JPS6049584B2 - Fireproof panels for building materials and their manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a fire-resistant panel for building materials comprising a wood-based cement board as a base material, and a method for manufacturing the same.

Wood-based cement boards are widely used as an inexpensive building material with excellent heat insulation and sound absorption properties, but their biggest drawback is that they are flammable. In recent years, as buildings have become taller, building panels used for exterior walls, interior walls, partition walls, ceiling materials, roofing materials, flooring materials, and interior materials are required to be noncombustible or fire resistant, and wood-based cement boards are required. Various methods have been proposed to improve the flammability of.

For example, there is a surface finishing method in which an asbestos slate board is closely integrated with the surface of a wood cement board using an adhesive such as melamine resin, urea resin, phenol resin, epoxy resin, or vinyl acetate resin.

This method has the disadvantage that heat causes the adhesive to become brittle and decompose, causing the asbestos slate board and the wood cement board to separate, significantly reducing the physical strength of the panel itself. Also, attempts have been made to spray or plaster mortar or plaster on the surface of wood-based cement boards, but because the finishing material itself has low physical strength, it absorbs the shrinkage of the base material and is unable to absorb the shrinkage of the finishing material. Together, they have fatal drawbacks such as large cracks occurring on the surface and easy peeling from each other due to heat.

The present invention was made as a result of intensive research in order to improve the deficiencies of the prior art, and its purpose is to use wood-based cement boards as a base material, which has good fire resistance, does not cause cracks or peeling, and is lightweight. An object of the present invention is to provide a fireproof panel for building materials that has high physical strength and a method for manufacturing the same.

That is, the present invention is a fire-resistant panel for building materials, which is formed by laminating a sodium silicate-based adhesive layer on at least one surface of a wood-based cement board, and further laminating an alkali-resistant glass fiber reinforced cement layer on the layer.

Further, the present invention is a cement-based adhesive in which a sodium silicate adhesive is applied to at least one surface of a wood-based cement board for 0.5 to 4k91 d, dried to form a coating film, and then alkali-resistant glass fiber is mixed onto the coating film. slurry 5~40k91
This is a method for manufacturing a fire-resistant panel for building materials, which is characterized by carrying out rr1 construction. The wood-based cement board used in the present invention is
A plate-shaped body made by compression molding wood materials such as wood wool, wood chips, bulbs, etc. and cement, such as wood wool cement boards, wood chip cement boards, wood wool cement boards, valve cement boards, etc.

In addition, the sodium silicate adhesive layer shown in the present invention is composed of an adhesive mainly composed of water glass (sodium silicate No. 1 to No. 3) and/or sodium metasilicate. Substances that can be mixed with sodium metasilicate include substances that are nonflammable and foamable when heated like sodium silicate, such as amine or amide phosphates, amine sulfates, aniline sulfonates, organic phosphorus compounds, etc. Furthermore, in order to impart a thickening effect to the adhesive, inorganic fibers such as asbestos, rock wool, and glass fiber, metal oxides such as alumina, silica, magnesia, calcium oxide, and zirconia, magnesium hydroxide, and water are added. A metal hydroxide such as zirconium oxide or a granular or powdery inorganic compound such as calcium carbonate or aluminum silicate may be appropriately selected and added.

The sodium silicate adhesive contains at least 5% by weight, preferably at least 7% by weight of sodium silicate, i.e., water glass and/or sodium metasilicate, and when sodium metasilicate is used. is preferably dissolved in an appropriate amount of water to form a homogeneous adhesive.

Among them, water glass has particularly favorable viscosity and excellent workability. If the content of sodium silicate and/or sodium metasilicate in the adhesive is less than 5% by weight, the adhesion to the wood cement board and the alkali-resistant glass fiber reinforced cement layer and the fire resistance imparted to the panel will be reduced. Sexuality becomes insufficient. The amount of the sodium silicate adhesive applied to at least one surface of the wood cement board is 0.5 to 4 kg.
Id is particularly preferably 1 to 2k91i.

The amount of application is 0.5k91r! If it is less than 4k91a, the adhesion between the wood cement board and the alkali-resistant glass fiber reinforced cement layer and the fire resistance of the panel will not be satisfactory in practical terms, and if it exceeds 4k91a, the bending strength and This is not preferred because impact resistance decreases. The sodium silicate adhesive is applied to the surface of the wood-based cement board base material by methods such as trowel coating, spatula coating, spray coating, and roll coater coating. The adhesive applied to the wood-based cement board is dried at room temperature or in a high-temperature atmosphere to form a coating film, and then an alkali-resistant glass fiber-containing cement slurry is laminated on the coating film.

At this time, it is possible to apply the alkali-resistant glass fiber-containing cement-based slurry without forming the above-mentioned coating film by drying, but the presence of the coating film may cause water in the slurry to be absorbed by the wood-based cement board. It hardens and cures in a homogeneous state, yielding an alkali-resistant glass fiber-reinforced cement layer with high strength. The amount of cement slurry containing alkali-resistant glass fibers to be applied is preferably 5 to 40 kgIrr1.

If the construction amount is less than 5k91 mm, the strength of the panel will be low, cracks will occur on the surface of the cement layer, and the fire resistance will be poor, so it is not suitable. Moreover, if the amount of construction exceeds 40k91d, the slurry will partially move on the construction surface due to its own weight, and the thickness will become uneven, making it impossible to obtain a homogeneous panel. The alkali-resistant glass fiber used in the present invention means a fiber whose strength does not deteriorate practically against strong alkalis in cement, such as an alkali-resistant glass fiber containing at least 5 mol% ZrO2, especially at least 9 mol% These include glass fibers made of glass or C glass coated with an alkali-resistant resin, or glass fibers coated with Zr salt and fired. Among the alkali-resistant glass fibers, when fibers obtained by melt-spinning glass fibers having the following composition range are used, a panel with excellent fire resistance, strength, and crack prevention effect can be obtained.

Composition Mol% SlO25
O~69Zr029~14 R20(Na2O.Ll2O) 10~
25R201~7R''00~10 CaF20~2 Formula 030~7 P20,0~5 Other metal oxides 0~10F20~5
However, the total of R2O (5K20) is 14 to 25 mol%, and R'' is an alkaline earth metal or Zn, Mn, Pb.

Other metal oxides are Al2O3, TiO2, Fe2
O3, ceO2, snO2, etc., and fluoride can be converted to F2. The amount of alkali-resistant glass fiber contained in cement-based slurry is 2 to 1 per cement.
It is essential that the content be 5% by weight.

If the fiber content is less than 2% by weight, the strength of the panel will be low and the crack prevention effect will be unsatisfactory;
If it exceeds this value, the fibers will become entangled with each other, resulting in a slurry layer with many voids, which will actually reduce the strength of the panel, so it is not suitable. Excellent effects can be obtained especially when the amount of alkali-resistant glass fiber is in the range of 3 to 1% by weight. Generally, it is effective to use alkali-resistant glass fibers with a fiber diameter of 5 to 40 μm to be mixed into the cement-based slurry. If the fiber diameter is smaller than the above range, it will be difficult to uniformly disperse the fibers in the slurry. On the other hand, if it exceeds the above range, handling of the fiber becomes difficult, and the tensile strength per cross-sectional area of the alkali-resistant glass fiber decreases, making it impossible to obtain good results. From this point of view, a particularly preferred range of fiber diameter is 9 to 20 microns. In addition, the fiber length is preferably in the range of 3 to 50 Tfrm; if the fiber length is smaller than the above range, sufficient strength and crack prevention effect as a panel cannot be obtained, and on the other hand, if it is too long, the dispersibility decreases and cement The mixed state with the system slurry becomes non-uniform, making it impossible to obtain a sufficient reinforcing effect, and workability is also lowered, which is undesirable.

From this point of view, a range of 6 to 25 m is particularly suitable.

It is also preferable to use a mixture of two or more types of alkali-resistant glass fibers with different fiber lengths in order to improve the dispersibility and enhance the effect.
It is best to use a ratio of about 1:5. Also usable are fabrics, nets, knits, non-woven fabrics, or chopped strand mats made of short fibers made of alkali-resistant glass filaments. The cement-based slurry used in the present invention refers to cements, such as general hydraulic cements, such as Boltland cement, white cement,
Commercially available cement such as fly ash cement, blast furnace slag cement, silica cement, alumina cement, jet cement, etc., or calcium silicate, hydraulic substances such as gypsum, aggregates such as silica sand, river sand, perlite, and shirasu balloons, talc, and diatomaceous earth. It is a mixture of water and a filler such as clay, asbestos or rock wool powder.

Further, various admixture materials such as dispersants, water reducing agents, hardening accelerators, retarders, emulsions of copolymerized acrylic resins and various vinyl resins, or pigments may be used as required. The amount of water in the slurry is 25 to 80 in terms of cement ratio.
% (weight ratio) may be selected appropriately within the above range, taking into consideration the water absorption properties of aggregates, fillers, admixture materials, workability during construction, etc.

These cement-based slurries can be applied to wood-based cement boards by troweling, roller finishing, spray finishing, etc.

Methods for mixing alkali-resistant glass fibers into cement-based slurry include the so-called premix method, in which the cement-based slurry and alkali-resistant glass fibers are stirred and mixed wet or dry, or the cement-based slurry and alkali-resistant glass fibers are mixed in separate guns. The so-called spray method, in which air pressure is used to spray and contact mix in a space or on the construction surface, or the spray suction method, in which excess moisture is removed after construction, can be selected and used as appropriate.

When alkali-resistant glass fiber structures (woven fabrics, knitted fabrics, nets, non-woven fabrics, chopped strands) are applied, the purpose can be achieved by embedding them in cement mortar or laminating them together with cement mortar. Furthermore, the surface of the cement layer of the manufactured panel can be coated and finished depending on the purpose of use.

The fire-resistant panel for building materials of the present invention has a laminated structure using a wood-based cement board as a base material and a sodium silicate-based adhesive layer and an alkali-resistant glass fiber reinforced cement layer on at least one surface, and the sodium silicate-based adhesive layer is A wood-based cement board and an alkali-resistant glass fiber reinforced cement layer are firmly bonded, and even when the surfaces of the cement layers come into contact with each other at high temperatures, they do not peel off from each other, and furthermore, the adhesive layer forms a nonflammable foam layer when heated. By blocking heat propagation to the wood-based cement board, the panel is given excellent fire resistance.

The fireproof panel is made of wood-based cement board on one side,
Various fireproof panels can be obtained by covering both sides or the entire surface with the two-layer structure. Further, the fireproof panel is lightweight and has excellent impact resistance, and is a building material panel suitable for use as interior and exterior wall materials, floor materials, ceiling materials, etc. of high-rise buildings. The present invention will be explained below with reference to Examples.

Various measurement methods in Examples are as follows.

Bending strength: Based on JIS-A-1408 (No. 3 test specimen), the breaking load (K9) was measured, and then the strength (K9l) was calculated by multiplying by a coefficient determined from the section modulus.

Impact resistance: In accordance with JIS-A-5403, a test was conducted in which a 1k9 heavy object of the shape shown therein was dropped from a height of 3Tr1, and 1 failure was performed, and the presence or absence of through holes and cracks was indicated. .

Fire resistance: Based on JIS-A-1304, the back side temperature of the panel after 1 hour of heating and the panel subjected to the heating test were 10 kg.
A test was conducted on 5 sheets in which a heavy object was dropped from a height of 17 TL, and the results were indicated by the presence or absence of through holes.

Example 1 Density 0 consisting of Boltland cement stamp part and Hosoki hair season part
．． Water glass (sodium silicate No. 2) was applied as a sodium silicate adhesive to a wood wool cement board with a size of 65 yId and a thickness of 25 yen by brushing at varying amounts and dried at room temperature.

Next, a cement slurry was prepared by mixing 10 parts of Bortland cement, 50 parts by weight of silica sand, 40 parts by weight of water, and 0.4 parts by weight of Mighty 150R (manufactured by Kao Soap Co., Ltd.) as a water reducing agent, and the glass composition was expressed as mol% SlO2. :67, ZrO2:
12. Glass made of Na2O: 17, K2O: 2, ZnO: 2 was melt-spun and strand-shaped alkali-resistant glass fibers with a fiber diameter of 13 μm and a number of filaments of 204 were cut into a length of 25 TWL while cement of the cement-based slurry was prepared. The cement slurry and the alkali-resistant glass fibers are uniformly mixed in the air by spraying them at the same time using a spray gun at a concentration of 5% by weight based on the water glass to be formed on both sides of the wood wool cement board. After spraying 7 kg of Ir11 on each membrane, the panels shown in the figure were obtained by natural curing for 28 days. The presence or absence of cracks, bending strength, impact resistance, and fire resistance of the panels were measured, and the results are shown in Table 1. As is clear from Table 1, good results were obtained when the coating amount of the sodium silicate adhesive was 0.5 to 4k9I, especially 1 to 2k91. When the coating amount was too small, the fire resistance was poor, and when the coating amount was too large, the bending strength and impact resistance of the panel were reduced. Example 2
In Example 1, asbestos, particulate calcium carbonate, and ammonium hypophosphite were added to water glass in a weight ratio of 5:4:1.
2k91r11 was applied to a wood wool cement board by varying the amount of the mixture added, and 7k91 was further applied with an alkali-resistant glass fiber reinforced cement slurry in the same manner for curing to produce panels.

The obtained panel was subjected to various measurements in the same manner, and the results shown in Table 2 were obtained. As is clear from the table above, the amount of additives to be mixed into the water glass is preferably 50% by weight or less, especially 3% by volume or less, and if the additive exceeds 5% by weight, it will reduce the adhesion between the wood wool cement board and the alkali-resistant glass fiber reinforced cement layer. Therefore, the bending strength and impact resistance of the panel were reduced. Example 3 Consisting of 55 parts by weight of Voltland cement and 45 parts by weight of thick wood wool, the density was 0.6 da Ic? 75 parts by weight of water glass (sodium silicate No. 3) and 25 parts by weight of asbestos were uniformly mixed on both sides of a wood cement board with a thickness of 25 m and 771 cm.
K91 was applied using a roll coater and dried.

Next, 10 parts by weight of Bortland cement, 1 part by weight of silica sand, 45 parts by weight of water, and Mighty 150 as a water reducing agent.
(manufactured by Kao Soap Co., Ltd.) 0. Example 1
The alkali-resistant glass fiber used in 20TIrITL
5% by weight of the cement was added to the cement, and the mixture was thoroughly stirred and mixed. Roller finishing was performed on both sides of the water glass-coated wood wool cement board by varying the amount of this premix applied.

After natural curing for 28 days, each of the obtained panels was measured for the presence of cracks, bending strength, impact resistance, and fire resistance, and the results are shown in Table 3. As is clear from Table 3, the amount of cement slurry applied is 5 to 40k.
Good results were obtained with 9Ib.

If the amount of construction is too small, the bending strength and impact resistance will be poor.
When the amount of construction was too large, the workability decreased. Example 4 A material with a density of 0.57 da Id and a thickness of 23T, consisting of a stamped weight part of Boltland cement, 35 parts by weight of fine wood wool, and 15 parts by weight of wood chips.
Water glass (sodium silicate No. 1) mixed with 2% by volume of sodium metasilicate (nase hydrate) was applied with a 20k91 scrub brush on both sides of an RTM wood wool cement board and dried.

Next, 10 parts by weight of colored cement, m parts by weight of pearlite,
Parts by weight of water and 0.45 parts by weight of Mighty 150R (manufactured by Kao Soap Co., Ltd.) as a water reducing agent were mixed, and the glass composition was SiO in mol%. :68.5, ZrO2:12, Na2
Alkali-resistant glass fibers with a fiber diameter of 10μ obtained by melt-spinning glass consisting of O: 17, K2O: 2, B2Oa: 0.5 were cut into lengths of 20 TWL, and the amount of glass fibers ( The white cement slurry was stirred and mixed with various F/C). A slurry of this premix was sprayed onto both sides of the wood wool cement board coated with the above-mentioned water glass using a spray method.
After natural curing for 28 days, each of the obtained panels was measured for cracking, bending strength, impact resistance, and fire resistance, and the results are shown in Table 4. As is clear from Table 4, the amount of fiber relative to cement is 2 to 15% by weight.
Particularly good results were obtained in the range of 3 to m weight %.

If the amount of fibers is too small, the bending strength and impact resistance will be poor, and if it exceeds 15% by weight, the glass fibers will become entangled with each other, causing non-uniform dispersion in the cement slurry, resulting in a decrease in bending strength.

[Brief explanation of drawings]

The drawing shows an embodiment of the present invention and is a perspective view of a portion of a composite panel according to the present invention. 1... Wood cement board, 2,2'... Sodium silicate adhesive layer, 3,3'... Alkali-resistant glass fiber reinforced cement layer.

Claims (1)

[Claims] 1. A cement slurry containing alkali-resistant glass fibers is applied on a layer formed by applying a sodium silicate adhesive at a rate of 0.5 to 4 kg/m^2 to at least one surface of a wood-based cement board. A fire-resistant panel for building materials that is coated and laminated at a rate of 5 to 40 kg/m^2. 2. The fireproof panel for building materials according to claim 1, wherein the content of sodium silicate is 50% by weight or more based on the sodium silicate adhesive layer. 3. The fire-resistant panel for building materials according to claim 1, wherein the content of alkali-resistant glass fiber is 2 to 15% by weight based on the cement slurry. 4. The fire-resistant panel for building materials according to claim 3, wherein the content of ZrO_2 is 5 mol% or more based on the alkali-resistant glass fiber. 5 Apply a sodium silicate adhesive containing sodium silicate to at least one surface of the wood cement board by 0.5 to 4
After applying kg/m^2 and drying to form a coating film,
A method for producing a fire-resistant panel for building materials, which comprises applying a cement slurry containing alkali-resistant glass fibers to the coating film at a rate of 5 to 40 kg/m^2. 6. The method for producing a fire-resistant panel for building materials according to claim 5, wherein the content of sodium silicate is 50% by weight or more based on the sodium silicate adhesive layer. 7. The method for producing a fire-resistant panel for building materials according to claim 5, wherein the content of the alkali-resistant glass fiber is 2 to 15% by weight based on the cement slurry.