JP4886196B2 - Manufacturing method of lightweight inorganic board - Google Patents
Manufacturing method of lightweight inorganic board Download PDFInfo
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- JP4886196B2 JP4886196B2 JP2005034236A JP2005034236A JP4886196B2 JP 4886196 B2 JP4886196 B2 JP 4886196B2 JP 2005034236 A JP2005034236 A JP 2005034236A JP 2005034236 A JP2005034236 A JP 2005034236A JP 4886196 B2 JP4886196 B2 JP 4886196B2
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- 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
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- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
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Description
本発明はケイ酸カルシウム水和物と木質補強材とを主成分とする軽量無機質板およびその製造方法に関するものである。 The present invention relates to a lightweight inorganic board mainly composed of calcium silicate hydrate and a wood reinforcing material, and a method for producing the same.
従来からケイ酸質原料と石灰質原料とを含むスラリーを高温高圧下で反応せしめてケイ酸カルシウム水和物を生成し、該ケイ酸カルシウム水和物を含むスラリーを抄造脱水成形し、得られた板状成形体を養生硬化せしめることによって製造される軽量無機質板が提供されている。
上記軽量無機質板は軽量ではあるが硬く脆い性質を有し、曲げ強度および剛性が不足している。
そこで該軽量無機質板の強度および剛性を向上せしめるために原料混合物にフェノール樹脂前躯体（プレポリマー）を添加し、養生硬化中に該フェノール樹脂前躯体を硬化（樹脂化）する方法が提案されている（例えば特許文献１，２，３参照）。
Conventionally, a slurry containing a siliceous raw material and a calcareous raw material was reacted at high temperature and high pressure to produce calcium silicate hydrate, and the slurry containing the calcium silicate hydrate was obtained by papermaking and dehydration molding. There has been provided a lightweight inorganic board produced by curing and curing a plate-like molded body.
The light inorganic board is light but hard and brittle, and lacks bending strength and rigidity.
Therefore, a method has been proposed in which a phenol resin precursor (prepolymer) is added to the raw material mixture to improve the strength and rigidity of the lightweight inorganic board, and the phenol resin precursor is cured (resinized) during curing. (For example, see Patent Documents 1, 2, and 3).
上記軽量無機質板の原料混合物にフェノール樹脂前躯体を添加し、硬化することによって強度を向上せしめる方法は、顕著な強度向上効果を得るために、フェノール樹脂前躯体の添加量を多くする必要があった。
しかしフェノール樹脂前躯体の添加量を多くすると、原料費が高くなり、軽量無機質板が安価に提供出来なくなる。
The method of improving the strength by adding a phenol resin precursor to the raw material mixture of the lightweight inorganic board and curing it requires increasing the amount of the phenol resin precursor added in order to obtain a remarkable strength improvement effect. It was.
However, if the amount of phenol resin precursor added is increased, the raw material cost increases, and a lightweight inorganic board cannot be provided at a low cost.
本発明は上記従来の課題を解決するための手段として、ケイ酸カルシウム水和物と木質補強材とを主成分とする板状硬化成形体の表面および／または裏面に熱硬化性樹脂層を形成した軽量無機質板を提供するものであり、該木質補強材は、径５μｍ以上および／または長さ１．５ｍｍ以上の太径長繊維木質補強材と、径０．１μｍ以下および／または長さ１．５ｍｍ未満の微細径短繊維木質補強材との混合物であることが望ましく、該主成分には更に水硬性無機物質が添加されていることが望ましい。
更に本発明はケイ酸質原料と、石灰質原料とを主成分とする原料混合物を水に分散せしめてスラリーを調製し、該スラリーを高温高圧下で上記ケイ酸質原料と石灰質原料とを反応せしめてケイ酸カルシウム水和物を生成し、該ケイ酸カルシウム水和物を含むスラリーを抄造脱水成形し、得られた板状成形体の表面および／または裏面に熱硬化性樹脂プレポリマー粉末を散布するかあるいは熱硬化性樹脂プレポリマー溶液を塗布し、該板状成形体を熱圧することによって該板状成形体と熱硬化性樹脂プレポリマーとを硬化せしめる軽量無機質板の製造方法を提供するものである。
As a means for solving the above-mentioned conventional problems, the present invention forms a thermosetting resin layer on the surface and / or the back surface of a plate-like cured molded body mainly composed of calcium silicate hydrate and a wood reinforcing material. A light-weight inorganic board comprising a large-diameter long fiber wood reinforcing material having a diameter of 5 μm or more and / or a length of 1.5 mm or more, a diameter of 0.1 μm or less and / or a length of 1 Desirably, it is a mixture with a fine-diameter short fiber wood reinforcing material of less than 5 mm, and it is desirable that a hydraulic inorganic substance is further added to the main component.
Furthermore, the present invention prepares a slurry by dispersing a raw material mixture mainly composed of a siliceous raw material and a calcareous raw material in water, and reacts the slurry with the siliceous raw material and the calcareous raw material under high temperature and high pressure. Calcium silicate hydrate is formed, the slurry containing the calcium silicate hydrate is made by papermaking and dewatering molding, and the thermosetting resin prepolymer powder is sprayed on the surface and / or the back surface of the obtained plate-like molded body. Or a method for producing a lightweight inorganic plate in which the plate-like molded body and the thermosetting resin prepolymer are cured by applying a thermosetting resin prepolymer solution and hot-pressing the plate-like molded body It is.
〔作用〕
本発明にあっては、熱硬化性樹脂を軽量無機質板の内部に添加するのではなく、板の表面および／または裏面に熱硬化性樹脂層を形成するので、熱硬化性樹脂による強度の向上効果が顕著に発現する。したがって熱硬化性樹脂の使用量を内部添加方式よりも大巾に減らすことが出来かつ、内部添加と同等の機械的挙動を得ることが可能となる。
[Action]
In the present invention, the thermosetting resin is not added to the inside of the lightweight inorganic board, but a thermosetting resin layer is formed on the front and / or back of the board, so that the strength is improved by the thermosetting resin. The effect is noticeable. Therefore, the amount of the thermosetting resin used can be greatly reduced as compared with the internal addition method, and the mechanical behavior equivalent to the internal addition can be obtained.
〔効果〕
本発明は軽量無機質板の表面および／または裏面に熱硬化性樹脂層を形成することによって板の強度向上を図るので、該熱硬化性樹脂の必要量を最小限にとどめることが可能であり、したがって材料コストを低減することが出来る。
〔effect〕
Since the present invention aims to improve the strength of the plate by forming a thermosetting resin layer on the front and / or back of the lightweight inorganic plate, it is possible to minimize the necessary amount of the thermosetting resin, Therefore, the material cost can be reduced.
以下に本発明を詳細に説明する。
〔ケイ酸質原料〕
本発明で用いられるケイ酸質原料としては、例えばケイ酸、無定形ケイ酸、ケイ砂、ケイ石粉、ケイ藻土、石英、長石類、粘土鉱物、白土、フライアッシュ、パーライト等のＳｉＯ2 を主成分とする原料である。
The present invention is described in detail below.
[Silicaceous material]
Examples of the siliceous material used in the present invention include SiO 2 such as silicic acid, amorphous silicic acid, silica sand, quartzite powder, diatomaceous earth, quartz, feldspar, clay mineral, white clay, fly ash, perlite and the like. It is a raw material with the main component.
〔石灰質原料〕
本発明で用いられる石灰質原料とは消石灰、生石灰、カーバイト滓等のＣａＯを主成分とする原料である。
[Calcium raw material]
The calcareous raw material used in the present invention is a raw material mainly composed of CaO, such as slaked lime, quick lime, and carbide cocoon.
〔木質補強材〕
本発明に使用される木質補強材としては、例えば木質パルプ、木質繊維束、故紙解繊または粉砕物、マイクロフィブリル化したセルロース（ＭＦＣ）等が例示される。
望ましい木質補強材としては、ダブルディスクリファイナー（ＤＤＲ）で処理した木質パルプ（平均繊維長１．５〜３ｍｍ、径５〜２５μｍ）、故紙解繊物（平均繊維長０．５〜１．５ｍｍ未満、径５〜２５μｍ）、ＭＦＣ（平均繊維長０．１〜１ｍｍ、径０．０１〜０．１μｍ）がある。上記木質補強材のソースとしては、針葉樹未晒し（ＮＵ）、針葉樹晒し（ＮＢ）、広葉樹未晒し（ＬＵ）、広葉樹晒し（ＬＢ）等が適宜選択される。
上記木質補強材は径や長さの異なるものを二種以上混合使用することが望ましい。望ましくは径５μｍ以上および／または長さ１．５ｍｍ以上の太径長繊維木質補強材と、径０．１μｍ以下および／または長さ１．５ｍｍ未満の微細径短繊維木質補強材との併用であり、具体的には、例えば径５〜２５μｍの木質パルプあるいは故紙解繊物と、径０．０１〜０．１μｍのＭＦＣとの組合わせがある。
上記組合わせにおいて、太径長の繊維は板の補強と共にスラリーの濾水性を向上させて良好な抄造性を付与し、微細径短の繊維は板の補強と共に板の構造を緻密にすることにより強度物性を向上せしめる。更に二種以上を組み合わせることで、濾水性を損なうことなく固形分捕捉を向上することが可能となり、マツト成形性、ブレス成形性を確保しつゝ安定した物性の板が得られる。
[Wood reinforcement]
Examples of the wood reinforcing material used in the present invention include wood pulp, wood fiber bundles, waste paper defibrated or pulverized material, and microfibrillated cellulose (MFC).
Desirable wood reinforcement materials include wood pulp treated with a double disc refiner (DDR) (average fiber length of 1.5 to 3 mm, diameter of 5 to 25 μm), waste paper defibrated material (average fiber length of less than 0.5 to 1.5 mm) , Diameter 5 to 25 μm), MFC (average fiber length 0.1 to 1 mm, diameter 0.01 to 0.1 μm). As a source of the above-mentioned wood reinforcing material, softwood unexposed (NU), coniferous exposed (NB), hardwood unexposed (LU), hardwood exposed (LB) and the like are appropriately selected.
It is desirable to use a mixture of two or more wood reinforcing materials having different diameters and lengths. Desirably, a combination of a large diameter long fiber wood reinforcing material having a diameter of 5 μm or more and / or a length of 1.5 mm or more and a fine diameter short fiber wood reinforcing material having a diameter of 0.1 μm or less and / or a length of less than 1.5 mm Specifically, for example, there is a combination of wood pulp or waste paper defibrated material having a diameter of 5 to 25 μm and MFC having a diameter of 0.01 to 0.1 μm.
In the above combination, the large diameter long fibers improve the drainage of the slurry together with the reinforcement of the plate to give a good papermaking property, and the fine short diameter fibers make the structure of the plate dense with the reinforcement of the plate. Improve strength properties. Further, by combining two or more kinds, it becomes possible to improve the solid content capture without impairing the drainage, and it is possible to obtain a plate having stable physical properties while ensuring mat formability and breath formability.
〔熱硬化性樹脂プレポリマー〕
本発明に使用される熱硬化性樹脂プレポリマーとしては、フェノール樹脂初期縮合物、メラミン樹脂初期縮合物、尿素樹脂初期縮合物、ウレタン樹脂プレポリマー、ポリイソシアナート、エポキシ樹脂プレポリマー等が例示される。円滑に硬化（樹脂化）する点からみて、フェノール樹脂初期縮合物および／またはエポキシ樹脂プレポリマーを使用することが望ましいが、コストの面、作業性の面からみるとフェノール樹脂初期縮合物の使用が望ましい。
上記熱硬化性樹脂プレポリマーは粉末、あるいは水溶液、あるいは有機溶剤溶液あるいは１００％液状物として提供される。
[Thermosetting resin prepolymer]
Examples of the thermosetting resin prepolymer used in the present invention include phenol resin initial condensate, melamine resin initial condensate, urea resin initial condensate, urethane resin prepolymer, polyisocyanate, and epoxy resin prepolymer. The From the viewpoint of smooth curing (resinization), it is desirable to use a phenol resin initial condensate and / or an epoxy resin prepolymer, but from the viewpoint of cost and workability, use of a phenol resin initial condensate Is desirable.
The thermosetting resin prepolymer is provided as a powder, an aqueous solution, an organic solvent solution, or a 100% liquid.
〔第三成分〕
上記原料以外に、本発明では例えば高炉スラグ、高炉セメント、フライアッシュ、シリカヒューム、ポルトランドセメント等の水硬性無機物質、パーライト、石膏粉末、炭酸カルシウム、炭酸マグネシウム、木質セメント板廃棄物粉末等の充填材、ポリエステル繊維、ポリアミド繊維、アクリル繊維、アセテート繊維、綿繊維等の有機繊維、ガラス繊維、セラミック繊維、岩綿、金属繊維等の無機繊維等の補強材が添加されてもよい。また耐水性または内部接合力の向上を目的としてアクリル樹脂エマルジョン等の合成樹脂エマルジョンを添加してもよい。
[Third component]
In addition to the above raw materials, in the present invention, for example, filling of hydraulic inorganic materials such as blast furnace slag, blast furnace cement, fly ash, silica fume, Portland cement, perlite, gypsum powder, calcium carbonate, magnesium carbonate, wood cement board waste powder, etc. Reinforcing materials such as materials, polyester fibers, polyamide fibers, acrylic fibers, acetate fibers, cotton fibers and other organic fibers, glass fibers, ceramic fibers, rock wool, metal fibers and the like may be added. A synthetic resin emulsion such as an acrylic resin emulsion may be added for the purpose of improving water resistance or internal bonding strength.
〔ケイ酸カルシウム水和物スラリーの調製〕
上記ケイ酸質原料と石灰質原料とを水に分散させてスラリーとし、該スラリーのｐＨを苛性ソーダ等のアルカリにより調整した後、高温高圧下で攪拌すると、ケイ酸カルシウム反応によって該スラリー中にトバモライト（５ＣａＯ・６ＳｉＯ2・５Ｈ2Ｏ）あるいはゾノトライト（６ＣａＯ・６ＳｉＯ2・Ｈ2Ｏ）あるいはトバモライトとゾノトライトとの混合物が生成する。
上記トバモライトはケイ酸質原料と石灰質原料との比率をＣａ／Ｓｉ＝０．６５〜１．２になるような範囲に設定し、反応温度を１５０〜２００℃の範囲に設定することによって生成し、上記ゾノトライトはケイ酸質原料と石灰質原料との比率をＣａ／Ｓｉ＝０．７５〜１．５になるような範囲に設定し、反応温度を１７０〜３００℃の範囲に設定することによって生成する。
上記水硬性無機物質を添加する場合、通常上記ケイ酸カルシウム反応によってケイ酸カルシウム水和物が生成された後に添加する。上記水硬性無機物質は該スラリー固形分に対して通常２０〜５０質量％程度添加される。
上記木質補強材、水硬性無機物質以外の第三成分も、通常上記ケイ酸カルシウム水和物の生成後に添加する。上記木質補強材は通常スラリー固形分中３〜２０質量％程度添加されるが、１０質量％以下の添加量で充分な補強効果が得られる。
[Preparation of calcium silicate hydrate slurry]
The siliceous raw material and calcareous raw material are dispersed in water to form a slurry, and the pH of the slurry is adjusted with an alkali such as caustic soda and stirred under high temperature and high pressure. Then, tobermorite ( 5CaO · 6SiO 2 · 5H 2 O) or zonotlite (6CaO · 6SiO 2 · H 2 O) or a mixture of tobermorite and zonotrite.
The tobermorite is produced by setting the ratio of siliceous raw material to calcareous raw material in a range such that Ca / Si = 0.65 to 1.2, and the reaction temperature in a range of 150 to 200 ° C. The zonotlite is produced by setting the ratio of the siliceous raw material to the calcareous raw material in a range such that Ca / Si = 0.75 to 1.5 and the reaction temperature in the range of 170 to 300 ° C. To do.
When the hydraulic inorganic substance is added, it is usually added after calcium silicate hydrate is produced by the calcium silicate reaction. The hydraulic inorganic substance is usually added in an amount of about 20 to 50% by mass with respect to the slurry solid content.
A third component other than the wood reinforcing material and hydraulic inorganic substance is also usually added after the calcium silicate hydrate is formed. The wood reinforcing material is usually added in an amount of about 3 to 20% by mass in the solid content of the slurry, but a sufficient reinforcing effect can be obtained with an addition amount of 10% by mass or less.
〔抄造〕
抄造はフローオン方式、ハチェック方式、脱水プレス方式等公知の装置を用いた方法で行なわれるが、抄造に際してはスラリー中の固形分濃度は通常１〜１５質量％程度に調節される。そして抄造されたマットは真空吸引あるいはプレスにより脱水され、所望なればメイキングロール等を用いて該マットを所定枚数積層してもよい。
[Paper making]
Paper making is performed by a method using a known apparatus such as a flow-on system, a check system, or a dewatering press system. During paper making, the solid content concentration in the slurry is usually adjusted to about 1 to 15% by mass. The paper mat is dehydrated by vacuum suction or pressing, and if desired, a predetermined number of mats may be laminated using a making roll or the like.
〔プレス成形〕
上記抄造されたマットは所望なればプレス成形によって所定の形状に成形される。この場合の成形圧力は通常０．５〜５．０ＭＰａである。
〔Press molding〕
The paper mat is formed into a predetermined shape by press molding if desired. The molding pressure in this case is usually 0.5 to 5.0 MPa.
〔養生硬化〕
上記抄造され望ましくは成形された成形物は養生される。養生条件は通常５０〜８０℃で６〜２４時間行なわれる。養生温度が低い場合は勿論養生時間は長くなる。上記養生工程において、水硬性無機物質を添加した場合は、該水硬性無機物質中に含まれる活性ＳｉＯ2 がスラリー中の石灰質原料から溶出したアルカリ、主としてＣａ++イオンと反応してケイ酸カルシウムあるいはアルミン酸カルシウムゲルを生成して硬化する。
養生後は通常８０〜１２０℃、２〜５時間程度加熱乾燥を行なって製品とする。
[Curing curing]
The above formed and preferably molded product is cured. Curing conditions are usually 50 to 80 ° C. for 6 to 24 hours. Of course, when the curing temperature is low, the curing time becomes longer. In the curing process, when a hydraulic inorganic substance is added, the active SiO 2 contained in the hydraulic inorganic substance reacts with alkali eluted from the calcareous raw material in the slurry, mainly Ca ++ ions, and calcium silicate. Alternatively, calcium aluminate gel is produced and cured.
After curing, the product is usually dried by heating at 80 to 120 ° C. for about 2 to 5 hours.
〔熱硬化性樹脂プレポリマーの散布または塗布〕
上記プレス成形後あるいは養生硬化後において、上記熱硬化性樹脂プレポリマーの粉末を成形体の表面および／または裏面に散布するか、あるいは上記熱硬化性樹脂プレポリマーの溶液を成形体の表面および／または裏面に塗布する。上記熱硬化性樹脂プレポリマーの散布または塗布量は、表裏面に散布または塗布する場合には、通常片面に固形分として０．０３〜０．０８ｇ／ｃｍ2、片面のみに塗布する場合には、通常固形分として０．０５〜０．１５ｇ／ｃｍ2程度に設定する。
熱硬化性樹脂プレポリマーは粉末として成形体表面および／または裏面に散布することが望ましい。溶液として成形体表面および／または裏面に塗布する場合には、成形体表面および／または裏面から内部に溶液が浸透して強化効果が低下するおそれがあるが、粉末散布の場合には該粉末が成形体表面および／または裏面に粉末が留まり易い。
熱硬化性樹脂プレポリマーを該成形体表面および／または裏面に散布または塗布後は、該成形体を通常圧力０．５〜５．０ＭＰａ、温度を該熱硬化性樹脂プレポリマーの硬化（樹脂化）温度に設定してプレスを行なう。フェノール樹脂初期縮合物の場合は、通常１６０〜２２０℃で１０分間の熱プレスが行なわれる。
プレス後は自然乾燥、所望なれば加熱乾燥して軽量無機質板製品を得る。
[Spreading or application of thermosetting resin prepolymer]
After the press molding or curing and curing, the thermosetting resin prepolymer powder is sprayed on the surface and / or the back surface of the molded body, or the solution of the thermosetting resin prepolymer is applied to the surface of the molded body and / or Or apply to the back. When the above-mentioned thermosetting resin prepolymer is sprayed or applied on the front and back surfaces, it is usually 0.03 to 0.08 g / cm 2 as a solid content on one side, and applied only on one side. Usually, the solid content is set to about 0.05 to 0.15 g / cm 2 .
It is desirable that the thermosetting resin prepolymer is dispersed as a powder on the surface and / or the back surface of the molded body. When applied as a solution to the surface and / or back of the molded body, the solution may permeate into the interior from the surface and / or back of the molded body, and the reinforcing effect may be reduced. The powder tends to stay on the surface and / or the back surface of the molded body.
After the thermosetting resin prepolymer is sprayed or applied to the surface and / or back of the molded body, the molded body is usually subjected to pressure of 0.5 to 5.0 MPa, and the temperature is set to cure (resinize) the thermosetting resin prepolymer. ) Set to temperature and press. In the case of the phenol resin initial condensate, the hot pressing is usually performed at 160 to 220 ° C. for 10 minutes.
After pressing, it is naturally dried and, if desired, dried by heating to obtain a lightweight inorganic board product.
〔実施例１〜６、比較例１〜５〕
実施例１〜５については、ケイ石粉と消石灰とを水に分散させて固形分濃度３０質量％のスラリーを調製する。該ケイ石粉と消石灰との混合比率はケイ石粉に含まれるＳｉＯ2と消石灰に含まれるＣａＯとのモル比が５：５になるようにする。
該スラリーのｐＨを苛性ソーダ等のアルカリにより調整した後アジテーターのついた水熱合成用のオートクレーブ中で２ＭＰａの圧力下、２００℃の温度に加熱し、攪拌しつゝ９時間反応させる。該反応によりケイ石粉のＳｉＯ2と消石灰のＣａＯとが反応してゾノトライトが生成され、またスラリー中にはケイ酸カルシウム反応中間生成物が存在する。
実施例６については、ＳｉＯ2とＣａＯとのモル比が７：３になるように調節し、オートクレーブ中で２５０℃の温度で９時間反応させる。
上記ゾノトライトまたはトバモライトスラリー中に表１に示す木質補強材、水硬性無機物質等を表１に示す量で配合し、固形分濃度１０質量％のスラリーを調製する。
上記混合スラリーはハチェック式抄造機によって抄造脱水されてマットとされ、該マットを１．５ＭＰａの圧力でプレスして所定形状に成形する。
実施例１，２，５，６については、プレス成形後に成形物表裏面にフェノール樹脂初期縮合物粉末を片面０．０５ｇ／ｃｍ2、両面０．１ｇ／ｃｍ2、の割合で散布し、圧力０．８ＭＰａ、温度２００℃で１０分間熱プレス成形し、その後自然乾燥、自然養生した。実施例３，４については上記抄造脱水成形された成形物は６０℃の温度で１２時間養生し、養生後、上記成形物は乾燥した上で、表裏面にフェノール樹脂初期縮合物粉末を片面０．０５ｇ／ｃｍ2、両面０．１ｇ／ｃｍ2、の割合で散布し、その後圧力０．６ＭＰａ、温度２００℃で１０分間熱プレス成形し、その後自然乾燥した。
比較例１，２については実施例１，２，５，６と同様に表１の配合のスラリーを抄造脱水成形し、熱プレス成形後自然乾燥、自然養生し、比較例３，４，５については、実施例３，４と同様に表１の配合のスラリーを抄造脱水成形し、該成形物を養生硬化した後自然乾燥した。
実施例１〜６、比較例１〜５の軽量無機質板の物性を表１に示す。
[Examples 1-6, Comparative Examples 1-5]
About Examples 1-5, a silica stone powder and slaked lime are disperse | distributed to water, and a slurry with a solid content concentration of 30 mass% is prepared. The mixing ratio of the quartzite powder and slaked lime is set so that the molar ratio of SiO 2 contained in the quartzite powder and CaO contained in the slaked lime is 5: 5.
After adjusting the pH of the slurry with an alkali such as caustic soda, the slurry is heated to a temperature of 200 ° C. under a pressure of 2 MPa in an autoclave for hydrothermal synthesis with an agitator and stirred for 9 hours while stirring. By this reaction, SiO 2 of silica powder and CaO of slaked lime react to produce zonotlite, and a calcium silicate reaction intermediate product exists in the slurry.
For Example 6, the molar ratio of SiO 2 and CaO is 7: adjusted to 3, are reacted for 9 hours at a temperature of 250 ° C. in an autoclave.
A wood reinforcing material, a hydraulic inorganic substance, and the like shown in Table 1 are blended in the above-mentioned zonotlite or tobermorite slurry in amounts shown in Table 1 to prepare a slurry having a solid content concentration of 10% by mass.
The mixed slurry is made into a mat by paper dewatering by a Hatschek paper machine, and the mat is pressed at a pressure of 1.5 MPa to form a predetermined shape.
For Examples 1, 2, 5, 6, sprayed with phenolic resin precondensate powder molding front and back surfaces after press molding sided 0.05 g / cm 2, both surfaces 0.1 g / cm 2, at a ratio of the pressure Hot press molding was performed at 0.8 MPa and a temperature of 200 ° C. for 10 minutes, followed by natural drying and natural curing. For Examples 3 and 4, the above-mentioned papermaking dehydrated molded product was cured at a temperature of 60 ° C. for 12 hours. After curing, the molded product was dried, and the phenol resin initial condensate powder was applied to the front and back surfaces on one side. .05g / cm 2, was sprayed at a rate of double-sided 0.1g / cm 2,, then the pressure 0.6 MPa, and 10 minutes heat pressed at a temperature 200 ° C., and then air dried.
For Comparative Examples 1 and 2, similar to Examples 1, 2, 5 and 6, the slurry having the composition shown in Table 1 was subjected to papermaking and dehydration molding, followed by heat drying and natural drying and natural curing. In the same manner as in Examples 3 and 4, the slurry having the composition shown in Table 1 was subjected to papermaking and dehydration molding, the molded product was cured and cured, and then naturally dried.
Table 1 shows the physical properties of the lightweight inorganic plates of Examples 1 to 6 and Comparative Examples 1 to 5.
表１を参照すると、フェノール樹脂初期縮合物粉末を散布した実施例１，２，５およびトバモライトを使用した実施例６はフェノール樹脂初期縮合物を散布しない比較例１，２に比べると曲げ強度、ヤング率共に大巾に向上している。またポルトランドセメントと高炉スラグとを添加した実施例３，４、比較例３は共に曲げ強度、ヤング率において向上がみられるが、該フェノール樹脂初期縮合物を散布した実施例３，４は該フェノール樹脂初期縮合物粉末を散布しない比較例３に比較して大巾な強度の向上が見られる。更に木質補強材として木質パルプのみを使用した比較例４、故紙解繊物のみを使用した比較例５は両方使用した比較例１および比較例２に比して強度は略同等あるいは低下が見られる。 Referring to Table 1, Examples 1, 2, and 5 in which the phenol resin initial condensate powder was dispersed and Example 6 using tobermorite were compared with Comparative Examples 1 and 2 in which the phenol resin initial condensate was not dispersed. Both Young's modulus is greatly improved. In Examples 3 and 4 to which Portland cement and blast furnace slag were added, Comparative Example 3 was improved in bending strength and Young's modulus, but Examples 3 and 4 in which the phenol resin initial condensate was sprayed were used. Compared to Comparative Example 3 in which the resin initial condensate powder is not sprayed, a significant improvement in strength is observed. Further, Comparative Example 4 using only wood pulp as the wood reinforcing material, and Comparative Example 5 using only the waste paper defibrated material have substantially the same or lower strength than Comparative Examples 1 and 2 using both. .
本発明では高強度でかつ軽量な不燃性の無機質板が得られる。該軽量無機質板は建築板等に有用である。 In the present invention, a non-flammable inorganic plate having high strength and light weight can be obtained. The lightweight inorganic board is useful for building boards and the like.
Claims (1)
A raw material mixture mainly composed of a siliceous raw material and a calcareous raw material is dispersed in water to prepare a slurry, and the slurry is reacted with the siliceous raw material and the calcareous raw material under high temperature and high pressure to obtain calcium silicate. A hydrate is formed, and the slurry containing the calcium silicate hydrate and the wood reinforcing material is subjected to paper-making dehydration molding. On the surface and / or the back surface of the obtained plate-like molded body, a phenol resin initial condensate powder and / or Alternatively, an epoxy resin prepolymer powder is sprayed or a phenol resin initial condensate solution and / or an epoxy resin prepolymer solution is applied, and the plate-shaped molded body is 0.5 to 5.0 MPa, the phenol resin initial condensate and / or the epoxy resin prepolymer curing (gelling) plate-shaped molded by hot press at a temperature and the phenolic resin precondensate and / or Method for producing a lightweight inorganic board, wherein Rukoto allowed to cure and the epoxy resin prepolymer.
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