JP5855348B2 - Non-flammable substrate - Google Patents

Description

  The present invention relates to a nonflammable substrate.

  In recent years, it is non-flammable and has excellent workability such as cutting and nailing. Gypsum-based, calcium silicate-based, cement-based hydraulic non-combustible base materials, and hydraulic properties mainly composed of magnesium carbonate, calcium carbonate, etc. Inorganic non-combustible substrates are widely used.

Furthermore, in addition to these, a non-combustible composite base material obtained by depositing a surface layer mainly composed of rock wool and an intermediate layer made of foamed inorganic material in a slurry, dehydrating and drying, and hot-press molding, and a surface layer and an intermediate layer. Some are deposited with foamed inorganic powder, and others are formed by spraying glass fibers to form a plurality of layers and then hot pressing.
JP 2006-336159 A JP 2000-15719 A JP-A-11-79859

  However, it has been extremely difficult to reduce the thickness of the hydraulic inorganic non-combustible base material due to the restriction of casting or pressing time during production.

  In addition, since the method using the surface layer mainly composed of rock wool and the intermediate layer made of foamed inorganic material is a method similar to the wet papermaking method, it is easy to reduce the thickness and can be used for mass production. It is unsuitable for small-scale production, and there are restrictions on the specific gravity suitable for the stability of the slurry in the blended raw material, and there is a restriction on the water treatment used for the slurry, which requires considerable technology for production.

The present invention has been studied in view of such circumstances, and is a non-combustible base material obtained by hot-pressing a sheet obtained by wet-making a slurry. In the slurry, (a) inorganic fibers and (b) Water-containing inorganic filler, (c) lightweight aggregate, and (d) resin emulsion as essential components, and the blending ratio of (d) resin emulsion in the essential components (a + b + c + d) is 1 to 5 wt. %, And when the sheet is hot-press molded, a resin emulsion is applied to the front and back and dried.

According to the present invention, a lightweight, high-strength and non-flammable substrate is obtained, and formaldehyde is not diffused. Moreover, since the organic resin is contained, there are few defects at the time of a cut compared with an inorganic incombustible base material.
Hereinafter, the present invention will be described in detail.

  Examples of the inorganic fiber (a) used for blending in the present invention include fibers such as carbon fiber, glass fiber, rock wool, warrestnite, and sepiolite. The blending of these inorganic fibers improves the rigidity of the substrate when humidified and also improves the nonflammability. Of these, rock wool, glass fiber, or a combination thereof is preferable. The inorganic fiber preferably has a diameter of 1 to 30 μm and a length of 0.1 to 20 mm. The proportion (mixing proportion) of the component (a) in the essential component (a + b + c + d) is preferably 5 to 25% by weight. When the component (a) decreases, the bending strength as a non-combustible substrate tends to be poor, and when it increases, the rigidity tends to deteriorate.

  (B) As the water-containing inorganic filler, aluminum hydroxide, magnesium hydroxide, and dihydrate gypsum having an average particle diameter of about 1 to 300 μm are preferably used. These decompose at high temperatures and release heat and bound water. Most suitable in terms of nonflammability effect. The proportion (mixing ratio) of the component (b) in the essential component (a + b + c + d) is desirably 50 to 80% by weight. If the amount of the component (b) is small, the nonflammability performance tends to be inferior. .

  (C) The lightweight aggregate used in the present invention is used for the purpose of reducing the specific gravity and reducing the weight. Specifically, fine hollow fine particles such as pearlite, vermiculite, shirasu balloon, glass balloon, and fly ash balloon are used. It is preferable from the viewpoint of weight reduction, and can be used alone or in combination. (C) The light-weight aggregate is appropriately selected according to the molding pressure, the thickness after lamination and the density, and the particle size distribution and bulk specific gravity. (C) The light-weight aggregate preferably has an average particle diameter of 1 to 1000 μm. If the average particle diameter is less than the lower limit, a sufficient weight reduction effect cannot be obtained, and if the upper limit is exceeded, the base material becomes non-uniform. The proportion (mixing ratio) of the component (c) in the essential component (a + b + c + d) is desirably 10 to 30% by weight. If the component is less than the lower limit, the desired light weight cannot be obtained. Bending strength tends to be inferior, which is not preferable.

  The blending ratio of (b) + (c) is 73 to 91% by weight in the essential components of (a + b + c + d), and the blending ratio of (b) :( c) is 1: 0.13 to 0.58 by weight. A nonflammable base material having the nonflammability of the invention can be obtained.

  Examples of the (d) resin emulsion that functions as a binder component used in the present invention include a mixed liquid of one or more resin emulsions selected from acrylic emulsions, vinyl acetate emulsions, and synthetic rubber emulsions. . An acrylic emulsion is preferable from the viewpoint of light resistance. The acrylic resin corresponds to an acrylic resin composed of a copolymer of methyl acrylate, methyl methacrylate and alkyl acrylate having a glass transition point of from room temperature to 100 ° C. and having flexibility in a temperature range of normal temperature or higher, and has a solid content of 20 An aqueous emulsion type containing at least% by weight can be used. The proportion (mixing ratio) of (d) in the essential component (a + b + c + d) is preferably set to a blending ratio in the range of 1 to 5% by weight in terms of solid content, and if the component (d) is small, the binder component decreases. The strength as a nonflammable base material tends to be inferior, and when it is large, the nonflammable performance tends to be lowered.

The incombustible substrate of the present invention is obtained by suspending a mixture containing the above (a) to (d) as essential components in water to obtain an aqueous slurry, adding a paper strength enhancer / polymer flocculant, and performing wet papermaking. When a resin emulsion, especially an acrylic emulsion, is applied and dried on the front and back, and hot pressing is performed, the strength is improved. The same resin emulsion as described above can be used. The hot pressure conditions are a temperature of 120 to 150 ° C., a pressure of 10 to 50 kg / cm ² , and a time of 5 to 30 minutes.

For 800 ml of water, the essential components (a) to (d) (rock wool: diameter 7 μm or less, 8 parts by weight, glass fiber: diameter 13.5 μm × length 6 mm, 4 parts by weight, aluminum hydroxide: average particle diameter 15 to 25 μm, 65 parts by weight, Shirasu balloon: average particle size 35 to 45 μm, 20 parts by weight, acrylic emulsion (glass transition temperature 50 ° C., 3 parts by weight) were suspended to obtain an aqueous slurry. A paper strength enhancer and a polymer flocculant were added to this, and after paper making, dehydration and heat drying were performed. Acrylic emulsion was applied to both the front and back surfaces of the obtained substrate. The emulsion used for coating was coated with a solid content of 25% and 300 g / m ² per side. After drying, hot pressing was performed at a temperature of 140 ° C., a pressure of 30 kg / cm ² , and a time of 15 minutes to obtain a target non-combustible substrate.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

  It manufactured like Example 1 by the mixing | blending shown in Table 1.

It manufactured like Example 1 by the mixing | blending shown in Table 1.
As the pearlite of Example 11, Hattori Co., Ltd. Hatrite Perlite N-3 (particle size 1.20 mm, sieve passing weight 100%) was used.

It manufactured like Example 1 by the mixing | blending shown in Table 1.
As the fly ash of Example 12, Cenolite SA (average particle size: 85.06 μm) manufactured by Sakai Kogyo Co., Ltd. was used.

Comparative Example 1
It manufactured like Example 1 by the mixing | blending shown in Table 1.
As the calcium carbonate of Comparative Example 1, heavy coal N-35 (average particle size of 17 μm) from Maruo Calcium Co., Ltd. was used.

Comparative Example 2
It manufactured like Example 1 by the mixing | blending shown in Table 1.

配合割合の数値は固形分値である。

The numerical value of the blending ratio is a solid content value.

The test method was as follows.
Bending strength [MPa]: Measured based on JIS K 6902; 1998 (Testing method for thermosetting resin high-pressure decorative board).
Elastic modulus [GPa]: Measured based on JIS K 6902; 1998 (Test method for thermosetting resin high-pressure decorative board).
Total calorific value [MJ / m ² ]: Nonflammability: Measured by exothermic test of 20-minute test using a corn calorimeter according to ISO5660.

Claims (5)

A non-combustible base material obtained by hot-pressing a sheet obtained by wet-making a slurry, and in the slurry, (a) inorganic fibers, (b) a hydrous inorganic filler, (c) a lightweight aggregate, (D) The resin emulsion is contained as an essential component, and the blending ratio of the (d) resin emulsion in the essential component (a + b + c + d) is 1 to 5% by weight in solid content, and when the sheet is hot-press molded Is a non-flammable base material characterized in that a resin emulsion is applied and dried on both sides. The (a) inorganic fiber is selected from the group consisting of carbon fiber, glass fiber, rock wool, warrestnite, sepiolite, and its shape is 1 to 30 μm in diameter and 0.1 to 20 mm in length. The nonflammable base material according to claim 1, wherein a blending ratio in a + b + c + d) is 5 to 25% by weight. The (b) hydrous inorganic filler is selected from the group consisting of aluminum hydroxide, magnesium hydroxide, and dihydrate gypsum, has an average particle diameter of 1 to 300 μm, and the blending ratio in the essential component (a + b + c + d) is 50 The nonflammable substrate according to claim 1 or 2, characterized in that it is -80% by weight. (C) The lightweight aggregate is selected from the group consisting of pearlite, vermiculite, shirasu balloon, glass balloon and fly ash balloon, the average particle diameter is 1-1000 μm, and the blending ratio in the essential component (a + b + c + d) The nonflammable substrate according to any one of claims 1 to 3, wherein is 10 to 30% by weight. The blending ratio of the (b) hydrous inorganic filler and the (c) lightweight aggregate is 73 to 91% by weight in the essential components of the (a + b + c + d), the (b) hydrous inorganic filler and the (c The non-combustible base material according to any one of claims 1 to 4, wherein the light-weight aggregate is mixed in a weight ratio of 1: 0.13 to 0.58.