JP4532932B2 - Architectural interior materials - Google Patents

Description

  The present invention consists of hardened diatomaceous earth, gypsum hardened body, magnesia cement hardened body with mesopores and macropores, and is a high-strength, lightweight large-sized board that is a high-strength, lightweight large-sized board with high adsorption performance such as water vapor, VOC, and odor. The thing which improves is supplied at low cost.

  Many patents relating to humidity control materials using diatomaceous earth and deodorizing materials have been filed, but there are the following technologies for the purpose of adsorption function.

  Japanese Patent Application Laid-Open No. 11-217256 is a foam product obtained by adding diatomaceous earth hardened material and chemicals to diatomaceous earth and brick powder and hardening them with special cement.

  Japanese Patent Laid-Open No. 6-321655 discloses an inorganic building material obtained by curing cement clay, coal ash, diatomaceous earth or the like to paint waste and curing an autoclay part.

  Japanese Patent Application Laid-Open No. 7-206539 uses sodium silicate and sodium aluminate as binders in the production of high-strength lightweight ceramic molded bodies. Some of these raw materials contain diatomaceous earth, and high strength by pressing, molding and roll molding. It is a method of obtaining the molded object.

  JP-A-10-291850 is a cured product obtained by adding diatomaceous earth to a hydraulic material, and Portland cement is used for these hydraulic materials.

  Japanese Patent Laid-Open No. 2001-302308 is a method for forming a porous body having the same humidity control and deodorizing effects as the present invention, and cement, gypsum and a polymer curing agent are used as the curing agent.

  Japanese Patent Application Laid-Open No. 2002-348168 is a coating wall material made of diatomaceous earth and is hardened with cement.

  Japanese Patent Laid-Open No. 2003-96930 is also a building material having the same purpose as the present invention, but some include cement, slag and gypsum as hydraulic substances.

  Japanese Patent Laid-Open No. 2003-335564 uses diatomaceous earth as a main material and is molded with an inorganic curing agent.

  As described above, many techniques are known for producing a building material by curing diatomaceous earth as a raw material with a curing agent. A combination using gypsum, magnesia cement, or the like as a curing agent as in the present invention can be easily considered, but it is a novelty of the present invention, and a feature of the present invention is that it is vacuum depressurized using a vacuum kneader. By pressing and extruding after pressurization, the columnar diatomaceous earth particles can be made into a plate-like body having a directionality like wood oriented in the extrusion direction, and the high strength is increased by deaeration. It is possible to manufacture large plate materials for building.

  In addition, the manufacturing method of a high-density gypsum board has Unexamined-Japanese-Patent No. 2002-241155 by an inventor, and the zeolite-magnesia light refractory material in Unexamined-Japanese-Patent No. 7-81997 is the light weight of a magnesia cement, and high intensity | strength The invention was invented to take advantage of the characteristics of these materials and to further improve the physical properties by a vacuum extrusion molding method.

  The present invention is a method for producing a large-sized board having a high porosity and strength and particularly high toughness at low cost as an architectural interior material.

  Gypsum board, plywood, flexible board, etc. that are popular in the market as building interior boards are all 900 x 1800 in size, and the weight does not exceed 20 kg per piece due to restrictions on construction work, etc. There is a need for products in the range that have higher toughness and that do not break during handling, and that interior boards can be nailed and have nail retention.

The first problem to solve these conditions is to make a homogeneous pore structure having a target strength of 40 kg / cm ² or more and a bulk specific gravity of 1.3 or less. The gypsum hardened body is a macroporous body of approximately 3000 mm to 10 μm, which is approximately the same as diatomaceous earth, and is a magnesia cement hardened body having a similar pore size. By combining these, a board with a high density (bulk specific gravity of about 1.3) There is a theoretical possibility to do. According to the experiment, the gypsum obtained by vacuum extruding had a bulk specific gravity of 1.3 to 1.4 and a bending strength of 40 kg to 45 kg.

  As a plasterboard product that can be nailed, a board recently imported from Germany has a bulk specific gravity of 1.2 and a bending strength of 35 kg, and these physical properties serve as a guide for the present invention.

  If magnesia cement is used as the binder, it is possible to develop strength about twice that of gypsum, and there is much bound water and the bulk specific gravity is small.

The second problem is bending strength and toughness. The material made of this kind of hydrated compound has inherently toughness compared to ceramic materials and exhibits a flexural modulus of 50 × 10 ^{3 to} 100 × 10 ³ kg / cm ² , When the product thickness is 10 mm or less, the tensile strength is remarkably improved by adding 2% to 3% of a fibrous material. In the present invention, a product having strength anisotropy such as wood is obtained by adding and orienting pulp or clothing fibers.

The third problem is the homogeneity of the product structure. Conventional board manufacturing processes, especially German boards, which are the target product, are molded with a large hydraulic press at a pressure of 20 kg / cm ² , which requires huge capital investment. The air contained at the time of mixing and mixing the raw materials is extremely difficult to deaerate because it is contained in the tissue, and these secondary bubbles are unevenly distributed in the molded body, resulting in a strong surface. It becomes a defect, and causes a variation in quality and a defect rate. Extrusion molding by vacuum degassing according to the present invention is a molding method characterized in this aspect. Up to this point, many manufacturers and engineers have tried this method, but inherently fast-setting gypsum and magnesia cement have a very short pot life and no compositional research has been conducted. Therefore, it has not been put into practical use.

  The fourth problem is that the diatomaceous earth particles are said to be columnar with a width of 0.015 mm to 0.035 mm and a length of 0.1 mm to 0.15 mm. The gypsum crystals are needle-like and ribbon-like, and the same is true for magnesia cement, but the rectangular particles are oriented in the direction of extrusion by extrusion to make the width and length of the board like wood. Although it has anisotropy in the length direction, it produces a characteristic structure with extremely high strength and elasticity in the long axis direction.

  The fifth problem is cost. The interior materials for construction are in great demand as represented by gypsum board, but the cost is very low. The main points of cost reduction are productivity and production speed. In cementitious boards, equipment such as autoclave is used for curing and curing, and huge capital investment has been made. However, gypsum and magnesia cement are inherently fast-setting and open time during molding. However, it is possible to restore quick setting under the heating conditions after molding. That is, in the far-infrared treatment shown in claims 5 and 6, when the irradiation time is several minutes and the material itself absorbs heat rays and is heated to 80 ° C. to 90 ° C., the curing reaction proceeds rapidly, and excess moisture is removed. If dehydrated, it will be a product in a very short time.

  The reason why the diatomaceous earth is 600 ° C. or lower is that the amorphous silicic acid content in the diatomaceous earth component is left and dehydrated clayy and organic crystallization water is reduced in weight. It is because the effect of is shown.

  Gypsum board is the most widely used interior material for buildings, but because of its low tissue density, it is a disadvantage that it cannot be used as a surface material because it is laminated with kraft paper and cannot be nailed. Development and production of high-density gypsum board has begun all over the world. Moreover, since the wallpaper is applied to the surface layer as a housing interior material, the countermeasure against sick house is an environmental problem. The present invention solves these conditions, and the recycling of gypsum board is a major theme of building material waste. Therefore, it becomes an effective means for solving these problems and is supplied to the market as a low-cost recycled product.

  The present invention is a large-sized board as an interior material for buildings, and has a strength and toughness that can be nailed, and has a new product with functions for improving the environment such as humidity control and deodorization as well as lightness due to the characteristics of the material. An example of the embodiment will be described.

CaSO₄となった無水石膏を主剤として用いるが、硬化時間を促進させる為に半水石膏を少

となる時間が遅くなる事を実験により確認し、350℃〜500℃に間で焼かれたものは好適であった。石膏の配合量は製品の使用目的により変えるものであり、調湿機能を要求されるものは珪藻土量を多く、石膏を少なく配合するが、石膏量30％以下では押出成型が困難であり、また強度の面に於いても不充分である。また、この種の非可塑性の材料の押出成型は出来るだけ水分を少なくして腰を強くし、且つ粘着性の高い高分子材料としてポリエチレンオキサイドを0.1％〜0.2％加え、更に水分を30％〜35％加えて成形する。 Diatomaceous earth is a diatomaceous earth converted to dry matter that has been dried to a moisture content of 40% or less.

Anhydrous gypsum that has become CaSO ₄ is used as the main agent, but a small amount of hemihydrate gypsum is used to accelerate the setting time.

It was confirmed by experiments that the time to become slow was obtained, and those baked between 350 ° C. and 500 ° C. were suitable. The amount of gypsum varies depending on the intended use of the product, and those that require humidity control function contain a large amount of diatomaceous earth and a small amount of gypsum, but extrusion molding is difficult with a gypsum amount of 30% or less. In terms of strength, it is insufficient. In addition, this type of non-plastic material can be extruded to reduce moisture as much as possible to make it firm and to add 0.1% to 0.2% of polyethylene oxide as a high-adhesive polymer material. Add 35% and mold.

なり、急速に硬化反応は進行する。更に30分間湿度80％〜90％、温度90℃〜100℃で湿度乾燥して余剰の水分を脱水させて製品が出来る。 The raw green plate to be extruded is processed on the far-infrared radiation space with a wavelength of 5 μm to 20 μm while moving on the conveyor, and when it is treated for 5 to 6 minutes, moisture absorbs the heat rays and becomes 80 ° C. to 90 ° C.

The curing reaction proceeds rapidly. Further, the product can be produced by drying at a humidity of 80% to 90% and a temperature of 90 ° C to 100 ° C for 30 minutes to dehydrate excess water.

Also, when using magnesia cement, but the in zeolite in JP-A 7-81997 by the present inventor are those prepared by replacing the diatomaceous earth, a typical 5MgO as magnesia cement, MgCl ₂ · 8H ₂ O The oxychloride cement composition is mixed with diatomaceous earth in the range of 30% to 70% and extruded as a plastic state. Magnesia cement adjusted to the above composition is stirred in a slurry tank after blending. In order to carry out the primary hydration reaction, a viscous slurry was processed at a temperature of 40 ° C. to 50 ° C. for about 1 hour and mixed with a predetermined amount of diatomaceous earth in a mixer to obtain a plastic state. Put in a vacuum kneader and mold. In order to temporarily suppress the curing reaction of the slurry-like magnesia cement, 0.1% to 0.2% of a polymer material is added. The formed green board is treated with far infrared rays in the same manner as in the case of gypsum, and then dried to become a product.

  Compared to gypsum and Portland hardened cement, magnesia cement has a specific strength that is several times higher, and the material itself has a high hygroscopic property. . Moreover, the surface strength of the cured body is hard and suitable as an interior material.

  Molded body with plaster

型無水石膏を用いた。 1. material

Type anhydrous gypsum was used.

2. Mixing ratio (weight ratio)

3. Mixing and molding (50kg)
1) Place the aqueous solution (1.5 kg of fiber, 5 kg of water and 75 g of alkox) in a high speed mixer to disperse the fiber in the viscous aqueous solution.
2) Next, prepare a fiber dispersion with 10kg of water added, mix in a mixer that mixes 25kg of diatomaceous earth and 25kg of gypsum, and knead to form a plastic paste.
3) A 300 mm width x 1000 mm length x 10 mm thickness flat plate was extruded using a vacuum kneader and heated for 7 minutes on a far infrared irradiation conveyor.
4) Placed in a drying room at 80% humidity and 90 ° C, cured for 30 minutes, dried and dehydrated to obtain a product.

※釘保持力は丸釘2.47φ×長さ50mm、打ち込み深さ12.5mmで行い、速度0.5mm／分で
引き抜いたときの保持力。
※曲げ強度及び弾性率、スパン200mmで測定。 4). Physical properties

* The nail holding force is the holding force when the nail is pulled out at a speed of 0.5 mm / min with a round nail 2.47φ x length 50 mm, driving depth 12.5 mm.
* Measured with bending strength and elastic modulus, span 200mm.

以上の様に主要物性はほぼ同等であるが、特に弾性率に於いて特徴を示し、靱製の高いものである。 5). Evaluation When comparing physical properties with a high-density gypsum board made in Germany,

As described above, the main physical properties are almost the same, but the characteristics are particularly high in elasticity, and the toughness is high.

  Molded body made of magnesia cement

1. Ingredients Use dry diatomite powder, activated magnesia baked at 800 ° C for clothing fibers and magnesite.

2. Mixing ratio (weight ratio)

3. Mixing and molding (50kg)
1) Add 5 kg of water to 1.5 kg of fiber, add 75 g of alkox, and disperse the fiber in a viscous aqueous solution in a high-speed mixer.
2) Add 8kg of water to 10kg of active magnesia and 5kg of anhydrous calcium chloride and mix.
Treat for 1 hour with stirring in a tank heated to 50 ° C. (Magnesius Rally)
3) Put 35kg of diatomaceous earth into a mixer, then add 23kg of magnesia slurry and mix, then add 5kg of fiber dispersion and knead to make a plastic paste.
4) Put into a vacuum kneader and extrude a 300mm wide x 1000mm long x 10mm thick flat plate and heat for 7 minutes on a far infrared irradiation conveyor.
5) The product was cured by curing for 3 hours in a drying chamber at 80% humidity and 90 ° C.

4). Physical properties

5). Evaluation It should be noted from the above measured values of physical properties that the material has extremely high bending strength, has high hygroscopicity, and has a humidity control function.

Claims (4)

And diatomaceous earth of 30% to 70% dried below water content 40%, water stone Aburamata composition comprising a weight ratio of magnesia cement 30% 70% as a curing agent, a thickener, a fibrous material Is added to the plastic state and then deaerated using a vacuum kneader and extruded into a flat plate to orient the crystal particles in the same direction, warm in the far-infrared radiation space, and cure and cure. This makes it possible to nail with a homogeneous pore structure with a bulk specific gravity of 1.3 or less . The gypsum shown in claim 1 is an interior material for construction which is obtained by adding hemihydrate gypsum to anhydrous gypsum obtained by calcining gypsum of waste gypsum board at 350 ° C or higher . Magnesia cement shown in claim 1 comprising an active magnesia, magnesium chloride, building interior material made of one or more kinds of magnesium sulfate. Diatomaceous earth of claim 1, building interior materials is obtained by firing at 600 ° C. or lower.