JPH03187707A - Manufacture of decorative alc - Google Patents

Abstract

PURPOSE:To provide an ALC with beautiful and solid decoration easily by a method wherein a multi-layer sheet, consisting of a fibrous sheet impregnated with thermoset ting resin and a weather-resistant transparent film laminated on the fibrous sheet, is hot-pressed and is released from a mold before curing the thermosetting resin perfect ly while aqueous slurry, consisting of the principal constituents of calcareous matter, siliceous matter and aluminum powder, is poured into a mold frame or the molded sheet to foam and cure through autoclave curing. CONSTITUTION:A decorative sheet is constituted of a multi-layer sheet consisting of a weather-resistant transparent film 1 and a thermosetting resin impregnated fibrous sheet 2. Which are laminated. A molding frame is obtained by molding the multi-layer sheet through hot-press molding. Upon releasing the molding frame, it is necessary that the curing reaction of the thermosetting resin, impregnated into the fibrous sheet, is not finished perfectly yet and when the reaction is advanced too much upon the mold releasing, the adhering property of ALC can not be obtained sufficiently. Aqueous slurry, consisting of the principal constituents of calcareous matter, siliceous matter and aluminum powder, is poured into the molding frame and, thereafter, the aqueous slurry is foamed, hardened and cured in an autoclave whereby a decorative ALC, having beautiful and solid decoration, may be obtained easily.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for producing an ALC decorated with a decorative sheet.

[Prior art] ALC is made by reacting an aqueous slurry containing calcareous, silica, and aluminum powders as main components and various additives in a mold, and after reaching a certain hardness, it is taken out from the mold and placed in an autoclave. It is cured and hardened. During the reaction in the mold, hydrogen gas is generated to form uniform bubbles. The obtained ALC is lightweight with an apparent specific gravity of 0.3 to 0.9, and is excellent in heat insulation, fire resistance, and strength, so it is suitably used for the outer walls of houses and the like.

[Problems to be Solved by the Invention] However, on the other hand, ALC has a drawback in that the surface is flat and the design is poor. Japanese Patent Publication 1986-100
No. 40, JP-A-60-141509, JP-A-63-2
Each publication of No. 5284 describes a method of imparting a design to such ALC, but all of them merely provide unevenness on the surface and express a pattern using the unevenness. There is a limit to the patterns that can be expressed using this method; for example, it is not possible to express multicolored patterns or detailed patterns.

Therefore, an object of the present invention is to provide a method for producing @f*ALc that can easily impart beautiful and solid decorations to ALC.

[Means for Solving the Problems] The present inventors have previously proposed the ri! As a result of intensive research in view of the problems, the above object of the present invention is to produce a fibrous sheet impregnated with a thermosetting resin and a weather-resistant transparent film. Il! ! After hot-pressing the multilayer sheet, the thermosetting resin is removed from the mold before it is completely cured, and the resulting molded sheet is used as a mold, and the main components are calcareous, silicic acid, and aluminum powder. It has been found that this can be achieved by a method for manufacturing decorative ALC in which an aqueous slurry is poured, foamed and hardened, and then A-1 to crepe curing is carried out.

The present invention will be explained in more detail below based on the drawings.

Figure 1 shows a decorative ALG obtained by the manufacturing method of the present invention.
It is a schematic perspective view of one example seen from the decoration sheet side.

FIG. 2 shows a cross-sectional view of an example of a decorative sheet used in the Hf1iALG, which is made by laminating a weather-resistant transparent film 1 and a thermosetting resin-impregnated m* quality sheet 2 by a known method. It is made of multilayer sheets.

The weather-resistant transparent film 1 is made of a transparent sheet having weather resistance, heat resistance, etc., such as a fluororesin film or a film laminated with an acrylic film or the like. These weather-resistant transparent films are decorative ALC obtained by the method of the present invention.
It is the final outermost layer of the wall, and ensures weather resistance as an outer wall.

Further, as the fibrous sheet constituting the thermosetting resin-impregnated fibrous sheet 2, nonwoven fabric or paper made of one or a combination of two or more of inorganic fibers, valves, synthetic resin fibers, etc. can be used. As the thermosetting resin to be impregnated into this, for example, phenol resin, urea resin, melamine resin, guanamine resin, furan resin, polyester resin, diallyl phthalate resin, epoxy resin, urethane resin, etc. are used. In the present invention, these fibrous sheets can be printed with a desired pattern in advance.

FIG. 3 is a schematic perspective view showing an example of a decorative mold obtained by press-molding the decorative sheet made of the multilayer sheet.

That is, for example, the multilayer sheet shown in FIG. 2 is hot-press molded under predetermined conditions by various known methods to obtain a molding frame as shown in FIG. It is necessary that the curing reaction of the thermosetting resin impregnated into the sheet is not completely completed. That is, for example, it is necessary to remove the mold when the reaction has reached a point where shape retention appears, and if the reaction progresses too much at the time of removing the mold, the adhesion with the ALC that is to be cast and cured afterwards may deteriorate. The problem arises of not getting enough. The degree of curing reaction of the thermosetting resin, such as the extent to which shape retention appears, can be determined in various ways depending on the type of thermosetting resin selected.

FIG. 4 is a partial process diagram of an example of the manufacturing method of the present invention,
FIG. 2 is a schematic perspective view showing a state in which an aqueous slurry of ALC raw material is poured into a decorative mold. In other words, it shows a state in which an aqueous slurry mainly composed of calcareous, silicic acid, and aluminum powder is poured into a molding frame made of a molded sheet obtained by hot press molding in which the thermosetting resin has not completely hardened. .

In the present invention, after pouring the aqueous slurry into a molding frame made of a molded sheet as described above, a reinforcing material is put in and left at room temperature for 1 to 10 hours to foam the aqueous slurry and harden it to a certain extent. By curing in an autoclave under predetermined conditions, the raw material aqueous slurry enters the voids in the nonwoven fabric, hardens together with the previously impregnated uncured thermosetting resin, and is integrated with the decorative sheet, for example, as shown in Figure 1. A decorated ALC as shown is obtained.

The aqueous slurry according to the present invention has limestone, silica, and aluminum powder as main components.

Calcareous material is a hardening agent for ALC, and quicklime, slaked lime, or cement such as Portland cement can be used.

The silica material is pozzolan or fine aggregate, and powders such as silica sand and crushed stone, clay, finely ground tiles, slag powder, and volcanic ash can be used.

The aluminum powder reacts with calcareous matter in the presence of water to generate hydrogen gas and foam the slurry, and preferably has a particle size of 10 to 3000 microns.

In addition, various additives can be added to the aqueous slurry as necessary. Examples of such additives include foaming promoters such as sodium hydroxide, dispersants made of surfactants, foam stabilizers such as saponin, and antifreeze agents such as zinc oxide and zinc sulfate.

In the aqueous slurry, the calcareous material and the silicic material are preferably mixed in a weight ratio of 1:1 to 1:5. More preferably, the ratio is 1:1 to 1:3. Aluminum powder is 0.001 for a total of 11,100 heavy lifting parts of calcareous and silicic materials.
~0.5 fold ff1 part is appropriate.

In preparing the above aqueous slurry, water is first added to calcareous and silicic acid, and the slurry is thoroughly stirred and mixed, and then aluminum powder is added and mixed. Additives are added at the same time as silica.

Further, the curing in the autoclave may be carried out for example at 150 ml.
It is carried out using steam at a high temperature of ~200°C at a pressure of 5 to 20 atmospheres for 5 to 15 hours.

[Example] The present invention will be explained in more detail below with reference to Examples.

A pre-printed melamine resin-impregnated paper and a laminate film of fluororesin and acrylic resin are laminated so that the acrylic resin and the impregnated paper are in contact with each other, and the resulting laminated sheet is hot-pressed to obtain a molding frame. Ta. (The reaction was 50% complete.) An aqueous slurry having the composition shown below was poured into this molding frame and left in this state for about 8 hours, causing the aqueous slurry to foam and harden. This was cured in an autoclave with saturated steam at 180° C. for 8 hours to completely cure it. i! has beautiful and solid decorations! flALc was obtained.

Water-based slurry Portland cement 2 parts quicklime
1 part by weight finely ground silica
1 part by weight aluminum powder
0.008 parts by weight water
6 parts by weight [Effect of the invention] As explained in detail above, the manufacturing method of the present invention allows
Decorative ALG with beautiful and solid decoration can be easily obtained.

[Brief explanation of drawings]

FIG. 1 shows a decorative ALC obtained by the manufacturing method of the present invention.
FIG. 2 is a schematic perspective view of one example seen from the decorative sheet side;
The figure is a schematic sectional view of an example of a decorative sheet used in the present invention, and FIG. 3 is a schematic perspective view showing an example of a decorative mold obtained by press-molding the decorative sheet by the method of the present invention. FIG. 4 is a partial process diagram of one example of the manufacturing method of the present invention, and is a schematic perspective view showing a state in which an aqueous slurry of ALC raw material is poured into a decorative mold.

Claims (1)

[Claims] After hot-pressing a multilayer sheet made by laminating a fibrous sheet impregnated with a thermosetting resin and a weather-resistant transparent film, the mold is removed before the thermosetting resin is completely cured, and the resulting molded sheet is A method for manufacturing decorative ALC obtained by pouring an aqueous slurry mainly composed of calcareous, silicic acid, and aluminum powder into a formwork, foaming and curing it, and then curing it in an autoclave.