JPH0732442A - Panel material and its manufacture - Google Patents

Abstract

PURPOSE:To manufacture efficiently a panel material which is superior in moisture conditioning properties, heat resistance, fire resistance and dimensional stability and free from generation of a crack. CONSTITUTION:An inorganic flowing composition containing a porous inorganic powdery and granular body such as diatomaceous earth, a reinforcing fiber, an inorganic curing substance such as slaked lime and water is extrusion-molded in a boardlike state through a die 13 of an extruding molding machine 11, solidified by drying by a heater 16 and a panel material is manufactured. A pattern can be formed on the surface of the extrusion-molded boardlike molded product by bringing a comb-shaped member 15 into contact with the surface. Then a panel which possesses a cave, is light in weight and has high heat insulation properties also can be obtained. When an extrusion molding method is used, extrusion molding can be performed even if use of a quantity of water is little and drying efficiency is high.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel material useful as a building interior material such as a wall material and a floor material, and a method for producing the panel material.

[0002]

2. Description of the Related Art Diatomaceous earth, which is widely used for wall materials, is excellent in humidity control, heat insulation, sound insulation, deodorization and radio wave absorption. Therefore, when mortar containing diatomaceous earth, lime, water, etc. is applied to the base material of the wall to form the wall surface, dew condensation can be prevented and the heat insulating property can be improved. However, when forming the wall surface by on-site construction,
Not only is work efficiency inferior, but it also takes a long time to dry. For example, it takes about one week to cure the mortar, and the work must be stopped during that time. In addition, cracks may occur on the wall surface due to poor construction, changes in the composition of the composition, and the like.

On the other hand, a gypsum board is also known as a wall material in order to improve workability. This gypsum board is
Manufactured by pouring a slurry containing water such as baked gypsum, aggregates such as glass fiber, pulp and perlite, and water onto the lower paper, stacking the upper paper, molding it into a board with a specified thickness using a molding roll, and drying and curing. ("Chemical Handbook Applied Edition, Revised 3rd Edition" (Chemical Society of Japan), edited by Maruzen Co., Ltd., March 15, 1980, pages 402-404, "Gypsum").

However, even with such a method, since it takes a long time to dry the board, the production efficiency is lowered. In addition, the steps of pouring the slurry, laminating with the top paper, and forming steps are required, which complicates the work.

Incidentally, Japanese Patent Publication No. 58-46973, Japanese Unexamined Patent Publication No. 1-208125, Japanese Utility Model Publication No. 54-85, Japanese Utility Model Publication No. 60-148417, and Japanese Utility Model Publication No. 280-280.
No. 6 discloses a panel material in which an inorganic layer containing a porous fine powder such as diatomaceous earth and a synthetic resin is formed on at least one surface of a heat insulating layer such as expanded polystyrene.

However, also in these panel materials, in order to form the inorganic layer, it is necessary to apply a coating material containing porous fine powder and synthetic resin. Therefore, the production efficiency of the panel material is reduced, and the panel material is apt to warp, and the dimensional stability is reduced.

[0007]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a panel material which has high humidity control, heat resistance, fire resistance and sound insulation, and is free from cracks and excellent in dimensional stability. is there.

Another object of the present invention is to provide a panel material which is lightweight and has a high heat insulating property.

Still another object of the present invention is to provide a method capable of mass-producing the panel material having the above-mentioned excellent properties with high productivity.

[0010]

The present inventors have paid attention to the fact that the productivity of the panel material is mainly controlled by the drying step, and as a result of earnest studies to achieve the above-mentioned object, as a result, a porous inorganic powder,
Extrusion molding of an inorganic flowable composition containing reinforcing fibers, an inorganic curable substance and water using an extrusion molding method enables efficient molding even for mortar and plaster with a low water content, improving dimensional stability. The present invention has been completed and the present invention has been completed.

That is, the panel material of the present invention contains a porous inorganic powder, a reinforcing fiber and an inorganic curable substance.

In the method of the present invention, an inorganic fluid composition containing a porous inorganic powder, reinforcing fibers, an inorganic curable substance and water is extruded into a plate shape and dried and cured to produce a panel material.

In the present specification, the "void ratio" means the longitudinal direction (extrusion direction) of a plate-shaped molded product or panel material.
It means the area ratio of the cavities in the cross section in the direction orthogonal to the.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings as needed.

As the porous inorganic powdery particles contained in the panel material of the present invention, porous powdery particles having an adsorbing property such as activated carbon, diatomaceous earth, acid clay, activated clay, activated alumina, titanium oxide, Examples include bentonite, perlite, vermiculite, shirasu balloon, calcined kaolin, and magnesium silicate. These porous inorganic powders can be used alone or in combination of two or more.

The preferred porous inorganic powdery particles include porous inorganic powdery particles having excellent moisture absorption and desorption properties, particularly diatomaceous earth. Diatomaceous earth is, for example, 500 ° C. or higher, preferably 6
A fired powder of diatomaceous earth fired at a temperature of about 00 to 1000 ° C. is preferable.

The particle size of the inorganic powder is often, for example, 150 mesh or less, and the specific surface area is 5 to 300.
It is often about 0 m ² / g.

The content of the inorganic powdery particles is 10 to 95% by weight, preferably 30 to 75% by weight, based on the whole panel material. When the content of the inorganic powdery particles is less than 10% by weight, the heat insulating property and the humidity control property are deteriorated, and when the content exceeds 95% by weight, the mechanical strength is easily decreased.

Examples of the reinforcing fiber include glass fiber;
Rock wool; Slag wool; Aluminum silicate fiber,
Ceramic fibers such as alumina fibers and silicon carbide fibers; polymers such as polyacrylonitrile, phenolic resins, rayon and other polymers, petroleum or coal pitch carbon fibers; polyethylene fibers, polypropylene fibers, cellulose fibers, rayon fibers, acetate Fiber, nylon fiber, polyester fiber, polyvinyl alcohol synthetic fiber (vinylon fiber), polyether sulfone fiber,
Polymer fibers such as aromatic polyamide fibers (such as aramid fibers) are included. At least one of these fibers can be used.

Among these fibers, in order to enhance the reinforcing effect and the dimensional stability, fibers having a large tensile elastic modulus such as glass fiber, carbon fiber, polypropylene fiber, polyvinyl alcohol-based synthetic fiber and aramid fiber are used. preferable.

The strand diameter of the reinforcing fiber is, for example, 5 to 30 μm.
It is often about m. Reinforcing fibers are often used as short fibers. The length of the short fiber is, for example, 0.1 to
It is about 30 mm, and short fibers of about 0.5 to 10 mm are often used.

The aspect ratio of the short fibers is from 40 to 5,000, preferably from 100 to 2,000, in order to enhance the reinforcing property. If the aspect ratio is less than 40, the reinforcing property may decrease, and if it exceeds 5000, the uniform dispersibility may decrease.

The content of the reinforcing fiber is, for example, 0.1 to 20% by weight, preferably 0.2 to 5% by weight of the whole panel material.
It is a degree. When the content of the reinforcing fiber is less than 0.1% by weight, the reinforcing property is lowered, the panel material is apt to be cracked or warped, and the dimensional stability is impaired. Reinforcing fiber content is 2
If it exceeds 0% by weight, the cost tends to increase.

The panel material containing the porous inorganic powder and the reinforcing fiber is excellent in humidity control, dewproofness, heat insulation, fire resistance and sound insulation. Further, since the reinforcing fibers can disperse the stress associated with the contraction / expansion, it is possible to prevent the occurrence of cracks and warps, increase the strength, and improve the dimensional stability.

Examples of the inorganic curable substance include gypsum;
Lime such as slaked lime and dolomite plaster; it contains hydraulic substances. Examples of hydraulic materials include cement (eg, Portland cement, early-strength Portland cement, alumina cement, rapid-hardening high-strength cement, self-hardening cement such as gypsum; lime slag cement,
Hydraulic cement such as blast furnace cement; mixed cement) and the like. Preferred inorganic curable substances include, for example, gypsum and lime.

The content of the inorganic curable substance is, for example, 5 to 90% by weight, preferably 20 to 75% by weight, more preferably 30 to 60% by weight, based on the whole panel material. When the content of the inorganic curable substance is less than 5% by weight, the strength of the panel material is likely to decrease, and when it exceeds 90% by weight, the moisture absorption and desorption property of the porous inorganic powder is impaired, and dew condensation is likely to occur. .

When an inorganic curable substance is contained, the strength of the panel material can be further improved by hardening the inorganic curable substance in combination with the reinforcing effect of the reinforcing fiber.

The panel material is a fine-grained aggregate such as sand, silica sand, perlite; a colorant, a hardening agent, a set retarder such as an organic acid salt or an inorganic acid salt, a hardening accelerator such as calcium chloride,
Water reducing agents such as sodium naphthalene sulfonate, coagulants, carboxymethyl cellulose, methyl cellulose,
It may contain various additives such as a thickener such as polyvinyl alcohol, a foaming agent, a waterproofing agent such as a synthetic resin emulsion, and a plasticizer.

The panel material of the present invention may have a flat plate shape or a curved plate shape. Although the thickness of the panel material can be selected according to the application, it is usually 5 to 200 mm, preferably 10 to 100 mm in many cases.

The surface of the panel material of the present invention may be flat or may have irregularities on the surface. The unevenness on the surface of the panel material may be scattered, or may be continuous or discontinuous uneven grooves extending in a streak shape. Further, the surface of the panel material may be provided with the pattern of the irregularities, or may be colored with a paint or the like.

FIG. 1 is a sectional view showing an example of the panel material of the present invention. In this example, the panel material 1 made of the porous inorganic powder, the reinforcing fibers and the inorganic curable substance has a plurality of cavities (through holes) 2 having a rectangular cross section extending in the longitudinal direction in the width direction. Is formed in. Each cavity 2
Are partitioned by a partition wall 3 extending in the longitudinal direction. The cavity rate of the cavity 2 of the panel material 1 is 5 to 75%, preferably 10 to 60%, more preferably 20 to 60%. When the porosity is less than 5%, the heat insulating property of the panel material is not improved so much, and when it exceeds 75%, the mechanical strength of the panel material tends to be lowered.

In order to enhance the workability of the panel material 1,
A ridge 4 is formed on one side end surface of the panel material 1, and a concave groove 5 that can be fitted into the ridge 4 is formed on the other side end surface.

The panel material having such a cavity has a small amount of material used, is lightweight, and has a high heat insulating property. Moreover, since the panel material is composed of the porous inorganic powder, the reinforcing fiber and the inorganic curable substance, the mechanical strength does not deteriorate so much. Further, by utilizing the ridges 4 and the concave grooves 5 formed on both end surfaces, a plurality of panel materials 1 can be easily installed adjacent to each other.

It should be noted that at least one cavity may be formed in the panel material having a cavity. However, if a plurality of cavities partitioned by a partition extending in the longitudinal direction is formed, the partition can prevent a decrease in mechanical strength. .

The panel material of the present invention is advantageously manufactured by an extrusion molding method. That is, the method of the present invention is
With the additive, if necessary, a step of extruding an inorganic fluid composition containing the porous inorganic powder, the reinforcing fibers and the inorganic mixed powder composed of the inorganic curable substance and water into a plate shape, and , And a drying process. After the drying step, the plate-shaped extrusion molded article is usually subjected to a cutting step of cutting it into a predetermined length, and the panel material is obtained by curing the obtained molded article.

When the extrusion molding method is used, a highly viscous inorganic fluid composition can also be molded, so that the amount of water used can be reduced, the drying efficiency is high, and the stress diffusion effect by the reinforcing fiber is combined with the panel material with high dimensional accuracy. There is an advantage that can be obtained. Further, since the water content can be reduced and the reinforcing property can be enhanced by the reinforcing fiber, the deformation of the molded product extruded in a plate shape can be suppressed, and the molded product can be easily handled.

The amount of water used is 10% by weight of inorganic mixed powder composed of porous inorganic powder, reinforcing fibers, inorganic curable substances and the like.
15 to 150 parts by weight, preferably 20 to 0 parts by weight
To 100 parts by weight, more preferably about 20 to 50 parts by weight. If the amount of water used is less than 15 parts by weight, the fluidity and extrusion moldability will deteriorate, and if it exceeds 150 parts by weight, it will take a long time to dry.

FIG. 2 is a schematic process drawing for explaining the panel material manufacturing method of the present invention.

In this example, the porous inorganic powder, the reinforcing fiber, the inorganic curable substance, and water together with the additive as needed are supplied to a hopper 12 of an extruder 11 equipped with a screw. While being kneaded by the screw,
Extruded in a plate shape from the die 13 having a slit-shaped hole,
The extruded plate-shaped molded product is transported by a plurality of transport rollers 14. The hopper may be supplied with an inorganic fluid composition prepared by mixing and agitating the porous inorganic powder, reinforcing fiber, inorganic curable substance, water and the additive.

The extrusion rate of the inorganic fluid composition can be selected according to the water content, the drying temperature in the drying step, the thickness of the plate-shaped molded article, etc., and is, for example, 0.5 to 10 m / min, preferably 0. It is about 7 to 5 m / min.

In the extruding direction of the plate-shaped molded product, a plurality of comb tooth-shaped members 15 having brushes, comb teeth, etc.
4 are arranged side by side so that they can move up and down. Further, the positions and intervals of the tips of the comb teeth in the adjacent comb tooth-shaped members 15 are different from each other in the width direction of the plate-shaped molded product. Therefore, the comb tooth-shaped member 1 is formed on the surface of the plate-shaped molded product.
By moving 5 up and down to make intermittent contact,
The surface of the molded product is scratched off in a streak shape, and a streak-like wall-like streak pattern can be formed on the surface of the plate-shaped molded product in the surface treatment step.

The molded product having the pattern formed on its surface is carried by the carrying roller 14 to a drying zone equipped with a heater 16. The drying temperature in the drying zone can be appropriately selected, but is, for example, 50 to 200 ° C., preferably 75 to 150.
It is about ℃. After being dried in the drying step, the plate-shaped molded product is cut into a predetermined length by the cutter 17 and cured to obtain the panel material 18. Therefore, it is possible to continuously manufacture a panel material having a surface pattern with a decorative feeling and a high design.

The comb-shaped member does not move up and down,
It may be in contact with the surface of the plate-shaped extruded product from the beginning. The pattern on the surface of the plate-shaped molded article may be formed by at least one comb tooth-shaped member. The intervals between the comb teeth in the adjacent comb-shaped members may be the same in the width direction of the plate-shaped molded product. Further, the plurality of vertically movable comb-teeth-shaped members may be reciprocated in the width direction of the plate-shaped molded product in order to form a wavy pattern.

Furthermore, in the surface treatment step, a plate-shaped pressing member having an uneven surface may be pressed against the plate-shaped molded product to form an uneven pattern. In this case, the plate-shaped pressing member may be circulated in the surface treatment step, and the plate-shaped pressed member may be pressed against the surface of the plate-shaped molded product while being entrained in the conveyance speed of the plate-shaped molded product.

Further, by utilizing the extrusion molding method, it is possible to obtain panel materials having various sectional shapes by changing the die shape of the die. For example, when a die having a slit-shaped die having an uneven portion on at least one long side is used, a panel material 21 having an uneven groove 22 on at least one surface can be obtained as shown in FIG.
Further, in the slit of the die, a flow path regulating member of an appropriate shape extending from the inner wall of the die to the discharge side of the slit (for example,
By disposing at least one rectangular flow path regulating member disposed on the discharge side of the die, a panel material having a cavity (through hole) as shown in FIG. 1 can be obtained.

Further, the inorganic fluid composition may be heated by the extruder or die. By heating an extruder or the like, the water content in the inorganic fluid composition can be reduced, and the water can be efficiently evaporated during the drying step after extrusion. Therefore, the drying energy in the drying step can be reduced, and the panel material can be dried and cured within a short time. The heating temperature can be appropriately selected depending on the type of the curable inorganic substance, within a range that does not cure in an extruder or a die, for example, within a range of about 50 to 200 ° C.

As described above, it is not necessary to completely dry the plate-shaped molded article in the drying step, but at least the surface layer portion may be dried. Even if only the surface layer portion is dried, the inorganic fluid composition has a low water content and can be reinforced with reinforcing fibers, so that deformation of the plate-shaped molded article can be suppressed.

The plate-shaped molded article may be cured under heating, but usually it can be cured, for example, in about 12 hours to 4 days by leaving it at room temperature.

The panel material thus obtained is useful as an interior or exterior material for construction such as wall material and floor material. The panel material may be attached to a plywood board, a plywood board, a gypsum board or the like, if necessary.

[0050]

EFFECT OF THE INVENTION Since the panel material of the present invention contains a porous inorganic powder, a reinforcing fiber and an inorganic curable substance, it has high humidity control, heat resistance, fire resistance and sound insulation and is free from cracks. Excellent dimensional stability. In addition, the panel material in which the cavity is formed is lightweight and has high heat insulation.

According to the method of the present invention, since the inorganic fluid composition is extruded into a plate shape and dried and cured, the water content and the drying energy in the inorganic fluid composition can be reduced.
A panel material having the above-mentioned excellent characteristics can be manufactured in large quantities with high productivity.

[0052]

EXAMPLES The present invention will be described in more detail based on the following examples.

Example 1 60 parts by weight of calcined diatomaceous earth (particle size 10 to 40 μm) and dolomite plaster (particle size 1 to 100 μm) 4
0 parts by weight and glass fiber (average fiber length 6 mm, fiber diameter 9
μm) 2 parts by weight and 25 parts by weight of water were mixed and supplied to an extruder. Extruded into a plate at a speed of 1 m / min from the die of an extrusion molding machine, dried in a drying zone at 150 ° C., cut with a cutter, and cut into a plate-shaped product (width 30 cm ×
A length of 90 cm and a thickness of 3 cm was obtained. When the plate-shaped molded product was left at room temperature for 2 days, it was completely cured and a crack-free panel material was obtained.

The bending strength of the panel material was measured by a 3-point bending test with a span of 60 cm to find that it was 88 kg / cm ^2.
Met. In addition, the difference in dimensional accuracy between the plate-shaped molded product and the panel material 4 weeks after curing was 0.2%.

Example 2 A panel material was obtained in the same manner as in Example 1 except that 1 part by weight of polypropylene fiber (average fiber length: 3 mm, fiber diameter: 20 μm) was used instead of 2 parts by weight of glass fiber. No cracks were found in the material.

The bending strength of the panel material was measured in the same manner as in Example 1 and found to be 65 kg / cm ^2. The difference in dimensional accuracy between the plate-shaped molded article and the panel material 4 weeks after curing was It was 0.5%.

Example 3 Instead of 2 parts by weight of glass fiber, carbon fiber (average fiber length 3
mm, fiber diameter 18 μm) A panel material was obtained in the same manner as in Example 1 except that 2 parts by weight were used, and no crack was found in the panel material.

When the bending strength of the panel material was measured in the same manner as in Example 1, it was 70 kg / cm ² , and the difference in dimensional accuracy between the plate-shaped molded product and the panel material after 4 weeks of curing was It was 0.1%.

Comparative Example 1 In the same manner as in Example 1 without using glass fiber,
When a panel material was obtained, cracks occurred in the panel material after drying and curing, and the difference in dimensional accuracy between the plate-shaped molded product and the panel material 4 weeks after curing was 1.2%.

Example 4 In the same manner as in Example 1, the inorganic fluid composition was extruded into a plate shape from a die of an extrusion molding machine, and three metal brushes provided on the discharge side of the die were formed into a plate shape. By making contact with one side surface of the extruded product of, scraping wall-like surface processing,
A plate-shaped molded product was obtained by drying and cutting in the same manner as in Example 1. When the plate-shaped molded product was allowed to stand at room temperature for 2 days, it was completely cured, and a panel material having no cracks and high designability was obtained.

Example 5 Extrusion molding was performed in the same manner as in Example 1 except that a die in which 15 rectangular flow path regulating members were laterally arranged in the slit was used as the die, and as shown in FIG. It has a cavity (1.2 cm x 1.2 cm) with a square cross section, and a cavity rate of 24
% Panel material was obtained. When the thermal conductivity of the obtained panel material was measured, it was 0.06 kcal / m · h · ° C,
The thermal conductivity of the solid panel material obtained in Example 1 was 0.15.
It became 1/2 or less of kcal / m · h · ° C. The bending strength of the panel material was 72 kg / cm ² .

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of a panel material of the present invention.

FIG. 2 is a schematic process drawing for explaining a method for manufacturing a panel material of the present invention.

FIG. 3 is a cross-sectional view showing another example of the panel material of the present invention.

[Explanation of symbols]

 1, 18 and 21 ... Panel material 2 ... Cavity 3 ... Partition wall 11 ... Extrusion molding machine 13 ... Die 15 ... Comb-shaped member 16 ... Heater 17 ... Cutter 22 ... Rough groove

Claims (8)

[Claims] 1. A panel material containing a porous inorganic powder, a reinforcing fiber and an inorganic curable substance. 2. The panel material according to claim 1, which has irregularities on its surface. 3. The panel material according to claim 1, wherein voids having a void ratio of 5 to 75% are formed. 4. A method for producing a panel material, which comprises extruding an inorganic fluid composition containing a porous inorganic powder, a reinforcing fiber, an inorganic curable substance and water into a plate shape, and drying and curing the composition. 5. The method for producing a panel material according to claim 4, wherein diatomaceous earth is used as the porous inorganic powder or granular material. 6. The method for producing a panel material according to claim 4, wherein the reinforcing fiber having an aspect ratio of 40 to 5000 is used. 7. The method for producing a panel material according to claim 4, wherein after the inorganic fluid composition is extrusion-molded, irregularities are formed on the surface of the extrusion-molded article and the composition is dried and cured. 8. An inorganic flowable composition having a porosity of 5 to 75.
The method for producing a panel material according to claim 4, wherein the panel material is extruded into a plate shape having a% void.