JP4528414B2 - Fiber-reinforced calcium silicate molded body and method for producing the same - Google Patents
Fiber-reinforced calcium silicate molded body and method for producing the same Download PDFInfo
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- JP4528414B2 JP4528414B2 JP2000129645A JP2000129645A JP4528414B2 JP 4528414 B2 JP4528414 B2 JP 4528414B2 JP 2000129645 A JP2000129645 A JP 2000129645A JP 2000129645 A JP2000129645 A JP 2000129645A JP 4528414 B2 JP4528414 B2 JP 4528414B2
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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
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/18—Waste materials; Refuse organic
- C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
- C04B18/241—Paper, e.g. waste paper; Paper pulp
-
- 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
- C04B28/18—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 mixtures of the silica-lime type
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- 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
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Environmental & Geological Engineering (AREA)
- Civil Engineering (AREA)
- Producing Shaped Articles From Materials (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Description
【0001】
【発明の属する技術分野】
本発明は、建築用材料や化粧基材として広く使用されている繊維補強珪酸カルシウム成形体及びその製造方法に関する。
【0002】
【従来の技術】
補強繊維を含有する珪酸カルシウム成形体の代表的なものとして、繊維補強珪酸カルシウム板がある。繊維補強珪酸カルシウム板は、石灰質原料、珪酸質原料、補強繊維および添加材からなる原料と水とを混合分散したスラリーを加圧成形又は抄造法により板状に成形して、さらに必要に応じて加圧成形後、オートクレーブ養生により硬化させ製造されている。
【0003】
従来、補強繊維としては、針葉樹あるいは広葉樹を原料とする木質パルプやセルロースパルプや木質パルプを使用した故紙が多用されており、最近では特開平10−29844号に示されるように微小フィブリル化セルロースと他の補強繊維と組み合わせて使用する無機質硬化体に関する技術や特開平7−286401号には補強繊維として繊維長の短いセルロース繊維とパルプ、有機合成長繊維を組み合わせた水硬性無機質抄造製品に関する技術が開示されている。
一方、これらの成形体の殆どは、その表面に塗装、化粧加工などが施されて建築用材料として用いられている。
【0004】
【発明が解決しようとする課題】
しかしながら、これらの成形体に塗装や化粧加工を施す場合にその基材としての性能には問題点が多い。例えば、木質パルプを使用した場合には、木質パルプの粉体捕捉性が問題となり、その成形体の表面平滑性が劣る。また、木質パルプの影響により珪酸カルシウムマトリクスとの結合力が弱く、木質パルプ自身や有機合成繊維が基材表面に突出(毛羽立ち)したり、さらに塗料の吸収速度(溶媒吸収速度)が速いため、塗膜タイプの塗料を使用すると所望の塗膜密着性を得るためには塗布量が多量に塗布しなければならない。一方、珪酸カルシウム成形体表面に塗布する塗料としては、含浸タイプのものしか使用出来ないという問題点がある。
【0005】
このため、表面平滑性が劣る場合には、基材表面を研磨処理したり、たとえ基材表面を研磨処理しても表面平滑性にはやや効果があるものの基材表面の毛羽立ちの問題は解消されない。さらにこの基材に塗装又は化粧加工を施した場合は、この毛羽立ちのため化粧表面にザラツキが生じるという問題点がある。
特開平10−29844号においては微小フィブリル化セルロースを使用しているため、溶媒吸収(吸水)速度が速く、また、表面平滑性及び歩留まりは、いまだ問題がある。特開平7−286401号においては抄造性あるいは補強性においては改善がなされているものの、表面平滑性や塗料の吸収速度(溶媒吸収速度)が速い点においては不十分である。
【0006】
また、一方紙・板紙の分野においてはその生産量は3,000万トン/年を超え、印刷用紙の生産量はその30%以上を占め、使用済みの印刷用紙のリサイクルが資源の有効利用や焼却処理は地球温暖化の観点から問題となってきている。
【0007】
本発明の目的は、従来の補強繊維を含有する珪酸カルシウム成形体における補強繊維の捕捉性、溶媒吸収速度、表面平滑性の不良などの問題点と使用済み印刷用紙のリサイクル(有効利用)の問題を解決する繊維補強珪酸カルシウム成形体及びその製造方法を提供することにある。
【0008】
【課題を解決するための手段】
本発明者らは、鋭意研究を重ねた結果、上記従来の課題を解決することを得た。
すなわち、第1の発明は、補強繊維を含有する珪酸カルシウム成形体において、該補強繊維の少なくとも一部に晒化学パルプを1〜10質量%、好ましくは2〜7質量%、さらに好ましくは3〜5質量%含有し、溶媒吸収(吸水)時間が20〜35秒であることを特徴とする繊維補強珪酸カルシウム成形体を提供するものである。
【0009】
第2の発明は、前記晒化学パルプが、晒化学パルプを70質量%以上、好ましくは90質量%以上含む印刷用紙の廃紙であることを特徴とする前記の繊維補強珪酸カルシウム成形体を提供するものである。
【0010】
第3の発明は、予め叩解処理された晒化学パルプと石灰質原料、珪酸質原料、補強繊維(晒化学パルプを除く)及び添加材と水とを混合分散して、抄造法により板状に成形し、さらに必要に応じて加圧成形した後、オートクレーブ養生することを特徴とする前記の繊維補強珪酸カルシウム成形体の製造方法を提供するものである。
【0011】
第4の発明は、予め叩解処理された晒化学パルプと石灰質原料、珪酸質原料、補強繊維(晒化学パルプを除く)及び添加材と水とを混合分散して、脱水プレスにより成形し、オートクレーブ養生することを特徴とする前記の繊維補強珪酸カルシウム成形体の製造方法を提供するものである。
【0012】
従来の繊維補強珪酸カルシウム成形体の問題点を解決すると共に、実質的に撥水(溶媒)作用のある薬品類を使用せずに建築材料用の化粧用基材としての適性すなわち表面平滑性、溶媒(塗料)吸収速度、塗膜密着性、毛羽立ちの問題を晒化学パルプ又はこれを含有する廃紙をもちいることにより改善すると同時にこれらの適性を制御可能にするものである。
【0013】
【発明の実施の形態】
本発明の繊維補強珪酸カルシウム成形体は、実質的に撥水(溶媒)作用のある薬品類を使用せずに建築材料用の化粧用基材としての適性すなわち表面平滑性、溶媒(塗料)吸収速度、塗膜密着性、毛羽立ちの問題を晒化学パルプ又はこれを含有する廃紙をもちいることにより改善すると同時にこれらの適性を制御可能にしたことを特徴とするもので、以下に本発明の繊維補強珪酸カルシウム成形体及びその製造方法について説明する。
【0014】
本発明でいう晒化学パルプとは、パルプ原料に含まれるリグニンやヘミセルロース、色素、タンニンなどの有機成分をさらし粉により分解処理したパルプである。これらの晒化学パルプは、パルプ原料に含まれる上記有機成分を酸化分解と塩素化反応により分解、低減されているため、珪酸カルシウムマトリクスとの結合力や分散性が良好なことから、表面平滑性に効果があり、また珪酸カルシウム成形体の製造系に及ぼす影響が少ないことから好適である。この時、前記晒化学パルプの含有量は、珪酸カルシウム成形体の全固形分に対して、1〜10質量%、好ましくは2〜7質量%、3〜5質量%である。含有量が10質量%以上になると耐火性や不燃性の点で問題がある。
【0015】
さらに、前記晒化学パルプを主に含有する印刷用紙の廃紙は、前記表面平滑性の効果や反応系に及ぼす影響が少ないほかに、また従来技術の溶媒吸収速度の速いために生ずる問題点を改善できるので好適である。印刷用紙の廃紙の晒化学パルプの含有量は、廃紙の全固形分質量に対して、70質量%以上、好ましくは90質量%以上であり、70質量%より少ないと珪酸カルシウムマトリクスとの結合力や分散性が低下するほか表面平滑性、溶媒(塗料)吸収速度、塗膜密着性、毛羽立ちへの効果が減少する。
【0016】
晒化学パルプの叩解は常法に従い、例えばパルパー離解機やビーター叩解機やディスクリファイナー等で晒化学パルプや印刷用紙の廃紙のみ、あるいは晒化学パルプや印刷用紙の廃紙と木質パルプやセルロースパルプと水とを混合分散し、濃度2〜15質量%好ましくは3〜8質量%のスラリー状に離解した後、ビーター叩解機、ロッドミル、あるいはディスク粉砕機等を用いて処理時間あるいは処理回数を適宜調節することにより、叩解処理することができる。このとき、混合したパルプ繊維のろ水度は、JIS P 8121に基づき、70〜350ml、好ましくは80〜200mlになるように叩解処理することが好ましい。
【0017】
特に未使用木質パルプまたはセルロースパルプと併用するすることが繊維補強珪酸カルシウム成形体の強度上好ましく、この場合、晒化学パルプ/未使用木質パルプまたはセルロースパルプの比は、質量比で6/4から2/8が好ましい。ここでいう未使用木質パルプとは従来から使用されている針葉樹あるいは広葉樹パルプが使用でき、漂白したものあるいは未漂白のものいう。
【0018】
ここでいう溶媒吸収(吸水)時間の測定は、予め60℃、24時間以上加熱乾燥させ、デシケーター中で室温まで放冷した試料の表面から10mmの高さからガラス製スポイト(外径3.2mm、内径1.5mm)を用いて溶媒を一滴、滴下する。滴下してから、試料表面に落下した溶媒表面の反射が無くなるまでの時間を計測したもので、異なる場所で測定して測定回数3回の平均値である。
本発明で言う塗膜タイプの塗料とは、比較的低分子量の樹脂を主成分とする塗料ものをいう。
塗膜タイプの塗料に適した化粧基材の溶媒吸収時間は、20〜35秒が好ましく、使用する塗料選定又は化粧基材の選定の条件になるパラメータの一つである。溶媒吸収時間が20秒より短いと塗膜タイプの塗料では、塗膜ムラの発生や過剰量の塗料を必要とするため好ましくなく、35秒より長いと化粧工程の生産性が低下したり、塗膜密着性が悪くなり好ましくない。
この時使用する溶媒により、吸収時間は、水>エタノール>トルエンの傾向が見られた。
【0019】
さて、製造方法としては、予め叩解処理された晒化学パルプ、他の補強繊維、石灰質原料、珪酸質原料及び添加材と水とを混合分散して固形分濃度を5〜15質量%程度に調整し、丸網式抄造機により板状に積層成形し、さらに必要に応じてプレス機により加圧成形した後、オートクレーブ養生し、硬化させることにより製造することができる。
【0020】
また、予め叩解処理された晒化学パルプ、他の補強繊維、石灰質原料、珪酸質原料及び添加材と水とを混合分散して固形分濃度を30〜50質量%程度に調整し、脱水プレス成形し、オートクレーブ養生することにより製造することができる。
【0021】
本発明でいう石灰質原料は固形分換算で30〜40質量%であり、消石灰、セメント、あるいは生石灰が用いられ、これらを単独または併用して使用することができ、また、本発明でいう珪酸質原料は固形分換算で25〜40質量%であり、珪石微粉、フライアッシュ等が使用され、嵩比重低減用珪酸質原料としては珪藻土、シリカヒューム、ホワイトカーボン、アロフェン等の非晶質珪酸質原料が使用できる。
石灰質原料と珪酸質原料の比率はCaO/SiO2モル比が0.4〜1.2の範囲とすることが好ましい。より好ましくは0.6〜1.0である。
【0022】
本発明でいう補強繊維(晒化学パルプを含む)は固形分換算で1〜10質量%であり、上記晒化学パルプや木質パルプまたはセルロースパルプの他にガラス繊維、炭素繊維、ロックウール繊維、ポリプロピレン、レーヨン、アクリル繊維、鋼繊維、ウィスカー等を用いることができ、このうち有機繊維の合計添加量は、1〜10質量%、好ましくは2〜7質量%にすることが好ましい。
【0023】
また、本発明でいう添加材は固形分換算で15〜25質量%であり、ゾノトライト、ワラストナイト、マイカ、炭酸カルシウム、タルク、パーライト、ベントナイト、セピオライト、二水石膏、無水石膏、コンクリート廃材、珪酸カルシウム板廃材等の増量材あるいは寸法安定材や凝集剤、消泡剤、増粘剤、減水剤などの助剤を用いることもできる。好ましい寸法安定材としてはゾノトライト、ワラストナイト、炭酸カルシウム、二水石膏である。
【0024】
なお本発明による珪酸カルシウム板のオートクレーブ養生温度は120〜220℃、好ましくは160〜200℃であり養生時間は3〜10時間である。
【0025】
(実施例)
以下、本発明の実施例について説明する。
まず晒化学パルプ原料をパルパーを用いて水とともに分散させて濃度が3質量%のパルプスラリーを作製し、次いでこのスラリーをビーター叩解機により叩解処理してろ水度を調整し、表1に示す水準の補強繊維スラリーを調整した。
なおここで廃紙としては予めシュレッダーにより短冊状に裁断された中質印刷用紙と上質印刷用紙を、未使用セルロースパルプとしては漂白した針葉樹パルプを使用した。ここで用いた中質印刷用紙の強熱残分6.5%、上質印刷用紙の強熱残分が5.2%であった。
【0026】
次に上記化学パルプ繊維を所定量含むスラリーに消石灰、珪砂、珪藻土、及び添加材を表1に示す配合割合となるように添加し、加水混練して約7質量%(固形分)濃度のスラリーとしたものを抄造法により板状に成形し、さらに加圧した後、オートクレーブにより180℃、6時間の養生を行い、幅40cm、長さ200cm、厚さ6mmの繊維補強珪酸カルシウム成形体を得た。
【0027】
このようにして得られた成形体を105℃で24時間乾燥し、JIS A 1408に準拠し試験体の大きさを4号(30cm×25cm)として曲げ強度を測定した。また得られた成形体を5cm×5cmに切断し、この両面に鉄製引っ張り治具を接着剤で接着し層間剥離強度を測定した。
【0028】
また表面平滑性については、表面粗さ形状測定器を用い、JIS B 0601付属書に従い、カットオフ2.5mmのときの中心線平均粗さ(Ra)を測定(n=3)し、その平均値を示した。また、これを研磨した場合の表面の毛羽立ち状況を観察した。溶媒吸収時間は成形体表面から10mmの高さの所から溶媒を1滴落とし、落下した溶媒表面の反射がなくなるまでの時間を測定(n=3)した。さらに、10cm×10cm×5mmの試験体に塗膜タイプ(低分子量)の樹脂塗料として日立化成工材製湿気硬化型塗料を30g/m2塗布し、加熱硬化させ、塗膜性能試験に供した。
【0029】
表1に本発明の実施例を示す。表1から判るように、本実施例で得られた珪酸カルシウム成形体は、嵩密度は800kg/m3以上で、中心線平均粗さは5.5μm以下で、溶媒吸収(吸水)時間は20から35秒であり、化粧基材として優れた特性を有している。また、建築用内装材料として十分な曲げ強度及び層間剥離強度を有している。さらに塗膜性能試験において、樹脂塗料の含浸深さは0.7mm以下であり、塗膜密着性に問題は無かった。
【0030】
(比較例)
新聞故紙及び未使用セルロースパルプを用いて表2に示す配合割合で実施例と同様にして成形体を作製し、同様の評価を行った。
その結果は、表2に示す通りで得られた珪酸カルシウム成形体の中心線平均粗さは5.5μmをこえ、表面平滑性が悪く、溶媒吸収時間は20秒未満と速かった。さらに塗膜性能試験において、樹脂塗料の含浸深さは1.2mmを超えており、塗料が基材に吸収され、良好な塗膜は得られなかった。
【0031】
【発明の効果】
以上のように従来の珪酸カルシウム成形体には表面平滑性、溶媒吸収(吸水)速度、塗膜密着性の不良ならびに毛羽立ちの問題があったが、本発明の補強繊維として晒化学パルプを10質量%以下、好ましくは2〜7質量%、さらに好ましくは3〜5質量%配合することにより表面平滑性を改善すると同時に、溶媒吸収(吸水)時間を20〜35秒に調整可能となり、塗膜タイプの塗料が使用でき、化粧基材として優れた性能を有し、しかも建築用内装材料として十分な曲げ強度及び層間剥離強度を有する繊維補強珪酸カルシウム成形体を得ることが出来る。
【0032】
【表1】
【0033】
【表2】
[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a fiber-reinforced calcium silicate molded article widely used as a building material or a decorative base material, and a method for producing the same.
[0002]
[Prior art]
A typical example of a calcium silicate molded body containing reinforcing fibers is a fiber-reinforced calcium silicate plate. The fiber reinforced calcium silicate plate is formed into a plate shape by pressure molding or papermaking method by mixing slurry of water and raw materials consisting of calcareous raw material, siliceous raw material, reinforcing fiber and additive, and if necessary After pressure molding, it is manufactured by curing by autoclave curing.
[0003]
Conventionally, as reinforcing fibers, waste paper using wood pulp, cellulose pulp, or wood pulp made from coniferous or hardwood has been widely used. Recently, as shown in JP-A-10-29844, microfibrillated cellulose and Technology related to inorganic cured bodies used in combination with other reinforcing fibers and Japanese Patent Application Laid-Open No. 7-286401 have technologies related to hydraulic inorganic paper products that combine cellulose fibers with short fiber length, pulp, and organic synthetic long fibers as reinforcing fibers. It is disclosed.
On the other hand, most of these molded products are used as building materials with their surfaces painted and decorated.
[0004]
[Problems to be solved by the invention]
However, there are many problems in the performance as a base material when these molded products are subjected to painting or cosmetic processing. For example, when wood pulp is used, the powder trapping property of wood pulp becomes a problem, and the surface smoothness of the molded article is inferior. In addition, due to the influence of wood pulp, the binding force with the calcium silicate matrix is weak, and the wood pulp itself and organic synthetic fibers protrude (fluff) on the substrate surface, and the paint absorption rate (solvent absorption rate) is fast, When a coating type paint is used, a large amount of coating must be applied in order to obtain the desired coating film adhesion. On the other hand, there is a problem that only an impregnation type paint can be used as the coating applied to the surface of the calcium silicate molded body.
[0005]
For this reason, if the surface smoothness is inferior, the surface of the base material is polished or even if the surface of the base material is polished, the surface smoothness is somewhat effective, but the problem of fluffing on the base material surface is solved. Not. Furthermore, when this base material is painted or decorated, there is a problem that the surface of the makeup is rough due to the fluff.
In JP-A-10-29844, since microfibrillated cellulose is used, the solvent absorption (water absorption) speed is high, and surface smoothness and yield still have problems. In JP-A-7-286401, although the papermaking property or the reinforcing property is improved, the surface smoothness and the coating absorption rate (solvent absorption rate) are insufficient.
[0006]
On the other hand, in the paper and paperboard field, the production volume exceeds 30 million tons / year, the production volume of printing paper accounts for more than 30%, and the recycling of used printing paper makes it possible to effectively use resources. Incineration has become a problem from the viewpoint of global warming.
[0007]
The object of the present invention is to solve problems such as poor fiber capture ability, solvent absorption rate, and poor surface smoothness in conventional calcium silicate moldings containing reinforcing fibers, and problems with recycling (effective use) of used printing paper. It is providing the fiber reinforced calcium silicate molded object which solves this, and its manufacturing method.
[0008]
[Means for Solving the Problems]
As a result of intensive studies, the present inventors have obtained a solution to the above conventional problems.
That is, according to the first aspect of the present invention, in the calcium silicate molded body containing the reinforcing fiber, the bleached chemical pulp is 1 to 10% by mass, preferably 2 to 7% by mass, and more preferably 3 to 3%. The present invention provides a fiber-reinforced calcium silicate molded body containing 5% by mass and having a solvent absorption (water absorption) time of 20 to 35 seconds.
[0009]
2nd invention provides the said fiber reinforced calcium silicate molded object characterized by the said bleached chemical pulp being waste paper of the printing paper containing 70 mass% or more of bleached chemical pulp, Preferably it is 90 mass% or more. To do.
[0010]
In the third invention, the bleached chemical pulp and the calcareous raw material, the siliceous raw material, the reinforcing fiber (excluding the bleached chemical pulp) and the additive material and water mixed and dispersed in advance are formed into a plate shape by a papermaking method. Further, the present invention provides a method for producing the above-mentioned fiber-reinforced calcium silicate molded body, which is subjected to autoclave curing after being pressure-molded as necessary.
[0011]
The fourth invention is a blended and dispersed bleached chemical pulp and calcareous raw material, siliceous raw material, reinforcing fiber (excluding bleached chemical pulp) and additive material and water that have been beaten in advance, molded by a dehydration press, and autoclave It is intended to provide a method for producing the above-mentioned fiber-reinforced calcium silicate compact, which is cured.
[0012]
While solving the problems of conventional fiber-reinforced calcium silicate molded products, suitability as a cosmetic base for building materials without using chemicals having a substantially water-repellent (solvent) action, that is, surface smoothness, The problem of solvent (paint) absorption rate, coating film adhesion and fluffing is improved by using bleached chemical pulp or waste paper containing the same, and at the same time, the suitability of these can be controlled.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
The fiber-reinforced calcium silicate molded article of the present invention is suitable as a cosmetic base material for building materials without using chemicals having a substantially water-repellent (solvent) action, that is, surface smoothness, solvent (paint) absorption. It is characterized by improving the speed, coating film adhesion, and fluffing problems by using bleached chemical pulp or waste paper containing the same, and at the same time, controlling the suitability of these. The fiber-reinforced calcium silicate molded body and the manufacturing method thereof will be described.
[0014]
The bleached chemical pulp referred to in the present invention is a pulp obtained by decomposing organic components such as lignin, hemicellulose, pigment, and tannin contained in the pulp raw material with bleaching powder. Since these bleached chemical pulps are decomposed and reduced by the oxidative degradation and chlorination reaction of the above organic components contained in the pulp raw material, the surface smoothness is good because of their good binding power and dispersibility with the calcium silicate matrix. This is suitable because it has an effect on the production of the calcium silicate molded body. At this time, content of the said bleached chemical pulp is 1-10 mass% with respect to the total solid of a calcium-silicate molded object, Preferably it is 2-7 mass%, 3-5 mass%. When the content is 10% by mass or more, there is a problem in terms of fire resistance and incombustibility.
[0015]
Further, the waste paper of the printing paper mainly containing the bleached chemical pulp has not only the effect of the surface smoothness and the influence on the reaction system, but also the problems caused by the high solvent absorption rate of the prior art. This is preferable because it can be improved. The content of bleached chemical pulp in the waste paper of the printing paper is 70% by weight or more, preferably 90% by weight or more, based on the total solid content of the waste paper. In addition to a decrease in bonding strength and dispersibility, surface smoothness, solvent (paint) absorption rate, coating film adhesion, and effects on fuzz are reduced.
[0016]
The bleached chemical pulp is beaten in accordance with a conventional method, for example, using a pulper disintegrator, beater beater, or disc refiner, etc., only bleached chemical pulp or printing paper waste paper, or bleached chemical pulp or printing paper waste paper and wood pulp or cellulose pulp And water are mixed and dispersed and disaggregated into a slurry having a concentration of 2 to 15% by mass, preferably 3 to 8% by mass, and then the treatment time or the number of treatments is appropriately determined using a beater beater, a rod mill, or a disk grinder. The beating process can be performed by adjusting. At this time, it is preferable that the freeness of the mixed pulp fiber is beaten so as to be 70 to 350 ml, preferably 80 to 200 ml, based on JIS P8121.
[0017]
In particular, it is preferable to use it together with unused wood pulp or cellulose pulp from the viewpoint of the strength of the fiber-reinforced calcium silicate molded product. In this case, the ratio of bleached chemical pulp / unused wood pulp or cellulose pulp is from 6/4 in mass ratio. 2/8 is preferred. The term “unused wood pulp” as used herein refers to conventionally used softwood or hardwood pulp, which is bleached or unbleached.
[0018]
The measurement of the solvent absorption (water absorption) time here is a glass dropper (outside diameter 3.2 mm) from a height of 10 mm from the surface of a sample that has been previously heated and dried at 60 ° C. for 24 hours or more and allowed to cool to room temperature in a desiccator. Then, a drop of the solvent is dropped using a 1.5 mm inner diameter). This is a time measured from dropping until the solvent surface dropped on the sample surface is no longer reflected, and is an average value obtained by measuring three times at different locations.
The paint film type paint referred to in the present invention refers to a paint mainly composed of a resin having a relatively low molecular weight.
The solvent absorption time of the decorative base material suitable for the paint film type paint is preferably 20 to 35 seconds, and is one of the parameters that are the conditions for selecting the paint to be used or selecting the decorative base material. If the solvent absorption time is shorter than 20 seconds, coating type paints are not preferable because of the occurrence of coating film unevenness and excessive amounts of coatings. Film adhesion deteriorates, which is not preferable.
The absorption time tended to be water>ethanol> toluene depending on the solvent used.
[0019]
Now, as a manufacturing method, bleached chemical pulp, other reinforcing fibers, calcareous raw materials, siliceous raw materials, additive materials, and water are mixed and dispersed in advance to adjust the solid content concentration to about 5 to 15% by mass. Then, it can be produced by laminating and forming into a plate shape with a round net type paper machine, and further press-molding with a press machine as necessary, followed by curing and curing.
[0020]
In addition, bleached chemical pulp, other reinforcing fibers, calcareous raw materials, siliceous raw materials, additive materials and water are mixed and dispersed in advance to adjust the solid content concentration to about 30 to 50% by mass, and dehydration press molding However, it can be produced by curing in an autoclave.
[0021]
The calcareous raw material referred to in the present invention is 30 to 40% by mass in terms of solid content, and slaked lime, cement, or quicklime is used, and these can be used alone or in combination. The raw material is 25 to 40% by mass in terms of solid content, and silica fine powder, fly ash, etc. are used, and siliceous raw materials for reducing bulk specific gravity are amorphous siliceous raw materials such as diatomaceous earth, silica fume, white carbon, allophane, etc. Can be used.
The ratio of the calcareous material and the siliceous material is preferably such that the CaO / SiO 2 molar ratio is in the range of 0.4 to 1.2. More preferably, it is 0.6-1.0.
[0022]
The reinforcing fiber (including bleached chemical pulp) in the present invention is 1 to 10% by mass in terms of solid content, and in addition to the bleached chemical pulp, wood pulp or cellulose pulp, glass fiber, carbon fiber, rock wool fiber, polypropylene , Rayon, acrylic fiber, steel fiber, whisker and the like can be used, and among these, the total addition amount of the organic fiber is preferably 1 to 10% by mass, preferably 2 to 7% by mass.
[0023]
Further, the additive referred to in the present invention is 15 to 25% by mass in terms of solid content, and includes zonotlite, wollastonite, mica, calcium carbonate, talc, perlite, bentonite, sepiolite, dihydrate gypsum, anhydrous gypsum, concrete waste, Auxiliary agents such as fillers such as calcium silicate board wastes, dimensional stabilizers, flocculants, antifoaming agents, thickeners, water reducing agents can also be used. Preferred dimensional stabilizers are zonotlite, wollastonite, calcium carbonate, and dihydrate gypsum.
[0024]
In addition, the autoclave curing temperature of the calcium silicate plate according to the present invention is 120 to 220 ° C., preferably 160 to 200 ° C., and the curing time is 3 to 10 hours.
[0025]
(Example)
Examples of the present invention will be described below.
First, a bleached chemical pulp raw material is dispersed with water using a pulper to prepare a pulp slurry having a concentration of 3% by mass. Next, the slurry is beaten with a beater beater to adjust the freeness, and the levels shown in Table 1 The reinforcing fiber slurry was adjusted.
Here, as waste paper, medium-quality printing paper and high-quality printing paper that had been cut into strips by a shredder in advance were used, and bleached softwood pulp was used as unused cellulose pulp. The ignition residue of the medium-quality printing paper used here was 6.5%, and the ignition residue of the high-quality printing paper was 5.2%.
[0026]
Next, slaked lime, silica sand, diatomaceous earth, and additives are added to the slurry containing a predetermined amount of the above chemical pulp fiber so as to have a blending ratio shown in Table 1, and are kneaded and slurry having a concentration of about 7% by mass (solid content). After forming into a plate shape by a papermaking method and further pressurizing, curing was performed at 180 ° C. for 6 hours by an autoclave to obtain a fiber-reinforced calcium silicate molded body having a width of 40 cm, a length of 200 cm, and a thickness of 6 mm. It was.
[0027]
The molded body thus obtained was dried at 105 ° C. for 24 hours, and the bending strength was measured according to JIS A 1408, with the size of the test body being No. 4 (30 cm × 25 cm). Moreover, the obtained molded object was cut | disconnected to 5 cm x 5 cm, the iron pull jig | tool was adhere | attached on this both surfaces with the adhesive agent, and the delamination strength was measured.
[0028]
For surface smoothness, a surface roughness shape measuring instrument was used, and the center line average roughness (Ra) at a cutoff of 2.5 mm was measured (n = 3) according to JIS B 0601 appendix, and the average was obtained. The value is shown. Moreover, the surface fluffing condition when this was polished was observed. The solvent absorption time was measured by dropping one drop of the solvent from a height of 10 mm from the surface of the molded body and measuring the time until reflection of the dropped solvent surface disappeared (n = 3). Furthermore, 30 g / m 2 of a moisture curable paint made by Hitachi Chemical Co., Ltd. as a paint film type (low molecular weight) resin paint was applied to a 10 cm × 10 cm × 5 mm test body, heat-cured, and subjected to a film performance test. .
[0029]
Table 1 shows examples of the present invention. As can be seen from Table 1, the calcium silicate molded body obtained in this example has a bulk density of 800 kg / m 3 or more, a center line average roughness of 5.5 μm or less, and a solvent absorption (water absorption) time of 20 35 seconds, and has excellent properties as a decorative base material. Moreover, it has sufficient bending strength and delamination strength as an interior material for construction. Furthermore, in the coating film performance test, the impregnation depth of the resin coating was 0.7 mm or less, and there was no problem in coating film adhesion.
[0030]
(Comparative example)
Using a newspaper waste paper and unused cellulose pulp, a molded body was produced in the same manner as in the Examples at the blending ratio shown in Table 2, and the same evaluation was performed.
As a result, the center line average roughness of the calcium silicate compact obtained as shown in Table 2 exceeded 5.5 μm, the surface smoothness was poor, and the solvent absorption time was as fast as less than 20 seconds. Furthermore, in the coating film performance test, the impregnation depth of the resin coating exceeded 1.2 mm, the coating was absorbed by the substrate, and a good coating was not obtained.
[0031]
【The invention's effect】
As described above, the conventional calcium silicate molded body has problems of surface smoothness, solvent absorption (water absorption) speed, poor coating adhesion and fluffing, but 10 mass of bleached chemical pulp is used as the reinforcing fiber of the present invention. %, Preferably 2 to 7% by mass, more preferably 3 to 5% by mass, the surface smoothness is improved and the solvent absorption (water absorption) time can be adjusted to 20 to 35 seconds. Thus, a fiber-reinforced calcium silicate molded article having excellent performance as a decorative base material and having sufficient bending strength and delamination strength as a building interior material can be obtained.
[0032]
[Table 1]
[0033]
[Table 2]
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JPH01208355A (en) * | 1988-02-15 | 1989-08-22 | Mitsubishi Mining & Cement Co Ltd | Production of non-asbestos calcium silicate board |
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JPH01208355A (en) * | 1988-02-15 | 1989-08-22 | Mitsubishi Mining & Cement Co Ltd | Production of non-asbestos calcium silicate board |
JPH04219356A (en) * | 1990-12-14 | 1992-08-10 | Kubota Corp | Production of fiber-reinforced cement product |
JPH06316453A (en) * | 1991-12-14 | 1994-11-15 | Sicowa Verfahrenstech Baustoffe Gmbh & Co Kg | Preparation of hydrated calcium silicate bound molded body |
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