JPH064243B2 - Method for manufacturing laminated body - Google Patents

Description

Detailed Description of the Invention

[0001]

Industrial Applicability The laminate of the present invention is nonflammable, has excellent heat insulating properties and can be easily post-processed. Therefore, it can be used for heat insulation of plants, vehicles, ships, etc. as well as interior panels of buildings.

[0002]

2. Description of the Related Art Since the US, there have been foamed gypsum boards, ALC boards, etc. in addition to urethane foam boards as foam insulation materials. These various types of plates have their respective characteristics and drawbacks. In the case of urethane foam plates, they are poor in non-combustibility, and inorganic foam gypsum plates and ALC plates are not good in terms of weight and flexibility.

[0003]

The problem is that the conventional inorganic type heat insulating panel is heavy and inflexible, and the saw is used for cutting the panel (including one having a dedicated saw blade), etc. Is necessary.

[0004]

[Means for Solving the Problems] In the present invention, inorganic gypsum and blast furnace slag exhibit noncombustibility, and urethane resin is included to provide flexibility, and mechanical foaming and reaction curing of urethane are utilized. It has a high expansion ratio and good production efficiency.

The structure of the present invention will be described in detail below.
On a moisture permeable base sheet a, a foaming agent is added to a slurry containing gypsum and blast furnace slag as essential components and mechanically foamed,
A urethane prepolymer having a solid content ratio of 1 to 20% is added to the slurry, the stirred foam slurry is applied, and a moisture permeable substrate sheet b is further laminated. When this foamed slurry is cured, it becomes a foamed mortar layer. Therefore, the laminated body is such that the foamed mortar layer 3 is sandwiched between the moisture-permeable substrate sheets a1 and b2 as shown in FIG. The thickness of this laminate may be regulated before or after the moisture-permeable substrate sheets are stacked.

With respect to the individual constituent elements, the moisture-permeable base sheet may be made of any material or structure that does not impair the air permeability, and examples thereof include synthetic papers such as polyester, polyurethane, polystyrene, rayon, tetron, nylon, and the like.
Alternatively, a non-woven fabric, a cloth material, natural paper such as cellulose paper, or a natural fiber cloth material is used. Here, the term “moisture permeability” is used to facilitate the diffusion of excess water in the mortar layer.

Next, the gypsum may be dihydrate gypsum, hemihydrate gypsum, or anhydrous gypsum, and if it is a stable one that is usually used industrially, it may be a byproduct gypsum such as phosphate gypsum. I don't care. Further, the blast furnace slag referred to in the present invention is generally obtained as a by-product of an iron manufacturing plant, and the basicity, that is, the total ratio of CaO, MgO and Al ₂ O ₃ is S.
A value divided by the ratio of iO ₂ is preferably 1.2 or more. When this value is 1.2 or less, the reaction between the gypsum and the blast furnace slag proceeds and the ethrin guide (3Ca
_{O · Al 2 O 3 · 3CaSO} 4 · 32H 2 O) to fail eventually good cured product is not obtained.

The foaming agent used in the present invention may be a surface-active agent used in the detergent industry in addition to those usually used as a foaming agent for gypsum and Portland cement. Examples thereof include polyoxyethylene alkylphenol ether, aromatic hydrocarbons, sulfonates, protein surfactants, alkylallyl sulfonates, and the like. Further, these foaming agents may be used in combination with a dispersion-type foaming agent (for example, sodium bicarbonate, azodicarbonamide, etc.).

The urethane prepolymer as referred to in the present invention is a high molecular weight compound having an isocyanate group as a part thereof, and is a compound containing an isocyanate group such as tolylene diisocyanate, polydiphenylmethane diisocyanate, xylene diisocyanate, and the like. Ethylene polyol ether is reacted at an NCO / OH equivalent ratio of 1.5 or more, and the oxyethylene content in polyoxyethylene polyol ether is 5% by weight in order to have an affinity with water. The thing obtained using what was contained above is the most preferable.

In addition to the above, the plasticizer (eg ethylene glycol monomethyl ether, methanol etc.), the thickener (eg methyl cellulose, polyvinyl alcohol, hydroxylmethyl cellulose etc.) Pigments (for example, calcium carbonate, titanium oxide, silica powder, clay), fibers (for example, lath fibers, synthetic fibers, etc.), hydraulic cement (Portland cement, silica cement, etc.) Aggregate (perlite,
It is possible to add a binder (colloidal silica, synthetic resin emulsion, etc.)) such as cold water stone, expanded polystyrene, etc.

A concrete method for mechanically foaming a slurry containing gypsum and blast furnace slag as essential components by using a foaming agent such as a surfactant may be the same as the method for producing normally foamed concrete or the like. The mixture may be stirred at high speed in a state where bubbles are entrained so that the specific gravity becomes a predetermined amount while controlling the volume of the slurry with a high speed mixer equipped with. At this time, since the slurry has hydraulic properties, a retarder or an accelerator may be mixed in advance in order to adjust the curing time. As such a retarder,
Examples thereof include citrate, magnesium silicofluoride, polyhydroxy compound, gluconate, lignin sulfonate and the like. Examples of the accelerator include calcium chloride, aluminum chloride, sodium carbonate, sodium silicate, sodium aluminate and the like.

As described above, the foamed slurry is stabilized by blending additives such as retarders or accelerators for about 3 hours in this state. Furthermore, in order to continuously produce the laminate of the present invention and increase production efficiency, it is necessary to rapidly cure it. For this reason, it is convenient to add the urethane prepolymer to the foamed slurry and stir the mixture to rapidly cure the foamed slurry, thereby obtaining highly efficient productivity. Therefore, it is considered efficient to add the urethane prepolymer just before the molding step.

The urethane prepolymer may be added to the foamed slurry by quantitative mixing using a static mixer or a stirring mixer. The amount of urethane prepolymer added at this time is 1 to 3 with respect to the total dry weight of gypsum and blast furnace slag used in the present invention.
It should be in the range of 0% by weight. If it is 1% by weight or less, the flexibility of the foamed cured product will be poor, and when external force is applied, cracking will occur. On the other hand, if it is 30% by weight or more, not only the incombustibility referred to in the present invention cannot be obtained, but also the hardness of the hydraulic cement is lowered without exhibiting the characteristics of the hydraulic cement.

To produce the laminated body 10 of the present invention, for example, an apparatus for supplying a moisture-permeable substrate sheet a, a foamed slurry, a moisture-permeable substrate sheet b, and a thickness regulating device is provided on a series of lines. The two sets of the moisture-permeable substrate sheets arranged side by side are supplied by rolling. On the other hand, the foaming slurry 9 quantitatively batches or continuously foams gypsum 4, blast furnace slag 5, foaming agent 6, water 7 and the like, and further, the urethane prepolymer 8 in a fixed amount ratio with the foaming slurry. Are continuously mixed, and the mixture is applied onto a base sheet. Further, the moisture-permeable base material sheet b is placed on the foamed slurry 9, and the thickness is regulated and dried. After that, cut into a desired size. FIG. 1 schematically shows this manufacturing method.

[0015]

[Operation] In the laminate of the present invention, a non-combustibility that cannot be obtained by a conventional urethane foam plate is given, the expansion ratio is controlled, and urethane resin is added to reduce the weight.
It exhibits flexibility.

[0016]

EXAMPLES Examples will be described below. Table 1 below shows a formulation table as a formulation of the foaming slurry.

[0017]

[Table 1]

Slurry substances are obtained by sequentially adding and mixing according to the above blending amounts. Further, the slurry is stirred with a high speed mixer until the specific gravity of the slurry reaches 0.8. After that, 5 parts by weight of urethane prepolymer [trade name: Polygrout W-1 (manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd.)] was added and mixed, and aluminum hydroxide mixed paper of non-combustible paper which is a moisture permeable base sheet [trade name: Cosmo ( Toyo Pulp)] was evenly applied to a thickness of 10 mm, and then the above-mentioned non-combustible paper was laminated. Then, it was confirmed that the composition was cured at room temperature of 25 ° C. after 2 minutes.
Further, the laminate according to the present invention was manufactured by the same method and used as a test piece for various tests. The results are shown in Table 2 below.

As a test and evaluation method, nonflammability is JIS
According to A1301, the water absorption was evaluated by the water absorption amount, and
1 g / cm ³ or less, 0.1 g / cm ^{3 to} 0.3 g / c
m ³ was Δ, and 0.3 gcm ³ or more was x. The weight is evaluated by the apparent specific gravity, and if less than 0.5, 0.5 or more 1.
A value less than 0 was evaluated as Δ, and a value of 1.0 or more was evaluated as x. 50x1 flexibility
A 0 cm plate was prepared so that it could be bent by 1.0 cm or more between 30 cm fulcrums. Workability is evaluated with the tools necessary for cutting, and it can be cut with a knife.
The saws for woodworking were evaluated as fair, and those requiring a special saw blade as x. A urethane foam plate (12
mm thickness), foam gypsum board (12 mm thickness), ALC board (37
mm thickness) was used.

[0020]

[Table 2]

[0021]

Since the laminate of the present invention is flexible, it is unlikely to be broken or chipped during handling.
In addition, since it is non-flammable, the damage at the time of fire is small. Since it is light and easy to process, the efficiency in use improves.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a laminated body obtained according to an example.

[Explanation of symbols]

 1 Base Material Sheet a 2 Base Material Sheet b 3 Foam Mortar Layer 4 Gypsum 5 Blast Furnace Slag 6 Foaming Agent 7 Water 8 Urethane Prepolymer 9 Foaming Slurry 10 Laminate

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Claims (1)

[Claims] 1. A urethane prepolymer having a solid content ratio of 1 to 30% is added to a slurry containing gypsum and blast furnace slag as essential components on a moisture-permeable base sheet a by mechanically foaming the foaming agent. The foamed slurry is added and stirred, and the foamed slurries are applied to the foamed mortar layer. A method for manufacturing a laminated body, characterized in that the thickness of the entire laminated body is regulated.