JPH0822788B2 - Inorganic lightweight board and manufacturing method thereof - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to an inorganic lightweight plate excellent in heat insulation, sound absorption, etc., which uses an inorganic foam as an aggregate and ultrafast cement as a binder, and a method for producing the same. It is a thing.

[Prior Art] Lightweight plates used in various fields including building materials are
Veneer boards, plywood, asbestos cement boards, hollow sandwich boards having a metal sheet as a surface material, or sandwich boards in which paper honeycomb or glass wool is filled in the hollow air layer have been mainly used. In addition, recently, cellular concrete is used as a core material and a reinforcing plate such as asbestos cement board and calcium silicate board is laminated on the surface, glass fiber reinforced polyester board is laminated on the surface of cellular concrete, and further inorganic foam is used. Many composite plates have been devised, such as those obtained by adhesively molding a body of molten sodium silicate glass.

However, in these existing composite plates, there are problems such as flammability, lack of strength, lack of lightness, and heat insulation and sound absorbing properties that can completely satisfy the requirements. Was not. And in the case of a laminated plate, the number of steps is increased in any case, the production efficiency is low and the manufacturing cost is high, and in the case of adhesive molding of the inorganic foam with glass, the heating step Because of this, the manufacturing equipment becomes complicated and the energy consumption also increases.

In this way, it can be said that conventional lightweight materials leave much room for improvement due to the characteristics of the plate material and its manufacturing method.

[Problems to be Solved by the Invention] By the way, as a material that has the possibility of opening a new frontier for lightweight plates that are lightweight and have excellent heat insulation and sound absorption effects, the use of an inorganic foam as an aggregate for the inorganic material Lightweight boards are being considered. Specifically, the inorganic foam is united with cement as a binder. However, in the case where the inorganic foam is simply adhesively molded using the cement paste as a binder, the manufacturing method is extremely simple, but on the other hand, it is inferior in strength and lightness, and the backing material is attached in actual use. Required. In addition, the actual situation is that the desired characteristics cannot be obtained in terms of heat insulation and sound absorption.

The present invention is based on the above technical background, in particular, by making further technical improvements to the above-mentioned inorganic foam-cement-based lightweight plate, while making use of its simple manufacturing characteristics, it is lightweight and The purpose of the present invention is to provide a high-performance inorganic lightweight plate which is excellent in strength, heat insulation and sound absorption.

[Means for Solving Problems] That is, the inorganic lightweight plate newly proposed by the present invention is
It is formed by uniting an inorganic foam coated with a polymer dispersion with a binder containing ultra-rapid cement. In addition, the manufacturing method for obtaining this inorganic lightweight board that is also proposed is that the polymer dispersion is added and stirred to the inorganic foam in which those having different average particle diameters are mixed, and then water and super-rapid cement are added. After mixing, pressure vibration molding is performed.

For the inorganic foam used in the present invention, various foamed particles obtained by crushing rocks such as pearlite and obsidian, firing and expanding can be used. In addition, the polymer dispersion covering this foam contains chloropropylene rubber (C
R), styrene latex such as styrene-budadiene rubber (SRB), polyacrylic ester (PAE), polyvinyl acetate (PVAC), resin emulsion such as ethylene vinyl acetate (EVA), etc. can be used, and its solid content (35% -50%) is dispersed in water (65-50%) together with an emulsifier, if necessary, and used. And, in the inorganic foam coated with this polymer dispersion, a water reducing agent (0.
An inorganic lightweight board having a peculiar internal structure according to the present invention is produced by uniting with a binder containing an appropriate amount of ultra-rapid hardening cement added with 5 to 1.5% / cement).

Further, in producing the inorganic lightweight plate of the present invention,
Use a mixture of inorganic foams with different average particle sizes,
It is advisable to increase the packing density. That is, by mixing foams having different particle diameters, particles having a small diameter are dispersed among particles having a large diameter, and as a result, the number of contacts between the particles is increased and the cohesive strength is increased. In addition, as a specific mixing mode, a small particle size (for example, 2 mm) and a medium particle size (small particle size × 2 to 2)
An example is a case in which three types of foam particles of 3 kinds, for example, 5 mm and large particle sizes (medium particle size × 1.2 to 2, for example, 7 mm) are mixed and used. In this case, in order to effectively develop high strength, it is necessary that the foam having a small particle size occupies 0.4 or more of the whole by volume. The volume ratio of the medium particle size foam and the large particle size foam is preferably about 1: 0.33 to 1.5.

Further, in manufacturing this kind of inorganic lightweight plate, it is effective to perform pressure vibration molding to promote the filling property thereof. As a means for vibrating the pressure, as will be described later, a method in which a vibrator is attached from above the molded lightweight plate that has been cast into the form may be used, or one or a plurality of columns of the lightweight plate that have been cast and molded may be installed. Then, it may be placed on the vibration table and pressed from the upper surface.

Hereinafter, the manufacturing method of the present invention will be described in more detail with reference to the schematic view of FIG.

In the present invention, an omni mixer is used as a suitable container for mixing and stirring cement and the like in the inorganic foam.
Then, the omni mixer is pre-wetted before processing.
Then, a predetermined amount of the inorganic foam A is first stored in the omni mixer 1 from the chute 2 of the lightweight device {Fig. 1 (a)}. As described above, the inorganic foam A is a mixture of plural kinds having different average particle diameters at an appropriate mixing ratio. Next, a predetermined amount of Polymer Dispersion B is similarly weighed and added to this, and is shaken and stirred {(b) in the same figure}. Then, a predetermined amount of water C and a water reducing agent D are added and the mixture is rocked and stirred {(c) in the figure}. Thereafter, the Omni mixer 1 is rocked to strongly stir, and a predetermined amount of the super-fast hardening cement E, which is similarly weighed, is added, and the mixture is stirred for about 20 seconds {(d) in the same figure}. Then, the agitated mixture F is charged from the omni mixer 1 to the mold 3 to which the mold release agent has been sufficiently applied in advance, and the surface thereof is finished to be a horizontal surface flush with the mold 3 (FIG. (E)). The empty omni mixer 1 is reused in the step (a). Then, after applying a mold release agent to the surface of the mixture (molding plate) F cast in the mold 3, the pressure vibrating plate 4 is set, and the vibrator 5 gives vibration to the mold for vibrating for about 1 minute. Molding {(f) in the figure}.
Thus, after about 20 minutes have passed, the molding plate F can be demolded from the mold 3 {FIG. (G)}.

In the inorganic lightweight plate of the present invention obtained by such a manufacturing method, as schematically shown in FIGS. 2 (a) and (b),
Small foam particles II are packed between the large foam particles I to form a dense packing structure, and microscopically, the surface of each inorganic foam A that constitutes the aggregate is A united structure in which the dispersion B is coated, and the large and small inorganic foams A and A are bonded to each other through the polymer dispersion B with the super fast-hardening cement E as a binder at a large joint surface with a very small void S. It has become.

FIG. 3 schematically shows the internal structure of another kind of lightweight plate shown for the purpose of comparison with this inorganic lightweight plate. The inorganic foam A shown in FIG. 3 (a) is simply a binder such as cement or water glass. The one that is hardened with or the one in which air bubbles H are mixed in the cement matrix G (ALC) shown in FIG.
It is understood that the internal structure of the present invention is significantly different.

[Operation] In the inorganic lightweight board of the present invention, since ultra-fast cement is used as the binder, the water repellency can be minimized and the amount of water used can be reduced, whereby the flow of cement can be effectively prevented. . At the same time, the use of ultra-rapid cement will greatly reduce the production time.

Further, the polymer dispersion is added to water and the initial stage of kneading before the addition of cement, thereby imparting waterproofness and abrasion resistance to the inorganic foam, and further adding water and cement into the cement matrix. Included to be a good binder.

Further, by positively mixing and using the inorganic foams having different average particle diameters, the filling property of the foams is increased as compared with the case where one kind of average particle diameter is used, and the pressure is applied to this. Since the filling action by vibration forming is also added, the formed lightweight plate has a solid joint structure with small voids.

Based on such an action, in the inorganic lightweight plate according to the present invention, the voids are small and the bond between the aggregate and the matrix is strong as described above. Therefore, the strength is significantly improved as compared with the conventional lightweight plate. Also AL
Since the volume occupied by the matrix is smaller than that of C, heat conduction is reduced and sound absorption is also increased.

Regarding the method of the present invention for producing this high-performance lightweight plate, as described above, it is possible to produce the lightweight plate simply and in a short time with simple equipment.

[Examples] The results of various tests conducted on the products of Examples for confirming the performance and effects of the inorganic lightweight plate according to the present invention will be shown below.

The example product was manufactured according to the process shown in FIG. 1, and the details of the manufacturing conditions of the example product are shown in Table 1 below.

(I) The degree of reduction of the cement paste (binder) required to coat the inorganic foam was examined by changing the addition amount of the polymer dispersion. Table 2 shows the results.

(Ii) The filling effect by pressure vibration was investigated by changing the molding method of the lightweight plate. The results are shown in Table 3 below.

 However, the composition of the lightweight plate is as follows.

Inorganic foam 100 parts by weight Superfast cement 100 parts by weight Water 40 parts by weight Polymer dispersion 20 parts by weight Water reducing agent 0.7 parts by weight (Iii) The same type or a plurality of types of foams having different average particle diameters were mixed and the filling property thereof was examined. The results are shown in Table 4 below.

The three items in the middle column of the above table are due to the preferable mixing mode of the foam, and the two items in the lower column are due to the unsuitable mixing mode.

Summarizing the above test results, the relationship shown in FIG. 4 is obtained between the bulk density and the bending strength.

(Iv) Next, Table 5 shows the effect of using ultra-rapid cement as a binder, as compared with the case of using early-hardening cement.

However, the inorganic foam used at this time has an average particle size of 2 m.
It is a mixture of m, 5 mm, and 7 mm at a volume ratio of 4: 3: 2. The composition of the binder is the same as that listed in the test (ii).

(V) Finally, various characteristics of the inorganic lightweight plate obtained by the present invention are summarized in Table 6 below in comparison with the conventional product.

[Advantages of the Invention] As described above, the present invention is one in which an inorganic foam coated with a polymer dispersion is united with a super-rapid hardening cement as a binder, so that the voids are small and the foams are more solid. It has a light weight, high strength, and breaks. It is possible to provide a novel and useful inorganic lightweight plate excellent in heat effect and sound absorbing effect.

Further, according to the production method of the present invention, this inorganic lightweight plate can be mass-produced easily and efficiently with simple equipment, and at the same time, it is preferable to use a mixture of inorganic foams having different particle diameters and pressurization. By using together with the means for vibration molding,
The filling property can be further improved, and the features described above can be more remarkably exhibited.

[Brief description of drawings]

1 (a) to 1 (g) are schematic perspective views showing steps of the manufacturing method according to the present invention. 2 (a) and (b) are schematic sectional views showing the structure of the inorganic lightweight plate according to the present invention,
(A) is an outline of the united structure, and (b) is an enlarged view of a part thereof. FIGS. 3 (a) and 3 (b) are schematic cross-sectional views showing the structure of a conventional lightweight plate, FIG. 3 (a) shows a foamed body simply bound by a binder, and FIG. 3 (b) shows an ALC plate.
FIG. 4 is a diagram showing the bulk density and bending strength of various lightweight plates. I, II, A ... Inorganic foam B ... Polymer dispersion E ... Super-fast cement S ... Void

Claims (2)

[Claims] 1. An inorganic lightweight board characterized by comprising an inorganic foam covered with a polymer dispersion, which is united with a binder containing ultra-rapid hardening cement. 2. A method in which a polymer dispersion is added to an inorganic foam having a mixture of particles having different average particle diameters, the mixture is stirred, and water and ultra-rapid cement are added and mixed, and then pressure vibration molding is performed. And a method for producing an inorganic lightweight plate.