JPH0627371Y2 - Nonwoven fabric for reinforcing inorganic molded body and inorganic molded body - Google Patents

Description

[Detailed Description of the Invention] [Industrial field of application] The present invention relates to a nonwoven fabric for reinforcing an inorganic molded body and an inorganic molded body reinforced by the nonwoven fabric.
A matrix of kneaded cement slurry or gypsum slurry, or a non-woven fabric joined as a reinforcing member to the surface of an inorganic molded product produced by curing the mixed matrix of the both, and an inorganic molded product reinforced by the non-woven fabric. Regarding

[Conventional technology]

In recent years, along with the increase in the structure of buildings, the method of constructing the outer wall is changing from the wet method to the dry method in order to shorten the construction period and simplify the construction method. With the spread of this dry method, it is desired to provide an outer wall material that is inexpensive, has excellent water resistance, and has a good construction method.

Conventionally, a large amount of gypsum board is used as a building panel, and it is used in a wide variety of applications, but its use is mostly limited to a base plate, and it is not used as an interior material such as a wall material or a partition material. It is rare, and due to lack of water resistance and strength, it was practically impossible to use as an outer wall material.

[Problems to be solved by the device]

By the way, the inorganic molded body as described above has been used as a wall layer material by adhering a surface covering material such as a board base paper to the surface thereof until now, but the board base paper may give water resistance. However, it was impossible to use it as a building material around water or as an outer wall. In addition, since the board base paper is accompanied by a strength problem of peeling the layer film of the paper,
It was difficult to use it in fields other than painted wall surfaces and wallpaper where delamination is not a serious problem.

In order to overcome the above restrictions found in board base paper, it has been attempted to use a non-woven fabric made of irregularly joined short fibers instead of board base paper, but due to lack of hydrophilicity, it was kneaded. It is difficult to exude the matrix of cement slurry or gypsum slurry into the three-dimensional lattice-like voids of the short fibers that make up the non-woven fabric.Therefore, there are major restrictions on the production of inorganic moldings with improved bonding strength with the surface covering material. Was attached.

On the other hand, cement-based compacts such as lightweight expanded concrete (ALC), which have been used as a surface material for building structures in recent years, have high water absorption and can be used as an exterior material only by applying an exterior finish including surface treatment. It has been pointed out that it can be used, and that it is easily damaged during the manufacturing process, during transportation, or during construction, and that it is damaged by the action of a slight impact load after construction. In addition, the cement-based molded product is accompanied by a construction constraint that it is difficult to bond it to another structure or to form a composite.

Further, conventionally, a mesh or a non-woven fabric which does not permeate an aggregate but permeates a paste has been proposed in JP-A-50-96617 (hereinafter referred to as the former). Japanese Patent Application Laid-Open No. 58-60682 (hereinafter referred to as the latter) proposes a method in which an adhesive containing a hydrophilic resin is impregnated with the former.
The non-woven fabric is not joined in advance with a binder, and the latter does not specify the blending ratio of the fiber and binder constituting the non-woven fabric and the blending ratio of the hydrophilic resin in the binder, and when joining with the binder. However, this has a drawback that the inorganic material cannot be uniformly exuded into the non-woven fabric and sufficient strength as a covering material or outer wall material cannot be provided. .

The present invention has been proposed in order to solve this in view of the above-mentioned drawbacks of the prior art, and its object is to leach out an inorganic material suitable as a surface material for an inorganic molded article,
It is an object of the present invention to provide a reinforcing non-woven fabric excellent in bonding property, water resistance, alkali resistance and impact resistance, and an inorganic molded product reinforced by the non-woven fabric.

[Means for Solving the Problems] In order to achieve the above object, the present invention provides a continuous inorganic molded body by pouring a kneaded cement slurry, a gypsum slurry matrix, or a mixed matrix of both into a mold. In the production of, is stretched on the inner surface of the mold prior to pouring, is a non-woven fabric that is integrated with the matrix and is controlled so that the matrix does not adhere to the mold, The non-woven fabric comprises the constituent fibers and the binder in a weight ratio of 55/45 to 6
It is blended in a ratio of 5/35, and the constituent fibers are bonded in advance in a three-dimensional lattice by a binder, and exuding voids of 30 μm to 400 μm are formed between the fibers in the bonded state, and the binder is used. The present invention provides a non-woven fabric for reinforcing an inorganic molded body, which comprises 10 to 30 parts by weight of a hydrophilic resin with respect to 100 parts by weight of a binder main agent.

In addition, the present invention uses a weight ratio of the constituent fibers and the binder of 55.
/ 45 to 65/35 in proportion, and with the binder in which 10 to 30 parts by weight of the hydrophilic resin is added to 100 parts by weight of the binder main component, the constituent fibers are
A non-woven fabric bonded in a three-dimensional lattice pattern with exudation voids of 30 μm to 400 μm formed between the fibers is stretched on the inner surface of the mold, and the matrix of the kneaded cement slurry or gypsum slurry is placed in the mold. Alternatively, the mixed matrix of the both is poured into a mold to form a strong joint structure between the non-woven fabric and the hardened body of the slurry due to uniform exudation of the slurry, and then taken out from the mold. The present invention provides an inorganic molded article characterized by the above.

[Operation] With the configuration of the present invention, the constituent fibers of the non-woven fabric are firmly bound together by both the binding force of the binder and the binding force of the inorganic material.

In particular, the present invention provides a "weight ratio of constituent fiber and binder of 5
5/45 to 65/35 "and" hydrophilic resin "in the binder at a ratio of 10 to 30 parts by weight with respect to 100 parts by weight of the binder main component. The constituent fibers are preliminarily 30 μm to 40 μm between the fibers.
Bonded in a three-dimensional lattice with 0 μm exudation voids formed, which improves the binding force between the fibers of the non-woven fabric and makes the exudation amount of the inorganic material slurry uniform and suitable. In addition, the affinity and the binding force between the inorganic material and the non-woven fabric can be improved, and the binding force between the inorganic material and the non-woven fabric can be further strengthened.

〔Example〕

The matrix of the cement slurry in the present invention is
It means uncured concrete or mortar that has been kneaded with water, and the matrix of gypsum slurry is a water-kneaded product of α-hemihydrate gypsum or β-hemihydrate gypsum, in which the hardening reaction occurs at room temperature as it is. means. As the cement, one having a particle size of about 10 μm is usually used, while as the gypsum, in addition to by-product gypsum such as flue gas desulfurization gypsum and phosphate gypsum, natural gypsum generally called hemihydrate gypsum can be used. The particle size is preferably 10 μm to 200 μm.

Matrix of the above cement slurry or gypsum slurry,
Alternatively, the non-woven fabric used as a reinforcing member for the mixed matrix of both is prepared by feeding the fibers (1) to a carding machine (not shown) according to a conventional method as shown in FIG. 1 and layering the individual fibers in a fleece shape. By joining these fibers into an integral structure with an appropriate amount of binder, a porous fiber structure having an irregular joining form is formed. The nonwoven fabric (2) formed by irregularly joining the fibers (1) (1) ... As shown in the enlarged view of FIG. 2, the fibers (1) (1) ... Exuding voids (4) of an inorganic component [cement particles or gypsum particles (3)] of 30 μm to 400 μm are formed between each other.

The amount of the inorganic component (3) seeping into the mold (5) is influenced by the size of the voids (4) formed between the fibers (1) (1) ... . If the amount of the inorganic component (3) seeping into the void (4) is too large, the mold (5)
Stains, and continuous production of the inorganic molded body (6) becomes impossible. In particular, when gypsum that easily aggregates is used as the inorganic component (3), the aggregate growth of the gypsum component adhering to the mold (5) rapidly progresses, and the stability of the molding process decreases.

On the other hand, when the exudation amount of the inorganic component (3) into the voids (4) is insufficient, the nonwoven fabric (6) stretched on the inner surface of the mold (5) as a reinforcing material for the inorganic molded product (6) ( 2) The joint strength with 2) will fall sharply.

In order to avoid such obstacles, the fibers (1) (1)
The size of the exudation voids (4) (4) formed between each other is set in the range of 30 μm to 400 μm, and the hydrophobic fiber (1) having a single fiber denier of 0.8 to 2.0 denier is In the production of the nonwoven fabric, it is desirable to adjust the fiber blending ratio in the carding process and the amount of the binder applied in the bonding process so as to occupy at least 40 parts by weight in the total weight of the nonwoven fabric (2).

Further, as the fibers (1) (1) forming the nonwoven fabric (2), hydrophilic fibers are used in addition to hydrophobic fibers such as polyester fibers, polypropylene fibers, polyethylene fibers, vinyl chloride fibers and glass fibers. However, in the case of producing the inorganic molded body (6) from the alkaline slurry matrix, it is desirable to selectively use polypropylene fiber.

The above fibers (1) depending on the state of the slurry matrix
When it is necessary to set the content of (1) to 70 parts by weight or more of the total weight of the nonwoven fabric (2), it is necessary to add an appropriate amount of penetrant. As the penetrant, dialkyl sulfosuccinic acid sodium salt is particularly effective. This sodium salt of dialkylsulfosuccinate exhibits excellent penetrability as a surfactant having a surface tension lowering action even at a low concentration.

Further, the cut length of the fibers (1) (1) ... is short (for example, 55 mm or less) in order to improve the carding action and to secure the degree of freedom in changing the fiber density in the nonwoven fabric (2). However, it is also possible to use vinylon filaments.

In the present invention, the fibers are applied to the fibers (1) (1) for the purpose of uniformly wetting the inorganic molded body (6) and the non-woven fabric (2) and forming a strong adhesive structure therebetween. The binder (8) is mixed with 10 to 30 parts by weight of the hydrophilic resin (7) based on the total weight of the binder. This hydrophilic resin (7) is used for the exudation void (4) of the nonwoven fabric (2).
The hydrophobic fiber (1) (1), which promotes the uniform exudation of the inorganic component (3) into the inside of the nonwoven fabric (2), and the matrix of cement slurry or gypsum slurry, or a mixed matrix of both. (3) (3) ... is firmly joined.

Polyvinyl alcohol or methyl cellulose is used as the hydrophilic resin (7).

Explaining the case of using polyvinyl alcohol, an adhesive containing synthetic rubber latex or acrylic resin as a main component is prepared, and 10 to 30 parts by weight of polyvinyl alcohol is added as the hydrophilic resin (7) therein. A binder (8) having excellent water resistance, mold resistance and oil resistance and high wettability is formed. Among the binders (8), those having a high degree of saponification (saponification degree) have particularly good water resistance, so that the inorganic molded body (6) reinforced by the nonwoven fabric (2) has a desirable chemistry as a surface material. Stability and physical strength can be provided.

On the other hand, methyl cellulose has been conventionally used as a crack preventive agent for cement mortar and gypsum plaster, but by blending 10 to 30% by weight in the binder (8), the nonwoven fabric (2) and cement slurry or The wettability of the gypsum slurry with the matrix (3) is improved, and not only the crack prevention but also the bonding strength between the hydrophobic fibers (1) (1) ... and the inorganic molded body (6) is significantly improved. Exerts a great effect.

Hereinafter, specific examples of the present invention will be described based on the description of the embodiments.

Example 1 As shown in FIG. 1, a conveyor-shaped mold (5) made of a strip having a width of 60 cm and a thickness of 4 cm was prepared, and 40 g / m ² was provided on the bottom surface thereof.
The dry non-woven fabric (2) having a product weight of 2 was attached. On the other hand, a slurry matrix (3) of kneaded foam cement was prepared, and 1.0 part by weight of vinylon fiber cut to a fixed length of 8 mm was added as a reinforcing fiber therein, and then the slurry matrix was placed in the form (5). Before injecting and curing, a dry non-woven fabric (2) similar to the above is applied to the upper surface thereof,
An inorganic molded body (6) reinforced with the non-woven fabric (2) was manufactured by drying at 48 ° C. for 48 hours. A part of this inorganic molded body is shown in an enlarged state in FIG. 2, and the measurement results of its characteristic values are shown in Table 1 below.

Example 2 A belt conveyor-like mold (5) having a width of 60 cm and a thickness of 6 cm was prepared, and a dry nonwoven fabric (2) having the characteristics shown in Table 2 below was attached to the bottom surface thereof. On the other hand, a matrix (3) of the kneaded foamed β-hemihydrate gypsum slurry was prepared, and 1 part by weight of E glass chopped strands cut to a constant length of 1/2 inch was added as a reinforcing fiber therein, and then the form ( 5) The above-mentioned slurry matrix is injected into the inside, and the same dry non-woven fabric (2) is applied to the upper surface before curing, and dried at 120 ° C. for 96 hours to form an inorganic molding reinforced with the non-woven fabric (2). Body (6) was produced. The measurement results of the characteristic values of this inorganic molded body (6) are shown in Table 2 below.

Example 3 A belt conveyor-shaped mold (5) having a width of 60 cm and a thickness of 4 cm was prepared, and a dry nonwoven fabric (2) having the characteristics shown in Table 3 below was attached to the bottom surface thereof. On the other hand, a matrix (3) of a mixed inorganic slurry consisting of 49.5 parts by weight of kneaded foam cement mortar and 49.5 parts by weight of foamed β-type hemihydrate gypsum is prepared,
1 part by weight of vinylon fiber cut to a fixed length of 8 mm as a reinforcing fiber was mixed therein, and the matrix of the above-mentioned mixed slurry was poured into the mold (5), and the same dry non-woven fabric as described above was placed on the upper surface before curing. By depositing (2) and drying at 120 ° C. for 48 hours, an inorganic molded body (6) reinforced with the dry nonwoven fabric (2) was produced. The results of measuring the characteristic values of this inorganic molded body (6) are shown in Table 3 below.

In addition, although the above-mentioned examples have been described using the fibers having the short cut length (55 mm or less), it is also possible to use the vinylon long fibers and the hydrophilic fibers (for example, vinylon / nylon). It is also possible to use 100%.

[Effects of the Invention] As can be understood from the above description, according to the present invention, a large number of voids formed in the reinforcing nonwoven fabric are formed by kneading the cement slurry matrix, the gypsum slurry matrix, or a mixed matrix of both. It functions as a three-dimensional lattice-shaped or capillary-shaped channel that guarantees uniform exudation, and firmly bonds the nonwoven fabric and the inorganic molded body. Therefore, water resistance, which can also be used as an outer wall material,
An inorganic molded article excellent in alkali resistance and impact resistance can be manufactured at low cost. Since the inorganic molded body according to the present invention has the above-mentioned characteristics, various finishing methods can be applied when it is used for a building structure, etc., and its application is easy to expand compared with conventional products. Is.

[Brief description of drawings]

FIG. 1 is a schematic vertical sectional view of an inorganic molded body according to the present invention, and FIG. 2 is a partially enlarged view thereof. (1) ... Fiber, (2) ... nonwoven fabric, (3) ... inorganic component, (4) ... exudation void, (5) ... formwork, (6) ... inorganic molded product, (7) ) ... Hydrophilic resin, (8) ... Binder.

Claims (2)

[Scope of utility model registration request] 1. When a matrix of a kneaded cement slurry or a gypsum slurry or a mixed matrix of both is poured into a mold to continuously produce an inorganic molded body, the inner surface of the mold is poured prior to the casting. A non-woven fabric which is stretched over the substrate and is integrated with the matrix to control the matrix so that the matrix does not adhere to the non-woven fabric, and the non-woven fabric comprises a constituent fiber and a binder in a weight ratio of 55 /
It is blended in a ratio of 45 to 65/35, and the constituent fibers are bonded in advance in a three-dimensional lattice with a binder, and exuding voids of 30 μm to 400 μm are formed between the fibers in the bonded state, A non-woven fabric for reinforcing an inorganic molded body, characterized in that the binder is blended with 10 to 30 parts by weight of a hydrophilic resin with respect to 100 parts by weight of a binder main component. 2. A weight ratio of the constituent fibers and the binder is 55/4.
The constituent fibers are preliminarily 30 μm between the fibers by the binder which is blended in a ratio of 5 to 65/35 and which is blended with 10 to 30 parts by weight of the hydrophilic resin with respect to 100 parts by weight of the binder main component. A non-woven fabric bonded in a three-dimensional lattice pattern with exuded voids of up to 400 μm is stretched on the inner surface of the mold, and the kneaded cement slurry or gypsum slurry matrix, or both The mixed matrix is poured into a mold to form a strong joint structure between the non-woven fabric and the hardened body of the slurry due to uniform exudation of the slurry, and then taken out from the mold. Inorganic molded body.