JPH03236458A - Laminated plate and its production - Google Patents

Abstract

PURPOSE:To produce a laminated plate excellent in adhesive strength of coating layer by thermally spraying a metal on the surface of an inorganic plate containing thermally melting material and anchoringly allowing a part of the resulting molten metal to infiltrate into voids in the surface layer and integrating them. CONSTITUTION:A hydraulic inorganic material, such as cement, is kneaded together with thermally melting material, such as vinyl resin, aggregate, and water so as to be molded into a plate-like green plate, which is cured. A molten metal, such as Sn, Pb, and Zn, is sprayed at least on one surface of the resulting inorganic plate by a thermal spraying method. The thermally melting material existing in the surface layer part of the inorganic plate is melted by means of heat at the time of thermal spraying. This thermally melting material is shrinked or infiltrated into the inorganic plate, by which many voids or minute pores are formed in the surface layer part of the inorganic plate. A part of the molten metal is infiltrated into these voids, and a molten metal layer integrated by means of an anchoring effect is formed. The molten metal is cooled and solidified, by which a metal coated layer can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a composite plate and a method for manufacturing the same, and more particularly to a composite plate in which a metal coating layer is formed on an inorganic plate and a method for manufacturing the same.

<Prior art> Japanese Patent Laid-Open No. 50-12948 discloses that 90%
A heat-resistant board is disclosed in which a metal or alloy having a melting point of 00C or lower is thermally sprayed, and a metal or alloy having a melting point of 100 to 1600C is further thermally sprayed thereon. This conventional board is thermally sprayed in two layers and is said to have excellent heat resistance and water resistance.

<Invention or Problem to be Solved> The heat-resistant board according to the above-mentioned prior art has a porous surface such as hardboard, plywood, or wood, and when the surface is porous, the heat-resistant board according to the above-mentioned prior art does not contain molten metal sprayed on the substrate. In the case of inorganic plates such as slate or ceramics, sufficient adhesion cannot be obtained because the surface is dense and smooth, and the metal layer It has the disadvantage that it easily peels off from the base material. In order to alleviate or eliminate this drawback, it may be possible to polish the surface of the inorganic board by sanding, brushing, etc. to make it rough and then spray molten metal on it, but the strength decreases due to the thinning of the board. As a result, a polishing process such as sanding and a dust removal process for removing dust generated by such polishing must be added to the production process, resulting in inefficiency and increased costs.

Means for Solving the Problems> The present invention was completed through intensive efforts to solve the problems in view of the drawbacks of the prior art. Thermal spraying is applied to at least one surface of an inorganic plate, which is obtained by mixing a heat-fusible material as the main raw material and is formed by melting the heat-fusible material present at least in the surface layer and forming a large number of voids. This is a composite plate characterized in that a metal coating layer is formed by closely integrating a metal part into the gap in an anchoring manner.

The present invention also provides a method for producing such a composite material, which comprises mixing and kneading a hydraulic inorganic material as a main raw material with a thermofusible material, aggregate, and water. A plate-shaped raw board is formed, this plate-shaped raw board is cured and hardened to form an inorganic board, and molten metal is sprayed onto at least one surface of this inorganic board by a thermal spraying method, and at least the surface layer of the inorganic board is sprayed by the heat during the spraying. A molten metal that is formed by melting a heat-fusible material existing in a part of the inorganic plate, and a part of the molten metal being anchored and integrated into a large number of voids formed in the surface layer of an inorganic plate by melting the heat-fusible material. form a layer,
It is characterized in that it is then cooled to solidify the molten metal layer as a metal coating layer.

Alternatively, the inorganic plate may be cured and hardened at a temperature higher than the melting temperature of the heat-fusible material, melted at this stage to form a large number of voids in the surface layer of the inorganic board, and the sprayed metal may be filled into the voids. The metal coating layer can also be formed so as to be brought into close contact with each other in an anchoring manner.

<Specific description of the structure of the invention> The substrate in the composite plate according to the present invention is formed into a desired shape by adding and mixing a thermofusible material, aggregate, and water to a hydraulic inorganic material as a main raw material. It is an inorganic board.

Although cement is generally used as the hydraulic inorganic material, other hydraulic inorganic materials such as slag, carunium silicate, gypsum, etc. can be used, or these can be used in combination with cement.

Examples of heat-melting materials include vinyl resin, polyvinyl chloride resin, polyethylene resin, polypropylene resin, and ethylene resin.
Organic materials made of synthetic resins such as vinyl acetate copolymer resins, polystyrene resins, and acrylic resins, specifically those obtained as organic fibers, organic granules, organic foam granules, organic foam pulverized granules, etc. It can be used alone or in combination.

The organic fiber preferably has a fiber length of 0.2 to 5 mm.

The organic granules preferably have a particle size of 0.5 to 5 mm.

The organic foamed granules preferably have an expansion ratio of 10 to 60 times. It is preferable that the organic foamed pulverized granules have a particle size of 0.5 to 5 mm obtained by pulverizing the above-mentioned organic granules or organic foamed granules.

As aggregates, slag, silica sand, calcium carbonate, glue,
/ Expanded aggregates or reactive aggregates such as lime flour, slang, incinerated ash, and recycled inorganic board powder are used.

In addition to these, reinforcing agents such as melamine resin, acrylic resin, methyl cellulose, polyethylene glycol, and polypropylene glycol, water reducing agents, and lubricants are added and mixed as necessary.

An appropriate amount of water is added to these mixtures and kneaded, and the resulting kneaded product is formed into a plate-like green board of a desired thickness by any method such as extrusion molding, Fourdrinier papermaking, round netting method, or pouring method. Then, this plate-like raw board is put into a steam curing chamber for primary curing, and then put into an autoclave apparatus for second curing and curing to obtain an inorganic board.

A necessary amount of molten metal is sprayed onto the surface of the inorganic plate thus obtained using a thermal sprayer. Metal spraying is not limited to the surface of the inorganic board, but also to the necessary areas such as the back side, buttside surface, etc.
Or, it can be applied to cover the entire surface.

It is preferable that the material temperature of the surface of the inorganic plate on which metal spraying is performed is at least room temperature or higher; if it is 10° C. or lower, the sprayed molten metal is likely to cool at the interface, resulting in a decrease in adhesion. Therefore, it is preferable to carry out metal spraying while the temperature of the inorganic plate after curing and hardening is high, or at least after warming the surface on which the molten metal is to be sprayed.

As the metal to be thermally sprayed, metals or metal alloys such as tin, lead, zinc, copper, brass, bronze, aluminum, nickel, iron, and stainless steel are preferably used.

In addition, thermal spraying methods include the commonly used electric wire thermal spraying method,
Either a gas wire thermal spraying method or a powder thermal spraying method may be employed.

As mentioned above, inorganic plates are mixed with heat-melting materials such as organic fibers made of synthetic resin, organic granules, organic foam granules, and organic foam pulverized granules. The heat-melting material present in the surface layer of the plate is melted. The melted thermofusible material shrinks or penetrates into the inorganic plate, forming a large number of voids or small pores in the surface layer of the inorganic plate. Therefore, a portion of the sprayed molten metal enters into these gaps, and a molten metal layer that is tightly integrated due to the anchoring effect is formed.

In this way, the inorganic plate fixed to the surface of the molten metal layer is naturally cooled or forcedly cooled, and the molten metal is cooled and solidified to obtain a metal coating layer.

If necessary, the surface layer of the metal coating layer can be oxidized by chemical treatment or the like to form an oxide coating layer.

In the above method, the heat-melting material mixed into the inorganic plate is melted by the heat during metal spraying to form a large number of voids in the surface layer of the inorganic plate. The thermofusible material is melted by the curing heat during the primary curing or secondary curing of the green board, and voids can be formed in the surface layer of the green board. In other words, primary curing or secondary curing is performed at a temperature higher than the melting temperature of the heat-fusible material mixed into the green board, and the inorganic board obtained after curing and hardening is cured at least in its surface layer. There are many scattered voids formed as the meltable material melts. The curing temperature in the primary curing or secondary curing performed to form a large number of such voids varies depending on the melting temperature of the heat-fusible material to be mixed, but is generally 6.
The curing time is generally 5 to 48 hours, which is sufficient to melt at least the heat-fusible material in the surface layer of the green board. In this way, an inorganic plate is obtained in which a large number of fine voids are formed due to the melting of the heat-fusible material at least in its surface layer, and a metal coating layer is formed on the surface by spraying molten metal as described above. be able to.

<Effects of the Invention> Since the composite material according to the present invention is composed of an inorganic plate mixed with a heat-fusible material, this heat-fusible material is melted by the heat during curing or metal spraying, and the heat-fusible material melts onto the surface of the inorganic plate. A large number of voids are formed. Therefore, the sprayed molten metal enters into these voids like an anchor, forming a metal coating layer with excellent adhesion.

Claims (7)

[Claims] (1) An inorganic material that is obtained by mixing a thermofusible material with a hydraulic inorganic material as the main raw material, and in which a large number of voids are formed by melting the thermofusible material present at least in the surface layer. 1. A composite plate, characterized in that a metal coating layer is formed on at least one surface of the plate by a part of a sprayed metal being tightly integrated into the gap in an anchoring manner. (2) The composite plate according to claim 1, wherein the surface layer of the metal coating layer is oxidized to form an oxidized metal coating layer. (3) Using a hydraulic inorganic material as the main raw material, mix and knead the thermofusible material, aggregate, and water to form a green plate, cure and harden the green plate to form an inorganic plate, and Molten metal is sprayed onto at least one surface of the inorganic plate by thermal spraying, and the heat during the spraying melts the heat-fusible material present at least in the surface layer of the inorganic plate, and the melting of the heat-fusible material melts the inorganic metal. A portion of the molten metal is anchored and integrated into a large number of voids formed in the surface layer of the plate to form a molten metal layer, and then cooled to solidify the molten metal layer as a metal coating layer. A method for manufacturing a composite board, characterized by: (4) Using a hydraulic inorganic material as the main raw material, mix and knead the heat-fusible material, aggregate, and water to form a green plate, and form the green plate at a temperature higher than the melting temperature of the heat-fusible material. Curing and hardening at a temperature of 100 to form an inorganic plate with a large number of voids formed by melting the heat-fusible material in at least the surface layer thereof, and spraying molten metal onto at least one surface of the inorganic plate by a thermal spraying method. , forming a molten metal layer in which a part of the molten metal is tightly integrated in an anchoring manner in the void of the surface layer of the inorganic plate, and then cooling to solidify the molten metal layer as a metal coating layer. A method for manufacturing a composite board, characterized by: (5) The heat-melting material is made of a synthetic resin, and is any one of organic fibers, organic granules, organic foam granules, and organic foam pulverized granules, or a mixture of several of them. The method for manufacturing a composite plate according to claim 3 or 4. (6) The method for manufacturing a composite plate according to claim 3 or 4, wherein the spraying of the molten metal is carried out in a state where the temperature of the inorganic plate is 10° C. or higher after curing and hardening. (7) The method for manufacturing a composite plate according to claim 3 or 4, further comprising oxidizing the surface layer of the metal coating layer to form an oxidized metal coating layer.