JPH01146739A - Laminated plate and its manufacture - Google Patents

Abstract

PURPOSE:To obtain the property excellent in strength, bending rigidity and surface hardness, while light weight and heat insulating property are held by laminating successively the thin layer of a cement cured object and the surface material selected from paper or cloth on the thick plate composed of polystylene foamed plastic or inorganic foam. CONSTITUTION:When the foamed plate 7 composed of polystylene foamed plastic or inorganic foam is transferred and enters under a coating roll 2 and then is brought in contact with said roll, since the peripheral speed V of the roll 2 is made larger than the running speed v of a conveyer belt 1, the cement paste layer 6a having the thickness of V/v times the thickness of the cement paste 6 on the surface of the roll 2, is formed on the surface of the transferred foamed plate 7. When the foamed plate 7 is further transferred and enters under a feed roller 5, the surface material 8 selected from appear or cloth is supplied and lapped thereon. The surface material 8 and the paste layer 6a are integrally contact-bonded mutually during its passage immediately under the roll, and simultaneously the surface of the paste layer 6a is leveled, and its thickness becomes uniform. After the laminating process, while the foamed plate is further transferred, the primary curing of the paste layer 6a is accelerated during the transfer, and then it is taken out from the conveyer belt 1 and is cured. Thus, its hardening is finished.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a lightweight laminate having good heat insulation properties and a method for producing the same, which is made of a thick plate made of foamed plastic or inorganic foam as a base material.

[Conventional technology]

Thick plates made of expanded polystyrene, glass foam, calcium carbonate foam, etc. are lightweight and have good insulation properties, and are widely used as building materials and in other fields.

When using boards made of these foams (hereinafter referred to as foam boards) as building materials, they are used as they are, but they are usually used by laminating them with base plate building materials such as plywood. Laminated with hard boards such as plywood, the shortcomings of foam board alone, namely the lack of strength and surface hardness (specifically, resistance to localized pressure and impact), can be solved, and it can be used in a wider range of applications than when it is used alone. However, the individual features of being lightweight and easy to handle are significantly impaired. There are also types with paper or cloth glued to the surface, but in terms of surface hardness, they are not much different from foam boards.

[Problem that the invention seeks to solve]

Therefore, an object of the present invention is to maintain sufficient strength, bending rigidity, and heat insulation properties, which are the original features of foam boards.
The object of the present invention is to provide a foamed laminate having excellent performance in terms of surface hardness and the like, and a method for producing the same.

[Means for solving problems]

The foamed laminate provided by the present invention is a thick plate made of polystyrene foam plastic or inorganic foam, in which a thin layer of cured cement and a surface material selected from paper and cloth are sequentially laminated on one or both surfaces. It is something that has been done.

In this specification, the term "cement" is used to mean a mineral powder that hardens by reacting with water (JIS A0203), and includes cement in a narrow sense such as various portland cements and alumina cements, as well as gypsum and magnesia cement. etc. Moreover, "cloth" includes nonwoven fabric.

The thin layer of cement hardened material in this laminate has a thickness of 0.
．． It is thin, about 5 to 3 mm, and cannot be called a handleable board in itself; therefore,
It is formed by curing cement paste on a foam board.

The foam board, the thin layer of hardened cement, and the surface material are bonded together using the hardened cement layer as an adhesive. The cured cement product may contain fibers, nets, etc. as reinforcing materials.

The surface material is also thin, with a basis weight of 10 in the case of paper.
0~3 Q Q g /m! degree, 20-5 for cloth
0 g/m''. Therefore, especially thin ones are almost integrated with the hardened cement material, forming a hard and beautiful surface on the laminate.

Furthermore, the present invention provides an advantageous method for manufacturing the above-mentioned laminate:
While conveying the foam board with a conveyor belt moving in the horizontal direction, the moving direction of the circumferential surface at a position facing the conveyor belt is opposite to the running direction of the conveyor belt, and the circumferential speed is higher than the running speed of the conveyor belt. The coating roll is brought into contact with the foam board, whereby the cement paste that has been thinly and uniformly adhered to the circumferential surface of the coating roll is transferred to the foam board, and then the surface is transferred onto the cement paste application layer formed on the foam board. This method is characterized by supplying the materials, overlapping them, bringing them into close contact with the cement paste, and then hardening the cement paste.

This manufacturing method will be explained below with reference to the drawings.

The main parts of the laminate manufacturing apparatus shown schematically in FIG. It consists of a feed roll 5 of material. The coating roll 2 rotates counterclockwise in the drawing, and the doctor roll 3 rotates clockwise. A gap of about 0.1 to 0.5 mm can be provided between both rolls.

When cement paste 6 is supplied from hopper 4 between coating roll 2 and doctor roll 3, cement paste 6 adheres to the surfaces of both rolls at a constant thickness. Since the gap between the coating roll 2 and the conveyor belt l is equal to the thickness of the foam board 7 used as a substrate, the foam board 7 is conveyed from the right side to the left in the figure and enters under the coating roll 2. When it comes into contact with the roll, the cement paste on the roll surface is rubbed onto the surface of the foam board 7. Since the peripheral speed V of the coating roll 2 is set higher than the traveling speed V of the conveyor belt 1, the surface of the foam board 7 being conveyed has a thickness V/v times the thickness of the cement paste 6 on the surface of the coating roll 2. A cement paste layer 61 with a thickness of . By making the circumferential speed V larger than the speed V, it is possible to reduce the variation in the thickness of the cement paste layer 63 formed on the board 7, and also to reduce the variation in the thickness of the cement paste layer 63 formed on the foam board 7! The thickness can be changed and adjusted easily. The speed ratio V/v is usually 1
It can be arbitrarily selected within the range of ~15.

When the foam board 7 on which the cement paste layer 61 is placed is further conveyed to the left and placed under the feed roll 5, the surface material 8 is supplied by the roll rotating in a clockwise direction and overlapped. Then, while passing directly under the roll, the surface material 8 and the cement paste layer 6a come into close contact with each other and are integrated, and the surface of the cement paste layer 6° is smoothed to eliminate minute irregularities and to have a uniform thickness.

After the lamination is completed, the cement paste layer 6a is further conveyed to the left, during which time the initial hardening of the cement paste layer 6a is promoted, and then it is taken out from the conveyor belt 1 and cured under appropriate conditions to complete hardening.

When manufacturing a board having a cement paste cured material layer 9 and a surface material 8 on both surfaces, the single-sided laminated foam board obtained as described above is turned over and subjected to the same lamination treatment again.

A second example of the laminate of the present invention manufactured as described above is shown below.
It is shown in Figs. In the example shown in FIG. 4, a glass fiber net 1-10 for reinforcing the hardened cement layer is embedded.

Examples of preferable cements used in this production method include ordinary Portland cement, various special Portland cements, alumina cement, Chichibu GRC cement (trade name: Chichibu Cement Co., Ltd.), mixed cement,
There are plaster etc. These cements contain additives such as setting retarders, thickeners, and water reducers, aggregates such as sand and fly ash, and alkali-resistant glass fibers to improve workability, productivity, and product quality. It is possible to appropriately mix and use reinforcing materials such as .

As the foam board, a plastic foam board may be used which has high rigidity, and an inorganic foam board such as a glass foam board or a calcium carbonate foam board may be used. The thickness can be arbitrarily selected depending on the application, and there is no limit.

Surface materials include board paper, kraft paper, liner paper,
Charcoal paper, various synthetic fiber nonwoven fabrics, glass fiber nonwoven fabrics, etc. are suitable.

〔Example〕

Hereinafter, the present invention will be explained with reference to Examples.

Examples 1-4 Laminates were manufactured using the apparatus shown in FIG. 1 and described above. In this case, the cement is Chichibu GRC cement or mixed quick-hardening cement, the surface material is polyester fiber nonwoven fabric or board paper, and the foam board is expanded polystyrene board/Styrofoam EX (thickness 25+A weight).

0, 85 k(/+”, Dow Kako), a foamed glass plate, or a foamed calcium carbonate plate was used.

Mata, the running speed of the conveyor belt l is 5,1 ta/
m, the peripheral speed of coating roll 2 is 22.0 m/w
in (therefore, V/v=4.3), the peripheral speed of the doctor roll 3 is 3, 77 rn/llll1Ils, the distance between the coating roll 2 and the doctor roll 3 is 0,
2 mm, and the distance between the coating roll 2 and the conveyor belt 1 was 25+1101. In Example 4, an alkali-resistant glass fiber net (mesh spacing: 5 mm) was embedded in the cement paste layer for reinforcement.

The combination of raw materials and physical properties of the product on each side,
It is shown in Table 1. The properties of the foamed polystyrene board used as the raw material are shown in the same table as Reference Example 1, and an example in which a laminate was manufactured using an epoxy resin adhesive instead of cement is shown in Reference Example 2.

Among the physical property values shown in the table, “surface circumferential pressure invagination” is 29 mm.
- This is the depth of penetration when a steel ball is pushed in with a force of 10 kg, and other physical property values are based on JIS A No. 083 test specimen.

〔Effect of the invention〕

Since the laminate of the present invention is mostly made of foam board based on the above-mentioned structure, it retains the original characteristics of foam board, such as lightness and heat insulation, while maintaining strength, bending rigidity, In terms of surface hardness, etc., it has sufficient performance to be used as a building material. Therefore, the laminate of the present invention is suitable as a building material, a display material, etc. used in areas where heat insulation and lightness are required, and can also be used as a formwork and heat insulator for constructing a concrete wall with a heat insulating material attached. It is an excellent product that can be used conveniently for many purposes.

In addition, the manufacturing method of the present invention can easily and uniformly form a thin layer of the cured cement paste, and can also complete the lamination with the surface material in a series of continuous steps. To make it possible to efficiently manufacture boards.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing an example of an apparatus used for carrying out the manufacturing method of the present invention, and FIGS. 2 to 4 are sectional views showing examples of the laminate of the present invention.

Claims (4)

[Claims] (1) A laminate in which a thin layer of cured cement and paper or cloth are sequentially laminated on a thick plate made of polystyrene foam plastic or inorganic foam. (2) Thin layer of cement hardened material has a thickness of 0.5 to 3.0 mm
A laminate according to claim 1, which is a laminate according to claim 1. (3) While conveying a thick plate made of polystyrene foam plastic or inorganic foam with a conveyor belt moving horizontally, the direction of movement of the circumferential surface at a position facing the conveyor belt is opposite to the running direction of the conveyor belt. A coating roll having a peripheral speed equal to or higher than the traveling speed of the conveyor belt is brought into contact with the foam plank, thereby transferring the cement paste that has been thinly and uniformly adhered to the coating roll circumferential surface onto the foam plank. Then, paper or cloth is supplied and overlaid on the cement paste coating layer formed on the foam plank, and after the paper or cloth and the cement paste are brought into close contact, the cement paste is cured. Characteristic manufacturing method for laminates. (4) The manufacturing method according to claim 3, wherein the peripheral speed of the coating roll is 1 to 15 times the running speed of the conveyor belt.