JPS6213457B2 - - Google Patents

Description

Detailed Description of the Invention (Field of the Invention) The present application uses a small amount of fibers by arranging a long-fiber orthogonal nonwoven fabric in the skin layer, and uses a non-flammable and fire-resistant inorganic aggregate material that is stiff, hard to bend, hard to crush, and non-flammable and fireproof. The purpose is to construct thin-layer building materials.

(Relationship with Prior Art) Conventional thin-layer building materials include cement and gypsum board mixed with asbestos, etc. However, asbestos is a carcinogenic substance, making it difficult to use or even prohibiting its use.

The combination of glass or organic short fibers is being considered as a substitute for asbestos, but non-directional short fibers account for 5%.
The following combinations have no effect: at least 8% or more, and asbestos, etc., are often mixed at 15% or more, and using a high percentage of expensive artificial fibers is not only effective in terms of heat-resistant properties but also in terms of cost. It is disadvantageous compared to asbestos.
Therefore, in order to use such expensive man-made fibers in as small a quantity as possible and achieve the full effect, they should not be used as short fibers, but rather as thin-layer building materials in the form of orthogonal non-woven fabrics made of filaments, which are long fibers. One of the features of the product composition of the present application is that it is placed in the cortical layer of the skin, and good results can be obtained with a fiber content of about 1 to 2%.

When reinforcing fibers in thin building materials, in order to work most effectively against bending stress, place filaments with a high Young's modulus or orthogonal nonwoven fabrics with filament yarn orientation in the skin layer of the building material. things are desirable.

Compound fibers that are not in the cortical layer serve as a joint material, but are not very useful for bending stress.

(Summary of the Invention) The first aspect of the present invention is to place a long-fiber orthogonal nonwoven fabric shallowly buried in the front and back surfaces of an inorganic coagulant, and fill the inorganic coagulant with a reinforcing material or filler in the middle of the front and back surfaces. It is a thin-layer building material having a long fiber orthogonal nonwoven fabric in the skin layer, which is characterized by a structure in which the entire structure is integrally coagulated. A thin-layer building material having a long-fiber orthogonal nonwoven fabric in its skin layer, which is characterized by a structure in which the space is filled with an inorganic coagulating material mixed with other reinforcing materials or fillers, and the whole is coagulated tightly. It is.

(Object of the invention) The present application uses less fiber than the long-fiber orthogonal nonwoven fabric placed in the cortical layer, and has a stiff waist and is difficult to bend.
The purpose is to construct a thin-layer building material based on inorganic coagulation material that is difficult to crush and is non-combustible and fireproof. These will be explained separately for each item. In the present application, a thin layer has a thickness of about 5 to 12 mm, and may be flat or corrugated.

(Properties and Types Required for Fiber Materials) In this application, various long fibers are used as fiber materials, but in particular, high Young's modulus glass fibers or organic fibers are those that have been drawn at a high magnification and have high Young's modulus and heat resistance. High fibers are preferred.

For example, polyvinyl alcohol (pVA) and polyacrylonitrile (pAN) fibers are particularly desirable fibers because they do not shrink when heated without contact with air, follow the direction of carbon fiber, and maintain strength when heated with flame. be.

These long fibers can be produced by spreading out tow-like fibers into a wide thin layer, by drafting many strips of stretch-cut sliver in parallel, or by forming a wide web layer in which filament systems are arranged at a fixed pitch. It is used as an orthogonal nonwoven fabric with a structure of (longitudinal layer x latitudinal layer) or (longitudinal layer x latitudinal layer x longitudinal layer).

A feature of the present application is that the orthogonal nonwoven fabric is embedded in the inorganic coagulant on the surface of the thin building material and exists in the skin layer, so that it is arranged in such a way that there is little contact with air.

(Characteristics of PVA and PAN fibers) The key point of this application is that a cloth body mainly made of filament orthogonal non-woven fabric is arranged in the skin layer of the thin-layer building material, and the thin-layer building material is reinforced using the lowest possible percentage of fiber material. be.

In particular, PVA and PAN fibers coated with the above-mentioned inorganic coagulant permeate sufficiently may shrink or melt when heated by a flame during heat-drying, causing relaxation of the molecular arrangement. Rather, it can be said that it is a fiber material with higher heat resistance than glass fiber because its molecular arrangement remains unchanged under oxygen deficiency and follows the direction of carbon fiber formation as described below.

It is emphasized that the glass fibers used in cement should not be ordinary glass, but especially alkali-resistant glass fibers, but it is said that the alkali-resistant glass fibers currently on the market are insufficient in alkali resistance.

In this respect, PVA has alkali resistance at room temperature, and dehydration decomposition occurs first at temperatures above 220°C under heating, and the decomposed water evaporates and evaporates under heating without softening PVA, and then dehydrates under oxygen-deficient conditions. We trace the process of dissolving and carbonizing. In PAN, −CN group is hydrolyzed under lime alkali to form −CONH ₂ or −
It becomes COOH, but this -COO- group combines with Ca, which is a component of cement, etc., and becomes insolubilized, so it can be said to be an alkali-resistant fiber in that the molecular arrangement does not relax at room temperature, and although it is colored brown, the strength does not decrease. . Under high-temperature heating such as flame, de-CN groups and de-
A CO-group reaction occurs first, followed by dehydrogenation, leading to carbon fiber formation. Therefore, when such a heat-infusible organic fiber fabric is used for reinforcement, as in the configuration of the present application, most of it is buried in the skin layer of the inorganic coagulant in contact with the front and back surfaces of the building material, so that even when exposed to flame, The structure of the present application is characterized in that the fibers are arranged in an oxygen-deficient non-flammable state, and even if heating continues, the molecular arrangement remains in the direction of carbon fiberization without any relaxation due to the oxygen deficiency, and the strength does not decrease. If organic fibers are exposed to the atmosphere, as in the case of the surface paper of a gypsum board, they will be burned away by flames and no fiber reinforcing effect can be expected, with the drawback that the building material will burn and crumble.

(Ratio of fiber used and degree of reinforcement for thin-layer building materials) Thin-layer building materials made of inorganic cohesive materials mentioned above can be made lighter by reinforcing them with sand, short organic/inorganic fibers, or adding foam particles, porous materials, etc. Generally, it has a thickness of 5 to 12 mm and a weight of 5 to 15 kg/m ² . The average weight is 10Kg/ ^m2 , and 50g/m2 is applied to the front and back sides.
If m ² of parallel filaments or orthogonal non-woven fabric of parallel filament yarns (950d x 6 threads x 6 threads/inch) are arranged, the amount of filament used on the front and back sides is 100g/inch.
m ² is about 1% of the weight of the thin-layer building material, and the tensile strength of the filament is about 200 kg/d, assuming it is 8 to 10 g/d.
The reinforcement is 50mm wide. Especially for low elongation and high strength
PVA, PAN fibers and glass fibers are preferably used alone or in combination as a filament orthogonal nonwoven fabric. Carbon fiber is also used in combination to improve thermal and electrical conductivity.

In addition, short fiber webs are sometimes used in a laminated form for the purpose of increasing the covering power of the orthogonal nonwoven fabric of filament yarns with a lattice pattern.

(Adhesiveness between fibers and coagulating material and low elongation of fibers) Spun yarns and highly twisted filament yarns cannot be bonded because adhesives and coagulating agents (matrix) such as cement and plaster do not permeate between each filament. It is not a desirable fiber material because it is weak and cannot be expected to have physical properties to which the law of compounding applies.

The reason why woven cloth is not used as the cloth body in this application is that in woven cloth, the warp and weft threads are intertwined vertically and have a wavy bent shape, and some tension unevenness in each thread cannot be avoided. This is because even if a yarn with a high Young's modulus is used, the fabric will have a high degree of elongation from a structural and practical standpoint, making it unsuitable for reinforcing low elongation cement, plaster, etc.

In this regard, the weft/warp orthogonal nonwoven fabric used in this application is made by laminating filaments or non-twisted or slightly twisted filament yarns in a straightly stretched form with any fiber/thread density, and if low elongation fibers are used, they will have low elongation as they are. When a slurry-like inorganic coagulant such as cement, gypsum, calcium-silicate, or charcoal-water glass is used, the coagulant permeates between the untwisted single fibers. However, it has good mutual adhesion and is the most effective for reinforcing thin-layer building materials.

When organic fibers are used, the need for the fibers to be buried in the inorganic coagulant is not due to the need for non-combustibility, but also to expand the bonding area between the fiber material and the inorganic coagulant and to increase the hooking effect. is also an effective measure. The most suitable method for obtaining such a product is to first prepare orthogonal non-woven fabrics with cement, α-type 1/2H 2 O plaster, or α-type 1/2H ₂ O plaster, which has a strong adhesive composition, especially in the production of thin-layer building materials. It is immersed in a slurry of calcium carbonate and water glass, etc. and squeezed, and if necessary, this operation is repeated to fully coat the surface of the unit filament of the cloth body with the above inorganic coagulant (material), and the squeezing process becomes sweet. An inorganic coagulating material that is made by adding and sizing as much coagulant as possible (several times the basis weight of the fabric) to form an orthogonal nonwoven fabric with front and back sides, and an inorganic coagulating material containing additives such as fillers in the middle layer. A method is used in which the entire layer is solidified and hardened by sandwiching the layers to a constant thickness.

As mentioned above, sizing with an inorganic coagulant in the form of a slurry is impossible with paper or other intertwined short fibers because the structure is torn, but since the fabric used in this application has a long fiber structure, it is difficult to perform sizing using a slurry-like inorganic coagulant. In particular, this type of fabric has a high strength, so a small basis weight, i.e., 40 to 60 g/ ^m2 , is sufficient to achieve the purpose of practical reinforcement. Since the fabric has a non-twisted filament structure, the penetration of the coagulant is good, and since the fiber basis weight is small, in order for the fabric to fully exhibit the coagulant catching effect, the fabric has to absorb the inorganic material on the surface of the thin building material. It is desirable that most of the material be buried in the coagulant and placed in contact with the surface, and the above-mentioned pre-treatment and sizing of the fabric is an effective and necessary practical means for this purpose.

(Blend and composition of coagulant used in intermediate layer) In the intermediate layer of the fabric sized as described above,
Sand as a bulking material (cement reinforcing bulking material), joint reinforcing materials such as asbestos, artificial short fibers, pulp fibers, sludge short fibers, porous lightening materials such as shirasu balloons and pearlite (volume bulking material), synthetic Inorganic setting agents such as resins and setting accelerators added for respective purposes are used as fillers in the intermediate layer.

(Production method of weaving orthogonal nonwoven fabric) High Young's modulus fibers, such as alkali-resistant glass fibers, carbon fibers, general glass fibers, or high-strength, low-elongation organic fibers tend to break easily, making weaving difficult. The orthogonal nonwoven fabric used in this invention is manufactured by the method of the applicant's earlier patent application, JP-A No. 52-124976 (JP-A-53-38783), which has a fabric-making capacity per machine that is two orders of magnitude higher than that of an ordinary loom. The fabric is laminated in the form of a wide web of twisted filaments or lightly twisted filament yarns, and has the advantage that a non-woven fabric can be mass-produced at low cost.

According to this manufacturing method of nonwoven fabric that is orthogonally laminated,
Even with such high Young's modulus fibers/yarns, fabrics suitable for industrial use can be mass-produced at low cost.From one perspective, this application is aimed at producing lightweight, non-flammable thin fabrics for which the demand has increased in recent years. This can also be considered as an invention for the use of orthogonal filament nonwoven fabrics, which are expected to be in huge demand as an alternative to asbestos in the composition of layered building materials.

(Explanation of product structure and manufacturing process using figures) Fig. 1 is a perspective view of a product belonging to the first aspect of the present invention, in which the nonwoven fabric shallowly buried in the surface consists of warp 1 and weft 2, and the nonwoven fabric on the back side consists of warp 3 and weft 3. Consists of 4 weft threads.
The intermediate layer 7 is between the front and back layers. FIG. 2 shows a cross section of the product shown in FIG. 1 cut in the transverse direction, and is composed of a surface layer 5, a back layer 6, and an intermediate layer 7. FIG. 3 is a cross section of a product belonging to the second aspect of the present invention, and the corrugated one in the intermediate layer shows an iron wave lath 8. FIG. 4 shows an outline of the product manufacturing process according to the first aspect of the present invention. The belt 18 is sent to a pinch roller 19, on which the back nonwoven fabric 10 is placed, and then an inorganic coagulating material 12 is placed on the belt 18.
flows out and covers the nonwoven fabric. The nonwoven fabric is lightly pressed by the press roller 15, and the nonwoven fabric is shallowly buried in the coagulating material. Then the intermediate layer material 14 flows out onto this,
The surface is made flat by the press roll 16. Next, the coagulating material 13 forming the surface layer flows out, the nonwoven fabric 11 forming the surface layer is placed on top of this, and the press roller 17
As a result, the nonwoven fabric 11 is shallowly buried in the surface layer of the aggregation material. The belt at the bottom is then turned back by the turn roller 22. Turn roller 22
Next there is a solid flat pedestal, and the thin layer that has left the belt is pushed onto it and placed on the cutter 2.
The product 23 is cut as appropriate at point 0. Although not shown, a high frequency heating device may be added between the press roller 17 and the pedestal 21 in order to accelerate solidification.

Embodiment A case will be described in which an iron wave lath is provided in the intermediate layer. A nonwoven fabric body sized with an inorganic cohesive material is continuously moved in the length direction, and a 0.35 mm thick nonwoven fabric body is placed on this fabric body.
A thin iron plate was made with 17mm long bird-shaped cuts at narrow pitches in the front and back, and the width was widened in a direction perpendicular to the length of the cuts to create a flat lath. This lath was passed between corrugating rollers and cut into a wave lath with a basis weight of 0.4 kg/m ² to a fixed length, and then arranged on a nonwoven fabric body that moved in an interrupted manner one after another. The blended inorganic coagulant is supplied from above the wave lath over the entire width, and is vibrated so that the coagulant passes through the holes of the lath and goes around the underside of the lath, degassing and filling the lath with the coagulant. It was passed between rollers and compressed to a predetermined thickness. At this time, the sized fabric was placed on top of the upper coagulant introduced through the upper roller and buried shallowly with a press roller, and the lath was cut at each seam.
Each sheet was left for a curing period to complete solidification and become a product.

[Brief explanation of the drawing]

Figure 1 is a perspective drawing of the product, Figure 2 is a cross-sectional view of the product in the lateral direction, Figure 3 is a cross-sectional view of a product with iron corrugated laths in the middle layer, and Figure 4 is how the product shown in Figure 1 is made. It is a journey diagram. Explanation of symbols in the drawings: 1, 2... Warp and weft of the surface layer, 3, 4... Warp and weft of the surface layer, 5, 6... Surface layer and back layer, 7... Intermediate layer, 8 ... Cross section of iron wave lath, 10, 11 ... Nonwoven fabric on the front and back surfaces, 12, 13 ... Inorganic setting material, 14 ... Compound setting material used for intermediate layer, 15,
16, 17...Press roller, 18...Belt,
19... Pinch roller that moves the belt, 20...
... cutter, 21 ... solid pedestal, 22 ... turn roller, 23 ... product.

Claims (1)

[Scope of Claims] 1. In a thin-layer plate material consisting of three layers: front, back and middle layers, a long fiber orthogonal nonwoven fabric is shallowly buried in the front and back surfaces of the thin layer of inorganic cohesive material, and a reinforcing material or Filled with inorganic coagulant mixed with filler,
A thin-layer building material whose skin layer is made of long-fiber orthogonal nonwoven fabric, which is characterized by a structure in which the entire structure is coagulated and adhered to each other. 2 In Claim 1, an inorganic coagulation material in which an iron wave lath is centrally arranged as a reinforcing material between the front and back layers containing the long-fiber orthogonal nonwoven fabric, and other reinforcing materials or fillers are added and blended in that space. A thin-layer building material whose skin layer is made of long-fiber orthogonal nonwoven fabric, which is characterized by a structure in which the entire structure is coagulated and adhered to each other.