JP6129941B1 - Tile panel and manufacturing method thereof - Google Patents
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- JP6129941B1 JP6129941B1 JP2015237638A JP2015237638A JP6129941B1 JP 6129941 B1 JP6129941 B1 JP 6129941B1 JP 2015237638 A JP2015237638 A JP 2015237638A JP 2015237638 A JP2015237638 A JP 2015237638A JP 6129941 B1 JP6129941 B1 JP 6129941B1
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- 238000004519 manufacturing process Methods 0.000 title claims description 12
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 97
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 57
- 239000000203 mixture Substances 0.000 claims abstract description 56
- 239000011230 binding agent Substances 0.000 claims abstract description 43
- 235000012241 calcium silicate Nutrition 0.000 claims abstract description 32
- 229910052918 calcium silicate Inorganic materials 0.000 claims abstract description 32
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 claims abstract description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000000843 powder Substances 0.000 claims description 37
- 239000000463 material Substances 0.000 claims description 14
- 239000002023 wood Substances 0.000 claims description 12
- 239000010456 wollastonite Substances 0.000 claims description 10
- 229910052882 wollastonite Inorganic materials 0.000 claims description 10
- 238000005520 cutting process Methods 0.000 claims description 6
- 238000004898 kneading Methods 0.000 claims description 4
- 238000000034 method Methods 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 68
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 26
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 26
- 239000002585 base Substances 0.000 description 25
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 17
- 229910001629 magnesium chloride Inorganic materials 0.000 description 13
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 13
- 235000019341 magnesium sulphate Nutrition 0.000 description 13
- 238000002156 mixing Methods 0.000 description 12
- 239000002994 raw material Substances 0.000 description 12
- 229920002522 Wood fibre Polymers 0.000 description 6
- 238000005452 bending Methods 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 239000002025 wood fiber Substances 0.000 description 6
- 238000013461 design Methods 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- 230000001771 impaired effect Effects 0.000 description 3
- 239000000123 paper Substances 0.000 description 3
- 239000010802 sludge Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 239000011083 cement mortar Substances 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 229930014626 natural product Natural products 0.000 description 2
- 229910052573 porcelain Inorganic materials 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910004762 CaSiO Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000000887 hydrating effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- FYYHWMGAXLPEAU-OUBTZVSYSA-N magnesium-25 atom Chemical group [25Mg] FYYHWMGAXLPEAU-OUBTZVSYSA-N 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000010445 mica Substances 0.000 description 1
- 229910052618 mica group Inorganic materials 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- BPILDHPJSYVNAF-UHFFFAOYSA-M sodium;diiodomethanesulfonate Chemical compound [Na+].[O-]S(=O)(=O)C(I)I BPILDHPJSYVNAF-UHFFFAOYSA-M 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000012549 training Methods 0.000 description 1
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- Finishing Walls (AREA)
- Floor Finish (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
【課題】機械的強度、耐久性、下地面への貼付性等に加え、表面光沢性を有するタイルパネルを提供する。【解決手段】下地層と下地層の表面に設けられた化粧層とを有するタイルパネルであって、前記化粧層が、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物に加水し硬化させた硬化物からなる化粧層であることを特徴とするタイルパネル。当該タイルパネルは、表面光沢性を有し、かつ、機械的強度に優れるため、外壁用や床面用のタイルパネルとして好適に使用できる。【選択図】図１Provided is a tile panel having surface gloss in addition to mechanical strength, durability, pastability to a base surface, and the like. A tile panel having a base layer and a decorative layer provided on the surface of the base layer, wherein the decorative layer contains a magnesia-based binder and acicular calcium metasilicate. A tile panel comprising a decorative layer made of a cured product obtained by adding water to a composition and curing. Since the said tile panel has surface glossiness and is excellent in mechanical strength, it can be used conveniently as a tile panel for outer walls or floors. [Selection] Figure 1
Description
本発明は、壁面用や床面用に使用され、製造に焼成工程を必要とせず、軽量で意匠性に優れた化粧層を有するタイルパネルに関する。 The present invention relates to a tile panel having a decorative layer which is used for wall surfaces and floor surfaces, does not require a baking step for production, and is lightweight and has excellent design properties.
建物の内外壁面等をタイル壁面に形成する場合や、建物の床面にタイル床面を形成する場合においては、下地となる壁面あるいは床面にセメントモルタルを塗布し、そのセメントモルタルにタイルパネルを押圧して貼付してタイル壁面やタイル床面を形成している。タイルパネルには、遮水性、機械的強度、耐候性、下地面への貼付性等が求められる。 When building the inner and outer wall surfaces of a building on a tile wall surface, or when forming a tile floor surface on the floor surface of a building, apply cement mortar to the underlying wall surface or floor surface, and attach a tile panel to the cement mortar. Pressing and pasting to form tile wall surfaces and tile floor surfaces. The tile panel is required to have water shielding properties, mechanical strength, weather resistance, adhesiveness to the ground surface, and the like.
このようなタイルパネルとして、従来からセラミック系タイルパネルが用いられているが、セラミック系タイルパネルは重量が大きく、貼付される壁面に対して負担が大きく、また、施工に多大な労力と時間を要するという問題がある。
そのため、近年、軽量なタイルパネルの開発が精力的に行われている。例えば、特許文献１には、ＳｉＯ2−Ａｌ2Ｏ3系粉体、アルカリ金属珪酸塩水溶液を主成分とする無機質硬化性組成物が硬化してなる基材に所定パターンでタイルの裏面側が埋設されているタイルパネルが開示されている。また、特許文献２には、床面にモルタルを接合剤として固定されるパネル本体とその上面に配置したタイルを含む床用タイルパネルであって、パネル本体の底面に前記モルタルとの接合面を形成する凸部をほぼ一様のパターンで配置してなる床用タイルパネルが開示されている。
Conventionally, ceramic tile panels have been used as such tile panels, but ceramic tile panels are heavy and have a heavy burden on the wall to which they are attached. There is a problem that it takes.
Therefore, in recent years, development of lightweight tile panels has been energetically performed. For example, in Patent Document 1, the back side of a tile is embedded in a predetermined pattern in a base material formed by curing an inorganic curable composition mainly composed of an SiO 2 -Al 2 O 3 powder and an alkali metal silicate aqueous solution. A tile panel is disclosed. Patent Document 2 discloses a floor tile panel including a panel main body fixed on a floor surface with a mortar as a bonding agent and tiles arranged on the upper surface of the panel main body, and a bonding surface with the mortar on the bottom surface of the panel main body. There is disclosed a floor tile panel in which convex portions to be formed are arranged in a substantially uniform pattern.
また、タイルパネルには、上述の遮水性、機械的強度、耐候性、下地面への貼付性等に加え、タイルパネルとしての色彩等の表面意匠性が求められる。
しかしながら、通常のセラミック系タイルパネルは意匠性に乏しいため、意匠性を持たせるには表面修飾等が必要となることが多い。例えば、床面タイルの場合、表面光沢性が求められることが多いが、セラミック系タイルパネルに表面光沢性を持たせるためには表面に釉薬等を塗布し、１０００℃以上の高温で焼成している。
Further, the tile panel is required to have surface design properties such as color as a tile panel in addition to the above-described water-blocking property, mechanical strength, weather resistance, adhesiveness to the ground surface, and the like.
However, since ordinary ceramic tile panels have poor design properties, surface modification and the like are often required to provide design properties. For example, in the case of floor tiles, surface gloss is often required, but in order to impart surface gloss to ceramic tile panels, glaze etc. is applied to the surface and fired at a high temperature of 1000 ° C. or higher. Yes.
一方、本発明者は特許文献３において、所定割合の酸化マグネシウム、硫酸マグネシウム及び塩化マグネシウムを含有するマグネシア系結合材とペーパースラッジ灰とを混合させ、これらを水硬化させてなる固形体を報告している。 On the other hand, the present inventor reported in Patent Document 3 a solid body obtained by mixing a magnesia-based binder containing a predetermined proportion of magnesium oxide, magnesium sulfate and magnesium chloride and paper sludge ash, and water curing these. ing.
特許文献３で開示されたマグネシア系結合材及びペーパースラッジ灰を主成分とする固形体は、幅広い曲げ強度（あるいは圧縮強度）を備えることができるため、建築材料として有望である。しかしながら、マグネシア系結合材及びペーパースラッジ灰を主成分とする固形体は曲げ強度は高いものの、当該固形体をタイルパネル（特には硬度が求められる床用タイルパネル）に使用するには衝撃強度が不足するおそれがある。また、当該固形体は表面光沢性を有さないため、別途表面光沢性の塗料を塗布するなどの表面処理を行う必要がある。 The solid body mainly composed of magnesia-based binder and paper sludge ash disclosed in Patent Document 3 is promising as a building material because it can have a wide range of bending strength (or compressive strength). However, although a solid body mainly composed of magnesia-based binder and paper sludge ash has a high bending strength, impact strength is insufficient to use the solid body for tile panels (particularly floor tile panels for which hardness is required). There may be a shortage. In addition, since the solid body does not have surface gloss, it is necessary to perform surface treatment such as separately applying a surface gloss paint.
このように壁面用や床面用のタイルパネルにおいて、従来技術には改善の余地があるのが実状である。
かかる状況下、本発明の目的は、機械的強度や下地面への貼付性に優れ、表面光沢性を有する化粧層を有するタイルパネルを提供することである。
As described above, in the tile panels for wall surfaces and floor surfaces, there is a room for improvement in the prior art.
Under such circumstances, an object of the present invention is to provide a tile panel having a decorative layer having excellent surface strength and excellent mechanical strength and adhesiveness to a base surface.
本発明者は、上記課題を解決すべく鋭意研究を重ねた結果、マグネシア系結合材と針状メタケイ酸カルシウムを組み合わせた粉状組成物を加水して得られる硬化物が、優れた機械的強度（曲げ強度、衝撃強度等）を有し、かつ、表面光沢性に優れ、これがタイルパネルの化粧層として適していることを見出し、本発明に至った。 As a result of intensive studies to solve the above problems, the present inventor has obtained a cured product obtained by adding a powdered composition comprising a combination of a magnesia-based binder and acicular calcium metasilicate, which has excellent mechanical strength. They have (bending strength, impact strength, etc.) and are excellent in surface gloss, and are found to be suitable as a decorative layer for a tile panel, leading to the present invention.
すなわち、本発明は、以下の発明に係るものである。
＜１＞ 下地層と下地層の表面に設けられた化粧層とを有するタイルパネルであって、
前記化粧層が、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物の硬化物からなる化粧層であるタイルパネル。
＜２＞ 前記マグネシア系結合材１００重量部に対する前記針状メタケイ酸カルシウムの重量割合が、５〜４５重量部である前記＜１＞に記載のタイルパネル。
＜３＞ 前記針状メタケイ酸カルシウムが、ワラストナイトである前記＜１＞または＜２＞に記載のタイルパネル。
＜４＞ 前記下地層が、マグネシア系結合材と木質断裁材とを含む下地層用粉状組成物の硬化物である下地層である前記＜１＞から＜３＞のいずれかに記載のタイルパネル。
＜５＞ 前記＜１＞から＜４＞に記載のタイルパネルの製造方法であって、前記水硬化型粉状組成物に加水し、混練して得られる混練物を、硬化する前に下地層の表面に塗工し、養生を行って化粧層を形成する工程を含む、タイルパネルの製造方法。
That is, the present invention relates to the following inventions.
<1> A tile panel having a foundation layer and a decorative layer provided on the surface of the foundation layer,
The tile panel, wherein the decorative layer is a decorative layer made of a cured product of a water-curable powdery composition containing a magnesia-based binder and acicular calcium metasilicate.
<2> The tile panel according to <1>, wherein a weight ratio of the acicular calcium metasilicate to 100 parts by weight of the magnesia-based binder is 5 to 45 parts by weight.
<3> The tile panel according to <1> or <2>, wherein the acicular calcium metasilicate is wollastonite.
<4> The tile according to any one of <1> to <3>, wherein the base layer is a base layer that is a cured product of a powdery composition for a base layer including a magnesia-based binder and a wood cutting material. panel.
<5> The method for producing a tile panel according to <1> to <4>, wherein the kneaded product obtained by adding water to the water-curable powder composition and kneading is cured before being cured. The manufacturing method of a tile panel including the process of apply | coating to the surface of this and performing curing and forming a decorative layer.
本発明によれば、機械的強度に優れるとともに下地面への貼付性等に加え、表面光沢性を有する化粧層を有するタイルパネルが提供される。 ADVANTAGE OF THE INVENTION According to this invention, in addition to the mechanical strength, in addition to the sticking property to a base surface, etc., the tile panel which has a decorative layer which has surface glossiness is provided.
以下、本発明について例示物等を示して詳細に説明するが、本発明は以下の例示物等に限定されるものではなく、本発明の要旨を逸脱しない範囲において任意に変更して実施できる。 Hereinafter, the present invention will be described in detail with reference to examples and the like, but the present invention is not limited to the following examples and the like, and can be arbitrarily modified and implemented without departing from the gist of the present invention.
＜１．タイルパネル＞
本発明のタイルパネルは、下地層と下地層の表面に設けられた化粧層とを有するタイルパネルであって、前記化粧層が、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物に加水し硬化させた硬化物からなる化粧層であることを特徴とする。
本発明のタイルパネルは化粧層が、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物に加水し硬化させた硬化物が、表面光沢を有すると共に、優れた機械的強度、耐久性を有するため、壁面用や床面用のタイルパネルとして好適である。
<1. Tile panel>
The tile panel of the present invention is a tile panel having a base layer and a decorative layer provided on the surface of the base layer, wherein the decorative layer contains water containing magnesia-based binder and acicular calcium metasilicate. It is a decorative layer made of a cured product obtained by hydrating and curing a curable powder composition.
In the tile panel of the present invention, the decorative layer has a surface gloss and a cured product obtained by adding and curing a water-curable powder composition containing a magnesia-based binder and acicular calcium metasilicate. Since it has mechanical strength and durability, it is suitable as a tile panel for wall surfaces or floor surfaces.
図１に示すように本発明のタイルパネルは、下地層と下地層の表面に設けられた化粧層を有する。本発明の目的を損なわない限り、すなわち、表面光沢や機械的強度等の性質を損なわない限り、これら以外にも他の層を有していてもよい。他の層としては接着層、保護層などが挙げられる。 As shown in FIG. 1, the tile panel of the present invention has a base layer and a decorative layer provided on the surface of the base layer. Unless the object of the present invention is impaired, that is, unless properties such as surface gloss and mechanical strength are impaired, other layers may be included. Examples of other layers include an adhesive layer and a protective layer.
タイルパネルの大きさ（縦寸法及び横寸法）は任意であり、通常、タイルパネルの使用用途によって選択され、特に制限されない。例えば、床用タイルパネルであれば、通常、数十ｃｍ×数十ｃｍである。なお、図１では正方形状のタイルパネルを示しているが、この形状に限定されず、直方形、六角形等の多角形形状や、円形、不定形等の多角形以外の形状、やこれらの組み合わせであってもよい。 The size (vertical dimension and horizontal dimension) of the tile panel is arbitrary, and is usually selected depending on the use application of the tile panel and is not particularly limited. For example, in the case of a floor tile panel, it is usually several tens of cm × several tens of cm. In addition, although the square tile panel is shown in FIG. 1, it is not limited to this shape, polygonal shapes, such as a rectangle and a hexagon, shapes other than polygons, such as a circle and an indefinite shape, and these It may be a combination.
また、タイルパネルの厚みは、タイルパネルの使用用途によって適宜設定すればよい。化粧層の厚みは、タイルパネルの使用用途によって適宜設定され、通常、１〜５ｃｍ程度である。下地層の厚みは、タイルパネルの使用用途によって適宜設定され、通常、１〜１０ｃｍ程度である。 Moreover, what is necessary is just to set the thickness of a tile panel suitably by the use application of a tile panel. The thickness of the decorative layer is appropriately set depending on the use application of the tile panel, and is usually about 1 to 5 cm. The thickness of the underlayer is appropriately set depending on the use application of the tile panel, and is usually about 1 to 10 cm.
本発明のタイルパネルにおいて、化粧層は、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物（以下、「本発明の水硬化型粉状組成物」と記載する場合がある。）に加水し硬化させた、表面光沢を有する硬化物（以下、「本発明の硬化物」と記載する場合がある。）により構成される。
本発明の水硬化型粉状組成物、本発明の硬化物の詳細については、＜２．水硬化型粉状組成物＞、＜３．硬化物＞にて、後述する。
In the tile panel of the present invention, the decorative layer is a water-curable powder composition containing a magnesia-based binder and acicular calcium metasilicate (hereinafter referred to as “the water-curable powder composition of the present invention”). And a cured product having a surface gloss (hereinafter sometimes referred to as “cured product of the present invention”).
For details of the water-curable powder composition of the present invention and the cured product of the present invention, <2. Water-curing powder composition>, <3. The cured product> will be described later.
本発明のタイルパネルにおいて、下地層は、タイルパネルの下地層としての機械的強度及び耐久性、化粧層との接着性があるものであればよい。下地層としては、マグネシア系結合材と木質繊維、木質チップなどの木質断裁材とを含む下地層用粉状組成物に加水して硬化させてなる下地層であることが好ましい。化粧層と同様に、マグネシア系結合材をベースとする下地層を使用することにより、下地層と化粧層との接着性が向上する。
マグネシア系結合材については、後述する＜２．水硬化型粉状組成物＞にて説明するマグネシア系結合材と同じものを使用することができる。
In the tile panel of the present invention, the base layer may be any layer having mechanical strength and durability as the base layer of the tile panel and adhesiveness with the decorative layer. The underlayer is preferably an underlayer formed by adding and curing a powdery composition for an underlayer containing a magnesia-based binder and a wood cutting material such as wood fibers and wood chips. Similar to the decorative layer, the adhesion between the base layer and the decorative layer is improved by using the base layer based on the magnesia-based binder.
The magnesia-based binder will be described later in <2. The same thing as the magnesia type | system | group binder demonstrated by water-curable powder-like composition> can be used.
下地層において、下地層用粉状組成物が、さらに針状メタケイ酸カルシウムを含むことが好ましい。針状メタケイ酸カルシウムとしてはワラストナイトが好ましい。このような下地層を使用することにより、化粧層との密着性が向上すると共に、機械的強度が向上する。針状メタケイ酸カルシウムの詳細については、＜２．水硬化型粉状組成物＞にて後述する。 In the underlayer, it is preferable that the powdery composition for the underlayer further contains acicular calcium metasilicate. Wollastonite is preferred as the acicular calcium metasilicate. By using such a base layer, the adhesiveness with the decorative layer is improved and the mechanical strength is improved. For details of acicular calcium metasilicate, see <2. It will be described later in “Hydrocurable powder composition>.
以下、本発明のタイルパネルの製造に使用される水硬化型粉状組成物、およびその硬化物、並びに本発明のタイルパネルの製造方法について説明する。 Hereinafter, the water-curable powder composition used for the production of the tile panel of the present invention, the cured product thereof, and the method for producing the tile panel of the present invention will be described.
＜２．水硬化型粉状組成物＞
本発明の水硬化型粉状組成物は、マグネシア系結合材と、針状メタケイ酸カルシウムとを必須成分として含有する。
<2. Water-curing powder composition>
The water-curable powder composition of the present invention contains a magnesia-based binder and acicular calcium metasilicate as essential components.
本発明の水硬化型粉状組成物は、原料に水硬化するマグネシア系結合材を含むため、加水して水と混合することにより、加熱しなくとも常温において容易に硬化する。本発明の水硬化型粉状組成物を水硬化して得られる硬化物（化粧層）は、優れた曲げ強度・圧縮強度といった機械的強度に優れる。 Since the water-curable powder composition of the present invention contains a magnesia-based binder that is water-cured in the raw material, it is easily cured at room temperature without heating by adding water and mixing with water. A cured product (decorative layer) obtained by water-curing the water-curable powder composition of the present invention is excellent in mechanical strength such as excellent bending strength and compressive strength.
以下、本発明の水硬化型粉状組成物が含有する各成分について詳細に説明する。 Hereinafter, each component contained in the water-curable powder composition of the present invention will be described in detail.
（マグネシア系結合材）
本発明の水硬化型粉状組成物において、マグネシア系結合材は、加水して混合することによって硬化し、水硬化型粉状組成物を固化させる作用を有する。
マグネシア系結合材として具体的には、酸化マグネシウム、塩化マグネシウム及び硫酸マグネシウム、並びにこれらの混合物が挙げられる。
特に、機械的強度に優れた硬化物が得られる点で、酸化マグネシウムを主原料とし、それに塩化マグネシウムと硫酸マグネシウムを含むマグネシア系結合材が好ましい。ここで、「酸化マグネシウムを主原料とする」とは、酸化マグネシウム、塩化マグネシウムおよび硫酸マグネシウムの３つの成分のうち、酸化マグネシウムの占める重量割合が最も高い場合であることを意味する。
(Magnesia binder)
In the water-curable powder composition of the present invention, the magnesia-based binder has an action of hardening by adding water and mixing to solidify the water-curable powder composition.
Specific examples of the magnesia-based binder include magnesium oxide, magnesium chloride and magnesium sulfate, and mixtures thereof.
In particular, a magnesia-based binder containing magnesium oxide as a main raw material and containing magnesium chloride and magnesium sulfate is preferable in that a cured product having excellent mechanical strength can be obtained. Here, “magnesium oxide is the main raw material” means that the weight proportion of magnesium oxide is the highest among the three components of magnesium oxide, magnesium chloride and magnesium sulfate.
マグネシア系結合材の原料として酸化マグネシウム及び塩化マグネシウムのみを用いた場合、当該原料に水を混合して水硬させてなる硬化物は、吸湿性が高いため反り及び膨張が生じ易いのに加え、耐水性及び耐久性が著しく低い場合がある。
一方、結合材の原料として酸化マグネシウム及び硫酸マグネシウムのみを用いた場合、当該原料に水を混合して水硬させてなる固形体に膨張又はひび割れが発生するおそれがある。
When only magnesium oxide and magnesium chloride are used as raw materials for the magnesia-based binder, a cured product obtained by mixing water with the raw material and hydraulically hardening is likely to be warped and expanded due to its high hygroscopicity, Water resistance and durability may be extremely low.
On the other hand, when only magnesium oxide and magnesium sulfate are used as the raw material of the binder, there is a possibility that expansion or cracking may occur in a solid body obtained by mixing water with the raw material and hardening it.
これに対して、結合材の原料として酸化マグネシウム、硫酸マグネシウム及び塩化マグネシウムを用いた場合は、３つの原料を所定の割合で混合することによって、固形体に前述した如き反り、膨張及びひび割れが生じることなく、また、「酸化マグネシウム及び塩化マグネシウムのみ」あるいは「酸化マグネシウム及び硫酸マグネシウムのみ」の場合よりも耐水性及び耐久性が著しく改善される。 On the other hand, when magnesium oxide, magnesium sulfate and magnesium chloride are used as the raw material for the binder, the solid material is warped, expanded and cracked as described above by mixing the three raw materials at a predetermined ratio. In addition, the water resistance and durability are remarkably improved as compared with the cases of “magnesium oxide and magnesium chloride alone” or “magnesium oxide and magnesium sulfate alone”.
ここで、酸化マグネシウム、硫酸マグネシウム及び塩化マグネシウムの３原料を混合する割合はマグネシア系結合材を構成する原料の総重量に対して酸化マグネシウムが５割以下であり、硫酸マグネシウムが２．５割以上４割未満であり、塩化マグネシウムが１割を超え２．５割以下であることが好ましい。より好ましい混合割合は、マグネシア系の結合材を構成する原料の総質量に対して酸化マグネシウムが５割であり、硫酸マグネシウムが２．５割以上４割未満であり、塩化マグネシウムが１割を超え２．５割以下である。 Here, the ratio of mixing three raw materials of magnesium oxide, magnesium sulfate and magnesium chloride is 50% or less of magnesium oxide and 2.5% or more of magnesium sulfate with respect to the total weight of the raw materials constituting the magnesia-based binder. It is less than 40%, and magnesium chloride is preferably more than 10% and 2.5% or less. More preferable mixing ratio is 50% of magnesium oxide, 2.5 to 40% of magnesium sulfate, and more than 10% of magnesium chloride with respect to the total mass of raw materials constituting the magnesia-based binder. 2.5% or less.
マグネシア系結合材の粒径は、針状メタケイ酸カルシウム（及び任意成分）と均一に混合できる範囲で決定され、通常、５〜６０μｍである。 The particle size of the magnesia-based binder is determined within a range where it can be uniformly mixed with acicular calcium metasilicate (and optional components), and is usually 5 to 60 μm.
なお、上述の通り、マグネシア系結合材は、化粧層の材料のみならず、下地層の材料として用いることもできる。 As described above, the magnesia-based binder can be used not only as a material for the decorative layer but also as a material for the base layer.
（針状メタケイ酸カルシウム）
針状メタケイ酸カルシウムは、いわゆる針状無機フィラーであり、本発明の硬化物に優れた機械的強度（曲げ強度、衝撃強度等）を与えることができる。また、針状メタケイ酸カルシウムは、化学的に安定が高いため、本発明の硬化物に耐久性を付与することができる。
(Acicular calcium metasilicate)
Acicular calcium metasilicate is a so-called acicular inorganic filler and can give excellent mechanical strength (bending strength, impact strength, etc.) to the cured product of the present invention. Moreover, since acicular calcium metasilicate is chemically stable, durability can be provided to the hardened | cured material of this invention.
針状メタケイ酸カルシウムは、化学式ＣａＳｉＯ3を主成分とする、白色の針状の結晶形状を有し、アスペクト比（直径に対する長さの比）が１０倍以上である物質である。針状メタケイ酸カルシウムは、数十〜数百μｍ程度の範囲で長さ分布があるが、本発明の水硬化型粉状組成物として適した長さ分布のものを使用すればよい。
なお、本発明で使用される針状メタケイ酸カルシウムには、針状形状に類似する細管状、短冊状の結晶形状も含まれるものとする。強度のバランスに優れた硬化物が供給される点で、アスペクト比（直径に対する長さの比）は、１５以上が好ましい。
Acicular calcium metasilicate is a substance having a white needle-like crystal shape, the main component of which is the chemical formula CaSiO 3 , and an aspect ratio (ratio of length to diameter) of 10 times or more. Acicular calcium metasilicate has a length distribution in the range of about several tens to several hundreds of μm, and a length distribution suitable for the water-curable powdery composition of the present invention may be used.
Note that the acicular calcium metasilicate used in the present invention includes a tubular and strip-like crystal shape similar to the acicular shape. The aspect ratio (ratio of length to diameter) is preferably 15 or more in that a cured product having an excellent balance of strength is supplied.
針状メタケイ酸カルシウムは、天然物であっても、人工物であってもよい。特に天然物であるワラストナイト（Wollastonite）が好適である。ワラストナイトは、硬度４．５〜５の結晶性鉱物であり、粉砕すると白色の針状粒子となる。当該針状粒子を針状メタケイ酸カルシウムとして本発明の水硬化型粉状組成物に使用すると、曲げ強度が顕著に増大する。 Acicular calcium metasilicate may be a natural product or an artificial product. In particular, the natural product Wollastonite is suitable. Wollastonite is a crystalline mineral having a hardness of 4.5 to 5, and becomes white needle-like particles when pulverized. When the acicular particles are used as acicular calcium metasilicate in the water-curable powder composition of the present invention, the bending strength is remarkably increased.
針状メタケイ酸カルシウムの長さはレーザー解析散乱式測定、アスペクト比は電子顕微鏡（ＳＥＭ）で観察した任意の粒子１０個の平均値として求めることができる。 The length of acicular calcium metasilicate can be determined by laser analysis scattering measurement, and the aspect ratio can be obtained as an average value of 10 arbitrary particles observed with an electron microscope (SEM).
本発明の水硬化型粉状組成物において、マグネシア系結合材１００重量部に対する針状メタケイ酸カルシウムの重量割合が、５〜４５重量部であることが好ましく、より好ましくは、２０〜４０重量部である。
この範囲であれば、得られる硬化物は結合性が高く、高硬度で緻密であり、ひび割れなどが生じづらい水硬化型粉状組成物を与えることができる。この範囲において、その使用時の状況に応じてそれぞれの成分含量を適宜設定し使用すればよい。
In the water-curable powder composition of the present invention, the weight ratio of acicular calcium metasilicate to 100 parts by weight of magnesia-based binder is preferably 5 to 45 parts by weight, more preferably 20 to 40 parts by weight. It is.
If it is this range, the hardened | cured material obtained will have a high bondability, and it can give the water hardening type powdery composition which is high hardness and dense, and is hard to produce a crack. Within this range, the content of each component may be appropriately set and used according to the situation at the time of use.
なお、上述の通り、針状メタケイ酸カルシウムは、化粧層の材料のみならず、下地層の材料として用いることもできる。 As described above, acicular calcium metasilicate can be used not only as a material for the decorative layer but also as a material for the base layer.
（その他の成分）
本発明の水硬化型粉状組成物は、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有するが、本発明の効果を損なわない範囲で他の成分を含んでいてよい。他の成分して、例えば、ドノマイト、酸性白土、水酸化アルミニウム、マイカあるいはパーライトなどが挙げられる。これらの他の成分の含有量は通常５重量％以下である。また、硬化物の意匠性を向上させるために、木質繊維、木質チップなどの木質断裁材、陶石等の添加物を添加してもよい。これらの添加物の添加量は任意であり、目的に応じて適時設定される。
(Other ingredients)
The water-curable powder composition of the present invention contains a magnesia-based binder and acicular calcium metasilicate, but may contain other components as long as the effects of the present invention are not impaired. Examples of other components include donomite, acidic clay, aluminum hydroxide, mica, and perlite. The content of these other components is usually 5% by weight or less. Moreover, in order to improve the designability of hardened | cured material, you may add additives, such as wood cutting materials, such as a wood fiber and a wood chip, and a ceramic stone. The addition amount of these additives is arbitrary, and is set appropriately according to the purpose.
本発明の水硬化型粉状組成物は、通常の粉体混合における従来公知の手段によって製造することができる。混合順序も任意であり、水硬化型粉状組成物の構成成分（マグネシア系結合材、針状メタケイ酸カルシウム、任意成分）のうち、何れか２成分又は３成分以上を予め配合し、その後に残りの成分を混合してもよいし、一度に全部を混合してもよい。 The water-curable powder composition of the present invention can be produced by a conventionally known means in ordinary powder mixing. Mixing order is also arbitrary, among the components (magnesia binder, acicular calcium metasilicate, optional components) of the water-curable powder composition, any two components or three or more components are blended in advance, and then The remaining components may be mixed or all at once.
＜３．硬化物（化粧層）＞
本発明の硬化物（化粧層）は、上述の水硬化型粉状組成物と、水とを混合し硬化してなることを特徴とし、本発明のタイルパネルにおいて化粧層を構成する。本発明の硬化物は、機械的強度に優れるため、機械的強度と表面装飾性を必要とされるタイルパネルにおける化粧層に好適である。
<3. Cured product (decorative layer)>
The cured product (decorative layer) of the present invention is obtained by mixing and curing the above water-curable powder composition and water, and constitutes the decorative layer in the tile panel of the present invention. Since the cured product of the present invention is excellent in mechanical strength, it is suitable for a decorative layer in a tile panel that requires mechanical strength and surface decoration.
本発明の硬化物（化粧層）は、所定の量の水硬化型粉状組成物に、適宜量の水を入れて十分に撹拌混練した混練物を、養生を行うことで形成することができる。水硬化型粉状組成物に対する水の量は、水硬化型粉状組成物の組成に応じて、十分に硬化する範囲で決定される。通常、水硬化型粉状組成物１００重量部に対し、１０〜４０重量部である。 The cured product (decorative layer) of the present invention can be formed by curing a kneaded product obtained by adding an appropriate amount of water to a predetermined amount of a water-curable powder composition and sufficiently stirring and kneading. . The amount of water relative to the water-curable powdery composition is determined within a range that is sufficiently cured according to the composition of the water-curable powdery composition. Usually, it is 10 to 40 parts by weight with respect to 100 parts by weight of the water-curable powdery composition.
本発明の硬化物（化粧層）は、針状メタケイ酸カルシウムに由来する表面光沢性を有する。また、木質繊維、木質チップなどの木質断裁材、陶石等の添加物を含む場合には、それぞれの添加物に由来する意匠性を有する。 The cured product (decorative layer) of the present invention has surface gloss derived from acicular calcium metasilicate. Moreover, when it contains additives, such as wood cutting materials, such as a wood fiber and a wood chip | tip, and a ceramic stone, it has the designability derived from each additive.
本発明の水硬化型粉状組成物は、加水し水と混合して硬化するまで、ある程度の時間があるため、適用状況に応じて適当な形状の硬化物（化粧層）を得ることができる。 Since the water-curable powdery composition of the present invention has a certain amount of time until it is mixed with water and cured, a cured product (decorative layer) having an appropriate shape can be obtained according to the application situation. .
＜４．タイルパネルの製造方法＞
本発明のタイルパネルの製造方法は特に限定されない。例えば、化粧層と、下地層とをそれぞれ別々に製造し、これを接着剤等で接着させることもできるが、化粧層と下地層とが一体成形されていることが好ましい。一体成形することにより、化粧層と下地層との接着性が向上し、より耐久性の高いタイルパネルとなる。
<4. Manufacturing method of tile panel>
The manufacturing method of the tile panel of this invention is not specifically limited. For example, the decorative layer and the base layer can be produced separately and adhered with an adhesive or the like, but it is preferable that the decorative layer and the base layer are integrally formed. By integrally molding, the adhesiveness between the decorative layer and the base layer is improved, and the tile panel is more durable.
本発明のタイルパネルにおける、化粧層と下地層との一体形成は、所定の量の水硬化型粉状組成物に、適宜量の水を入れて十分に撹拌混練した混練物を、下地層に塗工し、養生を行って化粧層を形成するより行うことができる。
特に、下地層として、マグネシア系結合材と木質繊維、木質チップなどの木質断裁材を含む下地層用粉状組成物を使用する場合には、所定の大きさの型枠に、下地層用粉状組成物を入れて、加水して硬化させた下地層を形成し、この下地層の上に、マグネシア系結合材と、針状メタケイ酸カルシウムとを含む本発明の水硬化型粉状組成物に、適宜量の水を入れて硬化・養成を行うことによって、化粧層と下地層とが一体成形されていたタイルパネルを製造することができる。
In the tile panel of the present invention, the decorative layer and the undercoat layer are integrally formed by adding a kneaded product obtained by adding an appropriate amount of water to a predetermined amount of a water-curable powder composition and sufficiently stirring and kneading the undercoat layer. It can be performed by coating and curing to form a decorative layer.
In particular, when using a powdery composition for an underlayer containing a magnesia-based binder and a wood cutting material such as a wood fiber or a wood chip as the underlayer, the powder for the underlayer is placed on a mold of a predetermined size. A water-curable powder composition of the present invention containing a magnesia-based binder and acicular calcium metasilicate on the underlayer formed by adding a hydrated composition to form a water-cured base layer In addition, a tile panel in which the decorative layer and the base layer are integrally formed can be manufactured by adding an appropriate amount of water and performing curing and training.
以下に実施例を挙げて本発明をより具体的に説明するが、本発明はこれらに限定されるものではない。 Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples.
＜水硬化性粉状組成物の製造＞
（実施例１）
酸化マグネシウム５０重量部、硫酸マグネシウム２５重量部、塩化マグネシウム２５重量部を、均一になるまで混合し、マグネシア系結合材を得た。得られたマグネシア系結合材１００重量部に対して、針状メタケイ酸カルシウムとして、ワラストナイト（NYCO Minerala社、長さ：６００μｍ、アスペクト比：１５）３０重量部を均一になるまで混合することにより、実施例１の水硬化性粉状組成物を得た。
<Production of water curable powder composition>
Example 1
Magnesium-based binder was obtained by mixing 50 parts by weight of magnesium oxide, 25 parts by weight of magnesium sulfate and 25 parts by weight of magnesium chloride until uniform. To 100 parts by weight of the obtained magnesia-based binder, 30 parts by weight of wollastonite (NYCO Minerala, length: 600 μm, aspect ratio: 15) is mixed as acicular calcium metasilicate until uniform. Thus, a water-curable powder composition of Example 1 was obtained.
（実施例２）
実施例１の水硬化性粉状組成物において、マグネシア系結合材１００重量部に対して、ワラストナイト２０重量部と共に、木質繊維５重量部、木質チップを５重量部添加した以外は、実施例１と同様にして、実施例２の水硬化性粉状組成物を得た。
(Example 2)
In the water-curable powder composition of Example 1, with the exception of adding 5 parts by weight of wood fiber and 5 parts by weight of wood chips together with 20 parts by weight of wollastonite with respect to 100 parts by weight of magnesia-based binder. In the same manner as in Example 1, the water-curable powder composition of Example 2 was obtained.
（実施例３）
マグネシア系結合材として、酸化マグネシウム４０重量部、硫酸マグネシウム３０重量部、塩化マグネシウム３０重量部を使用し、均一になるまで混合し、マグネシア系結合材を得た。得られたマグネシア系結合材１００重量部に対して、ワラストナイト５重量部と共に、破砕した陶石１５重量部添加した以外は、実施例１と同様にして、実施例３の水硬化性粉状組成物を得た。
(Example 3)
As the magnesia-based binder, 40 parts by weight of magnesium oxide, 30 parts by weight of magnesium sulfate, and 30 parts by weight of magnesium chloride were used and mixed until uniform to obtain a magnesia-based binder. The water-curable powder of Example 3 was the same as Example 1 except that 15 parts by weight of crushed porcelain stone was added together with 5 parts by weight of wollastonite to 100 parts by weight of the obtained magnesia-based binder. A composition was obtained.
＜タイルパネルの製造＞
（実施例１）
マグネシア系結合材１００重量部（酸化マグネシウム４０重量部、硫酸マグネシウム３０重量部、塩化マグネシウム３０重量部）に加水して混合した混練物を、硬化する前に、２０ｃｍ×２０ｃｍの型枠に入れて、２４時間養生して下地層を形成した。
次いで、実施例１の水硬化性粉状組成物に適等量の水（水硬化性粉状組成物１００重量部に対し、水３０重量部）を添加して得られた混練物を、硬化する前に、下地層の上に塗工し、４８時間養生したのちに、型枠を取り外して、実施例１のタイルパネルを得た。
実施例１のタイルパネルは、下地層、化粧層ともに十分に硬化しており、表面は、ワラストナイトに由来する表面光沢性を有していた。下地層の厚みは約５ｃｍ、化粧層の厚みは約１ｃｍであった。
<Manufacture of tile panels>
Example 1
The kneaded product mixed with 100 parts by weight of magnesia binder (40 parts by weight of magnesium oxide, 30 parts by weight of magnesium sulfate, 30 parts by weight of magnesium chloride) and mixed is put into a 20 cm × 20 cm mold before curing. The substrate was cured for 24 hours to form an underlayer.
Next, the kneaded product obtained by adding an appropriate amount of water (30 parts by weight of water to 100 parts by weight of the water-curable powdered composition) to the water-curable powdered composition of Example 1 is cured. Before the coating, the coating was applied on the base layer, and after curing for 48 hours, the mold was removed to obtain the tile panel of Example 1.
In the tile panel of Example 1, both the base layer and the decorative layer were sufficiently cured, and the surface had surface gloss derived from wollastonite. The thickness of the foundation layer was about 5 cm, and the thickness of the decorative layer was about 1 cm.
（実施例２，３）
実施例１の水硬化性粉状組成物に代えて、実施例２，３の水硬化性粉状組成物を使用した以外は実施例１と同様にして、実施例２，３のタイルパネルを得た。なお、水の添加量は、水硬化性粉状組成物１００重量部に対し、実施例２で３５重量部、実施例３で２５重量部とした。
実施例２，３のタイルパネルは、下地層、化粧層ともに十分に硬化しており、ワラストナイトに由来する表面光沢性を有しており、それぞれ木質繊維、木質チップ又は陶石に由来する意匠性を有していた。
(Examples 2 and 3)
In place of the water curable powder composition of Example 1, the tile panels of Examples 2 and 3 were obtained in the same manner as in Example 1 except that the water curable powder composition of Examples 2 and 3 was used. Obtained. The amount of water added was 35 parts by weight in Example 2 and 25 parts by weight in Example 3 with respect to 100 parts by weight of the water-curable powder composition.
The tile panels of Examples 2 and 3 are sufficiently cured in both the base layer and the decorative layer, have surface gloss derived from wollastonite, and are derived from wood fibers, wood chips or porcelain stone, respectively. Has design properties.
本発明によれば、機械的強度、耐久性、下地面への貼付性等に加え、表面光沢性を有するタイルパネルが提供される。 ADVANTAGE OF THE INVENTION According to this invention, in addition to mechanical strength, durability, the sticking property to a base surface, etc., the tile panel which has surface glossiness is provided.
Claims (5)
前記化粧層が、マグネシア系結合材と、針状メタケイ酸カルシウムとを含有する水硬化型粉状組成物の硬化物からなる化粧層であることを特徴とするタイルパネル。 A tile panel having a base layer and a decorative layer provided on the surface of the base layer,
The tile panel according to claim 1, wherein the decorative layer is a decorative layer made of a cured product of a water-curable powdery composition containing a magnesia-based binder and acicular calcium metasilicate.
前記水硬化型粉状組成物に加水し、混練して得られる混練物を、硬化する前に下地層の表面に塗工し、養生を行って化粧層を形成する工程を含むことを特徴とするタイルパネルの製造方法。 A method for manufacturing a tile panel according to any one of claims 1 to 4,
Characterized in that it comprises a step of applying a kneaded product obtained by adding water to the water-curable powder composition and kneading it onto the surface of the base layer before curing, and curing to form a decorative layer. To manufacture tile panels.
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| JPS5150929A (en) * | 1974-10-31 | 1976-05-06 | Asahi Chemical Ind | FUKITSUKE ZAINOSEKOHO |
| JPS59135141A (en) * | 1982-12-13 | 1984-08-03 | コンウエツド・コ−ポレ−シヨン | Manufacture of shape containing fiber |
| JPS6287450A (en) * | 1985-10-09 | 1987-04-21 | 大建工業株式会社 | Manufacture of mineral fiber formed body |
| JPH06298564A (en) * | 1993-04-12 | 1994-10-25 | Harima Ceramic Co Ltd | Carbonaceous magnesia fire brick |
| JP4228247B2 (en) * | 1997-02-14 | 2009-02-25 | 三菱マテリアル株式会社 | Improved hazardous substance removing member and method of manufacturing the same |
| US7429544B2 (en) * | 2004-04-16 | 2008-09-30 | Owens Corning Intellectual Capital, Llc | Coated facer |
| JP2014024728A (en) * | 2012-07-28 | 2014-02-06 | Shoji Iwahara | Method for producing solid body including magnesia-based binding material and paper sludge ash as main material, and the solid body |
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