JPH09169577A - Production of inorganic board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inorganic board producing method capable of increasing adhesive strength of a green sheet with a powdery layer. SOLUTION: In this method for producing the inorganic board by making an aq. slurry 3 containing fiber material into a sheet to form the green sheet 7 and scattering a powdery material 4 on the green sheet 7 to form the powdery layer 11, a joining material 8 constituted of non-fiber matter is scattered on the green sheet 7 before the powdery material 4 is scattered on the green sheet 7 to form a joining layer 1 joining the green sheet 7 to the powdery layer 11.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an inorganic plate, and more particularly, to a method for producing an inorganic plate useful for use as a building plate.

[0002]

2. Description of the Related Art Conventionally, as a method for producing an inorganic plate, there has been known a method for producing an inorganic plate by a papermaking method, or an extrusion method or a casting method. Among these, the method of producing an inorganic plate by a papermaking method has been commonly used because of its excellent productivity. Then, after papermaking to obtain a green sheet, a powder material is sprayed to form a powder layer on the surface of the green sheet, and a deeper pattern is formed on the surface of the inorganic plate obtained by press molding. It was something that could be added.

[0003]

However, in such a method for producing an inorganic plate, since the adhesion strength between the green sheet and the powder layer is weak, there is a problem between the green sheet and the powder layer. However, there is a problem that peeling easily occurs.

The present invention has been made in order to eliminate the above-mentioned drawbacks, and an object of the present invention is to provide a method of manufacturing an inorganic plate capable of increasing the adhesion strength between a green sheet and a powder layer. It is in.

[0005]

In the method for producing an inorganic plate according to claim 1 of the present invention, a green sheet (7) is produced by paper-making an aqueous slurry (3) containing a fiber component. In the method for producing an inorganic plate in which the powder material (4) is sprinkled on the above (4) to form the powder layer (11), the green material (7) is formed into paper, and then the above powder material (4) is added. Prior to spraying, a bonding material (8) composed of a fiber-free component is sprayed on the green sheet (7) to bond the green sheet (7) and the powder layer (11) together. It is characterized in that the layer (1) is formed.

The method for manufacturing an inorganic plate according to claim 2 of the present invention is characterized in that the bonding material (8) is cured by autoclave curing to form tobermorite.

The method for manufacturing an inorganic plate according to a third aspect of the present invention is characterized in that either vermiculite or pearlite is added to the bonding material (8).

In the method for manufacturing an inorganic plate according to claim 4 of the present invention, the amount of the bonding material (8) dispersed is 50 to 200 g /
m ² .

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

FIG. 1 is a schematic view showing a method for manufacturing an inorganic plate according to one embodiment of the present invention.

In the method for producing an inorganic plate of the present invention, as shown in FIG. 1, an aqueous slurry (3) containing a fiber component is made into a green sheet (7) and powder is applied onto the green sheet (7). Powder layer (11) by spraying body material (4)
In the method for producing an inorganic plate for forming a green sheet, the green sheet (7) is formed into a paper, and before the powder material (4) is sprayed, a bonding material (8) made of fiber-free material is used. It is sprayed on the sheet (7) to form a joining layer (1) for joining the green sheet (7) and the powder layer (11).

The above-mentioned aqueous slurry (3) contains a fiber component and contains, for example, cement and aggregate as main components, and if necessary, an auxiliary component such as a reinforcing material. It is included.

Examples of the above fiber components include cellulose-based pulp fibers, mineral fibers such as asbestos, organic resin fibers such as polypropylene and vinylon, glass fibers, and the like.
Carbon fibers, metal fibers, etc. can be used.

As the above-mentioned cement, for example, Portland cement, fly ash cement, blast furnace cement and the like are used. Further, as the aggregate, granite, crushed stone such as serpentine, silica stone powder, shirasu balloon, glass balloon, silica, pearlite, sand,
Also, beads and the like are used. Furthermore, although pulp powder or the like is usually used as the reinforcing material, the reinforcing material is not limited to this.

The green sheet (7) is obtained by making the aqueous slurry (3) into paper. As shown in FIG. 1, a papermaking machine (10) is used for papermaking. This papermaking machine (10) is, for example, a Hatschek system,
Examples include a long-net system.

In particular, when the papermaking machine (10) is of the fourdrinier system, as shown in FIG. 1, the suction box (2) is used to reduce the pressure to more effectively dehydrate the green sheet (7). Is something that can be done. And, by this suction box (2), 10 to 30 cmH
It can be placed under a reduced pressure of about g.

The papermaking machine (10) includes a conveyor (5).
The conveyor (5) is, for example, as shown in FIG. 1, wound around a roll (6) and arranged above the suction box (2).
The aqueous slurry (3) is placed on the conveyor (5), and the aqueous slurry (3) is made into paper to form a green sheet (7).

The powder layer (11) is formed by spraying the powder material (4) on the green sheet (7). As the powder layer (11), for example, in the case of the present embodiment, the powder material (4) is sprinkled so as to have a thickness of 3 mm after press molding when water is exhausted by evaporation or the like. To do. As the powder material (4), for example, a material containing cement and an aggregate as main components, and a material containing a reinforcing material and fibers as an auxiliary component are used, but the powder material (4) is not limited to this. Various formulations can be used without being processed.

The powder material (4) is, for example, Portland cement,
Materials such as fly ash cement and blast furnace cement are used, and the main components of the aggregate are crushed stones such as granite and serpentine, silica stone powder, shirasu balloons, glass balloons, silica, perlite, sand, and beads. Is used. In addition, as reinforcing materials and fibers of auxiliary components, pulp powder, vermiculite, cellulose-based pulp fibers, mineral fibers such as asbestos, organic resin-based fibers such as polypropylene and vinylon, glass fibers, carbon fibers, Metal fibers and the like can be used.

As shown in FIG. 1, the above bonding material (8)
After being made into the above green sheet (7),
Before the powder material (4) is sprayed, a bonding layer (1) is sprayed on the green sheet (7) to bond the green sheet (7) and the powder layer (11). To form.

This bonding material (8) is composed of fiber-free components, and bonds the green sheet (7) and the powder layer (11) formed of the powder material (4). Is. In the present embodiment, the bonding material (8) is, for example, a cement material such as Portland cement, fly ash cement, or blast furnace cement, and granite,
Crushed stone such as serpentine, silica stone powder, shirasu balloon, glass balloon, silica, pearlite, sand, and a material mixed with aggregates such as beads are used, but are not limited thereto.

In particular, when the above-mentioned bonding material (8) is one that is cured by autoclave curing to form tobermorite, the formed tobermorite can improve the durability and the like, and further improve the green. The adhesive strength between the sheet (7) and the powder layer (11) can be increased.

Furthermore, when either vermiculite or pearlite is added to the above-mentioned bonding material (8),
The adhesion strength between the green sheet (7) and the powder layer (11) can be further enhanced, and the warp of the obtained inorganic plate can be suppressed, so that the quality of the inorganic plate is comprehensively improved. It can be done.

The amount of the bonding material (8) sprayed was 50
When the amount is up to 200 g / m ² , the bonding layer (1) can be effectively formed, and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) can be further enhanced. Is.

Assuming that the sprinkling amount of the bonding material (8) is 50 g /
m^TwoIf it is less than, even if the bonding layer (1) is formed,
Adhesion between green sheet (7) and powder layer (11)
It is not enough to increase the strength, and the bonding material
Dispersion amount of (8) is 200 g / m ^TwoAbove the bonding layer
(1) becomes too thick and tends to be non-uniform
As a result, the green sheet (7) and the powder layer (1
It is difficult to sufficiently increase the adhesion strength with 1).

Further, as shown in FIG. 1, when press molding is performed after appropriately performing suction dehydration in a suction box (2) or the like, this green sheet (7) is divided into a lower mold and an upper mold. The lower mold is provided with a dehydration hole as required, and a felt may be laid on the upper surface of the lower mold.

Further, curing is performed to obtain an inorganic plate. The curing is carried out in an autoclave, which is cured at 150 to 200 ° C. for 7 to 15 hours to obtain an inorganic plate.

Before the autoclave curing, the green sheet (7) may be used at room temperature for 2 to 5 hours, if necessary.
It is also possible to adopt a method such as leaving it to stand, and then performing heat and moisture curing for 10 to 100 hours at a temperature of 50 to 90 ° C. filled with steam.

Further, as shown in FIG. 1, if necessary,
An overflow box (9) and the like can be installed so that the aqueous slurry (3) can be efficiently recycled.

According to the present invention, the green sheet (7) made from the aqueous slurry (3) and the powder layer (11) formed from the powder material (4) are obtained by using such a manufacturing method. Are bonded via a bonding layer (1) formed of a bonding material (8) composed of a fiber-free component, and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) is facilitated. And, it can be surely increased.

[0031]

Examples of the present invention will be described below.

EXAMPLE 1 An aqueous slurry having a concentration of 6 wt% was prepared by mixing 100 parts by weight of Portland cement, 40 parts by weight of silica stone, 15 parts by weight of pulp powder, and 100 parts by weight of fly ash, as shown in FIG. Machined (10) for paper making, thickness 12m
m green sheet (7) could be obtained.

Immediately after the green sheet (7) thus produced, 100 parts by weight of Portland cement, 40 parts by weight of silica stone, and 100 parts by weight of fly ash were mixed on the green sheet (7) to form a joining material (8). Is 50 g / m
² sprayed. Then, the green sheet (7) with the bonding layer (1) formed of the bonding material (8) was placed on the conveyor (5) having a width of 20 cm while being decompressed by the suction box (2) arranged for 10 m. 1
A powder material containing 100 parts by weight of Portland cement, 40 parts by weight of silica stone, 100 parts by weight of fly ash, 40 parts by weight of water, and 30 parts by weight of vermiculite while being flowed at a speed of 0.0 m / min (4 ) Is sprinkled on the bonding layer (1) to form a powder layer (11) having a thickness of 3 mm.
Was formed.

After that, the green sheet (7) made into paper
Was subjected to press molding at a pressure of 4 MPa and a time of 1.0 sec. At this time, the state of the green sheet (7) was good. After steam curing at a temperature of 60 ° C. for 10 hours, autoclave curing at a temperature of 175 ° C. for 10 hours, an inorganic plate having a thickness of 15 mm and a specific gravity of 1.11 could be obtained.

Then, the inorganic plate is heated at a temperature of 60 ° C. for 10 minutes.
After leaving for an hour, the same inorganic plate is 40 mm x 40 m
It cut into m and prepared 20 samples. Then, a jig is attached to both sides of this sample, and the pulling speed is 1
A tensile test of pulling at a speed of mm / min was performed on each sample, and the green sheet (7) and the powder layer (1
The number of boundary fractures, which is the number of sheets to be destroyed between the layers with 1), was examined. As a result, only one of the 20 samples broke at the boundary.

Example 2 The thickness was 15 mm and the specific gravity was 1.1 in the same manner as in Example 1 except that the amount of the bonding material (8) sprayed was 100 g / m ^2.
2 was obtained.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Example 3 100 g by weight of Portland cement, 40 parts by weight of silica stone powder, 100 parts by weight of fly ash, and 30 parts by weight of vermiculite were used, except that the bonding material (8) was sprayed at 50 g / m ² . A thickness of 15 m as in Example 1.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.11.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, only one of the 20 samples broke at the boundary.

Example 4 100 g / m ^{2 of} the bonding material (8) containing 100 parts by weight of Portland cement, 40 parts by weight of silica stone, 100 parts by weight of fly ash, and 30 parts by weight of vermiculite.
A thickness of 15 m is obtained in the same manner as in Example 1 except that it is sprayed.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.12.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, only one of the 20 samples broke at the boundary.

Example 5 150 g / m ^{2 of} a bonding material (8) containing 100 parts by weight of Portland cement, 40 parts by weight of silica stone, 100 parts by weight of fly ash, and 30 parts by weight of vermiculite.
A thickness of 15 m is obtained in the same manner as in Example 1 except that it is sprayed.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.13.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Example 6 A bonding material (8) containing 100 parts by weight of Portland cement, 40 parts by weight of silica stone, 100 parts by weight of fly ash and 30 parts by weight of vermiculite was 200 g / m ^2.
A thickness of 15 m is obtained in the same manner as in Example 1 except that it is sprayed.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.13.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, none of the 20 samples was broken at the boundary.

Comparative Example 1 Portion cement (100 parts by weight), silica stone powder (40 parts by weight), fly ash (100 parts by weight) and vermiculite (30 parts by weight) were used in combination except that 20 g / m ^{2 of} the bonding material (8) was sprayed. A thickness of 15 m as in Example 1.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.10.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, 5 of the 20 samples broke at the boundary.

Comparative Example 2 300 g / m ^{2 of} the bonding material (8) was prepared by mixing 100 parts by weight of Portland cement, 40 parts by weight of silica stone powder, 100 parts by weight of fly ash, and 30 parts by weight of vermiculite.
A thickness of 15 m is obtained in the same manner as in Example 1 except that it is sprayed.
It was possible to obtain an inorganic plate having m and a specific gravity of 1.14.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, two of the 20 samples were broken at the boundary.

Comparative Example 3 An inorganic plate having a thickness of 15 mm and a specific gravity of 1.06 could be obtained in the same manner as in Example 1 except that the bonding material (8) was not sprayed.

The number of boundary fractures was examined in the same manner as in Example 1. As a result, 12 of the 20 samples broke at the boundary.

Tables 1 below show Examples 1-6 and Comparative Examples 1-3.
The number of boundary fractures of the inorganic plate obtained in step 1 is summarized.

[0053]

[Table 1]

As can be seen by comparing Table 1 with those of Examples 1 to 6 and Comparative Examples 1 to 3 together with the above description, the number of boundary fractures is found in Examples 1 to 6. Is much less than Comparative Examples 1 to 3, and the green sheet (7) made from the aqueous slurry (3) and the powder layer (11) formed from the powder material (4) are fiber-free. Are joined together via a joining layer (1) formed of a joining material (8) composed of the following components, and as a result, the adhesion strength between the green sheet (7) and the powder layer (11) is easily and It can be said that it can be surely increased.

Further, those of Examples 1 to 6 and Comparative Examples 1 and 2
As can be seen by comparing the above, when the sprinkling amount of the bonding material (8) is 50 to 200 g / m ² , the bonding layer (1) can be effectively formed, and as a result, the green sheet is further improved. It can be said that the adhesive strength between (7) and the powder layer (11) can be increased.

[0056]

According to the method for producing an inorganic plate according to claim 1 of the present invention, a powder layer formed from the green sheet (7) made from the aqueous slurry (3) and the powder material (4). (11) and the green sheet (7) and the powder layer (11) are adhered to each other through the joining layer (1) formed of the joining material (8) composed of a fiber-free component. The strength can be easily and surely increased.

According to the method for producing an inorganic plate according to the second aspect of the present invention, in addition to the case of the first aspect, the formed tobermorite can improve the durability and the like, and can further improve the green color. The adhesive strength between the sheet (7) and the powder layer (11) can be increased.

According to the method for manufacturing an inorganic plate according to claim 3 of the present invention, in addition to the case of claim 1 or claim 2, further close contact between the green sheet (7) and the powder layer (11) is achieved. In addition to being able to increase the strength, it is possible to suppress the warp of the obtained inorganic plate and the like, and it is possible to comprehensively improve the quality of the inorganic plate.

According to the method for producing an inorganic plate according to claim 4 of the present invention, in addition to the case of any one of claims 1 to 3, the bonding layer (1) can be effectively formed, As a result, the adhesion strength between the green sheet (7) and the powder layer (11) can be further increased.

[Brief description of the drawings]

FIG. 1 is a schematic view illustrating a method for manufacturing an inorganic plate according to an embodiment of the present invention.

[Explanation of symbols]

 1 Bonding Layer 3 Aqueous Slurry 4 Powder Material 7 Green Sheet 8 Bonding Material 11 Powder Layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical indication C04B 40/02 C04B 40/02 // (C04B 28/18 16:02 14:20)

Claims (4)

[Claims] 1. A method for producing an inorganic plate, wherein an aqueous slurry containing a fiber component is formed into a green sheet, and a powder material is sprinkled on the green sheet to form a powder layer. After being made into paper, before spraying the powder material, a bonding material composed of fiber-free components is sprayed on the green sheet to form a bonding layer for bonding the green sheet and the powder layer. 1. A method for producing an inorganic plate, which comprises forming. 2. The method for producing an inorganic plate according to claim 1, wherein the bonding material is one that is cured by autoclave curing to form tobermorite. 3. The method for producing an inorganic plate according to claim 1, wherein either vermiculite or pearlite is added to the bonding material. 4. The sprinkling amount of the bonding material is 50 to 200 g.
/ M ² is set.
The method for producing an inorganic plate according to any one of claims.