WO2008016011A1 - Plaque inorganique et son procédé de production - Google Patents

Plaque inorganique et son procédé de production Download PDF

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Publication number
WO2008016011A1
WO2008016011A1 PCT/JP2007/064904 JP2007064904W WO2008016011A1 WO 2008016011 A1 WO2008016011 A1 WO 2008016011A1 JP 2007064904 W JP2007064904 W JP 2007064904W WO 2008016011 A1 WO2008016011 A1 WO 2008016011A1
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WO
WIPO (PCT)
Prior art keywords
weight
inorganic
mat
less
binder
Prior art date
Application number
PCT/JP2007/064904
Other languages
English (en)
Japanese (ja)
Inventor
Takashi Ishida
Takanori Kuroki
Masahiro Miura
Original Assignee
Daiken Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2006208538A external-priority patent/JP5137353B2/ja
Priority claimed from JP2006250837A external-priority patent/JP5137364B2/ja
Application filed by Daiken Corporation filed Critical Daiken Corporation
Publication of WO2008016011A1 publication Critical patent/WO2008016011A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00603—Ceiling materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to a cosmetic inorganic board suitable for use as a base material for interior materials, ceiling materials, eave roof materials, etc. of buildings such as houses, and a method for producing the same.
  • a board for a decorative surface material such as furniture
  • a wood board such as plywood or MDF
  • an inorganic board such as a plaster board or calcium silicate board.
  • Patent Document 1 a wet material obtained by mixing and dispersing a raw material containing mineral fibers, an inorganic powder, and a binder as essential components to form a slurry and wet papermaking
  • a method for producing an inorganic board that can obtain a decorative layer satisfactorily by drying a mat and sanding it, followed by heating and compression to cure the binder.
  • Patent Document 1 Japanese Patent Laid-Open No. 2005-289784
  • the present invention has been made in view of such points, and an object of the present invention is to make it possible to produce with high productivity an inorganic board from which a good decorative layer having high smoothness can be obtained.
  • the inorganic board of the first invention comprises an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight; a lightweight aggregate of 10 to 70% by weight; and an inorganic powder. 10 to 70% by weight of a solid body, 5 to 15% by weight of a binder, and 10 to 70% by weight of inorganic fibers having a length of 1 mm or less and a lightweight aggregate having a particle size of 500 ⁇ 111 or less 10 It is characterized in that a surface layer having ⁇ 50 wt%, inorganic powder 10-70 wt%, and binder 3 ⁇ ; 10 wt% is integrally formed.
  • fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer of the inorganic board.
  • the back layer is made of an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powdery material of 10 to 70% by weight, and a binder. Since this is a layer having 5 to 15% by weight, this back layer is stronger as a plate than the front layer. As a result, the surface layer can be supported by the back surface layer (by integrating the back surface layer with the surface layer, the relatively low strength surface layer can be reinforced and supplemented). A strong inorganic plate can be obtained by integrating the above.
  • This back layer uses inorganic fibers with a length of 3 to 15 mm, and therefore has a good mixing balance with other components such as lightweight aggregates, inorganic powders and binders. It is possible to uniformly disperse and mix inorganic fibers that do not easily become lumps (fiber lump). For this reason, a back layer having higher strength and hardness can be obtained, and the surface layer can be supported and supported.
  • the sheet-like material is integrated with the back surface of the inorganic board according to the first invention. According to this configuration, since the sheet-like material is integrated with the back surface layer, it is difficult to break and is strong. An inorganic plate with a thickness of 10 mm is obtained.
  • the third and fourth inventions relate to a method for producing an inorganic plate.
  • the length of 3 to 15 mm of inorganic fibers To 10 wt%, lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% And forming a back surface layer mat by forming a mixture having a binder of 5 to 15% by weight and water added to adjust the water content to 5 to 15%, Furthermore, 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ⁇ 111 or less, 10 to 70% by weight of an inorganic powder, and a binder of 3 to Forming a surface layer mat by forming a mixture having a water content of 5 to 10% and having a water content of 5 to 15% adjusted to 15%, and two layers of the back layer and the surface layer. It is characterized by comprising a step of forming the mat integrally
  • the back surface layer of the inorganic board manufactured through the above steps uses inorganic fibers having a length of 3 to 15 mm.
  • the inorganic fiber which has a good mixing balance with the material, the inorganic powder, and the binder and does not easily become a lump (fiber lump), is uniformly dispersed and mixed. For this reason, an inorganic board with higher strength and hardness can be obtained.
  • the binder can be reacted by performing heat compression at a high temperature for a short time. Moreover, since it is under high temperature and high pressure, the fluidity
  • the moisture content of each mat of the back surface layer and the front surface layer is adjusted to 5 to 15%, so that the productivity in which puncture hardly occurs at the time of hot press is good.
  • the length of 3 to 15 mm inorganic fiber To 10 wt%, light aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% And forming a back surface mat by forming a mixture adjusted to a water content of 5 to 15% by adding water and forming a mixture on a sheet-like material.
  • the sheet-like material is also formed by hot-pressing integrally with the two-layer mat, so that it is difficult to break and is a strong inorganic material. A board is obtained. Further, it can be manufactured with good productivity with fewer steps than when a sheet-like material is pasted later. Furthermore, in the manufacturing process, the mat-like material, which is a mixture, can be transported more easily because the sheet-like material is laid underneath.
  • An inorganic plate according to a fifth invention comprises a core layer, a surface layer integrated on the surface of the core layer, and a back layer integrated on the back surface of the core layer.
  • the core layer is an inorganic fiber having a length of 3 to 15 mm;!
  • fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer and the back layer, respectively. And can gain the back layer.
  • the core layer between the surface layer and the back layer is composed of 3 to 15 mm in length of inorganic fiber 1 to 10% by weight, light aggregate 10 to 70% by weight, and inorganic powder 10 to 10%. Since the layer has 70% by weight and a binder of 5 to 15% by weight, the core layer is stronger as a plate than the surface layer and the back layer. Supports the layer (by integrating the core layer with the back layer and the surface layer, the relatively low strength surface layer and back layer can be reinforced and supplemented), and the core layer, the surface layer and the back layer are integrated. Thus, a strong inorganic plate can be obtained.
  • the core layer uses inorganic fibers with a length of 3 to 15 mm, the mixing balance with other components such as lightweight aggregates, inorganic powders, and binders is good. Inorganic fibers that are difficult to become (fiber aggregates) can be uniformly dispersed and mixed. For this reason, a core layer having higher strength and hardness can be obtained, and the surface layer and the back layer can be further supported and supported. [0024] By these synergistic actions, it is possible to obtain a high-strength inorganic board that is excellent in nonflammability, handleability, workability, and workability as a whole.
  • the sixth invention is characterized in that in the inorganic plate according to the fifth invention, a sheet-like material is bonded and integrated on at least one (at least one side) of the front and back surfaces. According to this configuration, since the sheet-like material is adhered to at least one of the front and back surfaces, an inorganic plate that is hard to break and strong is obtained.
  • the seventh and eighth inventions relate to a method for producing an inorganic plate.
  • the core layer of the inorganic board manufactured through the above steps uses inorganic fibers having a length of 3 to 15 mm, so that lightweight bone which is another component is used.
  • the inorganic fibers which have a good mixing balance with materials, inorganic powders, and binders and do not easily become lumps (fiber lump), are uniformly dispersed and mixed. Therefore, a core layer having higher strength and hardness can be obtained, and the surface layer and the back layer can be supported and supported.
  • the binder can be reacted by heating and compressing at a high temperature in a short time.
  • the fluidity of the binder can be increased and distributed throughout, and the water can be evaporated in a short time. This maximizes the performance of the binder.
  • the amount of the binder can be made relatively small, and a strong inorganic board excellent in incombustibility can be obtained in a short time.
  • the method for producing an inorganic board according to the eighth invention comprises 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ⁇ 111 or less, and an inorganic powder. 10% to 70% by weight of a compact and 3% to 10% by weight of a binder, and a mixture adjusted to a water content of 5% to 15% by adding water is formed on a sheet and back. Step of forming a layer mat, on this back layer mat, 3 to 15 mm long inorganic fiber;!
  • lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 Forming a second core layer mat by forming a mixture having 5% by weight and a binder of 5 to 15% by weight and water added to adjust the water content to 5 to 15% And 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ⁇ 111 or less, and inorganic powders 10 to 70 on these two-layer mats.
  • % By weight and binder 3 Forming a third-layer surface mat by forming a mixture having a water content of 5 to 10% by weight and having a water content of 5 to 15%; 15%, and the three-layer mat And a step of integrally forming the sheet-like material with a hot press.
  • the sheet-like material is also integrally formed by hot-pressing together with the three-layer mat, it is hard to break and is a strong inorganic material. A board is obtained. Further, it can be manufactured with good productivity with fewer steps than when a sheet-like material is pasted later. Furthermore, in the manufacturing process, the mat-like material, which is a mixture, can be transported more easily because the sheet-like material is laid underneath.
  • the inorganic plate is formed by combining two layers of the back surface layer and the surface layer, and the back surface layer has a length of 3 to; ⁇ ; 10% by weight, lightweight aggregate 10-70% by weight, inorganic powder 10-70% by weight, binder 5 ⁇ ; 15% by weight, and the surface layer has a length of lmm or less 10 to 70% by weight of fine inorganic fibers, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ⁇ 111 or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder
  • the sheet-like material integrated with the back surface layer provides an inorganic plate that is hard to crack.
  • a length of 3 to 15 mm inorganic fiber To 10 wt%, lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% Agent 5 ⁇ ; Add water to 15% by weight and form a mixture adjusted to a moisture content 5 ⁇ ; 15% to form a back surface layer mat.
  • a fine lmm or less in length Add water to 10 to 70% by weight of inorganic fiber, 10 to 50% by weight of light aggregate with particle size of 500 m or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder.
  • Surface smoothness is achieved by forming a surface layer mat by forming a mixture adjusted to a moisture content of 5 to 15%, and forming the back layer and the surface layer in one piece by hot pressing. High-strength inorganic plates with excellent nonflammability, handleability, workability and workability can be obtained with high productivity.
  • the mixture for the back surface layer mat is formed on a sheet to form a back surface layer mat, and the mixture for the surface layer mat is formed on the back surface layer mat.
  • the surface layer mat is hard to crack and has a high strength.
  • a certain inorganic board is obtained.
  • the number of processes is less than when sheet-like materials are attached later, and the inorganic board can be manufactured with high productivity, and the carrying power of the mat becomes easy in the manufacturing process.
  • the inorganic plate is formed by integrating three layers of a back layer, a surface layer, and a core layer located between them, and the core layer has an inorganic fiber length of 3 to 15 mm.
  • 10% by weight, lightweight aggregate 10 ⁇ 70% by weight, inorganic powder 10 ⁇ 70% by weight, binder 5 ⁇ ; 15% by weight, surface and back layers are length 10 to 70% by weight of fine inorganic fibers of lmm or less, 10 to 50% by weight of light aggregate having a particle size of 500 ⁇ 111 or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder Therefore, a high-strength inorganic board excellent in surface smoothness, non-flammability, handleability, workability and workability can be obtained.
  • an inorganic plate having strength that is difficult to break can be obtained by the sheet-like material integrated with at least one of the front and back surfaces.
  • 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light aggregate having a particle size of 500 ⁇ 111 or less, and an inorganic powder 10 to 70% The mixture was adjusted to a water content of 5% to 15% by adding water to 3% by weight; a binder of 3 to; 10% by weight to form a back layer mat.
  • a mixture for a back layer mat similar to that of the above seventh invention is formed on a sheet to form a back layer mat, and the seventh invention is formed on the back layer mat.
  • a core layer mat is formed by forming a core layer mat similar to the above, and a surface mat is formed on the core layer mat by forming the same surface mat mixture as the back layer mat.
  • an inorganic plate that is hard to break and strong is obtained by integrally molding these three-layer mat and sheet-like material with a hot press.
  • the number of steps is smaller than when a sheet-like material is attached later, and the inorganic board can be manufactured with high productivity, and the mat can be transported more easily in the manufacturing process.
  • FIG. 1 is a cross-sectional view of an inorganic plate according to Embodiment 1 of the present invention.
  • FIG. 2 is a cross-sectional view of an inorganic plate according to Embodiment 2.
  • FIG. 3 is a cross-sectional view of an inorganic plate according to Embodiment 3.
  • FIG. 4 is a cross-sectional view of an inorganic plate according to Embodiment 4.
  • FIG. 5 is a diagram showing various characteristics of Examples;! To 6 and Comparative Example;! To 4;
  • FIG. 6 is a graph showing various characteristics of Examples 7 and 8 and Comparative Examples 5 to 8.
  • a inorganic board [0041] A inorganic board
  • FIG. 1 shows an inorganic plate A according to Embodiment 1 of the present invention.
  • This inorganic plate A is formed by integrating a surface layer 1 located on the front surface side (upper side in FIG. 1) and a back surface layer 2 located on the rear surface side (lower side in FIG. 1). .
  • the surface layer 1 is composed of 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 m or less, and 10 to 70% by weight of an inorganic powder. 3 to 10% by weight of the agent.
  • the fine inorganic fibers are added to form a mat and have high stickiness and strength while obtaining high surface properties.
  • pulverized rock wool, slag wool, glass fibers, etc. Can be mentioned.
  • the fine inorganic fibers are added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the entire solid component. If the added amount of the inorganic fiber is less than 10% by weight, it becomes difficult to form a mat and the stickiness is lost. On the other hand, if the added amount exceeds 70% by weight, other lightweight aggregates and inorganic powders are relatively reduced. This is because the desired strength cannot be obtained.
  • it is desirable that the length of the fiber is as fine as 1 mm or less.
  • the “fine inorganic fibers” added to the surface layer 1 are those having a small size while retaining the properties and functions of the fibers.
  • the lightweight aggregate is added to increase the bulk while securing the compressive strength, and examples thereof include perlite, shirasu foam, silica flour, and glass foam.
  • the size of the lightweight aggregate used is 500 Hm or less, preferably 10 to 500 m (10 m or more and 500 m or less). This lightweight aggregate is less than 10 m in size! On the other hand, when the size of the lightweight aggregate is larger than 500 m, the workability of the inorganic board A is deteriorated as well as the surface property is deteriorated.
  • This lightweight aggregate is added in an amount of 10 to 50% by weight (more than 10% by weight and less than 50% by weight) of the total solid components. If the amount of light aggregate added is less than 10% by weight, the bulk will be low and it will be difficult to spread uniformly during spraying, while if it exceeds 50% by weight, the pressure during pressing will be too high and production will occur. This is because the property decreases.
  • the inorganic powder is added in order to ensure fire resistance and hardness, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash, mic port silica, and slag.
  • This inorganic powder is added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the entire solid component. If the added amount of the inorganic powder is less than 10% by weight, the desired surface hardness cannot be obtained. On the other hand, if the added amount exceeds 70% by weight, the addition rate of other materials becomes relatively small, and the desired amount of the desired surface hardness is reduced. It is difficult to obtain the strength of
  • the binder is added to bind the fine inorganic fibers, lightweight aggregates, and inorganic powders.
  • melamine resin, phenol resin, MDI, urethane resin, attal resin, epoxy resin examples include poval and starch, which can be used alone or in combination.
  • the amount of the binder that satisfies both the strength and nonflammability of the inorganic board A is 3 to 10% by weight (more than 3% by weight and less than 10% by weight) of the total solid components. That is, if the added amount of the binder is less than 3% by weight, the strength is insufficient, whereas if it exceeds 10% by weight, the nonflammability is impaired.
  • a sizing agent As an auxiliary additive, a sizing agent, a coupling agent and the like may be added as necessary.
  • the back layer 2 is composed of an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powdery material of 10 to 70% by weight, and a binder of 5 to; 15% by weight.
  • the inorganic fiber is added in order to form a mat and to have stickiness and strength, and examples thereof include glass fiber and wollastonite.
  • This inorganic fiber is added from! To 10 wt% (1 wt% or more and 10 wt% or less) of the total solid components. If the added amount of the inorganic fiber is less than 1% by weight, it becomes difficult to form a mat and the stickiness is lost. On the other hand, if it exceeds 10% by weight, separation occurs during mixing. For example, in the case of glass fibers, it is preferable to use bundles such as chopped strands for easy handling.
  • the thickness of the fiber is preferably 6 to 13 m (6 m or more and 13 m or less). If the thickness is less than 6 mm, the fiber becomes too thin and the viscosity becomes low, and the strength is lowered. On the other hand, if it exceeds 13 ⁇ 111, the surface property is deteriorated.
  • the length of the fiber is preferably 3 to 15 mm (3 mm or more and 15 mm or less). If the length is shorter than 3 mm, the fiber will become less sticky, and if it exceeds 15 mm, it will be detrimental (fiber lump) and adversely affect the surface properties. Further, when the fiber length is 3 to 15 mm, the balance during mixing with the lightweight aggregate, the inorganic powder, and the binder does not become dull and can be uniformly dispersed and mixed. For this reason, the back layer 2 having higher strength and hardness can be obtained.
  • the lightweight aggregate is added to increase the bulk while securing the compressive strength, and examples thereof include perlite, shirasu foam, silica flour, and glass foam.
  • the size of this light aggregate is preferably 2000,1 m or less! /. This is because when the size force is larger than 000 ⁇ m, the processability of the inorganic plate A is lowered.
  • the lightweight aggregate is added in an amount of 10 to 70% by weight (not less than 10% by weight and not more than 70% by weight) of the total solid components. If this amount is less than 10% by weight, the bulk will be low and even when spraying. On the other hand, when it exceeds 70% by weight, the pressure at the time of compression becomes too high and productivity is lowered.
  • the inorganic powder is added in order to ensure fire resistance and hardness, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash, mic port silica, and slag.
  • This inorganic powder is added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the total solid components. If the amount added is less than 10% by weight, the desired surface hardness cannot be obtained, and if it exceeds 70% by weight, the addition rate of other materials becomes relatively small, making it difficult to obtain the desired strength. It is.
  • the binder is added to bind the above-mentioned lightweight aggregate, inorganic fiber, and inorganic powder.
  • melamine resin, phenol resin, MDI, urethane resin, acrylic resin, epoxy resin, poval, starch, etc. can be used alone or in combination.
  • As an addition amount satisfying both the strength and nonflammability of the inorganic board A 5 to 15% by weight (5% by weight or more and 15% by weight or less) of the whole solid component is added. This is because if the amount added is less than 5% by weight, the strength is insufficient, while if it exceeds 15% by weight, the nonflammability is impaired.
  • auxiliary additive functional materials such as silica gel or diatomaceous earth can be mixed to impart moisture absorption and desorption, or a deodorant or VOC adsorbent can be added.
  • This method includes a back surface layer mat forming step, a surface layer mat forming step, and a molding step.
  • the material for the back surface layer 2 that is, inorganic fiber having a length of 3 to 15 mm;!
  • To 10% by weight, lightweight aggregate 10 to 70% by weight, and inorganic powder 10 ⁇ 70 wt%, binder 5 ⁇ ; 15 wt% and auxiliary additives are put into a mixer and mixed while spraying water to obtain a mixture adjusted to water content 5 ⁇ ; 15% . Formin this mixture To form a back layer mat.
  • the water added when mixing these materials is preferably 5 to 15 wt% (5 wt% or more and 15 wt% or less) of the solid component.
  • the reason for this is that if it is less than 5% by weight, the powder is scattered during mixing and molding, resulting in poor workability. It is because it becomes easy to do.
  • the material for the surface layer 1 that is, 10 to 70% by weight of fine inorganic fibers having a length of lm m or less and a lightweight aggregate having a particle size of 500 m or less and 10 to 50% by weight.
  • 10 to 70% by weight of an inorganic powder 3 to 10% by weight of a binder, and mixed with spraying water to adjust the water content to 5 to 15%.
  • the mixture is formed on the back surface layer mat formed in the back surface layer mat forming step to form a surface layer mat.
  • the added water is preferably 5 to 15% by weight of the solid component.
  • the reason for this is the same as in the backside layer mat forming step.
  • the amount is less than 5% by weight, the powder scatters much during mixing and molding, and the workability deteriorates. 'This is because it takes time to press and it becomes easy to puncture.
  • the two mats for the back layer 2 and the front layer 1 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C.) to be integrally molded.
  • This hot press machine can be either a continuous press machine or a multi-stage press machine!
  • an inorganic plate A having a density of 0.3 to 1.5 g / cm 3 is formed. If this density is lower than 0.3 g / cm 3 , the desired strength cannot be obtained. On the other hand, if it exceeds 1.5 g / cm 3 , the workability and workability are deteriorated. Equipment is required and productivity is poor
  • the surface layer 1 of the inorganic plate A fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer 1 of the inorganic plate A. Therefore, the dense surface layer 1 Is obtained.
  • the back layer 2 has a length of 3 to; 15 mm of inorganic fiber 1 to 10% by weight Since it is a layer having 10 to 70% by weight of lightweight aggregate, 10 to 70% by weight of an inorganic powder, and 5 to 15% by weight of a binder, the surface layer 1 can be supported.
  • the back layer 2 uses inorganic fibers with a length of 3 to 15 mm, it has a good mixing balance with other lightweight aggregates, inorganic powders, and binders, making it difficult to become lumps (fiber clumps). Can be uniformly dispersed and mixed. For this reason, the back layer 2 having higher strength and hardness can be obtained, and the force S for firmly supporting the front surface layer 1 can be obtained. As a result, it is possible to obtain a high-strength inorganic board A that is excellent in nonflammability, handling, workability, and workability as a whole.
  • the back layer and the surface layer mat are adjusted to a moisture content of 5 to 15%! /. Therefore, the binder is reacted by performing heat compression for a short time and at a high temperature. You can force S.
  • the flowability of the binder can be increased so that it can spread throughout, and the moisture can be evaporated in a short time, thus maximizing the performance of the binder.
  • the amount of the binder that can be pulled out to a relatively low level can be made relatively small, and a strong inorganic board A excellent in incombustibility can be obtained in a short time.
  • FIG. 2 shows an inorganic plate A according to Embodiment 2 of the present invention (in the following embodiments, the same parts as those in FIG. 1 are denoted by the same reference numerals and detailed description thereof is omitted).
  • the sheet-like material 4 is integrated on the back surface of the inorganic plate A. Others are the same as in the first embodiment.
  • the sheet-like material 4 is not particularly limited, and may be a non-woven fabric, a veneer, an impregnated paper, a resin sheet, a fiber sheet or the like, and may be a cosmetic one.
  • a method for manufacturing the inorganic plate A of Embodiment 2 will be described.
  • a sheet-like material 4 is prepared. And like the back surface layer mat formation process of Embodiment 1, length 3 ⁇ ; 15mm inorganic fiber;! ⁇ 10wt%, lightweight aggregate 10 ⁇ 70wt%, inorganic powder 10 ⁇ 70 and weight% binder 5; was charged with 15 wt% to the mixer, and mixed with spraying water to obtain a mixture which is adjusted to hydrous rate of 5 to 15 percent, the sheet material and the mixture 4 Form on top to form the back layer mat.
  • the two-layer mat of the back layer and the front layer and the sheet-like material 4 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C) to be integrally formed.
  • an adhesive is applied to the sheet-like material 4 in advance in order to improve the adhesion of the sheet-like material 4.
  • the adhesive include phenol resin, melamine resin, urethane resin, acrylic resin, MDI, and butyl acetate resin, but it is desirable to select one having high water resistance when used for exterior use.
  • the coating amount is preferably 50 g / m 2 or less for solid formation! /. This is because if the solid component exceeds 50 g / m 2 , the nonflammability decreases.
  • the sheet-like material 4 is also integrally molded by hot-pressing, it can be produced with high productivity with fewer steps than when the sheet-like material 4 is attached later. Further, in the manufacturing process, the mat 4 as a mixture can be more easily transported because the sheet-like material 4 is laid underneath.
  • FIG. 3 shows an inorganic plate A according to Embodiment 3 of the present invention.
  • the inorganic plate A has a surface layer 11 located on the front surface side (upper side in FIG. 3) and a back surface located on the back side (lower side in FIG. 3).
  • the layer 12 and the core layer 3 positioned between the surface layer 11 and the back layer 12 are integrally formed.
  • the inorganic plate A includes the core layer 3, the surface layer 11 integrated on the surface of the core layer 3, and the back layer 12 integrated on the back surface of the core layer 3.
  • each of the surface layer 11 and the back layer 12 is composed of 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 111 or less, 10 to 70% by weight of body and 3 to 10% by weight of binder.
  • the fine inorganic fibers are the same as the “fine inorganic fibers” in the surface layer 1 of the first embodiment.
  • the lightweight aggregate is the same as the “lightweight aggregate” in the surface layer 1 of the first embodiment (see the description of “lightweight aggregate” in the surface layer 1 of the first embodiment).
  • the inorganic powder is the same as the “inorganic powder” in the surface layer 1 of the first embodiment (see the description of “inorganic powder” in the surface layer 1 of the first embodiment).
  • the binder is the same as the “binder” in the surface layer 1 of the first embodiment (see the description of the “binder” in the surface layer 1 of the first embodiment).
  • a sizing agent As an auxiliary additive, a sizing agent, a coupling agent and the like may be added as necessary.
  • the core layer 3 is the same as the back layer 2 in Embodiment 1, and has a length of 3 to; 15 mm of inorganic fiber;! To 10% by weight, lightweight aggregate of 10 to 70% by weight, and an inorganic powder. 10 to 70% by weight and 5 to 15% by weight of binder.
  • the inorganic fiber is the same as the “inorganic fiber” in the back layer 2 of Embodiment 1 (see the description of “Inorganic fiber” in the back layer 2 of Embodiment 1).
  • the lightweight aggregate is the same as the “lightweight aggregate” in the back surface layer 2 of Embodiment 1 (see the description of “Lightweight aggregate” in the back surface layer 2 of Embodiment 1). [0090] (3) Inorganic powder
  • the inorganic powder is the same as the “inorganic powder” in the back layer 2 of Embodiment 1 (see the description of “Inorganic powder” in the back layer 2 of Embodiment 1).
  • the binder is the same as the “binder” in the back layer 2 of Embodiment 1 (see the description of the “binder” in the back layer 2 of Embodiment 1).
  • auxiliary additive functional materials such as silica gel or diatomaceous earth can be mixed to impart moisture absorption and desorption, or a deodorant or VOC adsorbent can be added.
  • This method comprises a back layer mat forming step, a core layer mat forming step, a surface layer mat forming step, and a forming step.
  • the composition material for the back layer 12 that is, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less and a lightweight aggregate having a particle size of 500 Hm or less 10 to 50 10% by weight, 10 to 70% by weight of an inorganic powder, 3 to 10% by weight of binder, 10% by weight and auxiliary additives are added to the mixer and mixed while spraying water to obtain a water content of 5 to 5%; A mixture adjusted to 15% is obtained. This mixture is formed to form a backing mat.
  • the water added when mixing these materials is preferably 5 to 15% by weight of the solid component (more than 5% by weight and not more than 15% by weight) (moisture content 5 to 15%). ).
  • moisture content 5 to 15%.
  • the material for the core layer 3 that is, the inorganic fiber having a length of 3 to 15 mm;!
  • To 10% by weight, lightweight aggregate 10 to 70% by weight, and inorganic powder 10 to 70% by weight, binder 5 to 5%; 15% by weight and auxiliary additives are put into a mixer and sprayed with water.
  • This mixture is formed on the back layer mat formed in the back layer mat forming step to form a second core layer mat.
  • the added water is preferably 5 to 15% by weight of the solid component (water content 5 to 15%).
  • the reason for this is the same as in the above-mentioned back layer mat forming process. If the amount is less than 5% by weight, the scattering of the powder during mixing or molding deteriorates the workability, while if it exceeds 15% by weight. This is because it takes time to heat and press, and it becomes easy to puncture.
  • the same material as that for the surface layer 11, that is, the material for the back layer 12 is 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less and a particle size of 500 m or less.
  • Light weight aggregate 10-50% by weight, inorganic powder 10-70% by weight, binder 3-10% by weight, auxiliary additives are added to the mixer and mixed while spraying water, moisture content A mixture adjusted to 5-15% is obtained. This mixture is formed on the core layer mat formed in the core layer mat forming step to form a third surface mat.
  • the added water is preferably 5 to 15% by weight of the solid component (moisture content 5 to 15%).
  • moisture content 5 to 15%.
  • the amount is less than 5% by weight, powder scattering is large at the time of mixing or molding, while workability is deteriorated. 'It takes time to press and it becomes easy to puncture.
  • the three layers of mats laminated for the back layer 12, the core layer 3, and the surface layer 11 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C.) to be integrally molded.
  • This hot press machine can be a continuous press machine or a multi-stage press machine!
  • an inorganic sheet A having a density of 0.3 to 1.5 g / cm 3 is formed. If this density is lower than 0.3 g / cm 3 , the desired strength cannot be obtained. On the other hand, if it exceeds 1.5 g / cm 3 , the workability and workability are deteriorated. Equipment is required and productivity is poor
  • the core layer 3 comprises an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powder 10 to 70% by weight, and a binder 5 Since the layer has 15 wt%, the force S can be supported to support the surface layer 11 and the back layer 12.
  • the core layer 3 uses a length of 3 to 15 mm of inorganic fibers, so it has a good mixing balance with other lightweight aggregates, inorganic powders and binders (fiber lump). Can be uniformly dispersed and mixed. Therefore, the core layer 3 having higher strength and hardness can be obtained, and the surface layer 11 and the back layer 12 can be supported and supported. As a result, it is possible to obtain a high-strength inorganic board A that is excellent in incombustibility, handling, workability, and workability as a whole.
  • the mats of the back layer, the core layer, and the surface layer are adjusted to a moisture content of 5 to 15%. Power to react S.
  • the fluidity of the binder can be increased and distributed throughout, and the water can be evaporated in a short time, so that the performance of the binder can be maximized.
  • the amount of the binder can be made relatively small, and a strong inorganic board A having excellent nonflammability can be obtained in a short time.
  • FIG. 4 shows an inorganic board A according to Embodiment 4 of the present invention.
  • the sheet-like material 4 is integrated on the back surface of the inorganic plate A. Others are the same as in the third embodiment.
  • the sheet-like material 4 is not particularly limited, and may be a non-woven fabric, a veneer, an impregnated paper, a resin sheet, a fiber sheet, or the like, and may be a cosmetic one.
  • a sheet 4 is prepared. And, similarly to the back layer mat forming step of Embodiment 3, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 111 or less, 10 to 70% by weight of powdery substance and 3 to 10% by weight of binder are put into a mixer and water is injected. Mix with mist to obtain a mixture adjusted to a moisture content of 5 to 15%, and form the mixture on the sheet 4 to form a back layer mat.
  • inorganic fiber 1 to 10% in length 3 to 15 mm, light aggregate 10 to 70% by weight, inorganic powder 10 ⁇ 70 wt% and binder 5 ⁇ ; 15 wt% are put into a mixer and mixed while spraying water to obtain a mixture adjusted to a water content of 5 ⁇ ; 15%. Form on the mat to form the second core mat.
  • the three-layer mat of the back layer, the core layer and the surface layer and the sheet-like material 4 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C) to be integrally formed.
  • an adhesive may be applied to the sheet-like material 4 in advance in order to improve the adhesion of the sheet-like material 4.
  • the adhesive include phenol resin, melamine resin, urethane resin, acrylic resin, MDI, and butyl acetate resin.
  • the coating amount is preferably 50 g / m 2 or less as a solid component! /. This is because non-flammability decreases when the solid component exceeds 50 g / m 2 .
  • the sheet-like material 4 is also integrally formed by hot-pressing, it can be manufactured with less productivity than the case where the sheet-like material 4 is attached later. Further, in the manufacturing process, the mat 4 as a mixture can be more easily transported because the sheet-like material 4 is laid underneath. [0114] [Other Embodiments]
  • the sheet-like material 4 is molded and integrated together with the mats of the back surface layer and the surface layer.
  • the sheet-like material 4 is formed and integrated together with the mats of the back layer, the core layer, and the surface layer.
  • the back layer, the core layer, and the surface layer are integrated. After forming each mat, a sheet-like material may be bonded and integrated on the back surface thereof.
  • the sheet-like material 4 is molded and integrated only using the lower side of the back layer mat.
  • the sheet-like material is placed on the upper side of the surface layer mat, and this sheet-like material 3 Simultaneously with the formation of the mat of the layer and the lower sheet-like material 4, it can be formed by hot-pressing integrally. It is also possible to apply an adhesive to the sheet-like material used on the upper side. In this way, when the sheet-like materials are integrated up and down, an inorganic plate A having higher strength and balance can be obtained.
  • the sheet-like material can be molded and integrated only by using it on the upper side of the three-layer mat.
  • the sheet-like material is attached to at least one of the front and back surfaces of the inorganic plate (at least one surface).
  • a glass nonwoven fabric (sheet-like material) with a basis weight of 50 g / m 2 coated with acrylic resin 30 g / m 2 (solid component) is pasted, and an inorganic plate with a thickness of 3 mm and a density of 1.2 g / cm 3 is attached. Obtained.
  • the first mixture obtained by mixing in the same manner as described above was formed on the core layer mat to form a surface layer mat.
  • the three-layer mat performs hot press of 210 ° C5 minutes to obtain 9mm thickness, the inorganic board of density 0. 8 g / cm 3.
  • the first mixture obtained by mixing in the same manner as described above was formed on the core layer mat to form a surface layer mat.
  • the three-layer mat performs hot press of 210 ° C5 minutes to obtain 9mm thickness, the inorganic board of density 0. 8 g / cm 3.
  • the moisture absorption / release performance was measured in accordance with JIS A 1470-1, and it was 18 g / m 2 in Example 7, but 72 g / m 2 was measured in Example 8. I was able to.
  • the three-layer mat was hot-pressed at 210 ° C for 3 minutes to obtain an inorganic plate having a thickness of 9 mm and a density of 0.8 g / cm 3 .
  • this comparative example 5 had a low surface hardness and a poor smoothness.
  • the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface mat.
  • the three-layer mat was hot-pressed at 210 ° C for 3 minutes to obtain an inorganic plate having a thickness of 9 mm and a density of 0.8 g / cm 3 .
  • fiber lumps fiber clumps
  • the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface layer mat.
  • the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface layer mat.
  • the present invention provides a high-strength inorganic plate excellent in surface smoothness, nonflammability, handleability, workability, and workability, and thus is extremely useful and highly industrially applicable.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne la production efficace d'une plaque inorganique ayant une surface très lisse et une bonne couche décorative. L'invention concerne une plaque inorganique A produite en formant de manière intégrée une couche superficielle avant (1), laquelle contient de 10 à 70 % en masse d'une fibre inorganique fine d'une longueur ne dépassant pas 1 mm, de 10 à 50 % en masse d'un agrégat léger ayant une taille des particules non supérieure à 500 μm, de 10 à 70 % en masse d'une poudre inorganique et de 3 à 10 % en masse d'un liant, sur une couche superficielle arrière (2), laquelle contient de 1 à 10 % en masse d'une fibre inorganique d'une longueur de 3 à 15 mm, de 10 à 70 % en masse d'un agrégat léger, de 10 à 70 % en masse d'une poudre inorganique et de 5 à 15 % en masse d'un liant.
PCT/JP2007/064904 2006-07-31 2007-07-30 Plaque inorganique et son procédé de production WO2008016011A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2006-208538 2006-07-31
JP2006208538A JP5137353B2 (ja) 2006-07-31 2006-07-31 無機質板及びその製造方法
JP2006250837A JP5137364B2 (ja) 2006-09-15 2006-09-15 無機質板及びその製造方法
JP2006-250837 2006-09-15

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WO2008016011A1 true WO2008016011A1 (fr) 2008-02-07

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6143548A (ja) * 1984-08-08 1986-03-03 大建工業株式会社 鉱物質繊維板の製造方法
JPS6155297A (ja) * 1984-08-21 1986-03-19 大建工業株式会社 鉱物質繊維板
JPH0550417A (ja) * 1991-08-20 1993-03-02 Daiken Trade & Ind Co Ltd 無機建築板の製造方法
JPH0592407A (ja) * 1992-01-20 1993-04-16 Kikusui Kagaku Kogyo Kk 積層体の製造方法
JPH0890532A (ja) * 1994-09-22 1996-04-09 Junichi Haneda 建築材料の製造装置

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6143548A (ja) * 1984-08-08 1986-03-03 大建工業株式会社 鉱物質繊維板の製造方法
JPS6155297A (ja) * 1984-08-21 1986-03-19 大建工業株式会社 鉱物質繊維板
JPH0550417A (ja) * 1991-08-20 1993-03-02 Daiken Trade & Ind Co Ltd 無機建築板の製造方法
JPH0592407A (ja) * 1992-01-20 1993-04-16 Kikusui Kagaku Kogyo Kk 積層体の製造方法
JPH0890532A (ja) * 1994-09-22 1996-04-09 Junichi Haneda 建築材料の製造装置

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