JPH11254582A - Laminated mineral plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a laminated mineral plate having excellent surface decorativeness, light weight and excellent strength characteristics. SOLUTION: The laminated mineral plate comprises a core material containing a mineral cured hydrate as a main component and a fibrous material and covered with a fiber sheet. In this case, the core material is constituted by at least three or more layers. And, the layer in contact with the fiber sheet contains 5 vol.% or less of a fibrous material. And, a content of the fibrous material contained in a layer not brought into contact with the fiber sheet of the core material is more than that of the layer brought into contact with the fiber sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an architectural plate used as an interior / exterior material for a building, and more particularly, to a fiber sheet and a core material which are firmly adhered to each other, are lightweight and have high strength, and have a surface cosmetic property. An object of the present invention is to provide an excellent laminated inorganic plate.

[0002]

2. Description of the Related Art Conventionally, various plate materials made of inorganic substances, organic substances, metals or composites thereof are used for interior and exterior materials of buildings. It is an important required characteristic to have such properties as strength, smooth surface, and easy makeup such as painting and application of wallpaper.

[0003] As interior / exterior building materials of inorganic materials which have been well known, many materials having improved strength characteristics by fiber reinforcement, such as fiber-reinforced gypsum boards and fiber-reinforced cement boards, have been developed. Although these materials are matrices such as gypsum and cement reinforced with fibrous materials, they have excellent strength properties and workability, but because the base material is exposed on the surface, they can be painted or wallpapered. In order to apply a surface makeup such as that described above, a pretreatment such as a sealer treatment is required. For this reason, a labor is required for the painting work, which is a factor that causes an increase in the cost of the entire finishing work. In addition, sealers contain volatile components that affect the human body, which are dissipated during the painting operation, and their use is being restricted.

On the other hand, gypsum boards, which are coated with paperboard and can be easily painted or pasted with wallpaper, are widely used as interior materials in which makeup workability on site is prioritized. However, the base paper used for the gypsum board has poor water resistance and has problems such as peeling between layers of the base paper due to moisture absorption. For this reason, not only gypsum board and cement board, but it is also practiced to arrange a fiber sheet having excellent water resistance such as nonwoven fabric on the surface, but in order to improve physical properties such as bending strength, a fibrous material is used. When the core material is reinforced, the adhesiveness between the fiber sheet and the core material is extremely deteriorated, so that a phenomenon that the core material is easily separated from the surface portion occurs. As a result, the strength of the composite plate of such a form in which the surface portion is reinforced greatly depends on the adhesiveness between the material disposed on the surface and the core material, so that the strength of the composite plate in the peeled state is sufficiently exhibited. Disappears.

[0005] In addition, although various inorganic plates have been made to reduce the weight, the specific gravity and the expression strength are almost correlated, and the strength tends to decrease as the weight is reduced. That is, since the pursuit of weight reduction results in weak strength characteristics, recently, for example, a new type of high-density gypsum board called, for example, a high-strength type has come to market. However, even though such building materials have been improved in terms of strength, they have gone against the previous requirements in terms of weight, and even with the emergence of new boards, they are still lightweight and have excellent strength properties. There is still a long-awaited desire for sheet metal. As described above, while the performance of inorganic plates such as gypsum and cement emphasizes lightness, strength characteristics, and surface decorativeness, there is a solution concerning a method of providing a plate material satisfying these,
No drastic measures have yet been taken.

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a lightweight and high-strength laminated inorganic plate which is excellent in surface cosmetic properties and surface peelability.

[0007]

In view of this situation, the present inventors have conducted various studies on a method of laminating an inorganic plate, but in order to satisfy the above-mentioned required properties as a building material, two sheets were used. By using a fiber sheet as the front and back surface materials and examining the amount of fibrous material in each layer while making the core material a multilayer structure, the inorganic material without the loss of adhesion between the base paper and the core material Strength properties that could not be obtained with a board,
We have completed a new type of laminated inorganic plate with light weight and surface decoration.

That is, the present invention provides an inorganic plate comprising a core material mainly composed of an inorganic hydrated cured product and a fiber sheet covering the front and back surfaces thereof, wherein the core material is composed of three or more layers. The layer that is in contact with the fiber sheet contains 0 to 5% by volume of the fibrous material, and the layer of the core that is not in contact with the fiber sheet contains more of the fibrous material than the layer that is in contact with the fiber sheet. The present invention provides a laminated inorganic plate characterized in that:

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First, in the present invention, a surface sheet as a building material is secured by arranging fiber sheets having excellent smoothness on the front and back surfaces of a core material. At the same time, the fiber sheet firmly adheres to the core material of the present invention, and improves the strength of the entire plate material. Furthermore, in the present invention, in order to ensure the adhesiveness between the fiber sheet and the core material mainly composed of the inorganic hydrated cured product, the core material has a structure of three or more layers in order to secure the lightness of the entire plate material. Has been distributed.

First, in the laminated inorganic plate of the present invention, the layer in contact with the fiber sheet has a function of securing the adhesiveness to the fiber sheet. 5% by volume. That is, as is recommended in the prior art, when a large amount of a fibrous material is added in hope of a significant improvement in performance, the volume of the fibrous material occupied in a core material mainly composed of an inorganic hydrated and cured product is increased. Since the ratio increases, the surface of the cured body has a form in which the fibrous material is exposed according to the volume fraction. Even if the mixture having such a composition can be disposed on the fiber sheet, the bonding area between the hydration hardening component and the fiber sheet is reduced by the amount of the fibrous material, and the adhesive strength is reduced. It will be difficult to compensate. On the other hand, in the present invention, the content of the fibrous material was examined, and the fibrous material contained in the bonded portion was adjusted to 5% by volume or less to secure the adhesive strength. Thereby, the contact area of the inorganic hydrate cured product with the fiber sheet is secured, and sufficient adhesiveness is obtained.

Although the adhesiveness is better as the amount of the fibrous material is smaller, the addition of the fibrous material generally improves the strength of the cured inorganic material, and the fact that this is present on the surface layer side In order to more effectively improve the bending strength of the plate material obtained in the above, it is recommended that the amount thereof be appropriately selected within a range where the adhesiveness does not deteriorate so much as to be impractical. From such a viewpoint, the blending amount of the fibrous material in the present invention is 0 to 5% by volume, preferably 1 to 5% by volume.
It is 4% by volume, more preferably 1 to 2.5% by volume. Further, the length of the fibrous material is not particularly limited, but from the viewpoint of bending strength, 0.05 to 24 mm,
Preferably it is 0.5 to 12 mm.

The layer in contact with the fiber sheet may have a minimum specific gravity and a minimum thickness necessary for achieving the adhesion to the fiber sheet. In other words, the adhesion between the fiber sheet and the core material depends on the behavior in the minimum area near the interface, and even if the specific gravity and thickness of the adhesive layer are secured more than necessary, the adhesive strength with the fiber sheet does not change. However, the thickness of the layer having a higher specific gravity may increase the total weight.

Next, in the present invention, of the core material having a structure of three or more layers, a layer which is not in contact with the fiber sheet is made of a fiber material which is more than the layer which is in contact with the fiber sheet for the purpose of improving the lightness of the plate material. Add ingredients. As a result, a series of structures such as a fiber sheet, an adhesive layer, and a lightweight layer can be inclined,
Surface decorativeness, strength and lightness as a plate material can be secured. However, in the present invention, in order to ensure the lightness of the plate material, the content of the fiber contained in the layer not in contact with the fiber sheet needs to be larger than at least the layer in contact with the fiber sheet. That is, when the blending amount of the fibrous material in each layer is the same, there is no difference from the substantial single-layer structure, so that the lightening effect expected in the present invention cannot be obtained.

On the other hand, as the amount of the fibrous material increases, air tends to be entrained in the plate. This phenomenon is advantageous for reducing the weight of the plate material, but causes the core material to become weak. That is, even if a layer having a low fiber content is bent to form a bond with the fiber sheet, if the bonding strength between the core materials is reduced due to weakening, separation between the core material layers cannot be avoided. This embrittlement tends to proceed extremely when the blending amount of the fibrous material is about 30% by volume or more. For this reason, in the present invention, the content of the fibrous material is more preferably 30% by volume or less.
Also, the thickness of the entire plate can be freely adjusted by arbitrarily adjusting the thickness of the layer not in contact with the fiber sheet. That is, since the layer not in contact with the fiber sheet is arranged for the purpose of ensuring the lightness of the plate material, the specific gravity of the entire plate material can be adjusted by adjusting the thickness of this layer. In any case, the layered design realized by the present invention can be achieved by securing the adhesiveness between the fiber sheet and the core while dividing the core into a three-layer structure or more. Such a design was not possible with a layered structure.

Next, as the fibrous material used in the present invention, inorganic fibers such as glass fiber and mineral fiber and organic fibers such as pulp fiber, vinylon fiber, acrylic fiber and polypropylene fiber are used. The application of such a fibrous material can improve the strength characteristics of the cured product due to the compounding effect, and at the same time, can bring appropriate air into the inorganic hydrated cured product to reduce the weight of the cured product.

In any case, the blending of such a fibrous material affects the adhesiveness between the fiber sheet and the layer in contact with the fiber sheet. Adhesion between the sheet and the core material is extremely reduced. In addition, since the specific gravity of the fibers that can be used is various, when the blending amount is controlled by weight, it is important to determine the volume content of the fibrous material by converting the added weight by the specific gravity. is there.

The fiber sheet used in the present invention may be in the form of paperboard, woven fabric, nonwoven fabric or the like, and the material may be inorganic fiber, mineral fiber, organic fiber or the like. Such a fiber sheet has an appropriate gap as compared with a film sheet such as a vinyl sheet. For this reason, the inorganic hydrated cured product has a characteristic of easily penetrating, and in the present invention, the adhesive force is mainly exhibited by physical factors such as an anchor effect. Further, in the practice of the present invention, since it is possible to use a long form in the form of a roll at the time of production, it is possible and preferable to continuously supply the laminated inorganic plate at the time of production. That is, by taking measures such as bending the edge of the fiber sheet, a box-shaped form can be easily formed, and the inside thereof is easily filled with a raw material mainly composed of an inorganic hydrated component. can do.

The thickness or basis weight of the fiber sheet is
Commercially available grades can be used. The larger the thickness or basis weight of the fiber sheet, the higher the tensile strength of the fiber sheet itself. Therefore, in the present invention, since the strength of the obtained laminated board tends to depend on the tensile strength of the fiber sheet, it is necessary to appropriately select the fiber sheet according to the desired strength of the laminated inorganic board. .

In the present invention, gypsum and / or cement hydrate can be used as the inorganic hydrated hardened material. These raw materials are calcined gypsum, portland cement, early-strength cement,
Jet cement or the like easily hydrates and hardens when water is added, and is filled in voids on the surface of the fiber sheet and adheres firmly. In addition, in order to improve the properties and handling of the inorganic cured product, the use of a water reducing agent, a thickener, a waterproofing agent, etc. is known,
Also in the present invention, it can be appropriately selected and used so as to secure desired conditions. Further, in order to improve the adhesion between the fiber sheet and the inorganic hydrated cured product, use of an organic adhesive or the like as shown in the prior art is considered,
There is no reason to add these agents in the practice of the present invention because the application of these agents causes an increase in cost and at the same time reduces the fire resistance of the obtained plate. However, in the case where the laminated inorganic plate obtained by the present invention is used at a site where there is no restriction in terms of fire resistance and cost, it is not unfortunate that these agents are intentionally added.

Since the inorganic laminate according to the present invention is similar to a conventionally known gypsum board as a form in which a fiber sheet is arranged on the surface, continuous casting can be used in actual production, and the gypsum board can be used. The same high productivity as manufacturing can be secured. That is, for example, when a conventional gypsum board production line is used as it is, a fiber sheet is used as a type of formwork, a core material having a small amount of fiber is continuously poured, and a core material having a large amount of fiber is further poured thereon. In the case of using the manufacturing method of casting and molding, the conventional gypsum board production equipment can be directly used for handling of the raw material mixture.

On the other hand, as another continuous or batch production method, a mixture of a hydrated component such as gypsum or cement, an appropriate amount of a fibrous material and water is sprayed on a belt conveyor, and formed and cured. Has been proposed. Such a manufacturing method is also suitable for carrying out the present invention, for example,
A fiber sheet is placed on a belt conveyor, and the above mixture is thinly sprayed or formed, or a slurry is produced from the above mixture and an appropriate amount of water, and then the slurry is sprayed on the fiber sheet. An adhesive layer can be secured by a method such as rolling thinly by a suitable method.

In the core material having a structure of three or more layers,
Similarly, in forming a layer not in contact with the fiber sheet,
This can be achieved by using spray molding or slurry casting. When the purpose is to significantly increase the amount of the fibrous material, the layer not in contact with the paper can be formed by semi-dry molding. In addition, in the semi-dry molding method, a method equivalent to the conventional method of manufacturing a fiber-containing gypsum board,
That is, a dry defibrated fibrous material and a hydration-hardening component such as gypsum and cement are dry-mixed, and a composition obtained by adding a very small amount of water to such an extent that the mixture does not form a slurry is sprayed. A method of molding and pressing if necessary can be applied.

Conventionally, in the production of inorganic plates, there has been a demand for adding a large amount of fibrous material by semi-dry molding for the purpose of enhancing workability. However, when a large amount of fibrous material is added by this, air entrainment or granulation due to entanglement of the fibrous material causes irregularities on the surface of the obtained plate material, so polishing and painting are indispensable. there were. However, in the laminated inorganic plate according to the present invention, even if a large amount of fibrous material is added to the core material of the inner layer, a smooth fiber sheet is arranged on the surface,
A plate material excellent in performance can be provided.

[0024]

Next, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples. (Materials Used) Materials used in carrying out these test examples are shown. Fiber sheet: Plaster paper for plaster board Base paper for plaster board manufactured by Jujo Paperboard Co., Ltd. 300 g / m ² non-woven fabric Non-woven fabric made of Mitsui Petrochemical Polypropylene non-woven fabric basis weight 64 g / m ² Inorganic hydratable component: Plaster of plaster Sanes plaster cement Eco-cement made by Chichibu Onoda Fiber material: pulp fiber Crushed newspaper paper (Nara-type crusher screen 2 mm) Acrylic fiber RKW182 × 6 made by Kuraray Water: tap water

(Test Method) The specific gravity of the obtained specimen was calculated from the dimensions and the measured weight. The bending strength was calculated from the bending fracture load when two points of the obtained specimen were supported and one point was loaded from the upper center between the fulcrums. An autograph (manufactured by Shimadzu Corporation) was used for the measurement, and the loading speed was 2 mm / min. Regarding the delamination of the core material, in the test specimens subjected to the bending strength test described above, x was obtained when the delamination between layers was visually observed, and ○ was obtained when the substrate itself was broken. To adhere the fiber sheet and the core material, grasp the fiber sheet at the corner of the surface of the specimen with your finger, gently pull it up, observe whether the fiber sheet and the core material peel off, The result was indicated by x.

(Test Examples 1 to 8) The core material had a three-layer structure,
Specimens in which the volume content of the fibrous material contained in each of the layer adhering to the fiber sheet and the layer not in contact with each other were manufactured and evaluated. In these cases, the aforementioned gypsum board base paper was used as the fiber sheet of the test specimen, and calcined gypsum was used as the inorganic hydration-curable component. For the blending, pulp fiber was added to 100 parts by weight of dihydrate gypsum produced by hydration of calcined gypsum so as to have a volume% shown in Table 1, and the amount of water at which fluidity to obtain a standard softness was obtained was set. Then, a slurry composition for forming each core material was prepared.

The standard softness of the slurry composition was evaluated using an acrylic pipe having a diameter of 5 cm and a height of 5 cm, which was installed on a flow table for cement mortar test, and the optimum water ratio was used. That is, after the slurry composition was poured into a pipe and the pipe was gently pulled apart, the slurry composition was removed at a rate of 1 second per second.
A slurry composition was prepared at a water ratio such that the spread of the slurry composition when 10 vibrations were applied was 10 cm. In addition, since the fluidity of the slurry composition changes depending on the fiber blending amount, in the practice of the present invention, a water ratio was determined so as to have the standard softness, and a test was performed.

The layer in contact with the gypsum board base paper was prepared by pouring the slurry composition onto the gypsum board base paper, and applying vibration to give a thickness of 3 mm. In order to form a layer which did not come into contact with the gypsum board base paper prepared as a set,
The slurry composition obtained by adding the pulp fiber was sandwiched between two gypsum board base papers to which the adhesive layer was adhered, and was rolled to a thickness of 15 mm. The inorganic laminate thus obtained was cured at 20 ° C. for 3 days, dried at 45 ° C. for 2 days, and cut into 20 cm × 5 cm to obtain a test specimen. In addition, the specific gravity shown in Table 1 was calculated from the weight and dimensional measurement values of a cured product prepared from only the slurry composition forming each layer and subjected to similar curing and drying.

Table 1 shows the evaluation results of the examples of the present invention and the comparative examples. First, in Test Examples 1 to 7 in Table 1, since the pulp fiber contained in the adhesive layer was 5% by volume or less, it was confirmed that the adhesiveness between the gypsum board base paper as the fiber sheet and the core material was good. Is done. Further, it was confirmed that Test Examples 2 to 7 were lightweight while maintaining strength, as compared with Test Example 1 having a substantially single-layer structure. In addition, these were determined to be suitable for wallpaper or paint finishing because their surfaces are smooth and have good adhesion between the fiber sheet and the core material, and are included in a layer that adheres to the gypsum board base paper. In Test Example 8 in which the fibrous material exceeded 5% by volume, good adhesion between the gypsum board base paper as the fiber sheet and the core material was not obtained.

[0030]

[Table 1]

(Test Examples 9 to 12) The core material has a three-layer structure, eco-cement as an inorganic hydration-hardening component, a polypropylene nonwoven fabric as a fiber sheet, and a fibrous material contained in a layer in contact with the fiber sheet. Is a pulp fiber used as a fibrous material contained in a layer not in contact with a fiber sheet, and a fiber content of each core material layer as shown in Table 2. In the same manner, an inorganic laminate was prepared.

Table 2 shows the evaluation results of the examples of the present invention and the comparative examples. In Test Examples 9 to 11 in Table 2, since the vinylon fiber contained in the adhesive layer was 5% by volume or less, it was confirmed that the adhesiveness between the gypsum board base paper as the fiber sheet and the core material was good. . Test Examples 10 and 11
Compared to Test Example 9 having a substantially single-layer structure, it was confirmed that it was lightweight while maintaining strength. In addition, these were judged to be suitable for wallpaper and paint finishing because their surfaces are smooth and the adhesion between the fiber sheet and the core material is good. Further, in Test Example 12 in which the fibrous material contained in the layer bonded to the gypsum board base paper exceeded 5% by volume, good adhesion between the gypsum board base paper as the fiber sheet and the core material could not be obtained. .

[0033]

[Table 2]

[0034]

According to the present invention, it is possible to provide a laminated inorganic plate having excellent surface decorativeness, lightness and strength characteristics.

Claims (4)

[Claims] 1. An inorganic plate comprising a core material mainly composed of an inorganic hydrated cured material and a fiber sheet covering at least the front and back surfaces thereof, wherein the core material is composed of three or more layers. The layer in contact with the sheet contains 0 to 5% by volume of the fibrous material, and the layer of the core that is not in contact with the fiber sheet contains more of the fibrous material than the layer in contact with the fiber sheet. The laminated inorganic plate characterized by the above. 2. A layer of the core material in contact with the fiber sheet contains 0 to 5% by volume of a fibrous material, and a layer of the core material not in contact with the fiber sheet contains 5 to 30% by volume of a fibrous material. 2. The laminated inorganic plate according to claim 1, wherein 3. The laminated inorganic plate according to claim 1, wherein the hardened inorganic hydrate is gypsum and / or cement hydrate. 4. The fibrous material is one or a mixture of two or more selected from the group consisting of glass fiber, mineral fiber, pulp fiber, vinylon fiber, acrylic fiber, and polypropylene fiber. 4. The laminated inorganic plate according to any one of 1 to 3.