JPS6078735A - Composite board and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a hydraulic composition based on granulated blast furnace slag, sandstone, Portland cement, synthetic resin emulsion, or rubber latex, which is applied to a wooden board on which a waterproof layer is formed on at least the surface. This invention relates to a composite board having a cured material layer and a method for manufacturing the same, and its purpose is to be useful as a base material for mortar painting, spray painting, tiling, etc. of architectural structures. ,
It has excellent properties such as being able to be nailed into pillars, etc., being easy to apply mortar coating, spray painting, and tiling, and having no cracks and excellent waterproof properties. The present invention aims to provide a composite plate and a method for manufacturing the same.

Conventionally, when applying mortar coating or tiling9 to the exterior and interior walls of wooden buildings, etc., a base was obtained by pasting waterproof paper on top of the wood and then hammering metal lath over it with nails, staples, etc. Then, apply mortar as a base coat, intermediate coat,
A top coat is applied first, followed by a final coat, or after a rough coat of mortar, the tiles are pasted with cement or adhesive. In addition, in the case of spray painting, it is common for wooden buildings to be finished by applying mortar coating and then spray painting on top of the mortar coating. Since these foundation works are carried out on construction sites, they have drawbacks such as difficulty in selecting homogeneous materials and the need for a large amount of manpower and construction time. In addition, in these construction methods, cracks occur in the mortar due to shrinkage due to drying and hardening of the mortar, warping of wood shavings, etc. Currently, cracks that occur are not only aesthetically undesirable, but also cause leakage of rainwater,9 staining of interiors, and rotting of pillars and wood grains. Also, in recent years,
There are methods of using asphalt-based materials or synthetic resin emulsions mixed with bone phase on wooden boards as wall base materials, but these methods have poor mortar paintability, poor adhesion, and resistance to heat. The major disadvantage is that the strength is low and the mortar may peel off.

In addition, for walls with different paint layers such as cement, synthetic resin emulsion, sand, crushed stone, and synthetic resin foam, cutting workability during construction may be poor, or the adhesion of mortar may vary, sometimes resulting in extreme It has the disadvantage that it may be weak against Rui. Therefore, ordinary cement mortar is rarely used. This is because when the Portland cement used for the base material hardens with water, a large amount of calcium hydroxide is deposited on the surface of the base material, and this calcium hydroxide directly or indirectly reduces the adhesion of mortar. It is also possible that they are being allowed to do so. There have been various other attempts, such as those based on synthetic resin foam and those based on inorganic materials, but none of them are optimal as wall base materials and are used despite some drawbacks. is the current situation.

Granulated blast furnace slag is obtained by pulverizing blast furnace slag, which is produced as a by-product in the blast furnace during pig iron production, and has latent hydraulic properties, which become extremely hardenable in the presence of alkaline irritation. Also,
It is also well known that granulated blast furnace slag reacts with Ceracola to produce Etrin guide. Conventionally, granulated blast furnace slag has been used as blast furnace cement and high sulfate cement by taking advantage of its reactivity. Recently, attempts have been made to mix granulated blast furnace slag and Ceracola-based compositions with alkaline irritating substances, fibers, fillers, etc., form paper or mold the mixture, and use it as an inorganic molded plate.

Although these molded plates have excellent properties such as low curing shrinkage and low surface alkalinity, they also have drawbacks such as low initial strength and low surface hardness.

In view of the above, the present inventors investigated suitable materials for wall base materials. As a result, granulated blast furnace slag, Ceracola, Portland cement,
By applying a hardened layer made of a hydraulic composition whose main raw material is synthetic resin emulsion, resin, or rubber latex, it can be used as a base material for mortar painting, spray painting, tiling, etc. of architectural structures. We obtained something useful as a. In other words, the present invention provides a composite board that is easy to construct, has good adhesion to finishing materials such as mortar and spraying materials, does not generate cracks, and has excellent waterproof properties. The present invention was achieved based on the knowledge that That is, the present invention provides (1) a waterproof layer formed on at least the surface of a wooden board, and on the waterproof layer, 100 parts by weight of a mixture consisting of 60 to 95 parts by weight of granulated blast furnace slag and 5 to 40 parts by weight of Ceracola. On the other hand, a hydraulic composition consisting of slag, ceracola, and a cement phase material consisting of 3 to 100 parts by weight of Portland cement, a synthetic resin emulsion (still rubber latex), water, and, if necessary, a setting modifier and aggregate. A composite board characterized by having a cured material layer,
(2) A waterproof layer is formed on at least the surface of the wooden board, and on the waterproof layer, a mixture of 60 to 95% by weight of granulated blast furnace slag and 5 to 40% by weight of Ceracola is applied to 100% of Portland cement. Painting with a hydraulic composition slurry obtained by mixing 3 to 100 parts by weight of slag, ceracola, or cement material, a synthetic resin emulsion or rubber latex, water, and, if necessary, a setting regulator and bone phase. The present invention relates to a method for manufacturing a composite board, which comprises drying and then curing, or drying and then curing by replenishing moisture.

Next, the present invention will be explained in detail.

When wood boards come into contact with water, they easily absorb water, which causes dimensional changes. Furthermore, depending on the quality, it may cause warping or twisting, which is undesirable from the viewpoint of material strength and decay. Therefore, it is very important to protect wooden boards from water in some way. Plywood, particle board, fiberboard, wood wool cement board according to the present invention,
At least the surface of wooden boards such as wood cement boards is coated with an emulsion, latex, or solution of synthetic resin, rubber, bitumen, etc., or a film or sheet made of synthetic resin, rubber, bitumen, etc. is coated as is or with an adhesive. A waterproof layer is formed by pasting 9 together. A waterproof layer composited with a non-woven fabric or filled with sand% fiber can also be used, and any method that is normally called waterproofing can be applied. however,
In the present invention, since the waterproof property does not depend only on the waterproof layer, the waterproof layer does not necessarily have to be strong enough to completely block water. This waterproof layer not only protects the wooden board from water, but also
It is also expected to have effects such as reinforcing and preventing damage by penetrating the surface of wooden boards.

The waterproof layer may be formed not only on the front surface but also on the side and back surfaces. Wooden boards treated with rot-proofing, insect-proofing, termite-proofing, and fireproofing can also be used.

The composite board of the present invention has granulated blast furnace slag,
The product has a cured layer of a hydraulic composition consisting of Ceracola, Portland cement, synthetic resin emulsion, or rubber latex, water, a setting regulator, and bone phase if necessary, and is coated with a slurry of these hydraulic compositions. After that, it is cured and hardened. As mentioned above, granulated blast furnace slag is obtained by pulverizing blast furnace slag, which is produced as a by-product in a blast furnace during the production of pig iron, and is in the form of a fine powder. The ceracola used by mixing with the granulated blast furnace slag may be any of dihydrate slag, semi-hydrated ceracola, and anhydrous ceracola. Portland cement includes ordinary Portland cement, early strength Portland cement, white Portland cement, etc., but blast furnace cement and high sulfate cement can also be used as components of granulated blast furnace slag and Portland cement. Their mixing ratio is 3 to 100 parts by weight of Portland cement to 100 parts by weight of a mixture consisting of 60 to 95 parts by weight of granulated blast furnace slag and 5 to 40 parts by weight of Ceracola.

Granulated blast furnace slag has self-hardening properties due to alkali stimulation, but when ceracola coexists, it hardens by producing ettringite. Portland cement is hydrated to form Ca(OH)
) z, it acts as an alkaline stimulant and has hydraulic properties itself, making the composition layer stronger. Therefore, if the ratio of Ceracola to the granulated blast furnace slag is less than 5% by weight, the amount of ettringite produced will be small, and if it is higher than 40% by weight, the amount of remaining unreacted Ceracola will increase. Sexuality becomes worse. If the amount of Portland cement is less than 3 parts by weight, the amount of alkali produced will be small and the effect as an alkali stimulant for granulated blast furnace slag will be reduced.

If too much Portland cement is used, the alkalinity will increase and the adhesive force with mortar will become unstable, causing variations in strength.

The synthetic resin emulsion and rubber latex according to the present invention include aliphatic carboxylic acid vinyl esters, acrylic acid or its esters, methacrylic acid or its esters, vinyl chloride, vinylidene chloride, styrene, olefins, butadiene, chloroprene, Examples include emulsified polymers of one or more polymerizable monomers, such as acrylonitrile, dispersed in water. In use, one or more types of synthetic resin emulsion and rubber latex may be used. Furthermore, these may be modified by crosslinking or modified by thermosetting resins such as polyurethane and epoxy resins.

The function of these synthetic resin emulsions and rubber latexes is not merely to strengthen the entire hydraulic composition layer of the present invention, but also to prevent a decrease in surface strength, which is the biggest drawback of slag and Ceracola-based cured products. . The decrease in surface strength of slag and Ceracola-based cured products occurs because carbon dioxide in the air neutralizes the surface layer and prevents curing from proceeding.

In the case of adult products, this problem can be solved by some kind of reinforcement such as sealer treatment at the stage of secondary processing, but in the present invention, considering the purpose of use, some kind of reinforcement is applied afterward. Taking other measures is not preferable from the viewpoint of increasing the number of steps and construction costs. Therefore, in the present invention, the synthetic resin emulsion and rubber latex are essential components. In addition, it has the effect of imparting flexibility and waterproofness to the cured material layer, and increasing the adhesive strength with the waterproof layer and with finishing materials such as mortar. The mixing ratio of these synthetic resin emulsions and rubber latex is preferably 2 to 50% by weight in terms of solid content relative to granulated blast furnace slag, Ceracola, and Portland cement.

Setting regulators are added to the hydraulic slurry according to the present invention, for example,
Aluminum sulfate, alum, sodium sulfate, potassium sulfate, aluminum chloride, barium chloride, calcium chloride, sodium chloride, potassium chloride, sodium silicate, potassium silicate, sodium carbonate, potassium carbonate, caustic soda, caustic potassium, hydroxide Calcium or the like may be added and the coagulation time may be adjusted as appropriate. Also,
As the bone phase, for example, by mixing inorganic lightweight aggregates such as pallite, nonrus balloons, foamed glass spheres, vermiculite, calcined pumice, artificial lightweight bodies, foamed plastic particles, silica sand, kansui stone, crushed slag stone, etc. It is possible to give a composite moon a wide range of properties, such as by reducing its weight, and by considering the workability and workability of mortar and finishing materials.

Fibers can be mixed into the hydraulic slurry according to the present invention in order to reinforce the cured material layer or improve adhesiveness.

In that case, the fibers include inorganic fibers such as asbestos, rock wool, glass fiber, and slag wool, or cotton, pulp, polyethylene, polypropylene, and polyvinyl alcohol.
e) Natural fibers such as ester and nylon, and synthetic fibers.

Furthermore, by mixing a thickener, the hydraulic slurry can have an appropriate viscosity, thereby improving the workability of applying it to wooden boards. Polyvinyl alcohol as a thickener,
Examples include cellulose derivatives such as methylcellulose, hydroxyethylcellulose, Carbo-F-sylated cellulose and its alkali salts, silica, bentonite, and the like. In addition, dispersants such as alkyl sulfonates and melamine formalin resin sulfonates, foaming agents, coloring agents, fillers,
Antifoaming agents and the like may also be added.

Next, the mixing method of the hydraulic composition is not uniquely defined, but to give an example, synthetic resin emulsion,
Rubber latex, water, and if necessary, a dispersant and an antifoaming agent are mixed together, and to this, granulated blast furnace slag, ceracola, Portland cement, bone phase, filler, etc., which have been mixed separately, are added and further mixed. After uniformly dispersing it, if necessary, the viscosity can be adjusted using a thickener or the like. A common method for thickening agents is to mix them with granulated blast furnace slag. When mixing fibers, it is convenient to use fibers that have been defibrated and dispersed in advance. The hydraulic composition slurry thus obtained is applied onto the waterproof layer formed on the wooden board by applying it using a coating device such as a roll coater or a spreader, or by a method such as spray painting. Apply. The shape of the painted surface can be either flat or uneven, but if the purpose is to use it as a mortar base, an uneven surface increases the surface area, improves the adhesion of mortar, and improves application workability. It has advantages such as good performance. When painting a hydraulic composition slurry, it is possible to apply the same composition in multiple coats, or to change the composition ratio and apply it alternately, or to apply it directly. This allows the composite to have different properties, expanding the range of uses of the composite. To increase the thickness of the cured material layer so that it has the characteristics of a substrate, it is best to apply it in layers or by pouring it onto the board.

For curing, either leave it as it is after painting, or replenish moisture by spraying water after drying, and leave it indoors for 1 to 7 days or longer, taking care not to let it dry too much. Alternatively, the material may be left for 1 to 7 days or more in a moist heat state using steam or the like, preferably in an atmosphere of 90° C. or less.

The composite board obtained in this way is composed of a wooden board, a waterproof layer, and a cured layer of a hydraulic composition, so it has excellent strength, physical properties, and waterproofness, and has the advantages of wood-based materials. It combines the strengths of inorganic materials such as toughness, workability, and workability with hardness, nonflammable surface, durability, and stability. Therefore, the composite board has properties suitable for use as a base material.It has excellent waterproof properties and adhesion to mortar and finishing materials, prevents mortar from peeling off and cracks, and improves the durability of walls. It is possible to not only improve the appearance but also prevent the deterioration in aesthetic appearance caused by cracks. Furthermore, the workability of the composite board is such that it is only necessary to nail the composite board to a post, etc. to its dimensions, that it is easy to perform work such as cutting with a saw, notching, etc., and that the mortar and finishing layer are painted. It has many excellent properties as a base material, including good workability. Therefore, by constructing this composite board as a base board for mortar painting, spray painting, tiling, etc. of building structures, wood stains and
Waterproof paper, metal lath, etc. are not required, and the undercoating and intermediate coating of mortar can be omitted. This saves labor or streamlines the process, and shortens the construction period.

Hereinafter, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited to these unless the gist thereof is changed. The granulated blast furnace slag used in the examples has a specific surface area of 3720 c〃x2/f, and a weight percentage of S 1023 g-9 and A 20315.
0%, 1i”62030.6%, CaO41.7%
%MgO6,'1%, and other chemical compositions of 2.7 yen were used.

Example 1 Cystyrene-acrylic copolymer emulsion (solid content 57%) was applied to plywood (wood species Kapor, thickness 7.5M, 5-ply structure) using a roll coater to coat 120 S'/, ++
It was applied at a ratio of L2 and dried at 60°C for 20 minutes.

Next, 80 parts by weight of granulated blast furnace slag, 20 parts by weight of water slag, 25 parts by weight of ordinary Portland cement, and styrene-acrylic copolymer emulsion (solid content 5.7%) 4
A hydraulic composition slurry obtained by mixing 0 parts by weight, 1 part by weight of the dispersant side additive, and 25 parts by weight of water was coated in a roll coater.
Paint the surface at a rate of 0.8 H/m2 so that the surface becomes uneven and rough, and place it in an atmosphere of 40°C and a relative humidity of 90 coefficients or higher.
It was left to stand for a week, and after curing, it was dried at 60°C to obtain a composite board. Table 1 shows the physical properties of the composite plate thus obtained. Also, when this composite board was used as a base layer,
The mortar had a high adhesion strength, was waterproof, had good workability, and did not cause any cracks in the mortar.

Example 2 Acrylic emulsion (solid content 50%) was applied to plywood (wood species: white lauan, thickness 7.5+ nm, for 5-ply structure) at a ratio of 150 f/l112 using a roll coater, and dried at 60°C for 20 minutes. did.

Next, 90 parts by weight of granulated blast furnace slag, 10 parts by weight of dihydric slag, 67 parts by weight of ordinary Portland cement, 33 parts by weight of styrene-butadiene latex (solid content 45%), 1 part by weight of dispersant side additive, and 45 parts by weight of water. The hydraulic and li compound obtained by mixing the two parts was mixed using a roll coater.
Paint at a rate of 1.3 kg/m2 so that the surface becomes uneven and rough, dry at 60°G for 30 minutes, leave at 80°C and relative humidity of 90 coefficients or higher for 5 hours, and then leave indoors for a week. Then I got a composite board. Table 1 shows the physical properties of the composite plate thus obtained. However, when this composite board was used as a base material, it had high adhesion to mortar, was waterproof, and had good workability, and no cracks occurred in the mortar.

Example 3 Plywood (same as Example 1) was coated with 15 gepoxy-modified acrylic emulsion (solid content: 40 cm) using a roll coater.
It was applied at a ratio of 0/7712 and dried at 80°C for 20 minutes.

Next, 80 parts by weight of granulated blast furnace slag, 20 parts by weight of dihydric slag, 25 parts by weight of ordinary Portland cement, 10 parts by weight of perlite, 20ffi parts of ethylene vinyl acetate emulsion (solid content 56%), 1 weight part of dispersant and other additives. A hydraulic composition slurry obtained by mixing 35 parts by weight of water and 35 parts by weight of water was mixed with a roll coater.1. OA? A composite board was obtained in the same manner as in Example 1, by coating at a ratio of 2/Full so that the surface had an uneven surface. Table 1 shows the physical properties of the composite plate thus obtained. Furthermore, when this composite board was used as a base material, it had high adhesion to mortar finishing material made of white cement, had good waterproof properties and workability, and no cracks occurred in the finished layer.

Example 4 Diurethane-modified styrene-butadiene latex (solid content: 55%) was applied to plywood (same as Example 1) using a roll coater.
was applied at a rate of 100 f/7 m2 and dried at 60°C for 20 minutes.

Next, 80 parts by weight of granulated blast furnace slag, 20 parts by weight of dihydric gypsum, 67 parts by weight of ordinary Portland cement, 120 parts by weight of styrene-acrylic emulsion (solid content 57%), 2 parts by weight of setting accelerator, dispersant and other additives. 1 part by weight,
40 parts of hydraulic slurry obtained by mixing 10 parts by weight of water.
097m2 with a roll coater, and on top of that, 80 parts by weight of granulated blast furnace slag, 20 parts by weight of dihydric gypsum, 50 parts by weight of ordinary Portland cement, and 1 part by weight of Kansui stone.
50 parts by weight, 50 parts by weight of styrene acrylic emulsion (solid content 57%), 2 parts by weight of dispersant and other additives, 20 parts by weight of water
Mix the weight parts and apply it smoothly using a roll coater.
Thereafter, a composite plate was obtained in the same manner as in Example 2. The various physical properties of the composite plate thus obtained are shown in Table IK. When this composite board was used as a base material, it had high adhesion to emulsion-based spray paints, had good waterproof construction properties, and was suitable as a base material for spray paints.

Adhesive force: Adhesive force of the cured material layer, according to JISA6909.

Water resistance: Appearance change after immersion in water for 30 days Alkali resistance s Ca (OH) z Appearance change after immersion in saturated aqueous solution for 30 days Weather resistance: Adhesion of cured layer after 1000 hours of Sunshine Weather Meter irradiation, JISA6909 According to.

Water permeability: According to JISA6910.

Claims (2)

[Claims] (1) A waterproof layer is formed on at least the surface of the wooden board,
On top of the waterproof layer, granulated blast furnace slag of 60 to 95 weight,
For 100 parts by weight of a mixture consisting of 5 to 40 parts by weight of Ceracola, slag consisting of 3 to 100 parts by weight of Portland cement, Ceracola, cement-based material, synthetic resin emulsion, still rubber latex and water, and if necessary a setting condition. 1. A composite plate comprising a cured layer of a hydraulic composition comprising a narrowing agent and bone 'A4. (2) A waterproof layer is formed on at least the surface of the wooden board, and on the waterproof layer, Portland Hydraulic composition obtained by mixing slag, ceracola, or cement material containing 3 to 100 parts by weight of 7-mention, a synthetic resin emulsion or rubber latex, water, and, if necessary, a setting modifier and aggregate. A method for manufacturing a composite board, which comprises applying slurry and then curing it, or drying it and then curing it by replenishing moisture.