JPH0568431B2 - - Google Patents

Description

[Detailed description of the invention]

[Technical Field of the Invention] The present invention relates to a method for manufacturing a lightweight board material for a composite board that is lightweight, has good water resistance, and has high strength. [Disadvantages of the Prior Art] Various types of light board materials that are lightweight and have excellent fireproofing, soundproofing, and heat insulating properties have been manufactured and supplied for use in the manufacture of composite boards. In general, the above-mentioned lightweight board materials are used in combination with other decorative board materials, rather than being used alone, that is, they are used as composite board core materials for sand German boards. For example, specific examples of lightweight board materials include , wood wool cement board, perlite mortar board, perlite molded board, foam glass board, and other organic foams are well known. However, although wood wool cement boards, pearlite mortar boards, etc. have particularly excellent strength, their high specific gravity tends to limit their use as lightweight board materials for composite boards, and their heat insulation properties are not necessarily favorable. In addition, perlite molded plates, foam glass plates, etc.
Apart from its good fire resistance, it also has the drawbacks of high specific gravity and relatively brittleness.
This poses a problem in transportation, which still causes inconvenience in the production of lightweight composite board materials.
Furthermore, organic foam has excellent lightness, heat insulation, sound insulation, etc., and has the advantage that it can be easily filled into hollow parts when manufacturing lightweight board materials for composite boards, but it is not only weak against heat and fire. When this is a molded plate, it is inconvenient to carry, and when foaming on site, it may cause corrosion of the insulation target. Under these circumstances, various efforts have been made to use lightweight aggregates such as perlite, which are inexpensive and have elements that provide the above objectives.
For example, by bonding pearlite particles with a relatively small amount of binder such as cement, powder, synthetic resin, etc., by fusing pearlite particles with each other, or by interposing inorganic fibers between them, lightweight and fireproof properties can be achieved. However, it has not been possible to obtain a lightweight board material for composite boards that is suitable for such uses. [Means to be Solved by the Invention] The present invention aims to provide a lightweight board material as described above that can be used for a composite board that is lightweight and has excellent water resistance, fireproofing properties, soundproofing properties, heat insulation properties, etc. In particular, this can be achieved by blending a specific inorganic foam curable composition and lightweight aggregate, filling this into a space with a specific structure, that is, inside a mold having a honeycomb core, and foaming and hardening it. It is something that That is,
In the present invention, when manufacturing a lightweight board material for a composite board by filling a formwork with a foam-hardening composition, a honeycomb core is formed in the formwork in advance, and the voids of the honeycomb core are filled with (a) consisting of a water-soluble alkali metal silicate solution, (b) a metal blowing agent, (c) a water-soluble alkali metal silicate hardening agent, (d) a lightweight aggregate, and (e) water, and (d) component 100 volume. The composition is characterized by being filled with a foaming curable composition in which the total amount of (a) + (b) + (c) + (e) is 2 to 40 parts by volume per part, and then foaming and hardening. . [Object of the invention] The lightweight board material for composite board obtained in this way is lightweight, has good water resistance, high compression and bending strength, has excellent fireproofing properties, shrinkage-expansion resistance, soundproofing properties, etc., and is easy to process such as cutting and handling. It has very good workability and is of great utility in the production of composite plate materials. Hereinafter, the configuration of the present invention will be explained in detail. [Structure of the Invention] In the present invention, a water-soluble alkali metal silicate is used as the component (a), and this allows easy foaming and hardening with excellent performance by simply mixing it with other raw materials at room temperature. It exhibits effective caking properties and makes the foaming reaction efficient. Examples of the alkaline components constituting component (a) include lithium, sodium, potassium,
Alkali metal silicates such as rubidium can be exemplified, and sodium and potassium are particularly desirable because they are inexpensive and easily available, and moreover, they significantly accelerate the hardening effect of the composition. Furthermore, as long as component (a) is water-soluble, there are no restrictions on its composition or the molar ratio of the alkaline substance to SiO ₂ . Further, as the component (b), a metal foaming agent is used, and various metal elements, metal alloys, and intermetallic compounds can be used. Metal elements include B, A, B, A, B, A, B of the periodic table,
B, B, and those belonging to the group are preferable, and such metal elements include Cr, Mn, Ti, Zr, V, Si,
Examples include Ge, Sb, Co, Ni, Cu, Zn, Al, Ca, etc., and Ti, Zr, V, Al, Si, Ge, Sb, Zn, etc. are particularly desirable. Alloys or intermetallic compounds (chemical combinations between metals or between metals and nonmetals)
Representative examples include Al-Si, Al-Ti,
Al-Mn, Al-Cu, Al-Cu-Si, Zn-S, Zn-
Examples include Sn, Cu-Si, Fe-Si, Si-Ni, Co-Sb, and the like. One or more of these metal foaming agents are usually used in the form of fine powder. Next, as component (c), a water-soluble alkali metal silicate curing agent is used, and component (e) serves to reinforce the curing of component (a). Examples of such hardening agents include hydraulic cement, silica dust,
Acidic metal oxides, blast furnace slag, divalent or higher metal salts of higher fatty acids, divalent or higher metal salts of water-soluble polymer substances having carboxyl groups, phosphates, borates, sulfates of divalent metals, and It is at least one selected from the group of divalent metal sulfites. Specific examples of this curable component are as follows.
Hydraulic cements include portland cement, alumina cement, blast furnace cement, silica cement, etc. Divalent or higher metal salts of higher fatty acids are typical examples, such as zinc salts and aluminum salts of stearic acid and palmitic acid, and carboxyl group The water-soluble polymer is composed of alginic acid, polyacrylic acid, etc., and the divalent or higher-valent metal is Zn, Mg, Be, Sr, Ba,
A metal selected from Al, Ti, Zr, etc., which forms a salt with the water-soluble polymer and the metal, and acidic metal oxides such as ZnO, Cr ₂ O ₃ , MnO ₂ , MnO,
FeO, CoO, PbO, etc.; phosphates include aluminum phosphate, calcium phosphate, zinc phosphate, magnesium phosphate, etc.; borates include zinc borate, magnesium borate, calcium borate, etc. Examples of metal sulfates include magnesium sulfate, zinc sulfate, and calcium sulfate, and examples of divalent metal sulfites include calcium sulfite and magnesium sulfite. The component (d) in the present invention uses lightweight aggregates, including expanded pearlite (simply referred to as pearlite), which is a foamed or expanded natural mineral, expanded shale, expanded vermiculite, pumice,
In addition to whitebait balloons, it also includes artificial lightweight aggregates such as silica gel foam, granulated and foamed products of various slags, and foamed products of clay powder. Among these, expanded or foamed materials, particularly those with high bubble independence, light weight, and spherical shape, are preferred, such as pearlite, shirasu balloons, silica gel foams, glass balloons, and the like. As mentioned above, the foamed curable composition used in the present invention consists of the above-mentioned four components and (e) water added, and the blending ratio is the solid content equivalent of component (a).
For 100 parts by weight, component (b) is 2 to 100 parts by weight, component (c) is 5 to 100 parts by weight, and component (e) is 10 to 100 parts by weight,
In addition, the ratio of the total amount of these components (a) + (b) + (c) + (e) to the amount of component (d) is (a) + component (d) to 100 parts by volume.
(b) + (c) + (e) components should be 2 to 40 parts by volume, and when the so-called binder component ((a) + (b) + (c) + (e)) is less than 2 parts by volume , it is difficult to obtain a good one with the desired strength, and 40
If it exceeds the capacity part, not only the heat insulation properties but also the bending strength tends to decrease. The production method of the present invention comprises the above four components ((a) + (b) + (c)
The purpose of the present invention is to fill a mold having a honeycomb core with a foamed curable composition paste containing component (d) and water (e), and this operation can be easily performed at room temperature or under heating. Honeycomb core is also called hollow core material, and its materials include paper, metal, plastic, and
Although there are various types of cores such as those made of asbestos, paper honeycomb cores are the cheapest and most suitable for use in the present invention. Paper honeycomb cores are specifically specified in JIS A 6931, and in addition to those made of paper alone, there are also those impregnated with resin. Examples of the metal honeycomb core include aluminum, stainless steel, and titanium. Next, the shape of the honeycomb core includes, in addition to the typical hexagonal shape, a circular shape, a rib shape, a cardboard shape, an origami shape, etc., but it is not particularly influenced by the shape. The size of the core is not particularly defined, and may be appropriately selected depending on the application. In addition to the above five components, fillers, viscosity modifiers, anti-sag materials, etc. can be added as appropriate. [Effects of the Invention] According to the present invention, the following advantages can be enumerated in manufacturing the lightweight board material for the composite board. That is, (1) In practical use, a lightweight board material with a specific gravity of about 0.2 generally has low strength, but the lightweight board material obtained by the present invention can have a specific gravity adjusted to about 0.05 to 0.3, although it varies depending on the composition. Unexpected compressive strength and bending strength (also called shear strength) can be obtained by the combined effect of the strength of the honeycomb core itself and the foamed hardened body. It is estimated that such an effect is achieved when a honeycomb core is used alone, for example, when subjected to a compressive load, the stress is only dispersed to the partition walls forming the core, but according to the lightweight board material for composite board of the present invention, the core This is because it is dispersed and relaxed by the lightweight aggregate of the foamed hardened body formed inside. Therefore, a lightweight board material for a composite board that is lightweight and has high strength can be obtained. In addition, (2) even if the honeycomb core is made of paper, the foamed hardened material is nonflammable;
Since the water-soluble alkali metal silicate in the foamed hardening composition is partially impregnated into the paper, the fireproofing properties are very good. Furthermore, (3) as mentioned above, the honeycomb core functions like a cushion material for a cured foam and has higher elasticity than other lightweight inorganic board materials. Furthermore, (4) the sound absorbing properties of the honeycomb core and the sound insulating properties of the cured foam combine to improve soundproofing properties. On the other hand, (5) in the previous application, the present inventors created a product that did not use a water-soluble alkali metal silicate curing agent, but although the previous application did not have good water resistance, the present invention It has been found that the water resistance has been greatly improved and that it can withstand water penetration when used externally. Others (6) It is robust and exhibits considerable elastic strength, so it has excellent dimensional stability and cutting workability. Composite boards with a sandwich structure have traditionally been used, in which the lightweight board material mentioned above is used as the core material of the composite board, and various decorative materials such as decorative asbestos slate, colored galvanized iron plates, and colored aluminum plates are used above and below the core material. Extremely strong compared to composite boards. Hereinafter, this will be explained in detail using examples. [Embodiments of the Invention] Example 1 A foam curable composition having the following formulation was used.

[Foam curable composition] Sodium silicate (water glass No. 1, solid content 40%)
100 parts by weight (in terms of solid content) Metallic silicon powder 25 parts by weight Alumina cement 20 parts by weight Water 160 parts by weight These were mixed to make a paste, and the specific gravity was 1.4. To 12 parts by volume of this paste, 100 parts by volume of pearlite having a specific gravity of 0.05 and a particle size of 2 to 5 mm was blended to obtain a foam curable composition. Next, the paper core for panels specified in JIS A 6931 has a hexagonal shape, width 40 cm, length 80 cm, and thickness 25 cm.
Asbestos slate with a thickness of 3 mm is installed at the bottom of a honeycomb core with a cell size of 25 mm through a removable plastic sheet, and the foam curable composition is filled to about 1/4 of the height, and then the top of the honeycomb core is When the composition was pressed with asbestos slate through a removable plastic sheet and left at room temperature, the foam-curable composition started foaming after about 20 minutes, hardened after 35 minutes, and the specific gravity decreased.
A lightweight plate material of 0.15 was obtained. Using this composite plate material, a compressive strength and shear strength test specified in JIS A 6931 was conducted, and the compressive strength was 6.1 Kgf/cm ² and the shear strength was 1.1 Kgf/cm ² . Further, this paper was immersed in water for one week, but there was no change other than wrinkles in the paper. Furthermore, when the elastic modulus, saw cutting properties, and soundproofing properties were tested, they were better than the conventional lightweight board material 3. Comparative Examples 1 to 3 In the examples, a paper honeycomb core alone without using a foam curable composition was used as a lightweight board material (Comparative Example 1), and a paper honeycomb core was used as a lightweight board material in which a foam curable composition was foamed and hardened alone (Comparative Example 1). Example 2) and a foam curable composition using a composition excluding alumina cement (Comparative Example 3) were prepared and subjected to compressive strength, shear strength and water resistance tests. value was obtained. Compressive strength of Comparative Example 1: 1.3Kgf/cm ² Shear strength: 0.72Kgf/cm ² Water resistance: Shape completely collapsed Compressive strength of Comparative Example 2: 0.57Kgf/cm ² Shear strength: 0.34Kgf/cm ² Water resistance : Compressive strength of Comparative Example 3 with no abnormality: 5.9 Kgf/cm ² Shear strength: 1.2 Kgf/cm ² Water resistance: Paper has many wrinkles, cured product is 1/
It lost its shape by about 10 degrees.

Claims (1)

[Claims] 1. When manufacturing a lightweight board material for a composite board by filling a formwork with a foam-hardening composition, a honeycomb core is formed in the formwork in advance, and (a) a water-soluble Alkali metal silicate solution, (b)
It consists of a metal foaming agent, (c) a water-soluble alkali metal silicate hardening agent, (d) a lightweight aggregate, and (e) water, and for 100 parts by volume of the (d) component, (a) + (b) ) + (c) + (d) in a total amount of 2 to 40 parts by volume of a foamed curable composition;
A method for manufacturing a lightweight board material for a composite board, which is characterized by foaming and hardening.