JPS5944990B2 - Method for manufacturing sheet-shaped composite building materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to the production of a sheet-like composite building material that contains a large amount of inorganic powder and is lightweight, flexible, and has excellent workability.

More specifically, (a) an inorganic powder that does not harden by reacting with water such as gypsum dihydrate (hereinafter simply referred to as non-hydraulic inorganic powder), (b) a thermoplastic resin emulsion as a bangu component and/or Contains a water-soluble polymer, (c) a fibrous substance, (d) a foaming agent such as a foaming agent or an air-entraining agent as an essential component, and various reinforcing materials, pigments, plasticizers, anti-bacterial agents, etc. as necessary. An inorganic slurry containing additives is formed, which is then composited with a perforated nonwoven fabric, formed into a sheet, and dried.This sheet-like composite is lightweight, flexible, and has excellent foldability. It is related to the production of building materials, and its purpose is to produce wall covering materials, ceiling materials, and materials that are highly flame retardant, flexible, condensation-proof, heat-insulating, vibration-proof, processable, and easy to handle. The object of the present invention is to provide materials that can be used as interior materials for buildings such as flooring materials. BACKGROUND OF THE INVENTION Among the various building interior materials conventionally used, resin sheets, cloth, nonwoven fabrics, processed paper, etc. containing a large amount of organic matter have problems with flammability, and there is a strong demand for them to be made nonflammable.

On the other hand, gypsum boards, asbestos slate boards, etc. meet the requirements in terms of non-combustibility, but are difficult to handle because they are not flexible.
It has drawbacks such as insufficient processability, dew condensation resistance, water resistance, etc. Furthermore, although sheet-like materials such as rock wool and asbestos are nonflammable and flexible, they are produced using a wet papermaking method that uses large amounts of water, resulting in long drying times and problems in production. many. The present inventors have improved the flame retardancy of conventionally used wallpapers and decorative plywood, and created sheet-like foamed composite materials that are flexible, easy to handle, bendable, dew-proof, and water-resistant using a dry method. As a result of intensive research into a method that can be industrially and continuously produced, we have found that (a) an inorganic powder that does not harden by reacting with water;
(b) thermoplastic resin emulsion and/or water-soluble polymer as a binder component, (c) fibrous material, (d)
The sheet-like composite obtained by a process consisting of forming an inorganic slurry containing a foaming agent such as a foaming agent or an air-entraining agent as an essential component into a sheet together with a perforated nonwoven fabric and drying it has the desired physical properties. The present invention has been completed based on the discovery that the present invention has the following characteristics.

In the present invention, a non-hydraulic inorganic powder represented by gypsum dihydrate is used, so even if a large amount of this is used, it will not be used as a binder component, such as thermoplastic emulsion and/or water-soluble polymer, etc. The slurry can be easily prepared by mixing with the compounded ingredients using water as a solvent, and in terms of product performance, it gives flexibility and flame retardancy, and these performances are also good for heat insulation. By introducing fibrous substances and microbubbles into the sheet, the properties are further improved, and by combining it with a perforated nonwoven fabric, it not only increases the reinforcing effect of the sheet, but also improves the drying speed. It is also effective in preventing cracks during folded plate processing and preventing condensation. Furthermore, the method of the present invention is industrially advantageous in that it uses a dry manufacturing method without requiring the use of large amounts of water and long drying times, as seen in the wet papermaking method of rock wool sheets, for example. It's advantageous. Inorganic powders that do not harden due to reaction with water used in the present invention include, for example, gypsum dihydrate, calcium carbonate, silica sand,
Examples include silica powder, kaolin, clay, talc, aluminum hydroxide, etc., but gypsum dihydrate is the most suitable from the viewpoint of formability, flame retardant effect on the obtained sheet-like composite building material, and other performance points of view. .

As the dihydrate gypsum, any one obtained by any production method can be used, such as naturally occurring gypsum, phosphoric acid by-product gypsum, titanium by-product gypsum, and flue gas desulfurization by-product gypsum. Moreover, instead of these non-hydraulic inorganic powders, lightweight aggregates such as perlite, shirasu balloons, hollow glass spheres, etc. can also be used. Examples of the thermoplastic resin emulsion used in the present invention include vinyl acetate polymer emulsion, acrylic polymer emulsion, vinyl chloride polymer emulsion, vinylidene chloride polymer emulsion, urethane polymer emulsion, and the like. However, vinyl acetate polymer emulsion is particularly preferred.

In addition to vinyl acetate homopolymer emulsion, the vinyl acetate polymer emulsion used in the present invention includes, for example, vinyl acetate and ethylene, various acrylic acids, methacrylic acid, maleic acid, maleic acid esters, vinylversacic acid, and diacetone. Acrylamide, vinyl propio7ate,
Examples include copolymer emulsions with vinyl caprozoate, vinyl chloride, and the like. These thermoplastic resin emulsions can be used regardless of the emulsion obtained by any manufacturing method, and can be widely used without any restrictions on the type of emulsifier, solid content concentration, emulsion particle size, emulsion viscosity, etc. Can be used. It is also possible to use a plasticizer if necessary.

Vinyl acetate emulsion is the most suitable sheet-like composite building material for the purpose of the present invention because it has excellent physical properties such as weather resistance, heat resistance, blocking resistance, mechanical properties, and flexibility. Examples of water-soluble polymers used in the present invention include polyvinyl alcohol polymers, polyvinyl pyrrolidone, polyvinyl methyl ether, polyvinyl acrylamide, sodium polyacrylate, polyethylene oxide, polyethylene imine, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and alginic acid. Soda, casein, glue, dextrin, starch, alpha starch, hydroxylethyl starch,
Examples include gum arabic, gum tragacanth, water-soluble paper strength enhancers such as ketone aldehyde resin, polyamide resin, and melamine formaldehyde resin, but these water-soluble polymers can be used not only alone but also in combinations of two or more. Used as appropriate.

Among these, polyvinyl alcohol polymers are mainly used as binders from the viewpoints of moldability, flexibility of the obtained sheet-like material, anti-condensation properties, and the like. Such polyvinyl alcohol-based polymers are generally polymers obtained by saponifying polyvinyl acetate and various copolymers thereof, or polymers obtained by graft polymerizing various monomers to polyvinyl alcohol. The water-soluble polymer used usually has a degree of polymerization within the range of 500 to 3,500.Any polymer used in textile processing, paper processing, pigment binders, emulsifying dispersants, adhesives, etc. can be used, but water-soluble or It is required to be dispersible in water and to be made insoluble in water by heating, drying, pH change, addition of a crosslinking agent, etc. Examples of the fibrous material used in the present invention include inorganic fibrous materials such as rock wool, mineral wool, asbestos, and glass fiber, and organic fibrous materials such as vinylon, nylon, and vinyl chloride.

Among the inorganic fibrous materials, rock wool is the most preferred because it gives the sheet flexibility, and among the organic fibrous materials, vinyl chloride fiber is preferred because it imparts flame retardancy, but other materials may be used alone. Alternatively, it is also possible to use them together. Further, examples of the foaming agent used in the present invention include ethanol,
Evaporative blowing agents such as toluene and heptane or decomposition blowing agents such as sodium bicarbonate, ammonium carbonate, azobisisobutyronitrile, para-toluenesulfonyl hydrazide, polyvinyl alcohol, sodium stearate, polyethylene glycol monolaurate Air-entraining agents such as surfactants such as, etc. are used.

In addition, in the method of the present invention, if necessary in relation to the use of the final product, for example, when water resistance is particularly required, crosslinking agents for the various polymers constituting the binder component may be added to In this case, the plasticizer
Furthermore, if coloring or prevention of mold growth is required, pigments and anti-bacterial agents are appropriately added to the slurry. A preferred formulation for carrying out the present invention is 60 to 99 parts of non-hydraulic inorganic powder, preferably 70 to 90 parts,
Vanider polymer 1: 40 to 1 part, preferably 30 to 6 parts
parts, the fibrous material is 2 to 50 parts, preferably 6 to 12 parts,
Slurry moisture content during kneading is 20-600! ) preferably 4
0~550! ), but it is determined by the physical properties of the sheet and is not limited in any way. The inorganic slurry prepared as described above is molded into a sheet by conventional methods such as extrusion or casting. For example, the perforated nonwoven fabric used in
The nonwoven fabric manufactured by the method described in Japanese Utility Model Publication No. 6-7274 and the nonwoven fabric described in Japanese Utility Model Publication No. 39-4194 are preferred.

Such a perforated nonwoven fabric has appropriate elasticity due to the large number of pores present in the nonwoven fabric, so when used as a reinforcing material on the surface, the resulting sheet-like composite building material is easy to handle. and processability can be increased. Furthermore, the fiber material and basis weight of the reinforcing material can be appropriately selected according to requirements such as mechanical properties, water resistance, weather resistance, dew condensation resistance, flame retardance, and the like. EXAMPLES The present invention will be specifically explained below with reference to Examples, but the present invention is not limited to these Examples in any way.

Example 1 Polyvinyl alcohol (saponification degree 80 (!), polymerization degree 2
000) 10(f/) aqueous solution 4.3 parts, polyvinyl alcohol (saponification degree 980t), polymerization degree 1700) 10%
Aqueous solution 0.8 parts, water 50 parts, foaming agent (Kao Atlas Mighty AEO3) 0.02 parts, cationic special polyamide resin (Sumitomo Chemical Sumilaze Resin 650-30) 0
．． 6 parts, 16.2 parts of vinyl acetate-ethylene copolymer emulsion (Pamphrex 0M7000 manufactured by Kuraray, solid content 50% by weight) were mixed and stirred at high speed to foam the solution, 8 parts of rock wool, and flue gas desulfurization by-products. 82 parts of dihydrate gypsum powder was added, and the foamed slurry was poured onto a perforated nonwoven fabric (manufactured by Kuraray Chicopi, 4C Cross ADK2OO) spread on a Teflon-coated carrier sheet. It was dried at ℃ for 40 minutes.

The obtained sheet has a thickness of 4.1 mm and a specific gravity of 0.23, the tensile strength is 6.8 k9/CIi in the vertical direction, 1.2 k9/CTl in the horizontal direction, and the elongation is as follows: It was Tate 14 Hiro Yoko 3001). Also J
The water resistance dimensional change according to test 1 test method according to ISA57O5 is +0.5 (Ff), the dry heat cyclic dimensional change is -0.4%, and the water retention rate according to the test method according to JISLIO79 is 23%, The thermal conductivity was 0.054 KIn1/Mhr'C according to a test method based on JIS Al4l2.
Furthermore, the obtained sheet was laminated with the perforated non-woven fabric on the outside and a 0.6 mu lardtan flat plate for roof boards with a chloroprene adhesive, and then folded using a roller to produce an insulating folded plate roofing material. A good product was obtained without any sheet breakage. As a result of testing the composite board according to the fire protection material testing method according to Ministry of Construction Notification No. 1828 and No. 3417, it was found to be nonflammable. Comparative Example 1 A slurry having the same formulation as that shown in Example 1 was prepared by the same method, poured directly onto a carrier sheet without using a perforated nonwoven fabric as a reinforcing material, and dried to a thickness of 4. .0 fight,
A sheet with a specific gravity of 0.25 was obtained.

The tensile strength of the obtained sheet was 0.31<g/Cl?
It is weak at 0.3 kg/d across L1, and the sheet is likely to break during handling. When the sheet was folded in the same manner as in Example 1 by combining it with hard lard tan, the surface of the sheet was destroyed and a good roof board material could not be obtained. Comparative Example 2 A slurry with the same formulation as in Example 1 was prepared by the same method, and vinylon cheesecloth (
#200 made by Kuraray), thickness 3.8mm, specific gravity 0.
21 sheets were obtained.

The tensile strength of the obtained sheet was 161<g/C77L
The sheet had a width of 14k9/d, and was strong and easy to handle.However, in a folded plate processing test similar to Example 1, delamination occurred in the intermediate layer of the sheet, and the cheesecloth was cut at the corner. However, good roofing materials could not be obtained. Example 2 Polyvinyl alcohol (saponification degree 8001), polymerization degree 20
00) 115 parts of 10% aqueous solution, 30 parts of water, 3.8 parts of potassium hydroxide 30 (fl) aqueous solution, 0.0 parts of sodium bicarbonate.
8 parts, water-soluble ketone aldehyde resin (Epinox P468 manufactured by Deitz Hercules) 3, 3 parts, glycerin 2
．． 3 parts of cationic special polyamide resin (Sumitomo Chemical Co., Ltd., Sumiraze Resin 650-30) were mixed and stirred at high speed to foam the solution. , 10 parts of rock wool, and 76 parts of gypsum dihydrate powder, which is a by-product of flue gas desulfurization, were added to the slurry, which was foamed by vigorous stirring, and the resulting slurry was spread on a carrier sheet using a perforated nonwoven fabric (4C cloth NADKl made by Kuraray Chicopi Co., Ltd.).
6O) and dried at 130°C for 40 minutes.

Claims (1)

[Scope of Claims] 1 (a) Inorganic powder that does not harden by reaction with water, (b) Thermoplastic resin emulsion and/or water-soluble polymer as a binder component, (c) Fibrous (d) A slurry containing a foaming agent such as a foaming agent or an air-entraining agent as an essential component, and mixed with other additives as necessary, is composited with a perforated nonwoven fabric and formed into a sheet, A method for manufacturing sheet-like composite building materials with excellent flexibility and processability, which involves drying. 2. The method for producing a sheet-like composite building material according to claim 1, wherein gypsum dihydrate is used as the inorganic powder that does not harden by reaction with water. 3. The method for producing a sheet-like composite building material according to claim 1, wherein an ethylene-vinyl acetate copolymer emulsion is used as the thermoplastic resin emulsion. 4. The method for producing a sheet-like composite building material according to claim 1, wherein a polyvinyl alcohol polymer is used as the water-soluble polymer. 5 Claim 1 using rock wool as the fibrous material
A method for producing a sheet-like composite building material as described in .