JPH11156843A - Inorganic wall panel and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate opening by cutting and profile treatment by a method in which a carbon fiber net is embedded in a cured material of an inorganic curable composition to face a panel surface, and the meshes of the net are filled with the cured material. SOLUTION: A wall panel 1 is constituted from a cured material 2 formed from an inorganic curable composition and a carbon fiber net 3 embedded to face the back 1a of the panel 1. In the panel 3, since the meshes of the net 3 are filled with the cured material 2, the net 3 is fixed firmly in the cured material 2 without using an adhesive or uneven processing. Since a reinforced part is carbon fibers, even when an optional part is cut, a cutting blade of a diamond saw and others is not hurt, facilitating opening by cutting and profile treatment. Besides, a small amount of the necessary carbon fibers suppresses the elevation of costs.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic wall panel used for building materials and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, various carbon fibers have been used for the purpose of improving the mechanical performance of inorganic materials such as concrete. For example, in a concrete precast product, short fibers of carbon fibers are mixed, or carbon fibers are formed into a rod shape and incorporated as a substitute for a reinforcing bar. As a result, the mechanical properties such as tensile strength and bending strength of the precast product are improved. In addition, sheet-like carbon fibers are bonded to the surface of existing concrete structures and precast products with an adhesive to reinforce them.

[0003] Here, carbon fibers have low adhesion to inorganic materials such as cement. For this reason, in order to incorporate the rod-shaped carbon fiber into concrete, it is necessary to perform unevenness on the surface of the rod to prevent the carbon fiber rod and the concrete material from slipping. When carbon fibers are adhered to the surface to reinforce, it is necessary to use an organic adhesive having a strong adhesive force, such as an epoxy resin or methyl methacrylate, as the adhesive.

[0004] However, the cost of the raw material of carbon fiber itself is high, and in addition to the use of a concavo-convex processing for improving the adhesion and the use of an adhesive, the overall cost is unavoidable. For this reason, there is a problem in terms of cost in disseminating an inorganic material reinforced with carbon fibers as a general-purpose product. Furthermore, since bonding with an organic resin impairs heat resistance, it may be difficult to use it as a building material.

According to Japanese Patent Publication No. 4-45471, there is proposed a method for producing an inorganic cured body having extremely excellent properties as an outer wall panel. Here, a stainless steel reinforcing bar network is embedded near the back surface using a specific inorganic curable composition. The use of this material provides an inorganic wall panel having excellent impact strength and fire resistance.

[0006]

The present applicant has made various improvements based on the technology using the inorganic curable composition. For example, Japanese Patent Application No. 9-1584 filed earlier.
No. 90 proposes a wall panel in which a reinforcing member that spreads in a planar shape facing a panel surface is provided in a panel main body mainly composed of an inorganic curable composition.

Here, the inorganic wall panel used for the building is subjected to a cutting process for forming an opening or a deformed portion due to the necessity of communication with the outside and arranging an opening such as a window. Need arises. When cutting a wall panel using a metal material as a reinforcing member, a composite of a metal material and an inorganic material is cut. However, the composite has a problem that the cutting blade such as a diamond saw is easily damaged. On the other hand, if the carbon fiber is used to reinforce the inorganic material, the problem of cutting can be solved.However, due to the low adhesion of carbon fiber, the cost of the product is high when the workability and processing time are included, and the product becomes expensive. There is a problem that it is not a target.

SUMMARY OF THE INVENTION It is an object of the present invention to provide an inorganic wall panel which can be easily opened and deformed by a cutting process and suppresses an increase in cost, and a method of manufacturing the same.

[0009]

In order to achieve this object, according to the first aspect of the present invention, a network of carbon fibers is embedded inside a cured body made of an inorganic curable composition, facing a panel surface, An inorganic wall panel, wherein the mesh of the mesh is filled with the cured material.

[0010] According to a second aspect of the present invention, in the reticulated body, the opening between the converging fibers is 5 mm to 100 mm due to the converging fibers having 500 to 10,000 carbon fibers converged.
And the weight used of the carbon fibers per unit area is 5 g / m ^{2 to} 100 g / m ^2.
a mineral wall panel according to claim 1, characterized in that in the range of g / m ^2.

According to a third aspect of the present invention, there is provided the inorganic wall panel according to the second aspect, wherein the crossing points of the converging fibers are fixed by an adhesive to form a net.

According to a fourth aspect of the present invention, the inorganic curable composition comprises a reactive powder containing silicon dioxide and aluminum oxide, an alkali metal silicate and water, and optionally contains a foaming agent. The inorganic wall panel according to claim 1, characterized in that:

According to a fifth aspect of the present invention, water is added in an amount of 0.2 to 450 parts by weight of alkali metal silicate and 35 parts by weight of water with respect to 100 parts by weight of the reactive powder containing silicon dioxide and aluminum oxide. Using the inorganic curable composition blended in the range of 1 part by weight to 1500 parts by weight, the inorganic curable composition is charged into a mold provided with a carbon fiber network, and the inorganic curable composition is added. The inorganic curable composition is cured by embedding the reticulated body in, or after the inorganic curable composition is put into a mold, the inorganic curable composition is in an uncured state and the carbon fiber network is uncured. Charging the body into the uncured inorganic curable composition, embedding the network in the uncured inorganic curable composition, and curing the inorganic curable composition. 2. A method for producing an inorganic wall panel according to item 1.

According to the first aspect of the present invention, since the hardened material is filled in the mesh of the buried net, the net is separately adhered by using an adhesive or subjected to uneven processing. It is firmly fixed inside the cured product without increasing the fixability. Since the reinforcing portion is made of carbon fiber, opening processing such as cutting is facilitated. This provides a wall panel in which the opening and the deforming process by the cutting process are easy, and the increase in cost is suppressed.

According to the second aspect of the present invention, the amount of carbon fiber used is small and the reinforcing effect can be improved, so that a wall panel excellent in impact resistance and fire resistance can be obtained without increasing the cost. be able to.

According to the structure of the third aspect, it is easy to form a net which gives the effect of the second aspect. In this case, the adhesive is used only at the intersections and the amount of the adhesive used may be small, so that the fire resistance is not substantially impaired.

According to the fourth aspect of the invention, a wall panel having good mechanical strength can be obtained.

According to the fifth aspect of the present invention, the inorganic wall panel according to the first aspect of the present invention, wherein the carbon fiber network is firmly embedded in the cured body.

[0019]

Embodiment 1 Hereinafter, the present invention will be described with reference to Embodiment 1.
Will be described with reference to the drawings.

FIGS. 1 to 3 show an example of the first embodiment of the present invention. 1 and 2, reference numeral 1 denotes a wall panel, and the wall panel 1 is embedded in a cured body 2 formed of an inorganic curable composition, which will be described later, and directly opposite a back surface 1 a of the wall panel 1. And a reticulated body 3 of carbon fibers. Although the net 3 is completely embedded in the cured body 2 in the figure, a part thereof may be exposed on the surface. Further, the cured body 2 may be a foamed cured body described below (hereinafter, this may be referred to as a foamed cured body).

As shown in FIG. 3 (a), this net-like body 3 is composed of bundled fibers 4a aligned at a constant pitch in the vertical direction.
And the bundled fibers 4b arranged at the same pitch in the horizontal direction are formed in a square lattice 5 shape. A resin adhesive such as an epoxy resin, a methyl methacrylate resin, or a phenol resin is applied to the intersection 6 between the bundled fiber 4a and the bundled fiber 4b, and the intersection 6 is fixed so as not to be displaced. As shown in FIG. 3B, the reticulated body 3 may be one in which the bundled fibers 4a and the bundled fibers 4b are alternately entangled up and down.

This mesh has a rectangular grid 5 shown in FIG.
In addition, a rectangular lattice, a triangular lattice (triangular shape), and the like can be freely selected, and an arbitrary mesh shape can be selected according to a stress application state of the inorganic wall panel. Mesh aperture (distance between converging fibers)
a is not particularly limited, but in this example, about 5 mm to 1 mm.
It is set in the range of 00 mm.

The converging fibers 4a and 4b are formed by converging and fixing a large number of carbon fibers with a resin-based sizing agent such as an epoxy resin, a methyl methacrylate resin, or a phenol resin. The number of converging fibers is not limited. Preferably, the carbon fibers are converged within a range of about 500 to 10,000 fibers. Here, an organic adhesive is used for the convergence of the carbon fibers and the intersection 6, but the amount is small compared to the whole wall panel, so that the cost is greatly improved and the heat resistance of the wall panel is substantially reduced. There is no loss.

The reticulated body 3 set in the above preferred range
When using, 5 g / m ^{2 to} 100 g per unit area
By embedding carbon fibers in the cured body 2 in the range of / m ² , impact resistance and the like necessary for a wall panel are imparted. As described above, by reinforcing with a small amount of carbon fiber, the obtained wall panel 1 can reduce the cost. In addition, fire resistance performance is not significantly reduced.

As the inorganic curable composition which is the main component of the cured product (or the foamed cured product), an inorganic curable composition used for a general wall panel can be applied. They are, for example, high-temperature and high-pressure cured lightweight cellular concrete (ALC) described in, for example, Japanese Utility Model Publication No. 59-22817.
It may be. Further, a cured product of a water-containing molding material for molding described in Japanese Patent Publication No. 4-45471 may be used.

In the present invention, the composition comprises an SiO ₂ —Al ₂ O ₃ -based reactive inorganic powder (hereinafter abbreviated as a reactive powder) containing silicon dioxide and aluminum oxide, an alkali metal silicate, and water. Is preferably a cured product formed from an inorganic curable composition containing a foaming agent. Especially,
From the inorganic curable composition containing alkali metal silicate in the range of 0.2 to 450 parts by weight and water in the range of 35 to 1500 parts by weight with respect to 100 parts by weight of the reactive powder, the panel main body is prepared. In the case of forming a wall panel, it is possible to obtain a wall panel that is strong against impact and excellent in fire prevention performance, as is clear from the examples described later.

As such a reactive powder, those containing silicon dioxide in a range of 5% by weight to 85% by weight and aluminum oxide in a range of 90% by weight to 10% by weight are preferably used. Examples of such a reactive powder include fly ash, metakaolin, kaolin, mullite, corundum, dust for producing an alumina-based abrasive, pulverized and fired bauxite, and the like. It is not something to be done.

These reactive powders may be used as they are, but may be used after classifying those having high reaction activity (hereinafter simply referred to as activity), or may be subjected to thermal spraying or pulverization using mechanical energy. In this case, a material subjected to an activation treatment is preferably used. These activation means can be used in combination.

As a method of thermal spraying, a thermal spraying technique applied to ceramic coating is applied. In the thermal spraying technique, the material powder is usually 2,000 ° C. to 1600 ° C.
It is melted at a temperature of 0 ° C. and sprayed at a speed of 30 m / s to 800 m / s. Further, those activated by a plasma spraying method, a high energy gas spraying method, an arc spraying method, or the like may be used. By such a treatment, the specific surface area of the powder is improved and activated. A preferred specific surface area is 0.1 m
² / ^g~100m is about ² / g.

As a method for applying mechanical energy by pulverization, any conventionally known method is employed. Examples of the pulverizing means include a jet mill, a roll mill, and a ball mill. When using a ball medium mill, a medium stirring type mill, a roll mill or the like, 0.5 kwh / kg to 30 kwh /
The activation suitably proceeds when mechanical energy of about kg is applied. If the mechanical energy is small, the powder is hardly activated, while if the mechanical energy is large, the load on these pulverizers is large. The pulverized powder is classified by the above-described classification means as needed. Here, the applied mechanical energy is a numerical value representing the electric power supplied to the ball mill per unit weight of the processed powder.

The fly ash as the raw material powder may be fired if necessary. If the firing temperature is low, the black color of the fly ash remains and coloring becomes difficult, and if the firing temperature is high, the reactivity with the alkali metal silicate becomes low.
The temperature is preferably from 00C to 1000C.

The alkali metal silicate used in the present invention is represented by the general formula M ₂ O.nSiO ₂ (where M is K, Na,
One or more metals selected from Li
Indicates a positive number. ). When the value of n is small, a dense foam cannot be obtained, and when the value is large, the viscosity of the aqueous solution increases and mixing becomes difficult. Therefore, n is preferably in the range of 0.05 to 8, more preferably 0.5 to 2 .5.

The alkali metal silicate may be added as it is, but is preferably added as an aqueous solution dissolved in water. Here, as the concentration of the aqueous solution decreases, the reactivity with the fly ash powder decreases. On the other hand, when the concentration of the aqueous solution increases, the solid content is easily generated. Therefore, the range of 10 to 60% by weight is usually used.

Here, as a method for obtaining an aqueous solution of an alkali metal silicate, an ordinary method is employed as it is. For example,
The alkali metal silicate may be directly dissolved in water under pressure and heat. Alternatively, an aqueous alkali metal hydroxide solution may be separately prepared, and SiO ₂ components such as silica sand and silica powder may be dissolved in the aqueous solution under pressure and heat so that n has a predetermined value.

Such an alkali metal silicate is usually
0.2 parts by weight to 450 parts by weight based on 100 parts by weight of the reactive powder
It is blended in the range of parts by weight. If the blending amount of the alkali metal silicate is small, the curing does not proceed sufficiently, while if the blending amount is large, the water resistance of the obtained foam decreases. The preferred amount is 10 parts by weight of the reactive powder.
It is in the range of from 35 parts by weight to 350 parts by weight, more preferably in the range of from 20 parts by weight to 250 parts by weight.

The inorganic curable composition contains water as an essential component. The amount of water is not particularly limited,
Usually, 35 parts by weight to 100 parts by weight of the reactive powder
It is in the range of 1500 parts by weight. If the amount of water to be blended is small, not only does curing not sufficiently proceed, but also mixing becomes difficult. On the other hand, if the amount of water is more than necessary, the strength of the cured product tends to decrease. A preferred amount of water is in the range of 45 to 1000 parts by weight, more preferably 50 to 500 parts by weight, based on 100 parts by weight of the reactive powder. This water may be added in the form of the alkali metal silicate aqueous solution described above, or may be added independently.

In the present invention, the cured product may be a foamed cured product containing a foaming agent. Such a foamed cured product is made to have high added value by imparting heat insulation to the wall panel. For this purpose, a foaming agent is added to the above-mentioned inorganic curable composition together with a foaming aid as necessary (hereinafter, this composition may be referred to as an inorganic curable foam composition).

Examples of the foaming agent include peroxides such as hydrogen peroxide, sodium peroxide, potassium peroxide, and sodium perborate;
Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, A
Metal powders such as 1, Ga, Sn, Si, and ferrosilicon are exemplified. These foaming agents may be used alone or in combination of two or more. When hydrogen peroxide is used as a foaming agent, it is preferably used as an aqueous solution in consideration of safety and stable foaming. When a metal powder is used, it is preferable to use a fine powder having a particle diameter of 200 μm or less in order to obtain stable foaming.

In order to obtain a sufficient foamed cured product, the foaming agent is preferably used in an amount of 0.01 to 10 parts by weight based on 100 parts by weight of the reactive powder. If the amount of the foaming agent is too small, the expansion ratio is too low to obtain a sufficient foamed cured product, while if the amount of the foaming agent is too large, the foaming gas becomes excessive and foaming often occurs. .
When foaming is performed, it is preferable to add a foaming aid as needed in order to uniformly generate foaming.
Examples of such foaming aids include fatty acid metal salts such as zinc stearate, calcium stearate, and zinc palmitate, and porous powders such as silica gel, zeolite, activated carbon, and alumina powder. These foaming assistants may be used alone or in combination of two or more.

When the amount of the foaming aid is increased, the viscosity of the inorganic curable composition may be increased to easily cause foam breakage. Usually, this foaming aid is not more than 10 parts by weight based on 100 parts by weight of the reactive powder.

In the present invention, an inorganic filler may be added as required. The inorganic filler does not dissolve in water,
There is no particular limitation as long as it does not inhibit the curing reaction of the inorganic curable composition and does not react with the alkali metal silicate. For example, silica sand, river sand, zircon sand, crystalline alumina,
Rock powder, volcanic ash, silica flower, silica fume,
Blended materials for mixed cement such as bentonite and blast furnace slag,
Natural minerals such as sepiolite, wollastonite and mica,
Examples include calcium carbonate and diatomaceous earth. These may be added alone or in combination of two or more.

When a foamed cured product is obtained, the size (average diameter) of the inorganic filler is preferably in the range of 0.01 μm to 1000 μm. If the average diameter is small, the viscosity of the inorganic curable composition increases, and it becomes difficult to obtain a high-magnification foam. On the other hand, foaming with an increased average diameter may be unstable. Further, since the strength of the foam obtained decreases when the amount of the inorganic filler increases, the blending amount of the inorganic filler is preferably 700 parts by weight or less based on 100 parts by weight of the reactive powder. .

In the present invention, a smaller proportion of reinforcing fibers may be added if necessary. Any reinforcing fiber can be used depending on the performance to be imparted to the cured product. Examples thereof include vinylon fiber, polyamide fiber, polyester fiber, polypropylene fiber, carbon fiber, aramid fiber, glass fiber, potassium titanate fiber, and steel fiber.

When the fiber diameter of the reinforcing fiber becomes thinner, it reagglomerates upon mixing, and fiber balls are easily formed by entanglement, and the strength of the finally obtained foam is not further improved. On the other hand, as the fiber diameter increases or the fiber length decreases, the reinforcing effect such as improvement in tensile strength decreases.
Further, as the fiber length increases, the dispersibility and orientation of the fiber decrease. From the above viewpoint, the fiber diameter is 1 μm to 500 μm
And the fiber length is preferably in the range of 1 mm to 15 mm.
Since the dispersibility of the fiber decreases as the amount of the reinforcing fiber increases, it is preferable that the reinforcing fiber is blended in an amount of 10 parts by weight or less based on 100 parts by weight of the reactive powder.

For the purpose of further reducing the weight of the cured product, foaming of inorganic foams such as silica balloons, perlite, fly ash balloons, shirasu balloons, glass balloons, foamed and baked clays, and synthetic resins such as phenolic resins, urethane resins, and polyethylenes. Body, vinylidene chloride balloon and the like may be added. These may be added alone or in combination of two or more. If necessary, alumina cement, γ-alumina, sprayed alumina, alkali metal aluminate or aluminum hydroxide may be added.

The above-mentioned respective components are mixed in an appropriate combination so that the entire inorganic curable composition becomes uniform and the reaction becomes uniform, whereby a paste-like inorganic curable composition can be obtained. . The inorganic curable composition thus obtained cures at room temperature, but the curing reaction is accelerated by heating. For example, 50 ° C.-1
In a temperature range of 10 ° C., the composition is cured in about 30 minutes to 8 hours, and mechanical properties can be improved.

Table 1 shows one example of the mechanical properties of the above-mentioned inorganic curable composition obtained by measuring the actual measured values of the compressive strength of the molded articles in various composition compositions. In addition, as the reactive powder, fly ash (manufactured by Kanden Kako, JIS A 62
(Average particle size 20 μm according to 01) was classified by a classifier (Model: TC-15, manufactured by Nisshin Engineering Co., Ltd.), and a powder containing 100% by weight of a powder having a particle size of 10 μm or less was used. Further, as the alkali metal silicate, a general formula M ₂
A compound represented by OnnSiO ₂ (where n is 1.5 and M is a metal having a molar ratio of Na: K of 1: 1) is used in an autoclave at 130 ° C. and 7 kgf / cm.
² (≒ 0.7 MPa) dissolved in a predetermined amount of water was used.

[0048]

[Table 1] Next, a method of embedding the network 3 in the cured body 2 (or the foamed cured body) will be described.

The above-mentioned inorganic curable composition is put into a mold provided with the above-mentioned reticulated body 3, and the reticulated body is embedded in the inorganic curable composition to cure the inorganic curable composition. Can be manufactured. Further, if the inorganic curable composition is in an uncured state, the network can be embedded in the uncured inorganic curable composition later, and then cured. Also, after a part of the inorganic curable composition is put into a mold, an uncured state, a semi-cured state, a network is laid after curing, and the remaining amount of the inorganic curable composition is charged and cured to form a network. It can be buried.

In the wall panel configured as described above, 1 is
Since the mesh 5 of the buried mesh 3 is filled with the hardened body 2, the mesh 3 is bonded separately using an adhesive, or the hardened body 2 does not need to be subjected to unevenness to improve the fixability. It is firmly fixed inside. Further, since the reinforcing portion is made of carbon fiber, even if an arbitrary position is cut, a cutting blade such as a diamond saw is not damaged, and an opening and a deforming process by the cutting process are easy. In addition, the amount of carbon fiber used is small, and an increase in cost can be suppressed.

[0051]

Embodiment 2 Hereinafter, the present invention will be described with reference to Embodiment 2.
Will be described with reference to the drawings. Note that the same or equivalent parts as those of the first embodiment will be described with the same reference numerals.

As shown in FIGS. 4 and 5, in the wall panel 11 of the second embodiment, the wall panel 1 of the first embodiment is
Furthermore, it is reinforced by the metal frame 12. This metal frame 12
As shown in FIG. 5, a metal frame 13 having a substantially U-shaped cross section is generally formed by a flat portion 13a and legs 13b provided on both sides of the flat portion 13a by bending or the like. . At the tip of the leg portion 13b, an inner rib 13c is formed toward the inside of the metal frame 12. Reticulated body 3
Is fixed to the inner rib 13c with an adhesive such as an epoxy resin.

The metal frame 12 has a flat portion 13a exposed on the back surface 11a side of the wall panel 11, but has a leg portion 13a.
“b” is embedded in the foamed cured body 14. As a result, the mesh body 3 fixed to the leg 13b is embedded in the foamed cured body 14. Further, as the foamed cured body 14, the first embodiment
The same one is used. The foamed cured body 14 may be a cured body that is not foamed.

When such a metal frame 12 is used as a support for the net-like body 3, a lower mold having a decorative surface pattern of a wall panel is used as a lower mold, and the inorganic curable composition is charged into the lower mold. Then, the metal frame can be manufactured by placing an upper mold attached with a locking means such as an electromagnet or the like, clamping the mold, and after curing, opening the mold to remove the locking means.

In such a wall panel 11, the wall panel 11 is reinforced by the metal frame 12.
The inner portion which is not superposed has a space for sufficiently providing an opening such as a window. Other functions and effects are substantially the same as those of the first embodiment, and thus detailed description is omitted.

[0056]

EXAMPLES The effects of the present invention will be specifically described below with reference to examples. The parts in the examples relate to weight unless otherwise specified.

(Example 1) [Activation of reactive powder] Triethanol was added to 100 parts of metakaolin (SATINTONE SP 33 manufactured by Engelhard Co., average particle size 3.3 μm, specific surface area 13.9 m ² / g). Amine 25% by weight and ethanol 75% by weight
Of a mixed solution of Ultra Fine Mill AT
-20 (Mitsubishi Heavy Industries, zirconia ball diameter 10m
m used, ball filling rate 85% by volume)
/ Kg of mechanical energy was applied to obtain ground metakaolin.

[Preparation of Inorganic Curable Composition] 100 parts of the obtained ground metakaolin, an aqueous solution of potassium silicate as an alkali metal silicate (molar ratio 1.4, concentration 50% by weight)
165 parts of wollastonite as inorganic filler
00 parts, 100 parts of silica sand, vinylon fiber (Kuraray Co., Ltd.
3 parts of trade name: RM182 × 3) were blended and used as a paste-like inorganic curable composition.

[Preparation of Reticulated Body] As a reticulated body of carbon fibers, a bundle of 3,000 polyacrylonitrile-based carbon fibers converged and solidified with an epoxy resin is used.
Those arranged in a square at a pitch of 5 mm and whose intersections were solidified with an epoxy resin were used. The basis weight of this net is 20
g / m ² . The obtained mesh was cut in advance to the size of the wall panel.

[Production of Wall Panel] The above inorganic curable composition was put into a lower frame for a wall panel on which a rubber decorative mold was laid. Next, after applying vibration to perform leveling and defoaming, the above-mentioned reticulated body was laid, and furthermore, vibration was applied to fix the inorganic curable composition and the reticulated body. Next, after setting and heating and solidifying the upper mold, the cured product was taken out of the mold to obtain a wall panel shown in FIGS. This wall panel has a length of 1000 mm and a width of 1000 mm, and has a thickness of about 65 mm including a decorative portion provided with irregularities.

[Evaluation of Performance] The obtained wall panel was mounted on a wall according to a conventional method, and an impact test was performed by dropping a sand bag three times from a height of 100 cm according to JIS A 14146.15. It is understood that the impact resistance was improved by the net made of carbon fiber without any damage.

Further, the obtained wall panel was subjected to a fire test according to JIS A 1302, and was able to clear 45 minutes corresponding to the quasi-fire resistance.

(Example 2) [Preparation of inorganic curable composition] The inorganic curable composition used in Example 1 was further added with a particle diameter of 200 µm as a foaming agent.
0.1 parts of the following metal silicon fine powder and 3 parts of zinc stearate as a foaming aid were added to obtain an inorganic foamable curable composition used in Example 2.

[Preparation of Reticulated Body] As the reticulated body of carbon fibers, 5,000 polyacrylonitrile-based carbon fibers are converged, and bundled fibers solidified with an epoxy resin are arranged in a square at a pitch of about 40 mm in length and width. Then, the intersection was solidified with an epoxy resin. The basis weight of this net was 25 g / m ² .

The obtained net-like body was cut to be supported by the metal frame 12 shown in FIGS. 4 and 5, and was fixed to the inner rib 13c of the metal frame 12 with epoxy resin. Then, the frame was fixed to the upper mold with a magnet or the like.

[Production of Wall Panel] The above-mentioned inorganic foamable curable composition was put into a lower frame for a wall panel on which a rubber decorative mold was laid. Next, after vibration was applied to perform leveling and defoaming, the above-mentioned upper mold was set and heated and solidified, and then the foamed cured product was taken out from the mold to obtain an inorganic foamed wall panel shown in FIG. The resulting wall panel is 2820 mm long and 88 mm wide.
8 mm, and the thickness of the decorative portion 16
It is about 34 mm including mm.

[Evaluation of Performance] The obtained inorganic foamed wall panel was attached to a wall according to a conventional method, and the obtained panel was measured in accordance with JIS A 14146.15.
The impact test was performed by dropping the sand bag three times from a height of 0 cm. It is understood that the impact resistance was improved by the net made of carbon fiber without any damage.

The obtained inorganic foamed wall panel was manufactured by JI
When a fire test was conducted in accordance with SA 1302, it was possible to clear 45 minutes corresponding to semi-fire resistance.

Although the embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and the design may be changed without departing from the scope of the present invention. Included in this invention.

For example, in the second embodiment, a metal frame is used as a reinforcing member, but the metal frame may be an auxiliary bar such as a reinforcing bar. Further, the main body panel includes a decorative portion having a deep unevenness, but is not limited thereto.

In the embodiment, the net 3 is
Although it is a single layer (one sheet), a plurality of sheets may be laminated directly or at intervals.

[0072]

As described above, according to the first aspect of the present invention, the opening and the deforming process by the cutting process can be easily performed.
Further, a wall panel in which an increase in cost is suppressed is provided.

According to the second aspect of the invention, the amount of carbon fiber used is small and the reinforcing effect can be improved.
A wall panel having excellent impact resistance and fire resistance can be obtained without increasing the cost.

According to the third aspect of the present invention, it is easy to form a net which gives the effect of the second aspect. Further, since the amount of the adhesive used may be small, the fire resistance is not substantially impaired.

According to the fourth aspect of the present invention, a wall panel having good mechanical strength can be obtained.

According to the fifth aspect of the present invention, the inorganic wall panel according to the first aspect of the present invention, wherein the carbon fiber network is firmly embedded in the cured body.

[Brief description of the drawings]

FIG. 1 is a sectional view of a wall panel according to the present invention.

FIG. 2 is a perspective view of the wall panel shown in FIG. 1 as viewed from the back side.

3 (a) and 3 (b) are plan views illustrating details of the mesh body of FIG. 1. FIG.

4A and 4B are diagrams illustrating the entirety of a wall panel according to a modified example, where FIG. 4A is a plan view as viewed from the back surface, and FIG. 4B is a side view thereof.

5 (a) is a partially omitted cross-sectional view taken along line AA of the wall panel of FIG. 4, and FIG. 5 (b) is a line BB of the wall panel of FIG. It is a partially-omitted cross-sectional view when cut.

[Explanation of Signs] 1, 11: Wall panel 1a: Panel back surface 2, 14: Cured body (foamed cured body) 3: Reticulated body

Claims (5)

[Claims] The present invention is characterized in that a network of carbon fibers is buried directly inside a cured body made of an inorganic curable composition on a panel surface, and the mesh of the network is filled with the cured body. Inorganic wall panels. 2. The reticulated body has 500 to 1 carbon fibers.
The mesh between the converging fibers is processed into a mesh shape within the range of 5 mm to 100 mm by the converging fibers converged in the range of 0000 pieces, and the used weight of the carbon fibers per unit area is reduced. mineral wall panel according to claim 1, characterized in that in the range of ^{5g / m 2 ~100g / m 2} . 3. The inorganic wall panel according to claim 2, wherein the reticulated body has a reticulated body formed by fixing intersections of the converging fibers with an adhesive. 4. The inorganic curable composition comprises a reactive powder containing silicon dioxide and aluminum oxide, an alkali metal silicate and water, and optionally contains a foaming agent. 2. The inorganic wall panel according to 1. 5. An alkali metal silicate in an amount of 0.2 to 450 parts by weight and water of 35 parts by weight per 100 parts by weight of a reactive powder containing silicon dioxide and aluminum oxide.
Using the inorganic curable composition blended in the range of 1 part by weight to 1500 parts by weight, the inorganic curable composition is charged into a mold provided with a carbon fiber network, and the inorganic curable composition is added. After curing the inorganic curable composition by embedding the reticulated body in, or after charging the inorganic curable composition into a mold,
The network of carbon fibers in the state where the inorganic curable composition is uncured is charged into the inorganic curable composition in the uncured state, and the network is embedded in the inorganic curable composition in the uncured state. The method for producing an inorganic wall panel according to claim 1, wherein the inorganic curable composition is cured.