JP5129941B2 - Inorganic molded body and method for producing the same - Google Patents

Description

  The present invention relates to an inorganic molded body mainly composed of a hydraulic inorganic material, an inorganic lightweight body, a siliceous material, and a wood reinforcing material, and a method for producing the same.

Conventionally, a wood chip cement board manufacturing method using a so-called dry or semi-dry method, in which wood reinforcing materials such as wood chips and hydraulic inorganic materials such as cement are used as main raw materials, and the mixed raw material is sprayed and pressed. There is.
Since these wooden piece cement boards are uneven | corrugated to a product by giving an unevenness | corrugation to a template beforehand, it will become a very good-looking wood piece cement board.
However, after spraying the raw material, if the surface is not pressed considerably, the surface design is deteriorated and a sharp surface pattern cannot be expressed, so that the specific gravity of the product inevitably increases and the product weight tends to increase.
For this reason, various weight reductions have been studied, but the current situation is that no significant improvement has been achieved.
Japanese Patent No. 2931768 Japanese Patent No. 3352061 Japanese Patent No. 3434754

  The present invention intends to provide an inorganic molded body excellent in various physical properties such as freeze-thaw resistance and a method for producing the same while reducing the weight as a product.

Inorganic molded product according to the claims 1, and hydraulic inorganic material, the inorganic light weight body, a siliceous containing material, a mineral moldings containing a wood reinforcement, the hydraulic inorganic materials a 25 to 50% by weight based on the total solids, the inorganic lightweight body is 7 to 20% by weight based on the total solids I mean particle size 0.10~0.25mm der, the silicate quality-containing material is from 7 to 20% by weight based on the total solids I fly ash der finely ground with an average particle size of 1 to 15 m, the wood reinforcement relative to the total solid content of 7 to 20 It is characterized by mass% .

  In addition, the inorganic molded body according to claim 2 is characterized in that mica is further added to the inorganic molded body according to claim 1.

Further, the inorganic molded body according to claim 3 is the inorganic molded body according to claim 1 or 2, wherein the inorganic lightweight body is a fired foam, and the wooden reinforcing material includes a piece of wood, wood powder, and It is characterized by being a wood fiber.

Moreover, the inorganic molded object of Claim 4 is an inorganic molded object in any one of Claims 2-3 . Furthermore, the said mica is 1-10 mass% with respect to a total solid. Features.

Moreover, the manufacturing method of the inorganic molded object of this invention is the process which mixes a hydraulic inorganic material, an inorganic lightweight body, a siliceous material containing material, and a wooden reinforcement material to make a raw material mixture, Including a step of spraying the raw material mixture obtained in the step into a mat, a step of press-molding the mat, and a step of first-curing and curing the press mat. And

Moreover, the manufacturing method of the inorganic molded object of this invention is a manufacturing method of the inorganic molded object of Paragraph 0010 , Mica is further mixed with the said raw material mixture, It is characterized by the above-mentioned.

ADVANTAGE OF THE INVENTION According to this invention, the inorganic molded object excellent in various physical properties, such as freeze-thaw resistance, and its manufacturing method can be provided, reducing the weight as a product.

Hereinafter, the best mode for carrying out the present invention will be described.
The inorganic molded body of the present invention is mainly composed of a hydraulic inorganic material, an inorganic lightweight body, a siliceous material, and a wood reinforcing material.

[Hydraulic inorganic material]
A hydraulic inorganic material is one in which a hydration reaction occurs when it comes into contact with water and hardening begins, and includes cement and lime.
Examples of the hydraulic inorganic material used in the present invention include cement such as Portland cement, silica cement, fly ash cement, alumina cement, blast furnace slag, slaked lime, etc., but Portland cement, particularly ordinary Portland cement, may be used. preferable.

[Inorganic lightweight body]
Examples of the inorganic lightweight body used in the present invention include inorganic fired foams such as perlite, shirasu balloon, vermiculite, and incineration ash such as fly ash balloon and papermaking sludge incineration ash. preferable.
Particularly preferred is pearlite having an average particle size of 0.10 to 0.25 mm.
If the average particle size is too large, the surface properties of the molded product will be poor. If the average particle size is too fine, it will not work as a lightweight body.

[Silica-containing material]
The siliceous-containing material is a material containing silicic acid (SiO ₂ ) as a chemical composition, and includes siliceous sand and diatomaceous earth.
Examples of the siliceous material used in the present invention include quartz sand, quartzite powder, diatomaceous earth, silica fume, fly ash, bottom ash, blast furnace slag, steel slag, shirasu balloon, pearlite, etc. It is also preferable to use high-brane silica sand.
The siliceous material used in the present invention preferably has an average particle diameter of 1 to 15 μm.
If the average particle size is smaller than 1 μm, the probability of agglomeration increases, and the siliceous material is not sufficiently utilized for the calcium silicate reaction, and if the average particle size is larger than 15 μm, the calcium silicate reaction becomes remarkable. Difficult to occur, so the strength decreases.

[Wood reinforcement]
Examples of the wood reinforcing material include wood powder, wood pieces, wood hair, wood fiber, pulp, wood fiber bundle, wood fiber, etc. The wood reinforcement material used in the present invention includes wood powder, wood piece, pulp, wood fiber bundle. There are wood fibers and the like, but a combination of wood powder and wood pieces, or a combination of wood pieces and wood fibers is preferable.
Further, the wood powder preferably has an average particle diameter of 0.5 to 1.0 mm, and the wood fiber has an average fiber length of 20 to 50 mm and an average fiber diameter of 0.5 to 1.0 mm. Fiber is preferred.
In addition, as a piece of wood, for the front and back layers when forming three layers, those with an average length of 5 to 15 mm and an aspect ratio of 10 to 30, and for core layers when forming three layers, an average length of 15 to 25 mm And it is preferable to use a thing with an aspect ratio of 30-50.

[Mica]
Mica usually has a layered structure, is not hygroscopic and is a highly elastic body having rigidity, and thus contributes to the dimensional stability of the inorganic molded body.
As the mica used in the present invention, flakes having an average particle size of 200 to 700 μm or less and an aspect ratio of 60 to 100 are preferable.
In addition, the aspect ratio in this case means the ratio of thickness to particle diameter.

[Organic lightweight body]
In the present invention, an organic lightweight body may be used.
The organic lightweight body is preferably a resin foam, particularly preferably a styrene resin foam bead having an average particle diameter of 1 mm and an expansion ratio of about 20 times.

[Others]
In addition to these main components, mineral materials such as bentonite, return raw materials such as pulverized and rejected inorganic compacts, small amounts of hardening accelerators such as alum, water glass, and aluminate, wax, wax, paraffin, surface activity Agents, waterproofing agents such as silicon, water repellents, synthetic resin components such as polyvinyl alcohol, organic fibers such as polypropylene fibers, inorganic fibers such as wollastonite, and the like may be mixed as appropriate.

[Raw material composition]
Next, the blending of the raw material composition of the inorganic molded body according to the present invention will be described.
In the present invention, the hydraulic inorganic material is 25 to 50% by mass, the inorganic lightweight body is 7 to 20% by mass, the siliceous material-containing material is 7 to 20% by mass, and the wood is based on the total solid content. The reinforcing material is preferably 7 to 20% by mass, and the mica is preferably 1 to 10% by mass.
If the inorganic lightweight body is less than 7% by mass, a remarkable light weight effect cannot be obtained, and if it is more than 20% by mass, there is a problem in surface properties.
When the siliceous material is less than 7% by mass, the silicic acid component in the calcium silicate reaction is too small, and when it is more than 20% by mass, an unreacted siliceous component is generated.
Furthermore, if the amount of the hydraulic inorganic material is less than 25% by mass, the strength development after the primary curing is small, and if it is more than 50% by mass, the molded body may be hard and brittle.
When the amount of the wood reinforcing material is less than 7% by mass, there is a problem in physical properties such as toughness of the molded body. When the amount is more than 20% by mass, uniform dispersion of the raw materials becomes difficult, and there is a risk of causing a problem in moldability. .
If the amount of mica is less than 1% by mass, there is a risk of problems in workability such as nailing of the inorganic molded body, and if it is more than 10% by mass, it does not lead to a significant improvement in physical properties and is uniform. Dispersion becomes difficult.

[Production method]
Next, the manufacturing method of the inorganic molded object which concerns on this invention is demonstrated.
First, the raw material is mixed with an appropriate amount of water to obtain a raw material mixture.
A hydraulic inorganic material, an inorganic lightweight body having an average particle size of 0.10 to 0.25 mm, a siliceous material containing an average particle size of 1 to 15 μm, a wood reinforcing material, and mica are mixed to form a raw material mixture. The raw material mixture is sprayed onto the template to form a mat. Further, after the mat is press-molded, the press mat is cured at about 60 ° C. for 8 hours (primary curing curing), and further, 160 to 170 ° C., Autoclave curing (secondary curing curing) takes about 7 hours.
The pressing pressure is preferably 3 to 5 MPa.
By setting the press pressure to 3 MPa or more, a sharper surface pattern can be expressed.
In addition, an organic lightweight body is mixed with the raw material to prepare a raw material mixture for the core layer,
The raw material mixture is used as a raw material mixture for the front and back layers, and the raw material mixture for the front and back layers is dispersed on the template to form a surface layer or a back layer mat. Further, the raw material mixture for the core layer is further dispersed thereon to obtain a core layer mat. Further, a raw material mixture for the front and back layers may be sprayed thereon to form a back layer or a surface layer mat, and the three-layer mat may be press-molded and then cured and cured in the same manner as described above to obtain an inorganic molded body having a three-layer structure.

Examples of the present invention will be given below.
Examples 1 to 5 and Comparative Examples 1 to 4, which are inorganic molded bodies having a three-layer structure, were produced using the raw material composition for the front and back layers shown in Table 1 and the core material composition shown in Table 2.
As the siliceous material having an average particle diameter of 1 to 15 μm, finely pulverized fly ash having an average particle diameter of 7 μm was used.
As an inorganic lightweight body having an average particle diameter of 0.10 to 0.25 mm, pearlite having an average particle diameter of 0.17 mm was used.
Furthermore, the pearlite of the comparative examples 3 and 4 used that whose average particle diameter is 0.75 mm.
The expanded styrene beads used had an average particle size of 1.0 mm.
Fatty acid ester as a waterproofing agent was added in an amount of 0.25% by mass in terms of solid content, and Na alum and water glass were added as a curing agent in an amount of 1.75% by mass in terms of solid content by external addition to the total solid content.
The surface layer: core layer: back layer was manufactured at a mass ratio of 15:70:15.
Press pressure is 3MPa, primary curing is 60 ℃ 8 hours, autoclave curing is 17
Performed at 0 ° C. Various physical properties are shown in Table 3.
The bending strength was measured according to JIS A 1408.
The water absorption elongation was the change in water absorption elongation after 15 days of water absorption, with no problem → ○, elongation occurrence → Δ, and large elongation → ×.
The moisture-shrinkage shrinkage is a change in shrinkage when three cycles of one day of water absorption and one day of drying at 80 ° C. were performed, and there were no problems → ◯, occurrence of shrinkage → Δ, and large shrinkage → ×.
The thickness swelling rate is based on the thickness measurement before and after the autoclave curing.
The freeze-thaw resistance swelling rate is the thickness swelling rate after 600 cycles of the freeze-thaw test (the method of thawing in air in frozen water based on JIS A 1435).
Crack resistance is 4 hours for water absorption, 4 hours for carbonation (CO2 concentration 5%), and 1 cycle of drying at 100 ° C. for 15 to 16 hours. No visual crack after 10 cycles → ○, a little crack → △, crack Many → x.
The embossing resistance was determined to be no problem with the patterning when it was press-molded with a template having a convex portion with a rising angle of 60 ° → ○, pattern smear → Δ, crack generation → ×.

According to Table 3, Examples 1 to 5 using an inorganic lightweight body having an average particle diameter of 0.10 to 0.25 mm and a siliceous material containing an average particle diameter of 1 to 15 μm In addition, it was light and excellent in various physical properties.
On the other hand, the comparative example 1 which does not use the inorganic light body with an average particle diameter of 0.10 to 0.25 mm was not reduced in weight because the specific gravity increased to around 1.10.
In Comparative Example 2 in which the siliceous material having an average particle diameter of 1 to 15 μm is not used, the strength after secondary curing is lowered, the water absorption elongation rate and the moisture release shrinkage rate are slightly poor, and further the freeze-thaw resistance is poor.
In Comparative Example 3 using pearlite having an average particle size of 0.75 mm, the strength after secondary curing is lowered, the water absorption elongation rate and moisture release shrinkage rate are slightly poor, and the thickness swelling rate and freeze-thaw performance are also poor.
Further, Comparative Example 4 using pearlite having an average particle diameter of 0.75 mm and not containing a silicate-containing material having an average particle diameter of 1 to 15 μm has decreased strength after secondary curing, water absorption elongation, release rate. The wet shrinkage rate is slightly poor, and the thickness swelling rate, freeze-thaw performance and crack resistance performance are also poor.

Claims (4)

An inorganic molded body containing a hydraulic inorganic material, an inorganic lightweight body, a siliceous material, and a wood reinforcing material,
The hydraulic inorganic material is 25 to 50% by mass with respect to the total solid content,
The inorganic light-weight material is 7 to 20% by weight based on the total solids I mean particle size 0.10~0.25mm der,
The siliceous-containing material is from 7 to 20% by weight based on the total solids I fly ash der finely ground with an average particle size of 1 to 15 m,
The said inorganic material is 7-20 mass% with respect to the total solid, The inorganic molded object characterized by the above-mentioned . Furthermore, the mica is added, The inorganic molded object of Claim 1 characterized by the above-mentioned.   3. The inorganic molded body according to claim 1, wherein the inorganic lightweight body is a fired foam, and the wood reinforcing material is a piece of wood, wood powder, and / or wood fiber. Furthermore, the said mica is 1-10 mass% with respect to the total solid, The inorganic molded object in any one of Claims 2-3 characterized by the above-mentioned.