JP4432283B2 - Inorganic cement board and method for producing the same - Google Patents
Inorganic cement board and method for producing the same Download PDFInfo
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- JP4432283B2 JP4432283B2 JP2001179677A JP2001179677A JP4432283B2 JP 4432283 B2 JP4432283 B2 JP 4432283B2 JP 2001179677 A JP2001179677 A JP 2001179677A JP 2001179677 A JP2001179677 A JP 2001179677A JP 4432283 B2 JP4432283 B2 JP 4432283B2
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- 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
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00068—Mortar or concrete mixtures with an unusual water/cement ratio
-
- 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
- C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
- C04B2111/00413—Materials having an inhomogeneous concentration of ingredients or irregular properties in different layers
-
- 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
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Description
【０００１】
【発明の属する技術分野】
本発明は、建築用板材などとして用いられる無機質セメント板及びその製造方法に関するものであり、詳しくは、乾式法による無機質セメント板及びその製造方法の改良に関する。
【０００２】
【従来の技術及び発明が解決しようとする課題】
無機質セメント板の製造方法には、湿式法と乾式法がある。湿式法の場合は、無機質セメント板の表面に深く鋭い凹凸模様を付与することが困難であり、またろ過水が多量に発生するため、コストアップにつながっていた。
一方、乾式法の場合は、無機質セメント板の表面に深く鋭い凹凸模様を付与し易く、意匠性に優れた製品を製造することができ、またろ過水が発生しないとの利点があるが、無機質セメント板の機械的強度が低いとの問題があった。
【０００３】
そこで、乾式法では、無機質セメント板の機械的強度を高めるために、補強繊維として木質繊維（木片、木毛など）が一般に使用されている。該木質繊維は、無機質セメント板中に均質に分散でき且つ補強効果の高いものであるため、高強度で大型の無機質セメント板を製造することができる。
しかし、上記木質繊維を用いた場合、▲１▼木質繊維の品質変動が大きく、セメントの硬化阻害成分を溶出することがあるため、一定品質の製品を安定的に製造することが難しい、▲２▼そのために硬化促進剤を使用すると原料コストが高くなる、▲３▼木質繊維を多量に使用するため、無機質セメント板の不燃性が悪くなる、▲４▼木質繊維に起因する寸法変化が大きい、などの問題が生じる。
また、補強繊維としてパルプも使用されているが、上記木質繊維に比して、無機質セメント板中に均質に分散し難く補強効果が低いとの欠点がある。
【０００４】
また、上述の湿式法及び乾式法による無機質セメント板の問題を解決するために、無機質セメント板を積層構造にすることが提案されている。例えば、特開平４−３６４９０２号公報には、高含水率の無機質混練物から形成された上層、低含水率の無機質混練物から形成された中間層及び高含水率の無機質混練物から形成された下層の３層構造を有する無機質板の製造法が記載されている。
【０００５】
しかし、上記特開平４−３６４９０２号公報に記載の無機質板の製造法では、高含水率の無機質混練物層を２層設けているため、加圧成形時に依然として多量のろ過水が発生しており、また上層が高含水率の無機質混練物層であるため、深く鋭い凹凸模様を付与することも困難である。
【０００６】
従って、本発明の目的は、深く鋭い凹凸模様を容易に付与することができ、且つ製造時にろ過水が発生せず、しかも機械的強度に優れた無機質セメント板及びその製造方法を提供することにある。
【０００７】
【課題を解決するための手段】
本発明者らは、上記目的を達成すべく種々検討する中で、補強繊維としてパルプを使用する場合、パルプと水とを混合し、パルプを水中に分散させた後、無機質粉体を添加、混合すると、パルプの毛玉の発生が少なくなり、補強効果が高まり、しかも補強繊維として木質繊維（木片、木毛など）を使用した場合の上述の問題もないこと、また、乾式法による無機質セメント板の裏面に、特定厚の高含水率の無機質混練物層を設けることにより、該無機質セメント板の機械的強度及び耐衝撃性が向上し、且つろ過水も発生することがないことを知見した。
【０００８】
本発明は、上記知見に基づきなされたもので、上層及び下層からなる積層構造の無機質セメント板であって、上記上層が、パルプを固形分中４〜１５質量％含有する含水率２５〜５０質量％（対固形分）の無機質混練物から形成された層であり、上記下層が、含水率１５０〜２５０質量％（対固形分）の無機質混練物から形成された層であり、且つ上記上層の厚みが、無機質セメント板全厚の７５〜９４％であり、上記下層の厚みが、無機質セメント板全厚の６〜２５％であり、上記上層を、軽量化材を固形分中５〜１５質量％及びパルプを固形分中４〜１５質量％含有する含水率２５〜５０質量％（対固形分）の無機質混練物から形成された表面層と、軽量化材の配合量が該表面層における軽量化材の配合量とは異なり且つパルプを固形分中４〜１５質量％含有する含水率２５〜５０質量％（対固形分）の無機質混練物から形成された中間層とからなる２層構造とし、全体を上記表面層、上記中間層及び上記下層からなる３層構造としたことを特徴とする無機質セメント板を提供するものである。
【００１１】
また、本発明は、上記の３層構造を有する本発明の無機質セメント板の製造方法として、下層部に、含水率１５０〜２５０質量％（対固形分）の無機質混練物を配し、該無機質混練物上に、中間層として、軽量化材の配合量が表面層における軽量化材の配合量とは異なり且つパルプを固形分中４〜１５質量％含有する含水率２５〜５０質量％（対固形分）の無機質混練物を配し、更にその上に、表面層として、軽量化材を固形分中５〜１５質量％及びパルプを固形分中４〜１５質量％含有する含水率２５〜５０質量％（対固形分）の無機質混練物を配し、得られた３層構造の積層物を加圧成形し、硬化させることを特徴とする無機質セメント板の製造方法を提供するものである。
【００１２】
【発明の実施の形態】
以下、先ず本発明の無機質セメント板について詳しく説明する。
本発明の無機質セメント板は、低含水率の無機質混練物から形成された上層の厚みが、無機質セメント板全厚の７５〜９４％、好ましくは８５〜９０％で、高含水率の無機質混練物から形成された下層の厚みが、無機質セメント板全厚の６〜２５％、好ましくは１０〜１５％であるもので、上記上層を主体層とするもの、即ち乾式法によるドライマットを主体層とするものである。
【００１３】
上記上層を形成する低含水率の無機質混練物としては、セメントを主体とする含水率２５〜５０質量％、好ましくは３０〜４５質量％（対固形分）の無機質混練物で、パルプを固形分中４〜１５質量％、好ましくは６〜１０質量％含有するものが用いられる。
【００１４】
上記セメントとしては、特に制限されるものではなく、普通ポルトランドセメント、早強セメント、高炉セメント、フライアッシュセメントなどが用いられる。
また、上記パルプとしては、特に制限されるものではなく、木材パルプ、竹パルプ、ボロパルプ、リンターンパルプの他、ポリプロピレン、ビニロンなどの人工有機繊維、さらにはガラス繊維、炭素繊維などの人工無機繊維なども併用可能である。
また、上記無機質混練物には、パーライト、シラスバルーン、発泡ポリスチレンビーズなどの軽量化材などを配合することができ、また、シリカ質粉末として、珪石粉、フライアッシュ、石炭灰、シリカフューム、珪素を含有する廃棄物焼却灰などを配合することができる。
【００１５】
下記に、上記低含水率の無機質混練物の好ましい組成例の一例を示す。
セメント ３０〜４５質量％、好ましくは３５〜４０質量％
シリカ質粉末 ３０〜６０質量％、好ましくは４０〜５０質量％
軽量化材 ５〜５０質量％、好ましくは ８〜２０質量％
パルプ ４〜１５質量％、好ましくは ６〜１０質量％
水 （対固形分）２５〜５０質量％、好ましくは３０〜４５質量％
【００１６】
上記低含水率の無機質混練物は、先ずパルプと水とを混合し、パルプを水中に分散させた後、無機質粉体を添加、混合することにより調製されたものが、パルプの毛玉の発生が少なく、補強効果が高いので好ましい。
【００１７】
また、上記下層を形成する高含水率の無機質混練物としては、含水率が１５０〜２５０質量％、好ましくは１８０〜２３０質量％（対固形分）である以外は、上記上層を形成する低含水率の無機質混練物と同様の組成のものが用いられる。
【００１８】
本発明の無機質セメント板は、表面の平滑性及び意匠性を高めるために、上記上層を、軽量化材の配合量が異なる２層（表面層と中間層）構造、好ましくは軽量化材の配合量の少ない無機質混練物から形成された表面層と、軽量化材の配合量の多い無機質混練物から形成された中間層とからなる２層構造とし、全体を上記表面層、上記中間層及び上記下層からなる３層構造とすることができる。
【００１９】
上記表面層を形成する軽量化材の配合量の少ない無機質混練物としては、セメントを主体とする含水率２５〜５０質量％、好ましくは３０〜４５質量％（対固形分）の無機質混練物で、軽量化材を固形分中５〜１５質量％、好ましくは８〜１２質量％及びパルプを固形分中４〜１５質量％、好ましくは６〜１０質量％含有するものが用いられる。
また、上記中間層を形成する軽量化材の配合量の多い無機質混練物としては、セメントを主体とする含水率２５〜５０質量％、好ましくは３０〜４５質量％（対固形分）の無機質混練物で、軽量化材を固形分中５質量％より多く５０質量％以下、好ましくは８〜２０質量％及びパルプを固形分中４〜１５質量％、好ましくは６〜１０質量％含有するものが用いられる。
【００２０】
これらの表面層又は中間層を形成する無機質混練物のその他の配合成分は、前述の本発明の２層構造の無機質セメント板における上記上層を形成する低含水率の無機質混練物の配合成分と同様である。
【００２１】
下記に、上記の表面層又は中間層を形成する無機質混練物の好ましい組成例の一例を示す。
〔表面層を形成する無機質混練物の組成例〕
セメント ３０〜４５質量％、好ましくは３５〜４０質量％
シリカ質粉末 ３０〜６０質量％、好ましくは４０〜５０質量％
軽量化材 ５〜１５質量％、好ましくは 6.5〜10.5質量％
パルプ ４〜１５質量％、好ましくは ６〜１０質量％
水 （対固形分）２５〜５０質量％、好ましくは３０〜４５質量％
〔中間層を形成する無機質混練物の組成例〕
セメント ３０〜４５質量％、好ましくは３５〜４０質量％
シリカ質粉末 ３０〜６０質量％、好ましくは４０〜５０質量％
軽量化材 ５〜５０質量％、好ましくは ８〜２０質量％
パルプ ４〜１５質量％、好ましくは ６〜１０質量％
水 （対固形分）２５〜５０質量％、好ましくは３０〜４５質量％
【００２２】
上記表面層を形成する無機質混練物及び上記中間層を形成する無機質混練物は、前述の本発明の２層構造の無機質セメント板における上記上層を形成する低含水率の無機質混練物の場合と同様の理由により、先ずパルプと水とを混合し、パルプを水中に分散させた後、無機質粉体を添加、混合することにより調製されたものが好ましい。
【００２３】
上記３層構造を有する本発明の無機質セメント板においては、上記表面層の厚みが、無機質セメント板全厚の５〜３０％、特に１０〜２５％で、上記中間層の厚みが、無機質セメント板全厚の４５〜８９％、特に５０〜８４％で、上記下層の厚みが、無機質セメント板全厚の６〜２５％、特に１０〜１５％であることが好ましい。
【００２４】
本発明の無機質セメント板の厚みは、特に制限されるものではなく、従来の無機質セメント板の厚みと同様であり、通常１０〜３０ｍｍ程度である。
【００２５】
次に、本発明の無機質セメント板の好ましい製造方法について説明する。
前述の２層構造を有する本発明の無機質セメント板は、例えば、次のようにして製造される。
先ず、例えば所定の大きさの製板用型内の下層部に、前述の高含水率の無機質混練物を配し、該無機質混練物上に、上層として、前述のパルプを含有する低含水率の無機質混練物を配して、２層構造の積層物を得る。
この際の高含水率の無機質混練物の配合量及び低含水率の無機質混練物の配合量は、本発明の無機質セメント板において、低含水率の無機質混練物から形成された上層の厚みと、高含水率の無機質混練物から形成された下層の厚みとが、前述の範囲内となる量であり、且つ、全体の量は板が所定の重さとなるように調整する。
【００２６】
次いで、上記積層物の上面に、所定の凹凸模様に対応するエンボス型板を載置し、上記積層物を所定の厚さに加圧成形する。
【００２７】
上記加圧成形後、成形板を養生し硬化させることにより、２層構造を有する本発明の無機質セメント板が得られる。養生条件は、一次養生として蒸気養生及び二次養生としてオートクレーブ養生を行うのが好ましい。
【００２８】
また、前述の３層構造を有する本発明の無機質セメント板は、上記の２層構造を有する本発明の無機質セメント板の製造方法において、高含水率の無機質混練物上に配する低含水率の無機質混練物として、前述の軽量化材の配合量の少ない無機質混練物と軽量化材の配合量の多い無機質混練物との２種類の無機質混練物を用い、高含水率の無機質混練物上に、先ず中間層として軽量化材の配合量の多い無機質混練物を配し、次いでその上に表面層として軽量化材の配合量の少ない無機質混練物を配して、３層構造の積層物とする以外は、上記の２層構造を有する本発明の無機質セメント板の製造方法と同様にして製造することができる。
尚、この際の軽量化材の配合量の少ない無機質混練物の配合量及び軽量化材の配合量の多い無機質混練物の配合量は、本発明の無機質セメント板において、軽量化材の配合量の少ない無機質混練物から形成された表面層の厚みと、軽量化材の配合量の多い無機質混練物から形成された中間層の厚みとが、前述の範囲内となる量である。
【００２９】
【実施例】
以下に、本発明の実施例を比較例と共に示すが、本発明は下記の実施例に制限されるものではない。下記の実施例１〜３は参考例である。
尚、下記の実施例及び比較例に示した無機質セメント板の諸特性の試験方法は、次の通りである。
【００３０】
（１）曲げ強度
測定装置 「オートグラフ AGS-1000A 島津製作所製」
測定条件 ヘッドスピード３ｍｍ／分、スパン１２０ｍｍ
【００３１】
（２）寸法変化率
吸水膨張 乾燥（60℃×72時間）後、吸水２４時間
【００３２】
（３）付形性角度
エンボス型板の最大彫り角度を、付形性角度（α）とした〔図１（ｂ）を参照〕。尚、エンボスの彫り深さは４ｍｍとした。
【００３３】
実施例１
下記表１に示す配合組成の低含水率の無機質混練物及び高含水率の無機質混練物を用い、下記製造方法により、下記表１に示す２層構造を有する無機質セメント板を製造した。得られた無機質セメント板の各層の厚みの割合、板の特性、及び加圧成形時のろ過水の発生の有無を、下記表１に示した。
（無機質セメント板の製造方法）
製板用型内の下層部に、高含水率の無機質混練物を配し、該無機質混練物上に、低含水率の無機質混練物を配し、この積層物の上面に図１に示すエンボス型板（彫り深さ：４ｍｍ）を載置する。積層物を加圧成形後、成形板を一次養生として蒸気養生及び二次養生としてオートクレーブ養生し、８０℃で板の含水率が８±４％に乾燥する。
【００３４】
実施例２〜６
下記表１に示す配合組成の低含水率の無機質混練物及び高含水率の無機質混練物を用いる以外は、実施例１に準じて、下記表１に示す２層又は３層構造を有する無機質セメント板をそれぞれ製造した。得られた各無機質セメント板の各層の厚みの割合、板の特性、及び加圧成形時のろ過水の発生の有無を、下記表１に示した。
【００３５】
【表１】
比較例１〜５
下記表２に示す配合組成の低含水率の無機質混練物及び高含水率の無機質混練物を用いる以外は、実施例１に準じて、下記表２に示す単層、２層又は３層構造を有する無機質セメント板をそれぞれ製造した。得られた各無機質セメント板の各層の厚みの割合、板の特性、及び加圧成形時のろ過水の発生の有無を、下記表２に示した。
【００３７】
【表２】
【発明の効果】
本発明によれば、深く鋭い凹凸模様を容易に付与することができ、且つ製造時にろ過水が発生せず、しかも機械的強度に優れた無機質セメント板を提供することができる。
【図面の簡単な説明】
【図１】図１は、実施例及び比較例で用いたエンボス型板を示すもので、図１（ａ）は該エンボス型板の平面図であり、図１（ｂ）はその部分断面図である。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an inorganic cement board used as a building board or the like and a method for producing the same, and more particularly to an improvement in an inorganic cement board by a dry method and a method for producing the same.
[0002]
[Prior art and problems to be solved by the invention]
There are a wet method and a dry method as a method for producing the inorganic cement board. In the case of the wet method, it is difficult to provide a deep and sharp concavo-convex pattern on the surface of the inorganic cement board, and a large amount of filtered water is generated, leading to an increase in cost.
On the other hand, in the case of the dry method, there is an advantage that it is easy to give a deep and sharp concavo-convex pattern on the surface of the inorganic cement board, and it is possible to produce a product excellent in design, and no filtered water is generated. There was a problem that the mechanical strength of the cement board was low.
[0003]
Therefore, in the dry method, in order to increase the mechanical strength of the inorganic cement board, wood fibers (wood pieces, wood wool, etc.) are generally used as reinforcing fibers. Since the wood fiber can be uniformly dispersed in the inorganic cement board and has a high reinforcing effect, a large-sized inorganic cement board with high strength can be produced.
However, when the above wood fibers are used, (1) the quality fluctuations of the wood fibers are large and the hardening-inhibiting components of the cement may be eluted, so it is difficult to stably produce a product of a certain quality. ▼ For that purpose, the use of a curing accelerator increases the raw material cost. ③ Since a large amount of wood fiber is used, the non-combustibility of the inorganic cement board is degraded. ④ The dimensional change caused by the wood fiber is large. Problems arise.
Further, pulp is also used as the reinforcing fiber, but it has a drawback that it is difficult to uniformly disperse in the inorganic cement board and has a low reinforcing effect as compared with the wood fiber.
[0004]
Moreover, in order to solve the problem of the inorganic cement board by the above-mentioned wet method and dry method, it has been proposed that the inorganic cement board has a laminated structure. For example, JP-A-4-364902 discloses an upper layer formed from an inorganic kneaded material having a high water content, an intermediate layer formed from an inorganic kneaded material having a low water content, and an inorganic kneaded material having a high water content. A method for producing an inorganic plate having a lower three-layer structure is described.
[0005]
However, in the method for producing an inorganic plate described in JP-A-4-364902, since two layers of an inorganic kneaded material having a high water content are provided, a large amount of filtered water is still generated during pressure molding. Moreover, since the upper layer is an inorganic kneaded material layer having a high water content, it is difficult to provide a deep and sharp uneven pattern.
[0006]
Accordingly, an object of the present invention is to provide an inorganic cement board that can easily give a deep and sharp concavo-convex pattern, does not generate filtered water during production, and has excellent mechanical strength, and a method for producing the same. is there.
[0007]
[Means for Solving the Problems]
In various studies to achieve the above object, the present inventors use pulp as a reinforcing fiber, mix pulp and water, disperse the pulp in water, and then add inorganic powder. When mixed, the generation of pills of pulp is reduced, the reinforcing effect is enhanced, and there is no problem as described above when wood fibers (wood pieces, wood wool, etc.) are used as the reinforcing fibers, and the inorganic cement by the dry method It was found that the mechanical strength and impact resistance of the inorganic cement plate were improved by providing a high moisture content inorganic kneaded material layer with a specific thickness on the back surface of the plate, and filtered water was not generated. .
[0008]
The present invention has been made based on the above knowledge, and is an inorganic cement board having a laminated structure composed of an upper layer and a lower layer, wherein the upper layer contains a pulp in a solid content of 4 to 15% by mass with a moisture content of 25 to 50% by mass. % (Based on solid content) of the inorganic kneaded material, and the lower layer is a layer formed from an inorganic kneaded material having a water content of 150 to 250% by mass (based on solid content), and the upper layer thickness, is from 75 to 94% of the total thickness the inorganic cement board, the lower layer thickness, 6-25% der of the total thickness the inorganic cement board is, the upper layer, the solid content weight reduction material 5-15 The surface layer formed from an inorganic kneaded material having a moisture content of 25 to 50% by mass (vs. solids content) containing 4 to 15% by mass of pulp and 4 to 15% by mass of solids in the solid content, and the blending amount of the lightening material in the surface layer Different from the amount of light weight material and pulp A two-layer structure consisting of an intermediate layer formed from an inorganic kneaded material having a moisture content of 25 to 50% by mass (vs. solid content) containing 4 to 15% by mass, and the whole from the surface layer, the intermediate layer and the lower layer An inorganic cement board characterized by having a three-layer structure is provided.
[0011]
Moreover, this invention arrange | positions the inorganic kneaded material with a water content of 150-250 mass% (vs solid content) in a lower layer part as a manufacturing method of the inorganic cement board of this invention which has said 3 layer structure, This inorganic substance On the kneaded product, as an intermediate layer, the amount of lightening material is different from the amount of lightening material in the surface layer, and the moisture content is 25 to 50% by mass (relative to the solid content of 4 to 15% by mass). A solid content) inorganic kneaded material, and further, as a surface layer, 5 to 15% by mass of the lightening material and 4 to 15% by mass of pulp in the solid content of water content 25 to 50 The present invention provides a method for producing an inorganic cement board, characterized in that an inorganic kneaded material having a mass% (based on solid content) is arranged, and the resulting three-layer laminate is pressure-molded and cured.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, first, the inorganic cement board of the present invention will be described in detail.
In the inorganic cement board of the present invention, the thickness of the upper layer formed from the inorganic kneaded material having a low water content is 75 to 94%, preferably 85 to 90% of the total thickness of the inorganic cement board, and the inorganic kneaded material having a high water content. The thickness of the lower layer formed from 6 to 25% of the total thickness of the inorganic cement board, preferably 10 to 15%, and the upper layer as the main layer, that is, the dry mat by the dry method as the main layer To do.
[0013]
The inorganic kneaded material having a low water content forming the upper layer is an inorganic kneaded material having a water content of 25 to 50% by mass, preferably 30 to 45% by mass (based on solid content) mainly composed of cement. A medium containing 4 to 15% by mass, preferably 6 to 10% by mass is used.
[0014]
The cement is not particularly limited, and ordinary portland cement, early-strength cement, blast furnace cement, fly ash cement and the like are used.
The above-mentioned pulp is not particularly limited. In addition to wood pulp, bamboo pulp, boro pulp, and linter pulp, artificial organic fibers such as polypropylene and vinylon, and artificial inorganic fibers such as glass fiber and carbon fiber. Etc. can also be used together.
Further, the inorganic kneaded material can be blended with a lightening material such as pearlite, shirasu balloon, and expanded polystyrene beads, and siliceous powder, fly ash, coal ash, silica fume, and silicon as siliceous powder. The waste incineration ash contained can be blended.
[0015]
Below, an example of a preferable composition example of the inorganic kneaded material of the said low water content is shown.
Cement 30 to 45% by mass, preferably 35 to 40% by mass
Silica powder 30-60% by mass, preferably 40-50% by mass
Lightweight material 5-50% by mass, preferably 8-20% by mass
Pulp 4-15% by weight, preferably 6-10% by weight
Water (solid content) 25-50% by mass, preferably 30-45% by mass
[0016]
The above-mentioned low water content inorganic kneaded material is prepared by first mixing pulp and water, dispersing the pulp in water, and then adding and mixing the inorganic powder. Is preferable because it has a small reinforcing effect and a high reinforcing effect.
[0017]
Moreover, as an inorganic kneaded material with a high water content that forms the lower layer, the low water content that forms the upper layer except that the water content is 150 to 250% by mass, preferably 180 to 230% by mass (based on solid content). A composition having the same composition as that of the inorganic kneaded material having a high rate is used.
[0018]
In order to improve the smoothness and design of the surface, the inorganic cement board of the present invention has a two-layer structure (surface layer and intermediate layer) in which the amount of the lightening material is different, preferably a lightening material. A two-layer structure comprising a surface layer formed from an inorganic kneaded material with a small amount and an intermediate layer formed from an inorganic kneaded material with a large amount of lightening material, and the whole is the surface layer, the intermediate layer and the above A three-layer structure composed of lower layers can be formed.
[0019]
The inorganic kneaded material with a small amount of the lightening material forming the surface layer is an inorganic kneaded material mainly containing cement and having a water content of 25 to 50% by mass, preferably 30 to 45% by mass (based on solid content). Further, a material containing 5 to 15% by mass, preferably 8 to 12% by mass of the lightening material and 4 to 15% by mass, preferably 6 to 10% by mass of the pulp in the solid content is used.
Moreover, as an inorganic kneaded material with a large blending amount of the lightening material forming the intermediate layer, an inorganic kneaded material having a water content of 25 to 50% by mass, preferably 30 to 45% by mass (based on solid content), mainly composed of cement. In the product, the weight-reducing material is contained in an amount of more than 5% by mass in the solid content to 50% by mass or less, preferably 8 to 20% by mass, and pulp in the solid content of 4 to 15% by mass, preferably 6 to 10% by mass. Used.
[0020]
The other compounding components of the inorganic kneaded material forming these surface layers or intermediate layers are the same as the compounding components of the low water content inorganic kneaded material forming the upper layer in the above-described two-layered inorganic cement board of the present invention. It is.
[0021]
Below, an example of a preferable composition example of the inorganic kneaded material which forms said surface layer or intermediate | middle layer is shown.
[Example of composition of inorganic kneaded material forming surface layer]
Cement 30 to 45% by mass, preferably 35 to 40% by mass
Silica powder 30-60% by mass, preferably 40-50% by mass
Lightweight material 5-15% by mass, preferably 6.5-10.5% by mass
Pulp 4-15% by weight, preferably 6-10% by weight
Water (solid content) 25-50% by mass, preferably 30-45% by mass
[Example of composition of inorganic kneaded material forming intermediate layer]
Cement 30 to 45% by mass, preferably 35 to 40% by mass
Silica powder 30-60% by mass, preferably 40-50% by mass
Lightweight material 5-50% by mass, preferably 8-20% by mass
Pulp 4-15% by weight, preferably 6-10% by weight
Water (solid content) 25-50% by mass, preferably 30-45% by mass
[0022]
The inorganic kneaded material forming the surface layer and the inorganic kneaded material forming the intermediate layer are the same as those of the low water content inorganic kneaded material forming the upper layer in the above-described two-layered inorganic cement board of the present invention. For this reason, it is preferable that the pulp and water are first mixed and the pulp is dispersed in water, and then the inorganic powder is added and mixed.
[0023]
In the inorganic cement board of the present invention having the above three-layer structure, the thickness of the surface layer is 5 to 30%, particularly 10 to 25% of the total thickness of the inorganic cement board, and the thickness of the intermediate layer is the inorganic cement board. It is preferable that it is 45 to 89% of the total thickness, particularly 50 to 84%, and the thickness of the lower layer is 6 to 25%, particularly 10 to 15% of the total thickness of the inorganic cement board.
[0024]
The thickness of the inorganic cement board of the present invention is not particularly limited, and is the same as the thickness of a conventional inorganic cement board, and is usually about 10 to 30 mm.
[0025]
Next, the preferable manufacturing method of the inorganic cement board of this invention is demonstrated.
The inorganic cement board of this invention which has the above-mentioned two-layer structure is manufactured as follows, for example.
First, for example, the above-mentioned high water content inorganic kneaded material is arranged in the lower layer part in a predetermined size of the plate-making mold, and the low water content containing the above pulp as an upper layer on the inorganic kneaded material. The inorganic kneaded material is arranged to obtain a laminate having a two-layer structure.
In this case, the blending amount of the high water content inorganic kneaded material and the low water content inorganic kneaded material are the thickness of the upper layer formed from the low water content inorganic kneaded material in the inorganic cement board of the present invention, and The thickness of the lower layer formed from an inorganic kneaded material having a high water content is an amount that falls within the above-mentioned range, and the total amount is adjusted so that the plate has a predetermined weight.
[0026]
Next, an embossing template corresponding to a predetermined concavo-convex pattern is placed on the upper surface of the laminate, and the laminate is pressure-molded to a predetermined thickness.
[0027]
After the pressure molding, the molded board is cured and cured to obtain the inorganic cement board of the present invention having a two-layer structure. The curing conditions are preferably steam curing as the primary curing and autoclave curing as the secondary curing.
[0028]
Moreover, the inorganic cement board of the present invention having the above-mentioned three-layer structure is a low moisture content disposed on the high water content inorganic kneaded material in the method for producing an inorganic cement board of the present invention having the above two-layer structure. As the inorganic kneaded material, two kinds of inorganic kneaded materials, ie, the inorganic kneaded material with a small amount of the lightening material and the inorganic kneaded material with a large amount of the lightening material, are used. First, an inorganic kneaded material with a large amount of lightening material is disposed as an intermediate layer, and then an inorganic kneaded material with a small amount of lightening material is disposed thereon as a surface layer, and a laminate having a three-layer structure Except for this, it can be produced in the same manner as the production method of the inorganic cement board of the present invention having the above two-layer structure.
In this case, the blending amount of the inorganic kneaded material with a small amount of the lightening material and the blending amount of the inorganic kneaded material with the large amount of the lightening material are the blending amount of the lightening material in the inorganic cement board of the present invention. The thickness of the surface layer formed from the inorganic kneaded material having a small amount and the thickness of the intermediate layer formed from the inorganic kneaded material having a large amount of the lightening material are in the above ranges.
[0029]
【Example】
Examples of the present invention are shown below together with comparative examples, but the present invention is not limited to the following examples. The following Examples 1-3 are reference examples.
In addition, the test method of the various characteristics of the inorganic cement board shown to the following Example and comparative example is as follows.
[0030]
(1) Bending strength measuring device “Autograph AGS-1000A manufactured by Shimadzu Corporation”
Measurement conditions Head speed 3mm / min, span 120mm
[0031]
(2) Dimensional change rate water absorption expansion After drying (60 ° C x 72 hours), water absorption 24 hours
(3) Shapeability angle The maximum carving angle of the embossed template was defined as the shapeability angle (α) [see FIG. 1 (b)]. The embossed carving depth was 4 mm.
[0033]
Example 1
An inorganic cement board having a two-layer structure shown in Table 1 below was manufactured by the following manufacturing method using an inorganic kneaded material having a low moisture content and an inorganic kneaded material having a high water content shown in Table 1 below. Table 1 below shows the ratio of the thickness of each layer of the obtained inorganic cement board, the characteristics of the board, and the presence or absence of filtered water during pressure molding.
(Manufacturing method of inorganic cement board)
An inorganic kneaded material with a high water content is arranged in the lower layer part in the plate-making mold, an inorganic kneaded material with a low water content is arranged on the inorganic kneaded material, and the embossing shown in FIG. A template (carving depth: 4 mm) is placed. After pressure forming the laminate, the molded plate is subjected to steam curing as a primary curing and autoclave curing as a secondary curing, and the moisture content of the plate is dried at 80 ° C. to 8 ± 4%.
[0034]
Examples 2-6
Inorganic cement having a two-layer or three-layer structure shown in Table 1 below, except that a low water content inorganic kneaded material and a high water content inorganic kneaded material shown in Table 1 below are used. Each plate was manufactured. Table 1 below shows the ratio of the thickness of each layer of each inorganic cement board obtained, the characteristics of the board, and the presence or absence of filtered water during pressure molding.
[0035]
[Table 1]
Comparative Examples 1-5
A single layer, two-layer or three-layer structure shown in Table 2 below is used in accordance with Example 1 except that a low water content inorganic kneaded material and a high water content inorganic kneaded material having the composition shown in Table 2 below are used. Each inorganic cement board was produced. Table 2 below shows the ratio of the thickness of each layer of each inorganic cement board obtained, the characteristics of the board, and the presence or absence of filtered water during pressure molding.
[0037]
[Table 2]
【The invention's effect】
According to the present invention, it is possible to provide an inorganic cement board that can easily provide a deep and sharp concavo-convex pattern, does not generate filtered water during production, and has excellent mechanical strength.
[Brief description of the drawings]
FIG. 1 shows an embossing template used in Examples and Comparative Examples. FIG. 1 (a) is a plan view of the embossing template, and FIG. 1 (b) is a partial sectional view thereof. It is.
Claims (4)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001179677A JP4432283B2 (en) | 2001-06-14 | 2001-06-14 | Inorganic cement board and method for producing the same |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001179677A JP4432283B2 (en) | 2001-06-14 | 2001-06-14 | Inorganic cement board and method for producing the same |
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| Publication Number | Publication Date |
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| JP2002370305A JP2002370305A (en) | 2002-12-24 |
| JP4432283B2 true JP4432283B2 (en) | 2010-03-17 |
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