JPH04182372A - Glass coated plate and its production - Google Patents

Abstract

PURPOSE:To obtain a dense glass coated plate having high glossiness and fine fanciness without causing cracking or peeling due to heat by forming a heat insulating inorg. layer having specified thermal and physical properties on the surface of autoclave-cured lightweight gas concrete (ALC), and then forming a glass layer. CONSTITUTION:A heat insulating inorg. layer is formed on the surface of ALC, thermal spraying is carried out on the surface of the layer to form a glass layer on the surface of the underlayer heated to the softening temp. of the glass and a glass coated plate for building is obtd. The heat insulating inorg. layer has <=0.5% rate of residual linear shrinkage after heating at 1,000>=C, <=12X10<-6>/ deg.C coefft. of thermal expansion and <=0.3kCal/m.hr.K heat conductivity at 20 deg.C.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to an inorganic building board used for the interior and exterior walls of buildings, and a method for producing the same. In particular, it relates to a glass coated plate having a glass layer on its surface.

[Prior art]

In recent years, building materials having a glass layer on the surface have been attracting attention as exterior materials because of their luxurious appearance and good durability as housing becomes more luxurious.

In addition, autoclave-cured lightweight aerated concrete (hereinafter referred to as ALC) has excellent heat insulation, fire resistance, and sound insulation properties, and because it is produced in a factory, it shortens the construction period.2 It is also excellent in quality and reliability, so it is commonly used as an exterior wall material. ing. As for the exterior finish of ALC, - A durable exterior material such as epoxy resin is used on the membrane surface, which has poor durability in the natural environment, and the exterior material must be replaced once every 4 to 5 years. Must not be. Further, when tiles or the like are pasted on the ALC surface, the tiles must be pasted one by one on the ALC, which takes time and causes problems such as peeling. In addition, when pasting an enameled iron plate, etc., processing of the enameled iron plate is time-consuming and costs are high.

In view of the above circumstances, several methods have been proposed for constructing a glass layer on the ALC surface with the aim of improving the weather resistance, waterproofness, and strength of the two surfaces.

Examples are JP-A-60-200878 and JP-A-61-5887.
No. 5.

Publications No. 61-155278, No. 62-230684, and No. 63-95179 state that the temperature of the ALC body is 300
A method has been proposed in which glass is thermally sprayed to form a glass layer directly on the ALC surface while maintaining the temperature below .degree. Furthermore, in Japanese Patent Application Laid-open No. 61-205684, a glass having a low melting point is thermally sprayed.

A method of forming a glass layer directly on the ALC surface has been proposed.

[Problems to be Solved by the Invention] However, in the method of spraying molten glass by thermal spraying, the temperature of the ALC surface does not rise.

The applied glass layer becomes porous and easily absorbs water.

A sealing process must be performed. In addition, even if thermal spraying is performed to prevent water absorption, it is not sufficiently melted and integrated on the surface of the glass, so it is difficult to obtain a dense glass layer such as the glass layer of tiles made by a method of sufficiently melting by firing. Can not. In addition, in the method of using low melting point glass as a thermal spraying material, 1. It is necessary to use low melting point glass to lower the heating temperature of the surface. 1. Low melting point glass on the membrane surface is equivalent to dense tiles immediately after construction. The lower the melting point, the worse the durability becomes, and phenomena such as devitrification and discoloration occur over time.

Therefore, in order to construct a uniform, dense, and highly durable glass layer on top of ALC, it is necessary to use glass with a high melting point and
The LC surface temperature must be raised above the melting temperature of the glass, and if the ALC surface temperature is raised to such a temperature, the ALC will shrink due to dehydration and decomposition of the hydrates in the ALC.
There was a drawback that cracks were generated and a glass layer that was dense, durable, and had excellent gloss could not be obtained without damaging the ALC.

[Means to solve the problem]

As a result of intensive research in order to solve the above problems and achieve the purpose, the present invention has been developed to fully heat and melt the glass on the product surface in the same way as tiles, and to reduce ALC from the heat of glass melting.
In order to protect the
10-6/℃ or less and thermal conductivity of 0.3 Kcal/m
, hr, K (at 20 °C) or less by providing an inorganic heat insulating layer to eliminate peeling of the base layer from the ALC and cracks in the base layer caused by surface heating, and to reduce the surface temperature to the melting point of the glass in order to melt the glass. Even if it is raised above the limit, the ALC will not be damaged.

We have also discovered that this can be achieved by thermal spraying or glass coating with sufficient gloss.

The base material used in the present invention is ALC. ALC is conventionally used: cement, lime.

A foamable slurry made of silica stone and aluminum is poured into a reinforcing mold and allowed to foam and harden.The slurry is then cut to a predetermined size and steam-cured under high temperature and pressure to form a foamed molded product.

The base layer used in the present invention has a residual linear shrinkage rate of 0.5% or less at 1000°C and a coefficient of thermal expansion of 12X10-6.
/℃ or less, thermal conductivity is 0.3Kcal/m
A cement mortar layer with a specific composition is made of an inorganic layer having a temperature of 20° C. or less, and is closely integrated with the ALC base material and the glass layer. The cement mortar layer consists of aggregate, cement) hydrate, lightweight aggregate, and additives used as necessary. If the heating residual linear shrinkage rate exceeds 0.5%, the cement mortar layer will be damaged during thermal spraying.
It becomes easy to peel off from C or crack in ALC. Also, when the coefficient of thermal expansion exceeds 12X10-6/℃,
Peeling of the cement mortar layer and ALC during thermal spraying
cracks are more likely to occur.

The thermal conductivity of the base layer is 0.3 Kcal/m, hr,
Must be below K (at 20℃), 0.3K
AL when exceeding cal/m, hr, K (at 20℃)
It becomes difficult to maintain the temperature of the C surface below 300° C., and cracking and peeling of the ALC and underlying layer occur due to heating of the surface.

The gloss of the surface glass layer obtained by thermal spraying becomes insufficient.

The aggregate in the base layer is a substance having an average thermal expansion coefficient of 2.0X 10-6/°C or less between room temperature and 1000°C.

Quartz glass, lithium-aluminosilicate, aluminum titanate, etc. can be used. These can be used alone or in a mixture of two or more. Its particle size is 2
It is preferable to use particles with a particle size of 1 mm or less. If the thermal expansion coefficient of the aggregate exceeds 2.0 x 10-6/°C, it becomes difficult to reduce the thermal expansion coefficient of the cement mortar layer to 12 x 10-6/°C or less.

The cement hydrate in the above-mentioned base layer is a hydrate produced by mixing commonly used cement such as Portland cement, blast furnace slurry cement, or alumina cement with water and curing, or Among these, alumina cement hydrate, which has excellent heat resistance, is particularly preferred.

As additives to be present in the base layer, 2. Substances used as aggregates or reinforcing materials in ordinary cement mortar. 2. For example, silica sand, silica stone, porcelain chamotte, wollastonite, carbon fiber, etc. can be used. I can do it.

As the lightweight aggregate in the base layer, commonly used inorganic foams 2 such as glass balloons are used.

Shirasu balloons, perlite, etc. can be used.

The mixing ratio of aggregate and cement in the base layer is preferably 100 to 500 parts by weight of aggregate to 100 parts by weight of cement. If the amount of aggregate is less than 100 parts by weight, it is difficult to keep the residual linear shrinkage rate after heating to 0.5% or less, while if it exceeds 500 parts by weight, the difference between the cement mortar layer and the ALC It becomes difficult to obtain sufficient adhesive strength, and there is a possibility that the adhesive will peel off due to mechanical impact.

The amount of the above additive is 4 parts by weight per 100 parts by weight of cement.
It is preferable that the total amount of aggregate and additives be 500 parts by weight or less and 500 parts by weight or less.

The amount of the above lightweight aggregate is 1 for 100 parts by weight of cement.
It is preferable to use 0 to 100 parts by weight.

If the weight of lightweight aggregate is less than 10 parts by weight, the thermal conductivity should be set to 0 or 3.
It is difficult to keep Kcal/m, hr, K (at 20°C) or less, and on the other hand, if it exceeds 100 parts by weight, it becomes difficult to obtain sufficient adhesive strength between the cement mortar layer and ALC. .

The coefficient of thermal expansion of the base layer consisting of aggregate, cement hydrate, additives, and lightweight aggregate must be 12X10-6/℃ or less, and furthermore, it must be close to the coefficient of thermal expansion of the glass used. desirable. The thermal expansion coefficient of the base layer can be determined by adjusting the amounts of aggregate and additives used within the above conditions to obtain a base layer with a desired thermal expansion coefficient. However, in order to minimize the influence of heat during thermal spraying on the ALC and the underlying layer, it is particularly preferable that the coefficient of thermal expansion is 7 x 10-6/°C or less.

The thickness of the base layer is preferably in the order of 3 to 15 mm; if it is less than 3 mm, the protective effect from heat during thermal spraying will not be sufficiently exhibited, resulting in cracking and peeling of the ALC. Furthermore, it is uneconomical to make the thickness thicker than necessary. It is preferable to set the required minimum thickness depending on the softening temperature of the glass to be thermally sprayed and the thermal spraying conditions.

Thermal spraying methods for glass can be any method in which a thermal spraying material is heated using combustion or electrical energy, and molten or nearly molten particles are sprayed onto the substrate to form a film, including powder flame spraying and plasma methods. Other thermal spraying methods are possible.

In addition, the glass to be thermally sprayed is 5102. Na2O, K2
O.

Glass containing chemical components such as CaO, B2O3, and PbO can be used, such as glass commonly sold as frit 1. In order to minimize the burden of heat during thermal spraying, it is preferable to use glass with a low softening temperature, but the lower the softening temperature of low melting point glass, the less durable it is. Frit I, which is used for tiles etc. whose temperature is 600°C to 1000°C, can be used.

Thermal spraying conditions vary depending on the thermal spraying machine used and the softening temperature of the frit, but it is not necessary to keep the surface temperature below 600℃ by increasing the moving speed of the thermal spraying gun or increasing the spraying distance, and it is not necessary to keep the surface temperature below 600℃. The surface temperature of the frit can be sprayed by slowing the movement speed so that it reaches the firing temperature of the frit.

Because the spraying is carried out at a slow moving speed and a short spraying distance, a coating different from ordinary thermal spray coatings is formed.

- When spraying conditions are applied to a film surface, the molten particles emitted from the spray can will cool and solidify on the surface of the material to be sprayed, and will never melt again. They do not fuse together or on the surface. Therefore, the sprayed coating formed is an aggregate of solidified particles with gaps between the six particles, resulting in a porous and non-uniform sprayed coating.

According to the method of the present invention, the temperature of the surface of the material to be sprayed can be lowered to the melting temperature of the frit by slowing down the moving speed and shortening the spraying distance.

Therefore, the molten particles flying from the thermal spray gun are once solidified or remelted on the surface of the material to be sprayed, and then fused with the particles that have flown successively and become integrated. Therefore, the sprayed coating formed becomes a dense and homogeneous glass layer.

The thickness of the glass coating to be thermally sprayed varies depending on the thermal spraying conditions used, and is preferably 30 to 2000 μm. If the thickness is less than 30 μm, it will not function as a sprayed glass layer. Depending on the amount supplied to the thermal spray gun on the flip 1, a glass film layer of 100 to 300 microns is formed in one thermal spraying process. A glass coating of desired thickness can be obtained by narrowing the spraying pitch or repeating spraying. It is uneconomical to make the glass layer thicker than necessary, and
This may cause peeling.

〔Example〕

Hereinafter, the present invention will be specifically explained based on Examples. The method for measuring the residual linear shrinkage rate and coefficient of thermal expansion after heating in Examples, the method for thermal spraying glass, and the method for evaluating the durability of the glass film after thermal spraying are shown below.

Measuring method of residual linear shrinkage and thermal expansion coefficient after heating at 01000°C Measuring equipment = (a) Rigaku thermomechanical analyzer Specimen dimensions Diameter 5 mm, height 20 mm Load on cylindrical specimen 50.93 g / lifting resistance Temperature rate: 10°C/min Maximum temperature and holding time: 1000°C for 5 minutes
'°Before heating (2°°0) 0 length 5 [''] ○ Method of measuring thermal conductivity (at 20°C) JISA 1412. AST
Compliant with MC518, using HC-070H model manufactured by Anglo-French Seiki Co. Glass spraying method Glass used: Nippon Ferro (manufactured by Kikisha Glass supply rate 30g/min Thermal spraying device manufactured by Metco Co., Ltd. 6P- ■ Thermal spraying speed: 9m/ min Scanning interval 5 mm Spraying distance 8 cm 〇 Temperature measurement of the base layer and ALC interface PR thermocouples with a diameter of 0.3 mmφ were embedded in each position, and the temperature during thermal spraying was measured with a digital voltmeter at a rate of once every 1 x 20 seconds. It was measured.

○ Measurement of Glossiness 90° reflectance was measured using a VG-2P-D3 model manufactured by Nippon Heavy Industries (Kikusha).

[Example 1] 100 parts by weight of alumina cement, 250 parts by weight of glass powder (coefficient of thermal expansion 0.5 x 10-6/°C), 50 parts by weight of glass balloon (Sunkirai I-YO4 manufactured by Sanki Kogyo), and 130 parts by weight of water. Parts by weight were mixed to form a uniform slurry.

This was applied on ALC to a thickness of 5 mm and cured in saturated steam at 60°C for 8 hours.

Dry thoroughly. Glass is sprayed onto this molded body.

A multilayer lightweight cellular concrete with a glass layer on the surface was obtained.

Residual linear shrinkage and thermal expansion coefficient after heating measured for cement mortar layer, thermal conductivity, base layer and AL during thermal spraying
Table 1 shows the temperature of the C interface, the degree of damage to the base layer after thermal spraying, and the glossiness of the surface glass layer.

Example 2 Alumina cement 100 parts by weight 1 quartz glass powder (coefficient of thermal expansion 0.5 x 10-6/°C) l O0 parts by weight, crushed stone powder (coefficient of thermal expansion 14.0 x 10-'/°C) 300 parts by weight.

Glass balloon (Sankirai l-YO2 manufactured by Sanki Kogyo)
20 parts by weight and 150 parts by weight of water were mixed to form a uniform slurry. Thereafter, a multi-layer lightweight cellular concrete having a glass layer on the surface was obtained in the same manner as in Example 1.

Cement 1 - Residual linear shrinkage and thermal expansion coefficient after heating measured for mortar layer, thermal conductivity, base layer during thermal spraying and A
Table 1 shows the temperature of the LC interface, the degree of damage to the base layer after thermal spraying, and the glossiness of the surface glass layer.

Comparative Example 1 100 parts by weight of alumina cement, 300 parts by weight of quartz glass powder, and 130 parts by weight of water were mixed to form a uniform slurry.

Thereafter, a multilayer lightweight cellular concrete having a glass layer on the surface was obtained in the same manner as in Example 1.

Residual linear shrinkage and thermal expansion coefficient after heating measured for cement mortar layer, thermal conductivity, base layer and AL during thermal spraying
Table 1 shows the temperature of the C interface, the degree of damage to the base layer after thermal spraying, and the glossiness of the surface glass layer.

Comparative Example 2 1,00 parts by weight of alumina cement l, 250 parts by weight of Walrus I-night (coefficient of thermal expansion 6.5 x 10-6/°C).

50 parts by weight of a glass balloon (Sanki Light manufactured by Sanki Kogyo) and 130 parts by weight of water were mixed to form a uniform slurry.

Thereafter, a multilayer lightweight cellular concrete having glass layers on two surfaces was obtained in the same manner as in Example 1.

Residual linear shrinkage and thermal expansion coefficient after heating measured for cement I mortar layer, thermal conductivity, base layer during thermal spraying and A
Table 1 shows the temperature of the LC interface, the degree of damage to the base layer after thermal spraying, and the glossiness of the surface glass layer.

= 15- [Effect of the invention] The surface of autoclave-cured lightweight cellular concrete (ALC) has a heating residual linear shrinkage rate of 0.5 at 1000°C.
% or less, thermal expansion coefficient is 12X 10-6/℃ or less, and thermal conductivity is 0.3 Kcal/m, hr, K(at
By providing an inorganic heat insulating layer at a temperature of 20° C. or lower and thermal spraying on its surface, it is possible to raise the surface of the base layer to a temperature higher than the softening temperature of the glass and to construct a sufficiently fused and integrated glass layer. As a result, the glass is sufficiently melted and a dense, homogeneous, high-gloss glass layer is integrated on the ALC surface without cracking or peeling due to heat deterioration of the ALC.A ceramic coating composite with excellent design. You can get a board. By using this ceramic coating, there is no need to affix tiles to the ALC surface, a glass coating layer can be efficiently obtained on the ALC surface, and there is no fear of peeling.

Patent applicant: Asahi Kasei Industries, Ltd.

Claims (1)

[Claims] 1. Autoclave-cured lightweight aerated concrete (ALC)
) has a heating residual linear shrinkage rate of 0 at 1000°C.
．． 5% or less, the thermal expansion coefficient is 12 x 10^-^6/℃ or less, and the thermal conductivity at 20℃ is 0.3 Kcal/m
．． hr. 1. A construction board material, characterized in that a glass layer is present through an inorganic heat insulating layer of K or less, and each layer is closely integrated. 2. Autoclave-cured lightweight aerated concrete (ALC)
) has a heating residual linear shrinkage rate of 0 at 1000°C.
．． 5% or less, the thermal expansion coefficient is 12 x 10^-^6/℃ or less, and the thermal conductivity at 20℃ is 0.3 Kcal/m
．． hr. A method for manufacturing a glass-coated architectural board material, which comprises providing an inorganic heat insulating layer of K or less, and providing a glass layer on the surface by thermal spraying.