JPH0568431B2 - - Google Patents
Info
- Publication number
- JPH0568431B2 JPH0568431B2 JP18545585A JP18545585A JPH0568431B2 JP H0568431 B2 JPH0568431 B2 JP H0568431B2 JP 18545585 A JP18545585 A JP 18545585A JP 18545585 A JP18545585 A JP 18545585A JP H0568431 B2 JPH0568431 B2 JP H0568431B2
- Authority
- JP
- Japan
- Prior art keywords
- lightweight
- water
- board
- parts
- component
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired - Lifetime
Links
- 239000000463 material Substances 0.000 claims description 33
- 239000000203 mixture Substances 0.000 claims description 23
- 229910052751 metal Inorganic materials 0.000 claims description 21
- 239000002131 composite material Substances 0.000 claims description 20
- 239000002184 metal Substances 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 9
- 238000005187 foaming Methods 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 238000009415 formwork Methods 0.000 claims description 4
- 239000004088 foaming agent Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 claims description 3
- 239000011162 core material Substances 0.000 description 27
- 239000006260 foam Substances 0.000 description 14
- 239000000123 paper Substances 0.000 description 11
- 239000004568 cement Substances 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 7
- 230000005484 gravity Effects 0.000 description 7
- 229910001562 pearlite Inorganic materials 0.000 description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 238000009413 insulation Methods 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 5
- 239000010425 asbestos Substances 0.000 description 4
- 238000004079 fireproofing Methods 0.000 description 4
- 239000010451 perlite Substances 0.000 description 4
- 235000019362 perlite Nutrition 0.000 description 4
- 229910052895 riebeckite Inorganic materials 0.000 description 4
- 150000003839 salts Chemical class 0.000 description 4
- 239000010936 titanium Substances 0.000 description 4
- 229910052719 titanium Inorganic materials 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 239000010454 slate Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229920003169 water-soluble polymer Polymers 0.000 description 3
- 229910052725 zinc Inorganic materials 0.000 description 3
- 239000011701 zinc Substances 0.000 description 3
- 229910052726 zirconium Inorganic materials 0.000 description 3
- 229910017758 Cu-Si Inorganic materials 0.000 description 2
- 229910017931 Cu—Si Inorganic materials 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052787 antimony Inorganic materials 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 150000001642 boronic acid derivatives Chemical class 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 2
- 235000014113 dietary fatty acids Nutrition 0.000 description 2
- -1 etc. Substances 0.000 description 2
- 239000000194 fatty acid Substances 0.000 description 2
- 229930195729 fatty acid Natural products 0.000 description 2
- 150000004665 fatty acids Chemical class 0.000 description 2
- 239000011494 foam glass Substances 0.000 description 2
- 229910052732 germanium Inorganic materials 0.000 description 2
- IPCSVZSSVZVIGE-UHFFFAOYSA-N hexadecanoic acid Chemical class CCCCCCCCCCCCCCCC(O)=O IPCSVZSSVZVIGE-UHFFFAOYSA-N 0.000 description 2
- 239000011396 hydraulic cement Substances 0.000 description 2
- 229910000765 intermetallic Inorganic materials 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 235000021317 phosphate Nutrition 0.000 description 2
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 2
- 239000002985 plastic film Substances 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- 239000000741 silica gel Substances 0.000 description 2
- 229910002027 silica gel Inorganic materials 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 2
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 2
- 229910052720 vanadium Inorganic materials 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 229910018131 Al-Mn Inorganic materials 0.000 description 1
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018182 Al—Cu Inorganic materials 0.000 description 1
- 229910018461 Al—Mn Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910018575 Al—Ti Inorganic materials 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- 229910020712 Co—Sb Inorganic materials 0.000 description 1
- 229910017082 Fe-Si Inorganic materials 0.000 description 1
- 229910017133 Fe—Si Inorganic materials 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 235000021314 Palmitic acid Nutrition 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- 241000975357 Salangichthys microdon Species 0.000 description 1
- 229910008071 Si-Ni Inorganic materials 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910006300 Si—Ni Inorganic materials 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229920002125 Sokalan® Polymers 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910007609 Zn—S Inorganic materials 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 239000000783 alginic acid Substances 0.000 description 1
- 229920000615 alginic acid Polymers 0.000 description 1
- 229960001126 alginic acid Drugs 0.000 description 1
- 235000010443 alginic acid Nutrition 0.000 description 1
- 150000004781 alginic acids Chemical class 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- 239000011400 blast furnace cement Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- GBAOBIBJACZTNA-UHFFFAOYSA-L calcium sulfite Chemical compound [Ca+2].[O-]S([O-])=O GBAOBIBJACZTNA-UHFFFAOYSA-L 0.000 description 1
- 235000010261 calcium sulphite Nutrition 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 239000000306 component Substances 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- GVALZJMUIHGIMD-UHFFFAOYSA-H magnesium phosphate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O GVALZJMUIHGIMD-UHFFFAOYSA-H 0.000 description 1
- 239000004137 magnesium phosphate Substances 0.000 description 1
- 229910000157 magnesium phosphate Inorganic materials 0.000 description 1
- 229960002261 magnesium phosphate Drugs 0.000 description 1
- 235000010994 magnesium phosphates Nutrition 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- JESHZQPNPCJVNG-UHFFFAOYSA-L magnesium;sulfite Chemical compound [Mg+2].[O-]S([O-])=O JESHZQPNPCJVNG-UHFFFAOYSA-L 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- WQEPLUUGTLDZJY-UHFFFAOYSA-N n-Pentadecanoic acid Chemical class CCCCCCCCCCCCCCC(O)=O WQEPLUUGTLDZJY-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052755 nonmetal Inorganic materials 0.000 description 1
- 150000002843 nonmetals Chemical class 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical class CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 239000008262 pumice Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- IGLNJRXAVVLDKE-UHFFFAOYSA-N rubidium atom Chemical compound [Rb] IGLNJRXAVVLDKE-UHFFFAOYSA-N 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000011863 silicon-based powder Substances 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- VLCLHFYFMCKBRP-UHFFFAOYSA-N tricalcium;diborate Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]B([O-])[O-].[O-]B([O-])[O-] VLCLHFYFMCKBRP-UHFFFAOYSA-N 0.000 description 1
- NFMWFGXCDDYTEG-UHFFFAOYSA-N trimagnesium;diborate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]B([O-])[O-].[O-]B([O-])[O-] NFMWFGXCDDYTEG-UHFFFAOYSA-N 0.000 description 1
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 150000003751 zinc Chemical class 0.000 description 1
- LRXTYHSAJDENHV-UHFFFAOYSA-H zinc phosphate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LRXTYHSAJDENHV-UHFFFAOYSA-H 0.000 description 1
- 229910000165 zinc phosphate Inorganic materials 0.000 description 1
- NWONKYPBYAMBJT-UHFFFAOYSA-L zinc sulfate Chemical compound [Zn+2].[O-]S([O-])(=O)=O NWONKYPBYAMBJT-UHFFFAOYSA-L 0.000 description 1
- 229960001763 zinc sulfate Drugs 0.000 description 1
- 229910000368 zinc sulfate Inorganic materials 0.000 description 1
Landscapes
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Producing Shaped Articles From Materials (AREA)
Description
〔発明の技術分野〕
本発明は、軽量且つ耐水性が良好で高強度な複
合板用軽量板材の製造方法に関する。
〔従来技術の欠点〕
従来より、軽量で、防火性、防音性、断熱性等
の優れた軽量板材としては各種各様のものが製造
され、複合板製造用に供給されている。一般に上
記軽量板材は、単独で使用されるよりもどちらか
というと他の化粧板材と複合する、即ちサンドイ
ツチ板のための複合板用心材として供されてお
り、例えばその具体例な軽量板材としては、木毛
セメント板、パーライトモルタル板、パーライト
成形板、泡ガラス板、その他有機質フオーム等が
よく知られている。
しかしながら、木毛セメント板、パーライトモ
ルタル板等は強度が特に優れている反面、比重が
大きいので複合板用軽量板材としての用途が制限
され易く、断熱性が必ずしも好ましいとはいえな
い。また、パーライト成形板、泡ガラス板等は、
防火性が良好であるという点を除けば、やはり比
重が大きいという欠点、比較的脆いという欠点、
その為に生じる持ち運び上の問題があり、複合板
用軽量板材の製造にはなお不便を来たしている。
更に有機質フオームは、軽量性、断熱性、遮音性
等が優れており、複合板用軽量板材を製造するに
際してその中空部に簡単に充填できるという利点
があるが、熱や火に弱いのみならず、これが成形
板の時には持ち運ぶが不便、現場発泡の時には断
熱対象物の腐食を発生することもある。
このような事情から、以前より価格的に安価で
上記目的を付与する要素を有するパーライト等の
軽量骨材を利用することが色々実施されており、
例えばパーライト粒子を比較的少量の結合剤、即
ちセメントやゆう薬、合成樹脂等で結合する、又
はパーライト粒子を互いに融着させる、或いはこ
れらに無機質繊維を介在させる等によつて、軽量
性、防火性、断熱性、強度向上をはかつている
が、係る用途に適合する複合板用の軽量板材は得
ることができなかつた。
〔発明が解決しようとする手段〕
本発明は、上述したような軽量で、耐水性、防
火性、防音性、断熱性等の優れた複合板に使用し
得る軽量板材を提供しようとするもので、特に特
定の無機質発泡硬化性組成物と軽量骨材を配合
し、これを特定の構造を有する空間部、即ちハニ
カムコアを有する型枠内部に充填し、発泡硬化せ
しめることによつて成し得たものである。即ち、
本発明は、型枠に、発泡硬化性を有する組成物を
充填し複合板用軽量板材を製造するに際し、予め
型枠内にハニカムコアを形成し、該ハニカムコア
の空隙部に、(a)水可溶性アルカリ金属珪酸塩溶
液、(b)金属系発泡剤、(c)水可溶性アルカリ金属珪
酸塩の硬化剤、(d)軽量骨材及び(e)水から成り、か
つ(d)成分100容量部に対して、(a)+(b)+(c)+(e)の
合計量が2〜40容量部である発泡硬化性組成物を
充填、発泡硬化せしめることを特徴とするもので
ある。
〔発明の目的〕
こうして得られる複合板用軽量板材は、軽量
で、耐水性が良く、圧縮及び曲げ強度が高く、防
火性、収縮膨脹抵抗、防音性等が優れ、切断等の
加工性、取扱い作業性等も非常に良好であり、複
合板材製造の上で非常に利用価値が高い。
以下、本発明の構成について詳述する。
〔発明の構成〕
本発明において、第(a)成分としては水可溶性ア
ルカリ金属珪酸塩を使用し、これにより初めて常
温下で他の原料物質と混合するだけで容易に諸性
能の優れた発泡硬化体を得ることができ、有効な
粘結性を呈してその発泡反応を効率良くなさしめ
る。この第(a)成分を構成するアルカリ成分として
は、例えば、リチウム、ナトリウム、カリウム、
ルビジウム等のアルカリ金属珪酸塩を例示できる
が、特にナトリウム、カリウムの場合は安価で入
手し易く、しかも組成物の硬化効果の促進が顕著
であり、望ましい。また、第(a)成分は水溶性であ
る限り、その組成やアルカリ物質とSiO2とのモ
ル比には制限されるものではない。
また、第(b)成分としては金属系発泡剤を使用
し、各種の金属元素及び金属合金乃至金属間化合
物が使用できる。金属元素としては周期律表の
B、A、B、A、B、A、B、
B、B及び族に属するものが好ましく、係る
金属元素としては、Cr、Mn、Ti、Zr、V、Si、
Ge、Sb、Co、Ni、Cu、Zn、Al、Ca等が例示で
き、特にTi、Zr、V、Al、Si、Ge、Sb、Zn等は
望ましいものである。合金乃至金属間化合物(金
属相互間もしくは金属と非金属との化学結合体)
の代表的なものを例示すれば、Al−Si、Al−Ti、
Al−Mn、Al−Cu、Al−Cu−Si、Zn−S、Zn−
Sn、Cu−Si、Fe−Si、Si−Ni、Co−Sb等が挙
げられる。この金属系発泡剤は通常1種又は2種
以上を微粉末の形態で使用する。 次に、第(c)成
分としては水可溶性アルカリ金属珪酸塩の硬化剤
を使用するものであり、この(e)成分は、(a)成分の
硬化を補強するに役立つものである。係る硬化剤
の例としては、水硬性セメント、シリカダスト、
酸性金属酸化物、高炉スラツグ、高級脂肪酸の二
価以上の金属塩、カルボキシル基を有する水溶性
高分子物質の二値以上の金属塩、リン酸塩、ホウ
酸塩、二価金属の硫酸塩及び二価金属の亜硫酸塩
の群から選ばれる少なくとも1種である。この硬
化性成分を具体的に例示すれば次の通りである。
水硬性セメントとしては、ポルトランドセメン
ト、アルミナセメント、高炉セメント、シリカセ
メント等、高級脂肪酸の二価以上の金属塩は、代
表的なものとしてステアリン酸やパルミチン酸の
亜鉛塩、アルミニウム塩等、カルボキシル基を含
有する水溶性高分子の二価以上の塩として、水溶
性高分子がアルギン酸、ポリアクリル酸等で構成
され、二価以上の金属がZn、Mg、Be、Sr、Ba、
Al、Ti、Zr等から選ばれる金属で、該水溶性高
分子と金属とで塩を形成しているもの、酸性金属
酸化物としては、ZnO、Cr2O3、MnO2、MnO、
FeO、CoO、PbO等が、またリン酸塩としてはリ
ン酸アルミニウム、リン酸カルシウム、リン酸亜
鉛、リン酸マグネシウム等が、ホウ酸塩としては
ホウ酸亜鉛、ホウ酸マグネシウム、ホウ酸カルシ
ウム等、二価金属の硫酸塩としては硫酸マグネシ
ウム、硫酸亜鉛、硫酸カルシウム等、二価金属の
亜硫酸塩としては亜硫酸カルシウム、亜硫酸マグ
ネシウム等が例示できる。
本発明における第(d)成分としては軽量骨材を使
用するもので、天然鉱物の発泡又は膨脹した物質
である膨脹パーライト(単にパーライトといわれ
る)、膨脹頁岩、膨脹バーミキユライト、軽石、
シラスバルーン等の他、シリカゲルの発泡体、各
種スラグを造粒して発泡させた物、粘土粉体を造
粒して発泡させた物等のような人工軽量骨材を含
む。これ等の内、膨脹又は発泡した物質で、特に
気泡の独立性が高く、軽量性に富み、球状を呈す
るものが好ましく、例えばパーライト、シラスバ
ルンーン、シリカゲル発泡体、ガラスバルーン等
を例示できる。
上記の如く、本発明に使用する発泡硬化性組成
物は、上述4成分並びに(e)水を加えたものから成
るが、その配合比率は、(a)成分の固形分換算量
100重量部に対して、(b)成分2〜100重量部、(c)成
分5〜100重量部及び(e)成分10〜100重量部とし、
且つこれら(a)+(b)+(c)+(e)成分の合計量と(d)成分
の量との比率は、(d)成分100容量部に対して(a)+
(b)+(c)+(e)成分2〜40容量部とするもので、所謂
結合材成分((a)+(b)+(c)+(e))が2容量部を下回
る時には、所望の強度の良好なものが得難く、40
容量部を越えると断熱性の低下のみならず曲げ強
度も低下する傾向となる。
本発明の製造方法は、上記4成分((a)+(b)+(c)
+(d)成分)に(e)水を配合した発泡硬化性組成物ペ
ーストを、ハニカムコアを有する型枠に充填する
ことにあり、係る操作は常温下でも加熱下でも容
易に行える。ハニカムコアは、中空心材ともいわ
れ、その材質は紙製、金属製、プラスチツク製、
アスベスト製等種々あるが、紙製ハニカムコアは
最も安価であり、本発明の使用に最も適する。紙
製ハニカムコアは、具体的にはJIS A 6931にも
規定されているが、紙単独のものの他に、樹脂を
含浸したものもある。金属製ハニカムコアとして
は、アルミニウム、ステンレス、チタニウム等が
ある。次に、ハニカムコアの形状には、代表的な
六角形状の他に、円形状、リブ状、段ボール形
状、折紙形状等あるが、特にその形状には影響さ
れない。コアの大きさについては、格別に規定さ
れるものではなく、用途に応じて適時選択すれば
良い。
また、上記5成分の他に、必要に応じて適宜増
量材、粘性調整材、タレ防止材等を配合できる。
〔発明の効果〕
本発明によつて、当該複合板用軽量板材製造に
際し、次のような利点を列挙できる。即ち、(1)実
用上比重が0.2程度の軽量板材は一般に強度が低
いが、本発明によつて得られる軽量板材は、配合
によつても異なるが、比重が0.05〜0.3程度に調
整でき、ハニカムコア自体の強度と発泡硬化体と
の複合効果によつて予想外の圧縮強度、曲げ強度
(せん断強度ともいわれる)が得られる。係る効
果は、推定する処によると、ハニカムコア単独の
場合、例えば圧縮荷重を受けると、コアを形成す
る隔壁に応力が分散されるに留まるが、本発明複
合板用軽量板材によると、更にコア内に形成され
ている発泡硬化体の軽量骨材に分散され、緩和さ
れるからである。従つて、軽量且つ高強度の複合
板用軽量板材が得られるのである。また、(2)ハニ
カムコアが紙製であつても発泡硬化体が不燃で、
発泡硬化組成物中の水可溶性アルカリ金属珪酸塩
が一部紙に含浸されるので、防火性が非常に良
い。更に、(3)上述したようにハニカムコアは、発
泡硬化体のクツシヨン材的な機能を果たし、他の
無機質性軽量板材に比し弾力性に富む。更にま
た、(4)ハニカムコアの有する吸音性と発泡硬化体
の有する遮音性が複合して防音性を高める。他
方、(5)本発明者等は、先願においては水可溶性ア
ルカリ金属珪酸塩の硬化剤を使用しないものを創
作したが、先願のものは耐水性が芳しくなかつた
けれど、本願のものは耐水性が非常に向上し、こ
れを外部に使用して水が浸入しても良く耐えると
いうことが分かつた。その他(6)堅牢にしてかなり
の弾性強度を示す処から、寸法安定性や切断加工
性等も優れている。
上述のような軽量板材を複合板の心材とし、そ
の上下に種々の化粧材、例えば化粧石綿スレー
ト、着色亜鉛鉄板、着色アルミニウム板等を使用
したサンドイツチ構造の複合板は、従来から使用
されている複合板に比べて非常に強度が優れる。
以下、実施例により具体的に説明する。
〔発明の実施態様〕
実施例 1
発泡硬化性組成物として、次の配合のものを使
用した。
[Technical Field of the Invention] The present invention relates to a method for manufacturing a lightweight board material for a composite board that is lightweight, has good water resistance, and has high strength. [Disadvantages of the Prior Art] Various types of light board materials that are lightweight and have excellent fireproofing, soundproofing, and heat insulating properties have been manufactured and supplied for use in the manufacture of composite boards. In general, the above-mentioned lightweight board materials are used in combination with other decorative board materials, rather than being used alone, that is, they are used as composite board core materials for sand German boards. For example, specific examples of lightweight board materials include , wood wool cement board, perlite mortar board, perlite molded board, foam glass board, and other organic foams are well known. However, although wood wool cement boards, pearlite mortar boards, etc. have particularly excellent strength, their high specific gravity tends to limit their use as lightweight board materials for composite boards, and their heat insulation properties are not necessarily favorable. In addition, perlite molded plates, foam glass plates, etc.
Apart from its good fire resistance, it also has the drawbacks of high specific gravity and relatively brittleness.
This poses a problem in transportation, which still causes inconvenience in the production of lightweight composite board materials.
Furthermore, organic foam has excellent lightness, heat insulation, sound insulation, etc., and has the advantage that it can be easily filled into hollow parts when manufacturing lightweight board materials for composite boards, but it is not only weak against heat and fire. When this is a molded plate, it is inconvenient to carry, and when foaming on site, it may cause corrosion of the insulation target. Under these circumstances, various efforts have been made to use lightweight aggregates such as perlite, which are inexpensive and have elements that provide the above objectives.
For example, by bonding pearlite particles with a relatively small amount of binder such as cement, powder, synthetic resin, etc., by fusing pearlite particles with each other, or by interposing inorganic fibers between them, lightweight and fireproof properties can be achieved. However, it has not been possible to obtain a lightweight board material for composite boards that is suitable for such uses. [Means to be Solved by the Invention] The present invention aims to provide a lightweight board material as described above that can be used for a composite board that is lightweight and has excellent water resistance, fireproofing properties, soundproofing properties, heat insulation properties, etc. In particular, this can be achieved by blending a specific inorganic foam curable composition and lightweight aggregate, filling this into a space with a specific structure, that is, inside a mold having a honeycomb core, and foaming and hardening it. It is something that That is,
In the present invention, when manufacturing a lightweight board material for a composite board by filling a formwork with a foam-hardening composition, a honeycomb core is formed in the formwork in advance, and the voids of the honeycomb core are filled with (a) consisting of a water-soluble alkali metal silicate solution, (b) a metal blowing agent, (c) a water-soluble alkali metal silicate hardening agent, (d) a lightweight aggregate, and (e) water, and (d) component 100 volume. The composition is characterized by being filled with a foaming curable composition in which the total amount of (a) + (b) + (c) + (e) is 2 to 40 parts by volume per part, and then foaming and hardening. . [Object of the invention] The lightweight board material for composite board obtained in this way is lightweight, has good water resistance, high compression and bending strength, has excellent fireproofing properties, shrinkage-expansion resistance, soundproofing properties, etc., and is easy to process such as cutting and handling. It has very good workability and is of great utility in the production of composite plate materials. Hereinafter, the configuration of the present invention will be explained in detail. [Structure of the Invention] In the present invention, a water-soluble alkali metal silicate is used as the component (a), and this allows easy foaming and hardening with excellent performance by simply mixing it with other raw materials at room temperature. It exhibits effective caking properties and makes the foaming reaction efficient. Examples of the alkaline components constituting component (a) include lithium, sodium, potassium,
Alkali metal silicates such as rubidium can be exemplified, and sodium and potassium are particularly desirable because they are inexpensive and easily available, and moreover, they significantly accelerate the hardening effect of the composition. Furthermore, as long as component (a) is water-soluble, there are no restrictions on its composition or the molar ratio of the alkaline substance to SiO 2 . Further, as the component (b), a metal foaming agent is used, and various metal elements, metal alloys, and intermetallic compounds can be used. Metal elements include B, A, B, A, B, A, B of the periodic table,
B, B, and those belonging to the group are preferable, and such metal elements include Cr, Mn, Ti, Zr, V, Si,
Examples include Ge, Sb, Co, Ni, Cu, Zn, Al, Ca, etc., and Ti, Zr, V, Al, Si, Ge, Sb, Zn, etc. are particularly desirable. Alloys or intermetallic compounds (chemical combinations between metals or between metals and nonmetals)
Representative examples include Al-Si, Al-Ti,
Al-Mn, Al-Cu, Al-Cu-Si, Zn-S, Zn-
Examples include Sn, Cu-Si, Fe-Si, Si-Ni, Co-Sb, and the like. One or more of these metal foaming agents are usually used in the form of fine powder. Next, as component (c), a water-soluble alkali metal silicate curing agent is used, and component (e) serves to reinforce the curing of component (a). Examples of such hardening agents include hydraulic cement, silica dust,
Acidic metal oxides, blast furnace slag, divalent or higher metal salts of higher fatty acids, divalent or higher metal salts of water-soluble polymer substances having carboxyl groups, phosphates, borates, sulfates of divalent metals, and It is at least one selected from the group of divalent metal sulfites. Specific examples of this curable component are as follows.
Hydraulic cements include portland cement, alumina cement, blast furnace cement, silica cement, etc. Divalent or higher metal salts of higher fatty acids are typical examples, such as zinc salts and aluminum salts of stearic acid and palmitic acid, and carboxyl group The water-soluble polymer is composed of alginic acid, polyacrylic acid, etc., and the divalent or higher-valent metal is Zn, Mg, Be, Sr, Ba,
A metal selected from Al, Ti, Zr, etc., which forms a salt with the water-soluble polymer and the metal, and acidic metal oxides such as ZnO, Cr 2 O 3 , MnO 2 , MnO,
FeO, CoO, PbO, etc.; phosphates include aluminum phosphate, calcium phosphate, zinc phosphate, magnesium phosphate, etc.; borates include zinc borate, magnesium borate, calcium borate, etc. Examples of metal sulfates include magnesium sulfate, zinc sulfate, and calcium sulfate, and examples of divalent metal sulfites include calcium sulfite and magnesium sulfite. The component (d) in the present invention uses lightweight aggregates, including expanded pearlite (simply referred to as pearlite), which is a foamed or expanded natural mineral, expanded shale, expanded vermiculite, pumice,
In addition to whitebait balloons, it also includes artificial lightweight aggregates such as silica gel foam, granulated and foamed products of various slags, and foamed products of clay powder. Among these, expanded or foamed materials, particularly those with high bubble independence, light weight, and spherical shape, are preferred, such as pearlite, shirasu balloons, silica gel foams, glass balloons, and the like. As mentioned above, the foamed curable composition used in the present invention consists of the above-mentioned four components and (e) water added, and the blending ratio is the solid content equivalent of component (a).
For 100 parts by weight, component (b) is 2 to 100 parts by weight, component (c) is 5 to 100 parts by weight, and component (e) is 10 to 100 parts by weight,
In addition, the ratio of the total amount of these components (a) + (b) + (c) + (e) to the amount of component (d) is (a) + component (d) to 100 parts by volume.
(b) + (c) + (e) components should be 2 to 40 parts by volume, and when the so-called binder component ((a) + (b) + (c) + (e)) is less than 2 parts by volume , it is difficult to obtain a good one with the desired strength, and 40
If it exceeds the capacity part, not only the heat insulation properties but also the bending strength tends to decrease. The production method of the present invention comprises the above four components ((a) + (b) + (c)
The purpose of the present invention is to fill a mold having a honeycomb core with a foamed curable composition paste containing component (d) and water (e), and this operation can be easily performed at room temperature or under heating. Honeycomb core is also called hollow core material, and its materials include paper, metal, plastic, and
Although there are various types of cores such as those made of asbestos, paper honeycomb cores are the cheapest and most suitable for use in the present invention. Paper honeycomb cores are specifically specified in JIS A 6931, and in addition to those made of paper alone, there are also those impregnated with resin. Examples of the metal honeycomb core include aluminum, stainless steel, and titanium. Next, the shape of the honeycomb core includes, in addition to the typical hexagonal shape, a circular shape, a rib shape, a cardboard shape, an origami shape, etc., but it is not particularly influenced by the shape. The size of the core is not particularly defined, and may be appropriately selected depending on the application. In addition to the above five components, fillers, viscosity modifiers, anti-sag materials, etc. can be added as appropriate. [Effects of the Invention] According to the present invention, the following advantages can be enumerated in manufacturing the lightweight board material for the composite board. That is, (1) In practical use, a lightweight board material with a specific gravity of about 0.2 generally has low strength, but the lightweight board material obtained by the present invention can have a specific gravity adjusted to about 0.05 to 0.3, although it varies depending on the composition. Unexpected compressive strength and bending strength (also called shear strength) can be obtained by the combined effect of the strength of the honeycomb core itself and the foamed hardened body. It is estimated that such an effect is achieved when a honeycomb core is used alone, for example, when subjected to a compressive load, the stress is only dispersed to the partition walls forming the core, but according to the lightweight board material for composite board of the present invention, the core This is because it is dispersed and relaxed by the lightweight aggregate of the foamed hardened body formed inside. Therefore, a lightweight board material for a composite board that is lightweight and has high strength can be obtained. In addition, (2) even if the honeycomb core is made of paper, the foamed hardened material is nonflammable;
Since the water-soluble alkali metal silicate in the foamed hardening composition is partially impregnated into the paper, the fireproofing properties are very good. Furthermore, (3) as mentioned above, the honeycomb core functions like a cushion material for a cured foam and has higher elasticity than other lightweight inorganic board materials. Furthermore, (4) the sound absorbing properties of the honeycomb core and the sound insulating properties of the cured foam combine to improve soundproofing properties. On the other hand, (5) in the previous application, the present inventors created a product that did not use a water-soluble alkali metal silicate curing agent, but although the previous application did not have good water resistance, the present invention It has been found that the water resistance has been greatly improved and that it can withstand water penetration when used externally. Others (6) It is robust and exhibits considerable elastic strength, so it has excellent dimensional stability and cutting workability. Composite boards with a sandwich structure have traditionally been used, in which the lightweight board material mentioned above is used as the core material of the composite board, and various decorative materials such as decorative asbestos slate, colored galvanized iron plates, and colored aluminum plates are used above and below the core material. Extremely strong compared to composite boards. Hereinafter, this will be explained in detail using examples. [Embodiments of the Invention] Example 1 A foam curable composition having the following formulation was used.
【発泡硬化性組成物】
珪酸ソーダ(水ガラス1号、固形分40%)
100重量部(固形分換算で)
金属珪素粉末 25重量部
アルミナセメント 20重量部
水 160重量部
これらを混合してペーストに調製した処、比重
は1.4であつた。このペースト12容量部に対して
比重0.05で粒径2〜5mmのパーライトを100容量
部配合し、発泡硬化性組成物を得た。
次に、JIS A 6931に規定のパネル用ペーパー
コアの内六角形状で、幅40cm、長さ80cm、厚さ25
mm、セルサイズ25mmのハニカムコアの下部に剥離
性プラスチツクシートを介して3mm厚の石綿スレ
ートを設置し、上記発泡硬化性組成物を約1/4の
高さまで充填し、次にハニカムコアの上部を剥離
性プラスチツクシートを介して石綿スレートで押
さえ常温下で放置した処、約20分後に発泡硬化性
組成物は発泡を開始し、35分後には硬化し、比重
0.15の軽量板材が得られた。この複合板材を用い
てJIS A 6931に規定される圧縮強度及びせん断
強度の試験をした処、圧縮強度6.1Kgf/cm2、せ
ん断強度1.1Kgf/cm2であつた。また、これを水
中に1週間浸漬したがペーパーにしわができた以
外は何等変化はなかつた。更に、弾性率、鋸切断
性、防音性を試験した処、従来3の軽量板材に比
べて良好であつた。
比較例 1〜3
実施例において、軽量板材として発泡硬化性組
成物を使用しないペーパーハニカムコア単独のも
の(比較例1)、軽量板材として発泡硬化性組成
物を単独で発泡硬化せしめたもの(比較例2)及
び発泡硬化性組成物中のアルミナセメントを除い
た配合の組成物を使用したもの(比較例3)を調
製し、これらについて圧縮強度、せん断強度及び
耐水性試験をした処、次の値が得られた。
比較例1の圧縮強度:1.3Kgf/cm2
せん断強度:0.72Kgf/cm2
耐水性:形状が完全に崩壊
比較例2の圧縮強度:0.57Kgf/cm2
せん断強度:0.34Kgf/cm2
耐水性:全く異状なかつた
比較例3の圧縮強度:5.9Kgf/cm2
せん断強度:1.2Kgf/cm2
耐水性:ペーパーにしわが沢山入り、硬化体は1/
10程度形崩れした[Foam curable composition] Sodium silicate (water glass No. 1, solid content 40%)
100 parts by weight (in terms of solid content) Metallic silicon powder 25 parts by weight Alumina cement 20 parts by weight Water 160 parts by weight These were mixed to make a paste, and the specific gravity was 1.4. To 12 parts by volume of this paste, 100 parts by volume of pearlite having a specific gravity of 0.05 and a particle size of 2 to 5 mm was blended to obtain a foam curable composition. Next, the paper core for panels specified in JIS A 6931 has a hexagonal shape, width 40 cm, length 80 cm, and thickness 25 cm.
Asbestos slate with a thickness of 3 mm is installed at the bottom of a honeycomb core with a cell size of 25 mm through a removable plastic sheet, and the foam curable composition is filled to about 1/4 of the height, and then the top of the honeycomb core is When the composition was pressed with asbestos slate through a removable plastic sheet and left at room temperature, the foam-curable composition started foaming after about 20 minutes, hardened after 35 minutes, and the specific gravity decreased.
A lightweight plate material of 0.15 was obtained. Using this composite plate material, a compressive strength and shear strength test specified in JIS A 6931 was conducted, and the compressive strength was 6.1 Kgf/cm 2 and the shear strength was 1.1 Kgf/cm 2 . Further, this paper was immersed in water for one week, but there was no change other than wrinkles in the paper. Furthermore, when the elastic modulus, saw cutting properties, and soundproofing properties were tested, they were better than the conventional lightweight board material 3. Comparative Examples 1 to 3 In the examples, a paper honeycomb core alone without using a foam curable composition was used as a lightweight board material (Comparative Example 1), and a paper honeycomb core was used as a lightweight board material in which a foam curable composition was foamed and hardened alone (Comparative Example 1). Example 2) and a foam curable composition using a composition excluding alumina cement (Comparative Example 3) were prepared and subjected to compressive strength, shear strength and water resistance tests. value was obtained. Compressive strength of Comparative Example 1: 1.3Kgf/cm 2 Shear strength: 0.72Kgf/cm 2 Water resistance: Shape completely collapsed Compressive strength of Comparative Example 2: 0.57Kgf/cm 2 Shear strength: 0.34Kgf/cm 2 Water resistance : Compressive strength of Comparative Example 3 with no abnormality: 5.9 Kgf/cm 2 Shear strength: 1.2 Kgf/cm 2 Water resistance: Paper has many wrinkles, cured product is 1/
It lost its shape by about 10 degrees.
Claims (1)
て複合板用軽量板材を製造するに際し、予め型枠
内にハニカムコアを形成し、該ハニカムコアの空
間部に、(a)水可溶性アルカリ金属珪酸塩溶液、(b)
金属系発泡剤、(c)水可溶性アルカリ金属珪酸塩の
硬化剤、(d)軽量骨材及び(e)水から成り、かつ(d)成
分100容量部に対して、(a)+(b)+(c)+(d)の合計量
が2〜40容量部である発泡硬化性組成物を充填、
発泡硬化せしめることを特徴とする複合板用軽量
板材の製造方法。1. When manufacturing a lightweight board material for a composite board by filling a formwork with a foam-hardening composition, a honeycomb core is formed in the formwork in advance, and (a) a water-soluble Alkali metal silicate solution, (b)
It consists of a metal foaming agent, (c) a water-soluble alkali metal silicate hardening agent, (d) a lightweight aggregate, and (e) water, and for 100 parts by volume of the (d) component, (a) + (b) ) + (c) + (d) in a total amount of 2 to 40 parts by volume of a foamed curable composition;
A method for manufacturing a lightweight board material for a composite board, which is characterized by foaming and hardening.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP18545585A JPS6246980A (en) | 1985-08-22 | 1985-08-22 | Manufacture of lightweight board material for composite board |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP18545585A JPS6246980A (en) | 1985-08-22 | 1985-08-22 | Manufacture of lightweight board material for composite board |
Publications (2)
Publication Number | Publication Date |
---|---|
JPS6246980A JPS6246980A (en) | 1987-02-28 |
JPH0568431B2 true JPH0568431B2 (en) | 1993-09-28 |
Family
ID=16171090
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP18545585A Granted JPS6246980A (en) | 1985-08-22 | 1985-08-22 | Manufacture of lightweight board material for composite board |
Country Status (1)
Country | Link |
---|---|
JP (1) | JPS6246980A (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20050103232A1 (en) * | 2003-11-19 | 2005-05-19 | Gadkaree Kishor P. | Composition and method for making ceramic filters |
US9944468B2 (en) | 2014-04-30 | 2018-04-17 | Itoh Denki Co., Ltd. | Conveyor device |
-
1985
- 1985-08-22 JP JP18545585A patent/JPS6246980A/en active Granted
Also Published As
Publication number | Publication date |
---|---|
JPS6246980A (en) | 1987-02-28 |
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