KR101147073B1 - A resin-coated inorganic tissue-facer and board type construction materials with excellent waterproofing property comprising the same - Google Patents

Abstract

The present invention relates to a resin-coated inorganic tissue-facer and a board-like building material, preferably a gypsum board, which is excellent in water resistance including the same, and more particularly, an inorganic fiber base paper (matte); And an inorganic tissue-facer comprising a acrylic resin, a thermosetting resin and a curing catalyst on the surface thereof, and preferably a coating layer of a resin composition for coating, which also includes calcium carbonate. Excellent board-like building material, preferably gypsum board.

Description

A resin-coated inorganic tissue-facer and board type construction materials with excellent waterproofing property comprising the same}

The present invention relates to a resin-coated inorganic tissue-facer and a board-like building material, preferably a gypsum board, which is excellent in water resistance including the same, and more particularly, an inorganic fiber base paper (matte); And an inorganic tissue-facer comprising a acrylic resin, a thermosetting resin and a curing catalyst on the surface thereof, and preferably a coating layer of a resin composition for coating, which also includes calcium carbonate. Excellent board-like building material, preferably gypsum board.

Gypsum board is a building material for interior use that is widely used in terms of fire resistance, sound insulation, workability, and economy. Gypsum board is composed of calcined gypsum (plaster, calcium sulfate 1.5 hydrate) obtained by calcining calcium sulfate dihydrate at about 130 to 160 ° C to dehydrate a part of crystal water. It is a kind of nonflammable interior material which is made between two sheets of board paper and reduced into a stable crystalline gypsum. Among them, the waterproof gypsum board refers to a gypsum board in which a waterproofing agent is incorporated into gypsum, which is a core material (core material), to be applied to a wet bathroom, a bathroom, a kitchen, or the like.

Korean Laid-Open Patent Publication No. 10-2006-0021259 discloses a gypsum board comprising at least one mat-facer including an inner layer and an outer layer, wherein the inner layer is in contact with the core of the gypsum board and the cellulose fibers, inorganic fibers or organic fibers And a gypsum board is described wherein the outer layer essentially comprises cellulose fibers and the mat-facer further comprises a binder resin and inorganic filler particles. However, gypsum board coated with a silicone resin waterproofing agent while using cellulose base as an inner layer and an outer layer has a disadvantage of being vulnerable to moisture, and thus it has a limit to be applied to a bathroom, a bathroom, a kitchen, and the like, which are always exposed to moisture.

Korean Patent Publication No. 10-2002-0034987 discloses a gypsum board using a silicone compound as a waterproofing liquid. In this publication, a mineral additive absorbs a silicon compound and homogeneously mixes the mineral additive with a plaster substrate to produce a gypsum board exhibiting waterproofness. However, in the case of the gypsum board using the silicone resin as the waterproofing agent, the silicone resin acts as an antifoaming agent and eventually causes the quality of the gypsum board to be poor.

U.S. Patent Nos. 4,879,173, 5,148,645, 5,371,989 and the like describe gypsum boards comprising a fibrous mat coated with wax-asphalt emulsion as a waterproofing composition. However, in the case of a gypsum board having a waterproof coating layer formed on the surface using a wax component, there is a problem that a so-called blocking phenomenon occurs, in which boards stick together when laminating gypsum boards.

The present invention is to solve the problems of the prior art as described above, there is no blocking phenomenon sticking when laminated, the board-type building materials having a sufficiently good water resistance even when used in an atmosphere exposed to moisture, such as a bathroom, porch, kitchen It is a technical object of the present invention to provide a resin coated inorganic tissue-facer used in the preparation thereof.

According to an aspect of the invention, the inorganic fiber base paper (mat); And a coating layer of a resin composition for coating comprising an acrylic resin, a thermosetting resin and a curing catalyst on the surface thereof, and preferably further comprising calcium carbonate. The inorganic tissue-facer is provided.

According to another aspect of the present invention, there is provided a board-like building material, preferably a gypsum board, comprising the inorganic tissue-facer and the core material.

According to the present invention, it is possible to obtain a board-like building material, preferably a gypsum board, which does not have a blocking phenomenon that adheres to the lamination, and has sufficient water resistance even when used in an atmosphere exposed to moisture such as a bathroom, a veranda, and a kitchen.

Hereinafter, the present invention will be described in detail.

In the resin-coated inorganic tissue-facer of the present invention, the inorganic fiber base paper (matte) to which the resin is coated is most preferably made of only inorganic fibers, but organic fibers may be used within the scope of the present invention. It may be contained in a certain amount, such as 10 to 30 parts by weight per 100 parts by weight of inorganic fibers. And an inorganic fibrous inner layer (or inner surface) and an inorganic fibrous outer layer (or outer surface) in contact with the inorganic tissue-facer core material (eg, gypsum slurry in the case of gypsum board) of the present invention. Glass fibers are most preferred as the inorganic fibers.

There is no particular limitation on the basis weight and thickness of the inorganic fiber base paper (matte) for preparing the inorganic tissue-facer of the present invention, but considering the economical efficiency and workability, the basis weight of the base paper is suitably 50 to 150 g / m 2, and the thickness is appropriate. Is preferably 0.3 to 0.5mm.

In the inorganic tissue-facer of the present invention, the base paper (mat) is coated with a resin composition for coating containing an acrylic resin, a thermosetting resin and a curing catalyst.

It is preferable that the glass transition temperature (Tg) of the said acrylic resin is -4 degreeC or more (for example -4-50 degreeC), and it is more preferable that it is 20 degreeC or more (for example, 20-50 degreeC). If the glass transition temperature of the acrylic resin is less than -4 ℃ blocking may occur when the board laminated. On the contrary, too high may cause brittleness in the coating film.

The thermosetting resin prevents core slurry (e.g. gypsum slurry) from leaking by hardening the pores of the base paper (mat) while curing after application of the coating composition, and also prevents blocking between the boards when the gypsum board is laminated. Can be. Examples of the thermosetting resins include melamine resins, phenol resins, urethane resins, and the like, and melamine resins are most preferred. The usage-amount of a thermosetting resin in a coating composition becomes like this. Preferably it is 2-15 weight part per 100 weight part of acrylic resin, More preferably, it is 3-10 weight part. If the amount of the thermosetting resin per 100 parts by weight of the acrylic resin is less than 2 parts by weight, the coating composition may not sufficiently block pores of the paper (matte) or blockage may occur. have.

According to one embodiment of the present invention, p-toluenesulfonic acid (PTSA) may be used as the curing catalyst, but is not limited thereto. The amount of the curing catalyst used in the coating composition is preferably 1 to 5 parts by weight, more preferably 2 to 3 parts by weight per 100 parts by weight of the thermosetting resin. If the amount of the curing catalyst is too small, the coating film may not be cured sufficiently. If the amount of the curing catalyst is too large, the coating film may be too hard and easily broken.

Preferably, the coating resin composition may further include calcium carbonate. This calcium carbonate serves as a filler and blocking prevention of the resin composition. The calcium carbonate content in the coating resin composition is preferably 30 to 70 parts by weight per 100 parts by weight of the acrylic resin. If the calcium carbonate content is less than the above range blocking may occur, if more than that may have a problem that the water resistance is lowered.

There is no particular limitation on the method of coating the base paper (matte) with the coating composition, and a conventional resin coating method such as a gravure coating method may be used. Although there is no particular limitation on the thickness of the coating, it is preferable not to exceed 70% of the thickness of the base paper, and in terms of workability and production efficiency, the basis weight after coating is suitably 80 to 300 g / m 2. The viscosity of the resin composition during coating is suitably 2000 to 15000 cps.

The inorganic fiber base paper (matte) coated with the composition is then dried under high temperature. At this time, if the drying temperature is too low, there is a fear that the curing of the resin is not sufficient, and if it is too high, the coating may be denatured. According to one embodiment of the present invention, the drying temperature is suitably 150 ° C. or more (eg, 150 ° C. to 170 ° C.).

A core material slurry (such as gypsum slurry) is introduced into the inorganic tissue-facer of the present invention obtained by coating an inorganic fiber base paper (matte) with the coating composition as described above to prepare a board-like building material (such as gypsum board). . Therefore, according to another aspect of the present invention, there is provided a board-like building material, preferably a gypsum board, including the inorganic tissue-facer and the core material.

In the board-like building material of the present invention, the core material is appropriately selected depending on the end use of the building material. For example, to obtain a gypsum board, a gypsum slurry is used as a core material, and to obtain a cement board, a cement composition is used as a core material. When the building material produced according to the present invention is gypsum board, its specific gravity is usually 0.60 to 2.0.

In order to improve the water resistance of the board-like building material, the waterproofing material may be included in the core material. Suitable waterproofing agents include, for example, poly (vinyl alcohol); Metal resin salts; Wax or asphalt or mixtures thereof; Wax-asphalt emulsions; Silicone derivatives such as polyorganohydrogensiloxane and silicone oil; Paraffinic hydrocarbon derivatives; Insoluble thermoplastic organic materials such as petroleum and natural asphalt, coal, tar and thermoplastic synthetic resins such as poly (vinyl acetate), poly (vinyl chloride) and copolymers of vinyl acetate and vinyl chloride, and acrylic resins, and the like. Among them, preferred waterproofing agents are paraffinic hydrocarbon derivatives. In general, the amount of the waterproofing agent may vary depending on the type of the waterproofing agent. In the case of the paraffinic hydrocarbon waterproofing agent, about 1 to about 10 parts by weight, preferably about 3 to about 10 parts by weight of the total weight of the core material (core material) About 7 parts by weight.

Also preferably, the core material may include glass fiber, and the amount may be about 0.1 to 2 parts by weight based on 100 parts by weight of the total weight of the core material (core material).

In addition, the addition of a suitable fluidizing agent to the core can improve the fluidity of the slurry to allow sufficient penetration of the slurry between the glass tissue-facer pores, thereby improving the strength of the board.

Preferred gypsum board products made according to the invention exhibit a total absorption of not more than 10% when waterproofed according to KS F 3504.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the following examples are illustrative of the present invention, and the contents of the present invention are not limited by the following examples.

Example 1

32 wt% acrylic resin (Tg: 20 ° C.), 17 wt% calcium carbonate, 2.94 wt% melamine resin as thermosetting resin, 0.06 wt% p-toluenesulfonic acid (PTSA) as curing catalyst and 48 wt% water A resin composition for coating was prepared.

Using the prepared resin composition, glass base paper (matte) having a basis weight of 65 g / m 2 and a thickness of 0.35 to 0.40 mm was coated in a gravure manner. At this time, the viscosity of the resin composition was adjusted to be within the range of 2,000 to 15,000 cPs, the coating of the resin composition was not to exceed 70% based on the thickness of the glass tissue. It was then dried at 150 ° C. for 2 minutes and passed through a 250 ° C. hot roller to prepare a resin coated glass tissue-pacer.

Two glass tissue-facers prepared in the same manner were laminated and subjected to a load of 10 Kgf / cm 2 using a 250 ° C. hot press, and after 3 minutes was tested for adhesion of these layers, blocking was observed between these layers. The phenomenon did not occur at all.

Comparative Examples 1, 2 and 3

Glass tissues were prepared in the same manner as in Example 1, using a silicone resin [Comparative Example 1], paraffin wax [Comparative Example 2], and carbodiimide resin [Comparative Example 3] instead of the melamine resin in the constituent components of the coating resin composition. -A pacer was prepared, and the lamination and adhesion tests were conducted in the same manner. As a result, blocking phenomenon occurred in all of Comparative Examples 1, 2, and 3.

Example 2

A paraffinic hydrocarbon waterproofing agent (paraffin wax) was added to a gypsum slurry for ordinary gypsum board in the following content per 100 parts by weight of gypsum, and a 12.5 mm gypsum board was used by using the slurry and the glass tissue-pacer prepared in Example 1 above. Manufactured via wallboard line. The manufactured gypsum board was waterproof tested according to KS F 3504. The results are shown in Table 1 below.

Claims (12)

Inorganic fiber base paper (matte); And a coating layer of a resin composition for coating comprising a curing catalyst which is an acrylic resin, a thermosetting resin, and p-toluenesulfonic acid on its surface. The inorganic tissue-facer according to claim 1, wherein the inorganic fiber base paper (matte) is made of glass fiber only. The inorganic tissue-facer according to claim 1, wherein the inorganic fiber-based paper (matte) contains 10 to 30 parts by weight of organic fibers per 100 parts by weight of the inorganic fiber. The inorganic tissue-facer according to claim 1, wherein the acrylic resin has a glass transition temperature of -4 ° C or higher. The inorganic tissue-facer according to claim 1, wherein the thermosetting resin is a melamine resin. delete The inorganic tissue-facer according to claim 1, wherein the resin composition for coating further comprises calcium carbonate. The inorganic tissue-facer according to claim 1, wherein the coating layer of the resin composition is obtained by drying at a temperature of 150 占 폚. A board-type building material comprising the inorganic tissue-facer and the core according to any one of claims 1 to 5, 7 and 8. The building material according to claim 9, wherein the core material comprises a waterproofing agent. The building material according to claim 9, which is a gypsum board. The building material according to claim 11, wherein the total water absorption according to KS F 3504 is 10% or less.