and cured inorganic plate is fired.

〔作用〕
本発明の軽量無機質板にあっては、芯層が多孔質であるから軽量になり、切削加工性および施工性に優れたものとなるが、表裏層は多孔質でなく緻密構造であるから表面平滑で好ましい外観となり、明確なエンボス加工が容易となる。また表裏層によって板内部に水分が侵入することが防止されるので、内部構造が劣化しにくゝ耐久性のある耐凍結融解性能に優れた板になる。更に芯層にあっては、可燃性有機成分含有材料と共に木質セメント板廃材を使用する場合には、該廃材の有効利用が出来る。
本発明の無機質板を乾式あるいは半乾式法で製造すれば、生産性が向上して大量生産が容易になり、廃材を微粉砕する必要もない。押出成形の場合には原料混練物をダイから押出すので、ダイが詰まらないよう廃材を微粉砕する必要がある。またフォーミングされるマットの水分含有率は押出成形よりも低く、更に圧締養生硬化後に焼成するので、焼成前の生板もある程度強度があり破損しにくいので、作業性や歩留り等が向上し、焼成効率は押出成形品よりもはるかに高くなる。更に表面に凹凸模様を設ける場合には型板面に凹凸陰模様を形成し、その上に原料を撒布するので、明確な凹凸模様を付することが出来る。
[Action]
In the lightweight inorganic board of the present invention, since the core layer is porous, the core layer is light and excellent in machinability and workability, but the front and back layers are not porous but have a dense structure. A smooth and favorable appearance is obtained, and clear embossing is facilitated. In addition, the front and back layers prevent moisture from penetrating into the plate, so that the internal structure is hardly deteriorated and the plate is excellent in durability and freeze-thaw resistance. Further, in the core layer, when the wood cement board waste material is used together with the combustible organic component-containing material , the waste material can be effectively used.
If the inorganic board of the present invention is produced by a dry or semi-dry method, productivity is improved and mass production is facilitated, and there is no need to finely grind waste materials. In the case of extrusion molding, since the raw material kneaded product is extruded from the die, it is necessary to finely grind the waste material so that the die is not clogged. In addition, the moisture content of the mat to be formed is lower than that of extrusion molding, and further fired after compression biocure. The firing efficiency is much higher than that of the extruded product. Furthermore, when providing a concavo-convex pattern on the surface, a concavo-convex shade pattern is formed on the template surface, and the raw material is distributed thereon, so that a clear concavo-convex pattern can be given.

〔効果〕
本発明にあっては、軽量でかつ機械的強度が高く耐凍結融解性に優れ、加工性も良好でかつ表面平滑で意匠性にも優れた軽量無機質板が提供される。
〔effect〕
The present invention provides a lightweight inorganic board that is lightweight, has high mechanical strength, is excellent in freeze-thaw resistance, has good workability, has a smooth surface, and is excellent in design.

以下に本発明を詳細に説明する。
〔木質セメント板廃材〕
本発明において、可燃性有機成分含有材料として使用される木質セメント板廃材とは、木片、木質繊維束、木質パルプ、木毛、木粉等の木質補強材と、普通ポルトランドセメント、早強セメント、アルミナセメント、高炉スラグセメント、フライアッシュセメント等のセメント類や生石灰、消石灰等の石灰類、あるいは石膏、炭酸マグネシウム等の水硬性無機材料とを主体とする原料混合物を使用し、乾式法、半乾式法、湿式法、押出成形法等で板状に成形した木質セメント板の廃材であるが、製造工程中の端材や、増改築時に発生するこれらの廃材を粉砕して再利用するものである。
上記木質セメント板には上記木質分が通常10〜30質量%含有される。
The present invention is described in detail below.
[Wood cement board waste]
In the present invention, the wood cement board waste material used as a combustible organic component-containing material is a wood reinforcing material such as a piece of wood, wood fiber bundle, wood pulp, wood wool, wood powder, ordinary Portland cement, early strength cement, Using a raw material mixture mainly composed of cement such as alumina cement, blast furnace slag cement, fly ash cement, lime such as quick lime and slaked lime, or hydraulic inorganic material such as gypsum and magnesium carbonate, dry method, semi-dry method It is a waste material of wood cement board formed into a plate shape by the method, wet method, extrusion molding method, etc., but it is used to grind and recycle the scrap materials during the manufacturing process and these waste materials generated at the time of extension and reconstruction .
The wood cement board usually contains 10 to 30% by mass of the wood content.

上記木質セメント板には更にポリエステル繊維、ポリアミド繊維、ポリエチレン繊維、ポリプロピレン繊維、アクリル繊維等の有機繊維や発泡ポリスチレンビーズ、ポリエチレンビーズ、ポリプロピレンビーズ等の可燃性有機成分が含まれる場合があり、焼成時にはこれら可燃性有機成分も焼滅し、木質分と共に芯層の多孔質化に寄与する。   The wood cement board may further contain organic fibers such as polyester fiber, polyamide fiber, polyethylene fiber, polypropylene fiber and acrylic fiber, and flammable organic components such as expanded polystyrene beads, polyethylene beads and polypropylene beads. These combustible organic components are also burned out and contribute to the porous structure of the core layer together with the wood.

上記木質セメント板廃材は衝撃型粉砕機、磨砕型粉砕機等によって、通常粒径10〜100μm程度に粉砕され、本発明の原料として使用される。   The wood cement board waste is usually pulverized to a particle size of about 10 to 100 μm by an impact type pulverizer or a grinding type pulverizer, and used as a raw material of the present invention.

〔無機原料〕
本発明にあっては、無機原料の主たるものとして、水硬性無機材料を使用することが望ましい。上記水硬性無機材料としては、例えば普通ポルトランドセメント、早強セメント、アルミナセメント、高炉スラグセメント、フライアッシュセメント等のセメント類や生石灰、消石灰等の石灰類あるいは石膏、炭酸マグネシウム等がある。
上記水硬性無機材料を使用すると、焼成前に生板を硬化せしめることが出来、ある程度強度があり破損しにくい硬化生板とすることが出来、作業性、歩留り等が向上する。
更に無機材料としては、焼成により溶融してバインダーとなるガラス質材料を添加することが望ましい。このようなガラス質材料としては、例えばシラス、フライアッシュ、坑火石、ガラス粉、板ガラスの粉砕品、ガラス発泡体、スラグ、シラスバルーン、パーライト等がある。
[Inorganic raw materials]
In the present invention, it is desirable to use a hydraulic inorganic material as the main inorganic material. Examples of the hydraulic inorganic material include ordinary portland cement, early-strength cement, alumina cement, blast furnace slag cement, fly ash cement, and other cements, limes such as quick lime and slaked lime, gypsum, and magnesium carbonate.
When the above-mentioned hydraulic inorganic material is used, the green plate can be cured before firing, a hardened green plate having a certain degree of strength and not easily damaged can be obtained, and workability, yield, and the like are improved.
Further, as an inorganic material, it is desirable to add a vitreous material that is melted by firing and becomes a binder. Examples of such a vitreous material include shirasu, fly ash, gangue stone, glass powder, pulverized plate glass, glass foam, slag, shirasu balloon, pearlite, and the like.

更に本発明では、焼成により溶融して板構造の主体的要素となる骨材が添加される。上記骨材としては、例えば陶石、長石、ろう石、カオリン、ハロサイト、木節粘土、蛙目粘土、セリサイト、シャモット、ドロマイト等の粘土質鉱物やケイ砂、ケイ石、珪藻土、キラ、坑火石、シリカフューム等のケイ酸質原料がある。   Furthermore, in the present invention, an aggregate which is melted by firing and becomes a main element of the plate structure is added. Examples of the aggregate include clay minerals such as porcelain stones, feldspars, wax stones, kaolin, halosite, kibushi clay, glazed clay, sericite, chamotte, dolomite, quartz sand, quartzite, diatomaceous earth, glitter, There are siliceous materials such as minestone and silica fume.

更に本発明では、マット強度、製品強度等を向上せしめるために無機繊維が添加されてもよい。上記無機繊維としては、例えばワラストナイト、セピオライト等の鉱物繊維、スチールファイバー、ステンレスファイバー等の金属繊維、ガラス繊維、ムライト質のアルミナファイバー等のセラミック繊維等がある。   Furthermore, in the present invention, inorganic fibers may be added in order to improve the mat strength, product strength and the like. Examples of the inorganic fibers include mineral fibers such as wollastonite and sepiolite, metal fibers such as steel fibers and stainless fibers, glass fibers, and ceramic fibers such as mullite alumina fibers.

〔可燃性有機成分〕
本発明にあっては、芯層の原料として木質セメント板廃材と共に、あるいは木質セメント板廃材に代えて可燃性有機成分が使用されてもよい。このような可燃性有機成分としては、例えば木片、木質繊維束、木質パルプ、木毛、木粉等の木質材、ポリエステル繊維、ポリアミド繊維、ポリエチレン繊維、ポリプロピレン繊維、アクリル繊維等の有機繊維、発泡ポリスチレンビーズ、ポリエチレンビーズ、ポリプロピレンビーズ等の合成樹脂成分等がある。
[Flammable organic components]
In the present invention, a combustible organic component may be used as a raw material for the core layer together with the wood cement board waste or instead of the wood cement board waste. Examples of such flammable organic components include wood chips, wood fiber bundles, wood pulp, wood wool, wood flour and other wood materials, polyester fibers, polyamide fibers, polyethylene fibers, polypropylene fibers, acrylic fibers and other organic fibers, foam There are synthetic resin components such as polystyrene beads, polyethylene beads, and polypropylene beads.

〔表裏層用原料混合物〕
表裏層用原料としては、上記水硬性無機材料、ガラス質材料、骨材、および無機繊維が使用され、有機成分は使用されない。
表裏層用原料混合物にあっては、通常該水硬性無機材料10〜30質量%、ガラス質材料10〜30質量%、骨材35〜45質量%、無機繊維を使用する場合には15〜25質量%程度の比率とされる。骨材が45質量%を上回る量で添加された場合には板の比重が高くなり、軽量化が実施されにくゝ、かつ加工性も劣化する。一方骨材が35質量%を下回る量で添加された場合には、板の強度が低下しかつ耐凍性も劣化する。
[Raw material mixture for front and back layers]
As the raw material for the front and back layers, the above-mentioned hydraulic inorganic material, glassy material, aggregate, and inorganic fiber are used, and no organic component is used.
In the raw material mixture for the front and back layers, usually 10 to 30% by mass of the hydraulic inorganic material, 10 to 30% by mass of the vitreous material, 35 to 45% by mass of the aggregate, and 15 to 25 when the inorganic fiber is used. The ratio is about mass%. When the aggregate is added in an amount exceeding 45% by mass, the specific gravity of the plate becomes high, and it is difficult to reduce the weight, and the workability also deteriorates. On the other hand, when the aggregate is added in an amount less than 35% by mass, the strength of the plate is lowered and the frost resistance is also deteriorated.

〔芯層用原料混合物〕
芯層用原料としては、上記表裏層用原料に加えて木質セメント板廃材粉砕物および/または上記可燃性有機成分が使用される。
該芯層用原料混合物にあっては、木質セメント板廃材粉砕物および/または可燃性有機成分の添加量は5〜35質量%程度にすることが望ましい。該可燃性有機成分の量が5質量%を下回ると芯層に多孔性が充分付与されず、軽量化が実施されない。また該可燃性有機成分の量が35質量%を上回ると芯層が過度に多孔性になり、機械的強度や耐凍性に劣るようになる。
[Raw material mixture for core layer]
As the raw material for the core layer, in addition to the raw material for the front and back layers, the pulverized wood cement board waste material and / or the combustible organic component is used.
In the raw material mixture for the core layer, it is desirable that the amount of the pulverized wood cement board waste and / or the combustible organic component is about 5 to 35% by mass. When the amount of the combustible organic component is less than 5% by mass, the core layer is not sufficiently porous and the weight is not reduced. On the other hand, if the amount of the combustible organic component exceeds 35% by mass, the core layer becomes excessively porous, resulting in poor mechanical strength and frost resistance.

〔軽量無機質板の製造方法〕
本発明の軽量無機質板の製造方法としては、原料混合物に水を所定量(通常5〜20質量%)添加したものを使用する半乾式法が一般に適用されるが、原料混合物に水を添加せず、圧締養生硬化直前あるいは圧締養生硬化時に水を添加する乾式法が適用されてもよい。
即ち本発明の製造方法にあっては、型板上に表裏層用無機原料を撒布して表層または裏層マットをフォーミングし、該表層または裏層マット上に芯層用無機原料を撒布して芯層マットをフォーミングし、該芯層マット上に表裏層用無機原料を撒布して裏層または表層マットをフォーミングし、このようにして得られた3層構造のマットを水分存在下で圧締養生硬化せしめ、得られた無機質板生板を焼成して本発明の軽量無機質板とする。
[Method for producing lightweight inorganic board]
As a method for producing the lightweight inorganic board of the present invention, a semi-dry method using a raw material mixture in which a predetermined amount (usually 5 to 20% by mass) of water is added is generally applied, but water is added to the raw material mixture. Alternatively, a dry method in which water is added immediately before or after compression curing biocure may be applied.
That is, in the production method of the present invention, the inorganic material for the front and back layers is spread on the template to form the surface layer or the back layer mat, and the inorganic material for the core layer is spread on the surface layer or the back layer mat. Form the core layer mat, spread the inorganic raw material for the front and back layers on the core layer mat, form the back layer or the surface layer mat, and press the resulting three-layer mat in the presence of moisture. Curing and curing are performed, and the resulting inorganic plate raw plate is fired to obtain the lightweight inorganic plate of the present invention.

上記方法において上記型板面には所定の凹凸陰模様を形成してもよい。また圧締はフォーミングされた3層構造のマット上に更に型板を重ねた圧締装置において通常面圧5〜8MPaの圧力で行うが、該マットの上側の面を表面として上側の型板の面に所定の凹凸陰模様を形成してもよい。
養生硬化は上記圧締状態で行われ、通常45〜65℃の温度で6〜10時間の条件が採用される。
養生硬化後は解圧脱型し、望ましくは絶乾状態に乾燥させ、実加工等の所定の加工を施す。更に所望なれば該無機質板生板の少なくとも表面に釉薬を塗布する。本発明に使用される釉薬としては、鉛ユウ、フリットユウ、ブリストルユウ、磁器ユウ等の一般的な釉薬が使用される。その後該無機質板生板を焼成炉中に導入して焼成を行う。焼成条件としては、通常900〜1100℃、10〜20分の条件が採用される。
このようにして製造された軽量無機質板は、通常厚み15〜20mm、表裏層の比重は1.5〜1.8、芯層の比重は0.8〜1.3程度である。
In the above method, a predetermined uneven shade pattern may be formed on the template surface. In addition, the pressing is usually performed at a surface pressure of 5 to 8 MPa in a pressing device in which a template is further stacked on a formed three-layer structure mat. A predetermined uneven shade pattern may be formed on the surface.
Curing and curing is performed in the above-mentioned pressing state, and a condition of 6 to 10 hours is usually employed at a temperature of 45 to 65 ° C.
After curing and curing, it is depressurized and desirably dried in an absolutely dry state, and subjected to predetermined processing such as actual processing. Further, if desired, a glaze is applied to at least the surface of the raw inorganic plate. As the glaze used in the present invention, general glazes such as lead yu, frit yu, bristol yu, porcelain yu and the like are used. Thereafter, the raw inorganic plate is introduced into a firing furnace and fired. As firing conditions, conditions of 900 to 1100 ° C. and 10 to 20 minutes are usually employed.
The lightweight inorganic board thus produced usually has a thickness of 15 to 20 mm, a specific gravity of the front and back layers of 1.5 to 1.8, and a specific gravity of the core layer of about 0.8 to 1.3.

〔実施例1〜5、比較例1〜5〕
表1に示す表裏層用原料混合物を型板上に撒布し、その上に芯層用原料混合物を撒布し、更にその上に表裏層用原料混合物を撒布した3層構造のマットを形成し、該3層構造のマットを水分存在下で面圧5MPa、温度50℃の条件で8時間の圧締養生硬化を行い、得られた無機質板生板を温度105℃、24時間の絶乾状態に乾燥させ、表面に釉薬を塗布した上焼成炉中に導入し、温度1000℃、10分の条件で焼成して、厚み18mmとする3層構造の実施例1〜5および比較例1〜5の軽量無機質板試料を作成した。
[Examples 1-5, Comparative Examples 1-5]
Spread the raw material mixture for the front and back layers shown in Table 1 on the template, spread the raw material mixture for the core layer thereon, and form a mat with a three-layer structure on which the raw material mixture for the front and back layers is further spread. The mat having the three-layer structure is subjected to press-curing biohardening for 8 hours under the conditions of a surface pressure of 5 MPa and a temperature of 50 ° C. in the presence of moisture. Three layers of Examples 1 to 5 and Comparative Examples 1 to 5 having a thickness of 18 mm were dried and introduced into a firing furnace having a glaze applied to the surface and fired at a temperature of 1000 ° C. for 10 minutes. A lightweight inorganic board sample was prepared.

表1を参照すると、表裏層の原料混合物に骨材(シャモット)が45質量%を越える量で含まれている比較例1の試料の場合には、表裏層の比重が高くなり(1.85)、加工性が劣化する。また芯層の原料混合物に可燃性有機成分(ポリスチレン発泡ビーズ+木片)が10質量%に満たない量(8質量%)で含まれている比較例2の試料の場合には、芯層の比重が高くなり(1.35)、比較例1と同様加工性が劣化する。また表裏層用原料混合物においてワラストナイトに代えてセラミック繊維20質量%添加した比較例3の試料の場合は、表裏層の比重が低く、曲げ強度が低下し耐凍性が劣化している。更に芯層の原料混合物に可燃性有機成分(ポリスチレン発泡ビーズ+木片)が35質量%を越える量(40質量%)で含まれている比較例4の試料の場合には、曲げ強度が低下し耐凍性が劣化している。更に表裏層を多孔質にするために無機中空軽量体(パーライト)を使用した比較例5の試料の場合には、軽量化は実現されるが、曲げ強度が低下し、耐凍性が劣化し、その上表面が粗面になって外観も劣化する。   Referring to Table 1, in the case of the sample of Comparative Example 1 in which aggregate (chamotte) is contained in the raw material mixture of the front and back layers in an amount exceeding 45% by mass, the specific gravity of the front and back layers is increased (1.85). ), Workability deteriorates. Further, in the case of the sample of Comparative Example 2 in which the combustible organic component (polystyrene foam beads + wood chips) is contained in the core layer raw material mixture in an amount of less than 10 mass% (8 mass%), the specific gravity of the core layer Increases (1.35), and the workability deteriorates as in Comparative Example 1. Moreover, in the case of the sample of the comparative example 3 which added 20 mass% of ceramic fibers instead of the wollastonite in the raw material mixture for the front and back layers, the specific gravity of the front and back layers is low, the bending strength is lowered, and the frost resistance is deteriorated. Further, in the case of the sample of Comparative Example 4 in which the combustible organic component (polystyrene foam beads + wood chips) is contained in the core layer raw material mixture in an amount exceeding 35% by mass (40% by mass), the bending strength decreases. Freezing resistance has deteriorated. Furthermore, in the case of the sample of Comparative Example 5 using an inorganic hollow lightweight body (pearlite) in order to make the front and back layers porous, the weight reduction is realized, but the bending strength decreases, and the frost resistance deteriorates. In addition, the surface becomes rough and the appearance deteriorates.

本発明の無機質板は軽量で運搬性、施工性、加工性が良好で、機械的性質や耐凍結融解性にも優れ、かつ意匠性にも優れているので外壁材や内装材に有用である。   The inorganic board of the present invention is light and has good transportability, workability and workability, is excellent in mechanical properties and freeze-thaw resistance, and is excellent in design, so it is useful for exterior wall materials and interior materials. .

Claims (3)

芯層に水硬性無機材料とガラス質材料と骨材と可燃有機成分を含む無機原料層を配し、表裏層に水硬性無機材料とガラス質材料と骨材と無機繊維を含み、可燃有機成分を含まない無機原料層を配した3層構造の無機質板生板を焼成し、該芯層の可燃有機成分を焼滅させることによって該芯層を多孔質にした軽量無機質板であって、
芯層のガラス質材料は、シラス、フライアッシュ、坑火石、ガラス粉、板ガラスの粉砕品、ガラス発泡体、スラグ、シラスバルーン、パーライトのいずれかであり、
芯層の骨材は、陶石、長石、ろう石、カオリン、ハロサイト、木節粘土、蛙目粘土、セリサイト、シャモット、ドロマイトやケイ砂、ケイ石、珪藻土、キラ、坑火石、シリカフュームのいずれかであり、
表裏層のガラス質材料は、シラス、フライアッシュ、ガラス粉、板ガラスの粉砕品、スラグのいずれかであり、
表裏層の骨材は、陶石、長石、ろう石、カオリン、ハロサイト、木節粘土、蛙目粘土、セリサイト、シャモット、ドロマイトやケイ砂、ケイ石、珪藻土、キラ、シリカフュームのいずれかであり、
芯層の無機原料層は、可燃性有機成分を5〜35質量%含み、
表裏層の無機原料層は、骨材を35〜45質量%、無機繊維を15〜25質量%含み、
芯層は多孔質で、該芯層の比重は0.8〜1.3であり、
表裏層は多孔質でなく緻密構造であり、該表裏層の比重は1.5〜1.8である
ことを特徴とする軽量無機質板。
A core layer arranged inorganic material layer comprising a hydraulic inorganic material and glass material and aggregate and combustible organic component comprises a hydraulic inorganic material and glass material and aggregate and inorganic fibers on the front and back layers, flammable the inorganic board raw plate of three-layer structure in which arranging inorganic material layer containing no organic component by firing, a lightweight inorganic board where the core layer on a porous by Shometsu combustible organic components of the core layer And
The vitreous material of the core layer is one of shirasu, fly ash, mine stone, glass powder, crushed plate glass, glass foam, slag, shirasu balloon, pearlite,
The aggregate of the core layer is made of ceramic stone, feldspar, wax stone, kaolin, halosite, kibushi clay, glazed clay, sericite, chamotte, dolomite and silica sand, quartzite, diatomaceous earth, glitter, minestone, silica fume Either
The glassy material of the front and back layers is either shirasu, fly ash, glass powder, crushed plate glass, or slag,
The aggregate of the front and back layers is one of ceramic stone, feldspar, wax stone, kaolin, halosite, kibushi clay, glazed clay, sericite, chamotte, dolomite, quartz sand, quartzite, diatomaceous earth, glitter, silica fume Yes,
The inorganic raw material layer of the core layer contains 5 to 35% by mass of a combustible organic component,
The inorganic raw material layers of the front and back layers include 35 to 45% by mass of aggregate and 15 to 25% by mass of inorganic fibers,
The core layer is porous, and the specific gravity of the core layer is 0.8 to 1.3,
The lightweight inorganic board, wherein the front and back layers are not porous but have a dense structure, and the specific gravity of the front and back layers is 1.5 to 1.8 .
上記芯層の無機原料層は、可燃有機成分と共に、粒径10〜100μmに粉砕された木質セメント板廃材木質分を含み、該可燃性有機成分と粉砕された該木質セメント板廃材の含有量は5〜35質量%であることを特徴とする請求項1に記載の軽量無機質板。 Inorganic material layer of the core layer are both flammable organic components were ground to a particle size 10~100μm of wood cement board waste material comprises a wood component, wood cement board waste milled with the combustible organic components Content is 5-35 mass%, The lightweight inorganic board of Claim 1 characterized by the above-mentioned. 型板上に表裏層用無機原料を撒布して表層または裏層マットをフォーミングし、該表層または裏層マット上に芯層用無機原料を撒布して芯層マットをフォーミングし、該芯層マット上に表裏層用無機原料を撒布して裏層または表層マットをフォーミングし、このようにして得られた3層構造のマットを水分存在下で圧締養生硬化せしめ、得られた無機質板生板を焼成する軽量無機質板の製造方法であって、
圧締養生硬化は、面圧5〜8MPa、温度45〜65℃で6〜10時間行い、
焼成は、温度900〜1100℃で10〜20分行う
ことを特徴とする請求項1またはに記載の軽量無機質板の製造方法。
An inorganic raw material for the front and back layers is spread on the template to form a surface layer or a back layer mat, an inorganic raw material for the core layer is spread on the front layer or the back layer mat, and the core layer mat is formed. An inorganic raw material for front and back layers is spread on top to form a back layer or surface mat, and the three-layered mat thus obtained is pressed and cured in the presence of moisture. A method for producing a lightweight inorganic board for firing
The compression curing is performed at a surface pressure of 5-8 MPa and a temperature of 45-65 ° C. for 6-10 hours.
The method for producing a lightweight inorganic board according to claim 1 or 2 , wherein the firing is performed at a temperature of 900 to 1100C for 10 to 20 minutes .
JP2003291909A 2003-08-12 2003-08-12 Lightweight inorganic board and method for producing the inorganic board Expired - Fee Related JP4343617B2 (en)

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