WO2000059698A1 - Gypsum board, gypsum board producing method and gypsum board producing device - Google Patents

Gypsum board, gypsum board producing method and gypsum board producing device Download PDF

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Publication number
WO2000059698A1
WO2000059698A1 PCT/JP2000/001790 JP0001790W WO0059698A1 WO 2000059698 A1 WO2000059698 A1 WO 2000059698A1 JP 0001790 W JP0001790 W JP 0001790W WO 0059698 A1 WO0059698 A1 WO 0059698A1
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WO
WIPO (PCT)
Prior art keywords
gypsum
gypsum board
chips
dried
raw
Prior art date
Application number
PCT/JP2000/001790
Other languages
French (fr)
Japanese (ja)
Inventor
Norifumi Nagata
Sumio Honda
Shinkichi Tanabe
Kazuo Takeuchi
Koichi Kuwayama
Nobuyuki Kimura
Kunio Motoyoshi
Hidero Nakaya
Original Assignee
Building Materials Technology Laboratories, K.K.
Taiheiyo Engineering Co., Ltd.
Taiheiyo Cement Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Building Materials Technology Laboratories, K.K., Taiheiyo Engineering Co., Ltd., Taiheiyo Cement Corporation filed Critical Building Materials Technology Laboratories, K.K.
Priority to AU33266/00A priority Critical patent/AU3326600A/en
Publication of WO2000059698A1 publication Critical patent/WO2000059698A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/02—Conditioning the material prior to shaping
    • B28B17/023—Conditioning gypsum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • Gypsum board, gypsum board manufacturing method and gypsum board manufacturing apparatus Description Gypsum board, gypsum board manufacturing method and gypsum board manufacturing apparatus
  • the present invention relates to a gypsum board, a gypsum board manufacturing method, and a gypsum board manufacturing apparatus. More specifically, the present invention relates to a method and an apparatus capable of stably producing a gypsum board having remarkably excellent bending strength, resistance to pulling out screws and nails, and various performances with good productivity. Further, the present invention relates to a gypsum board capable of obtaining desired bending strength and screw / nail pull-out resistance even when manufactured by an arbitrary manufacturing method. Background art
  • gypsum board widely used as an inorganic interior building material that is inexpensive and has excellent fire resistance
  • a fiber material is mixed with a gypsum material. It is known.
  • a typical example of the fiber material is fiberized pulp.
  • the pulp raw material is fiberized using an impact-type pulverizer such as a hammer mill or a wet defibration machine such as pulper. This is done by dispersing in a gypsum material matrix. This method is effective for reinforcing gypsum board.
  • the defibrated fiber becomes very bulky, and this is the case. Even if you try to knead the bulky fiber and the powder of the gypsum material together with water, a uniform mixture is obtained. It is technically difficult to obtain efficiently.
  • the fiberized pulp in the prior art is usually fine fibers having a length of about 0.1 to 3 mm and a width of about 100 to 100 ⁇ m. Entangled with each other in the slurry, It significantly reduces the fluidity of the slurry. Therefore, in a gypsum board production line produced through slurrying of raw materials, usually, only about 0.1 to 2%, at most about 3%, of fibers can be blended. At such a fiber mixing ratio, the properties of the resulting gypsum board, especially the properties such as bending strength and screw and nail pull-out resistance, are not improved as expected, but rather, the separation of materials that occurs during manufacturing. In some cases, this property may be impaired even if fibers are blended.
  • the present inventors have proposed a composite gypsum board and a method for producing the same in WO 96/26166, which solve the above conventional problems.
  • This composite gypsum board is prepared by mixing paper chips and / or chips with a gypsum material, and the paper chips and / or chips are oriented substantially parallel to a plane perpendicular to the thickness direction of the composite gypsum board. Is what it is.
  • such composite gypsum board prepares a raw material slurry containing gypsum material, paper chips and / or chips, water, and various types of filler materials as needed, and supplies them to a movable conveyor. While moving the conveyor, the paper chips and / or chips contained in the raw slurry are oriented by an orientation means so as to be substantially parallel to the plane perpendicular to the thickness direction of the composite gypsum board to be obtained. Is done.
  • the present inventors have reported that, as WO 96/26616, a composition particularly suitable for gypsum board, the gypsum material is 100 parts by weight of hemihydrate gypsum and 100 to 25 gypsum. A gypsum material composition consisting of 0 parts by weight was also proposed.
  • the gypsum material, paper chips and / or chips, water, and, if necessary, various filler materials are continuously continuously used.
  • the raw material slurry is prepared by putting the slurry in a mixer, there is a problem that the supply to the continuous mixer becomes unstable due to the bulk of the paper chips and / or chips in the process. For example, since the rotor in the continuous mixer is rotating at high speed, the paper chips and / or chip bodies flowing from the supply path are blown up and flutter in the supply path, making it difficult to supply a predetermined amount. .
  • gypsum board is manufactured using the above-mentioned gypsum material composition
  • gypsum dihydrate that has not been dried usually has a water content of several% to several tens%. Adhesion to the path is severe, and stable supply to the continuous mixer becomes difficult. There are also problems.
  • FIG. 18 and FIG. 19 are process drawings for explaining in detail the problems when the above-mentioned composite gypsum board is manufactured using a conventional general gypsum board manufacturing line.
  • gypsum that has not been dried hereinafter referred to as raw gypsum
  • the raw dihydrate gypsum 11 is transferred to a dryer 12, and after drying, is ground by a mill 13.
  • a calciner 14 it is calcined in a calciner 14 to be converted into hemihydrate gypsum having hydration-hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16.
  • the kneading water 21, paper chips and / or chips 22 (hereinafter simply referred to as “chips”), and if necessary, additives (agents) 23, are stored in hemihydrate gypsum silos 16. It is introduced into the continuous mixer 31 together with the hemihydrate gypsum. Subsequently, the material kneaded in the continuous mixer 31 is introduced into the casting means 32. In the embodiment of FIG. 18, as described above, the chip may not be stably introduced due to the high-speed rotation of the mouth in the continuous mixer 31.
  • FIG. 19 is a process chart in the case of producing a gypsum board using no gypsum material composition and containing the above-described gypsum material composition.
  • the fresh gypsum plaster 1 1 is dried with a dryer 1 2, pulverized with a pulverizer 13, calcined in a calciner 14, and the obtained hemihydrate gypsum is pulverized with a pulverizer 15 to obtain semi-hydrated water.
  • the process of temporarily storing in gypsum silo 16 is the same as in FIG.
  • kneading water 21 and, if necessary, additives (agent) 23 are introduced into the continuous mixer 31 together with the hemihydrate gypsum stored in the hemihydrate gypsum silo 16.
  • a part of the gypsum dihydrate 11 is directly transferred to the continuous mixer 31 and kneaded so as to satisfy a predetermined mixing ratio of the composition.
  • the kneaded material is introduced into the casting means 32.
  • the raw dihydrate gypsum adheres to the transfer path toward the continuous mixer 31 and cannot be stably supplied to the continuous mixer 31.
  • an object of the present invention is to provide a method and an apparatus capable of stably producing a gypsum board with remarkably excellent bending strength and resistance to pulling out screws and nails, and various performances with good productivity. .
  • Another object of the present invention is to provide a gypsum board capable of obtaining desired bending strength and screw / nail pull-out resistance even when manufactured by an arbitrary manufacturing method. Disclosure of the invention
  • At least one gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum, and paper chips and / or chip bodies are kneaded in a premixer.
  • a premixing step a step of kneading a raw material containing the obtained kneaded material, water and, as necessary, various additives (agents) in a continuous mixer to prepare a raw material slurry, and pouring and forming the raw material slurry.
  • a method for producing a gypsum board comprising:
  • the raw material slurry contains hydration-hardening gypsum as an essential component.
  • the blending step comprises kneading a raw dihydrate gypsum or a dried dihydrate gypsum, a hydrate-curable gypsum, and a paper chip and / or a chip body in a premixer.
  • a method for producing a gypsum board is provided.
  • the premixing step may include: a first premixing step of kneading the raw gypsum or the dried gypsum, and a paper chip and / or a chip body in the first premixer; And a gypsum material having hydration-hardening properties in a second premixer, and a second premixing step of kneading the same in a second premixer.
  • the present invention provides the method for producing a gypsum board according to the above, wherein the premixing step comprises kneading the raw gypsum or the dried gypsum and the paper chips and / or chips in a premixer. Things.
  • the present invention provides a method of kneading at least one gypsum selected from the group consisting of fresh gypsum and dried gypsum, and gypsum having hydration-hardening property in a premixer.
  • a method for producing a gypsum board containing the same are examples of additives (agents) in a continuous mixer.
  • the present invention further comprises a step of drying the raw dihydrate gypsum to obtain a dried gypsum, and a step of only grinding or burning the dried gypsum to obtain a hydrate-setting gypsum. And a method for producing a gypsum board.
  • the present invention provides a gypsum board manufactured by the above manufacturing method.
  • the present invention comprises kneading at least one type of gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum with a paper chip and / or a chip body. And a raw material containing the obtained kneaded material, water, and, if necessary, various additives (agents) are continuously supplied and kneaded, and the obtained raw material slurry (provided that the raw material slurry Is a gypsum board having a hydration-hardening gypsum as an essential component), and a means capable of pouring and molding the raw material slurry.
  • a manufacturing apparatus is provided.
  • the present invention provides a dryer for drying raw dihydrate gypsum to obtain dried dihydrate gypsum, a pulverizer for pulverizing the dried dihydrate gypsum, and a hydration-curable gypsum obtained by calcining the pulverized dry gypsum.
  • An apparatus for producing a gypsum board further comprising: a calcining furnace;
  • the present invention provides a gypsum board in which a paper chip and / or a chip body is blended with a gypsum material, wherein the plane part of the paper chip and / or the chip body is a plane perpendicular to the thickness direction of the gypsum board.
  • the present invention provides a gypsum board characterized by having an average angle of 30 ° or less with respect to the gypsum board.
  • the present invention provides the gypsum board, wherein the mixing ratio of the paper chips and / or chips is 0.2 to 25% by weight based on the weight of the gypsum material.
  • the present invention also provides a paper chip and / or a chip body having a size of 1 mm X 1 mm to 50 mm. It is an object of the present invention to provide the gypsum board having a plane portion having a size of mm ⁇ 50 mm.
  • the present invention provides the gypsum board, wherein the paper chip and / or the chip body has a long side / short side ratio of 1 to 10.
  • FIG. 1 is a process chart for explaining one embodiment of the production method of the present invention.
  • 2 to 8 are process diagrams for explaining another embodiment of the production method of the present invention.
  • 9 to 15 are cross-sectional views for explaining a premixer suitably used in the production apparatus of the present invention.
  • FIG. 16 is a diagram for explaining the continuous mixer and the casting means.
  • C FIG. 17 is a diagram showing the relationship between the average angle of the paper sheet in Table 1 and the nail pull-out resistance.
  • FIGS. 18 to 19 are process diagrams for explaining in detail the problems in producing a composite gypsum board using a conventional general gypsum board production line.
  • FIG. 1 is a process chart for explaining one embodiment of the production method of the present invention.
  • the raw dihydrate gypsum 11 is transferred to the dryer 12 and dried and crushed by the pulverizer 13 c.Then, it is calcined in the calciner 14 to change to hydration-hardening gypsum. Then, it is ground to a desired size by a crusher 15 and temporarily stored in a hemihydrate gypsum silo 16 c. Subsequently, the hemihydrate gypsum in the hemihydrate gypsum rhinoceros 16 and the chips 22 are premixed. Kneaded (premixed) with 30.
  • the obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded, and the obtained raw material is obtained.
  • the slurry is cast Introduced in 32. According to this aspect, since the hemihydrate gypsum and the chips 22 are kneaded in advance by the premixer 130, the chips can be stably introduced into the continuous mixer.
  • FIG. 2 is a process chart for explaining another embodiment of the production method of the present invention.
  • the raw dihydrate gypsum 11 is transferred to a dryer 12 and is dried and ground by a mill 13. Subsequently, it is calcined in a calcining furnace 14 to be converted into hemihydrate gypsum having hydration hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16.
  • the hemihydrate gypsum and the chips 22 in the hemihydrate gypsum silo 16 and the raw dihydrate gypsum 11 are kneaded (premixed) by a premixer 30.
  • the obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded to obtain the raw material.
  • the slurry is introduced into the casting means 32.
  • the chips 22 and the raw dihydrate gypsum 11 are kneaded in advance by the premixer 30, the chips can be stably introduced into the continuous mixer.
  • the energy required for drying, milling and calcining can also be saved.
  • it is preferable that the time from mixing of the gypsum hemihydrate and gypsum to the introduction of the gypsum to the continuous mixer is shorter.
  • FIG. 3 is a process chart for explaining another embodiment of the production method of the present invention.
  • This production method is almost the same as that of the embodiment of FIG. 2, except that the dried dihydrate gypsum dried by the dryer 12 is mixed with the gypsum in the hemihydrate gypsum syrup 16 and the chips 22 together with the premixer 30. Is kneaded (premixed). By transferring part of the dried gypsum to the premixer, the energy required for grinding and calcination can be saved.
  • FIG. 4 is a process chart for explaining another embodiment of the production method of the present invention.
  • This production method is almost the same as that of the embodiment shown in FIG. 2, but first, raw dihydrate gypsum 11 and chip 22 are kneaded by a first premixer 301, and the obtained kneaded material and hemihydrate gypsum silo The hemihydrate gypsum in 16 is kneaded by the second premixer 302.
  • the surface of the chip can be wet with the adhering moisture of the raw gypsum to form a strong interface with the gypsum matrix, and more excellent gypsum such as bending strength, screw and nail pull-out resistance, etc. Board can be provided.
  • FIG. 5 is a process chart for explaining another embodiment of the production method of the present invention.
  • This production method is almost the same as the embodiment of FIG. 4, except that the dried dihydrate gypsum dried by the dryer 12 and the chips 22 are kneaded by the first premixer 301 (first premix).
  • the obtained kneaded material and the hemihydrate gypsum in the hemihydrate gypsum silo 16 are kneaded by the second premixer 302 (second premix).
  • FIG. 6 is a process chart for explaining another embodiment of the production method of the present invention.
  • the hemihydrate gypsum in the hemihydrate gypsum silo 16 is directly introduced into the continuous mixer 31 without passing through the premixer 30 in the embodiment of FIG.
  • the premixer 30 may be kneaded not with the fresh gypsum gypsum but with the dried gypsum gypsum dried by the dryer 12 and the chips 22.
  • FIG. 7 is a process chart for explaining another embodiment of the production method of the present invention.
  • This embodiment relates to a manufacturing method that does not use a chip.
  • the raw dihydrate gypsum 11 is transferred to a dryer 12 and is dried and crushed by a crusher 13. Subsequently, it is calcined in a calciner 14 to change into hemihydrate gypsum having a hydration-hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16.
  • a calciner 14 to change into hemihydrate gypsum having a hydration-hardening property
  • pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16.
  • the gypsum hemihydrate in the gypsum hemihydrate gypsum mouth 16 and the gypsum fresh dihydrate 11 are kneaded by the premixer 30.
  • the obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded, and the obtained raw material is obtained.
  • the slurry is introduced into the casting means 32.
  • the hemihydrate gypsum and the fresh dihydrate gypsum 11 are previously kneaded by the premixer 30, so that the raw dihydrate gypsum 11 can be stably introduced into the continuous mixer.
  • the energy required for drying, milling and calcining can be saved.
  • FIG. 8 is a process chart for explaining another embodiment of the production method of the present invention. This manufacturing method is almost the same as that of the embodiment of FIG. 7, but is dried by the dryer 12.
  • the dried dihydrate gypsum is kneaded with the hemihydrate gypsum in the gypsum hemihydrate gypsum 16 by the premixer 30.
  • the energy required for milling and calcination can be saved.
  • raw dihydrate gypsum is used as a starting material, which is dried, crushed and calcined to obtain hemihydrate gypsum, and water and other raw materials are added thereto to prepare a raw material slurry.
  • the process is described as one production line, but it is also possible to use a hydration-hardening gypsum material (for example, a commercially available gypsum material) manufactured at another location, and blend the chips with the gypsum material.
  • Gypsum having hydration-hardening properties is not limited to hemihydrate gypsum, and various types of gypsum materials described below can be used.
  • the dryer 11 and the crusher 13 are shown as separate devices.However, if necessary, high-temperature gas is blown into the mill to simultaneously perform drying and crushing. A device capable of performing the above may be used.
  • the production apparatus of the present invention includes a premixer 30, a continuous mixer 31, and a casting means 32 in order to carry out the production method of the present invention described above.
  • the production apparatus of the present invention is characterized in that it is provided with a blender 30 as compared with a conventional gypsum board production apparatus.
  • the premixer 30 that can be suitably used in the apparatus of the present invention will be described.
  • pre-mixer used in the present invention include a screw feeder 1, a paddle mixer, a pug mixer, a ribbon mixer, a pro-share mixer, a Henschel mixer, a spiral bottle mixer (trade name) and the like. These mixers will be briefly described with reference to the drawings.
  • FIG. 9 is a sectional view of the screw feeder.
  • the material is introduced into the case 2 from the inlet 1, is kneaded while being moved by the screw blade 51 provided on the rotating shaft 4 rotated by the motor 1, and is discharged from the outlet 6.
  • Screw feeders are small and inexpensive, and good mixing effects can be expected.
  • the screw feeder can be particularly preferably used in the embodiments of FIGS. 1, 3, 5, 6, and 8 described above.
  • FIG. 10 is a cross-sectional view of the paddle mixer.
  • Material is in case 2 from inlet 1
  • the mixture is kneaded while being moved by a paddle 52 provided on a rotating shaft 4 which is rotated by a motor 3, and is discharged from a discharge port 6.
  • Paddle mixers can be expected to have good mixing effects.
  • the paddle mixer can be suitably used in all the embodiments of FIGS. 1 to 8 described above.
  • Fig. 11 (a) is a cross-sectional view of the bag mixer, and (b) is a cross-sectional view taken along line AA.
  • the material is introduced into the case 2 from the inlet 1 and is kneaded while being moved by the screw blades 51 and the paddles 52 provided on the two rotating shafts 4, 4, which are rotated by the motor 3, and is discharged. Exhausted from 6.
  • Paddle mixers can be expected to have good mixing effects.
  • the pug mixer can be suitably used in all the embodiments of FIGS. 1 to 8 described above.
  • FIG. 12 is a cross-sectional view of the ribbon mixer.
  • the material is introduced into the case 2 from the input port 1, kneaded while moving by the ribbon blade 5 3 provided on the rotating shaft 4 rotated by the motor 13, and discharged from the discharge port 6.
  • Ribbon mixers are relatively inexpensive, can process large quantities, and have good mixing effects.
  • the ribbon mixer can be particularly preferably used in the embodiments of FIGS. 1, 3, 5, 6, and 8 described above.
  • Fig. 13 (a) is a cross-sectional view of a pro-share mixer, and (b) is a cross-sectional view taken along line BB.
  • the material is introduced into the case 2 from the inlet 1 and the flat shovel blades 54 provided on the rotating shaft 4 which is rotated by the motor 3, and the motor 1 provided separately below the case 2. It is kneaded while being moved by a chopper 55 rotating by a rotating (not shown), and is discharged from a discharge port 6.
  • Proshare mixers are relatively small and can be expected to have better mixing effects.
  • the pro-share mixer can be particularly preferably used in the embodiments of FIGS. 2, 4, and 7 described above.
  • Fig. 14 (a) is a cross-sectional view of the Henschel mixer, and (b) is a cross-sectional view taken along line CC.
  • the material is introduced into the case 2 from the inlet 1 and is kneaded by the mixing blades 56 provided on the rotating shaft 4 rotated by the motor 3.
  • the kneaded material is rotated by the rotating shaft 4 by the motor 1, 3. Screw blades 5 And is discharged from outlet 6.
  • the Henschel mixer can be expected to have a good mixing effect.
  • FIG. 15 is a sectional view of a spiral bin mixer.
  • the material is introduced into the case 2 from the inlet 1, kneaded by the dispersing pins 57 provided on the rotor 5 rotated by the motor 3, and discharged from the outlet 6.
  • Spiral pin mixer can be expected to have a good mixing effect.
  • the continuous mixer 31 has been conventionally used for the production by continuous casting of gypsum board, that is, capable of high-speed kneading, and of the raw material slurry 41 in the mixer. It is possible to use a material having a short residence time, but when compounding the chip 22, it is preferable that the chip 22 does not easily adhere to the inside.
  • the casting means 32 may be a known one which has been conventionally used for continuous gypsum board production by continuous casting, and is not particularly limited.
  • Fig. 16 is a diagram for explaining the continuous mixer and the casting means.c
  • the continuous mixer 31 is provided inside the container 311 and the container 311 and is rotated by the low speed and the low speed.
  • Various materials including chips 22 are introduced into the container 311 and a raw material slurry can be obtained by kneading (stirring and mixing).
  • the raw material slurry obtained by kneading can be continuously discharged from the discharge port 311.
  • the leveling roller is used.
  • the gypsum board 50 is obtained by being cut by a cutting machine 45 into the size shown in FIG.
  • the raw gypsum, dried gypsum, and hydration-hardening gypsum material that can be used in the present invention are chips
  • the material is not particularly limited as long as it is a gypsum-like material that can serve as a matrix capable of dispersing and holding the material.
  • the hydration setting gypsum includes calcined gypsum, cast hemihydrate gypsum, type III anhydrous gypsum, type II anhydrous gypsum, and the like. These are gypsum which changes to gypsum by the hydration reaction in the presence of water and hardens.
  • the raw dihydrate gypsum in the present invention is a gypsum material having an attached moisture of usually several percent to several tens percent, as described above, such as natural gypsum, drainage gypsum, phosphate gypsum, and the like.
  • By-product gypsum The dried dihydrate gypsum is a gypsum material that has been heated and dried to remove the attached moisture, and is not heated to a firing temperature for obtaining hydration curability.
  • the mixing ratio of the chips to the gypsum material can be appropriately selected according to the target gypsum board size and intended use.For example, it greatly improves the bending strength of the gypsum board and the resistance to pulling out screws and nails.
  • Raw materials for chips include, for example, newspaper paper, insert advertising paper, book paper such as magazines and paperbacks, copy paper, cardboard paper, packaging paper, work paper, these wastes, and building materials (eg, gypsum board using paperboard). Examples include paper separated from offcuts, generated materials, loss materials, and the like. In addition, floppy disks, recording tapes, video magnetic tapes, tickets, betting tickets, agricultural sheets, non-woven fabrics, woven fabrics, etc., and their waste can also be used as raw materials.
  • the size of the chip is appropriately selected in consideration of the strength and the type of the target gypsum board, for example, 1 mm x 1 mn! It is preferable to have a flat part of up to 5 O mm X 50 mm.
  • the thickness is preferably, for example, about 0.05 to 2 mm.
  • the shape of the chip can be, for example, a square, a rectangle having a long side / short side ratio of 1 to 10, a circle, a triangle, or an irregular shape.
  • the chip can be manufactured by a known dry pulverization method, wet pulverization method, or the like. If desired, surface treatment of the chip, fluffing, and the like can be combined.
  • a plaster material is mixed with an aqueous adhesive, and the chips are coated with a coupling agent. Is preferred.
  • a water-based adhesive and a coupling agent are blended, the mixing ratio thereof can be appropriately selected according to the size and application of the target composite gypsum board, the type of the chemical used, and the like.
  • the agent is for the gypsum material
  • the coupling material can be 0.01 to 3% by weight, preferably 0.1 to 1% by weight, based on the gypsum material. .
  • the chip has an average angle of 30 ° or less, preferably 20 ° or less with respect to a plane perpendicular to the thickness direction of the gypsum board, so that the chip can be manufactured by any manufacturing method. Even if it is, it becomes a gypsum board that can obtain the desired bending strength and screws' nail pull-out resistance.
  • the angle at which the chip exists was not considered at all, and when the angle was out of the above range, the bending strength and the screw / nail pull-out resistance were not sufficiently exhibited.
  • the chips are present in a direction perpendicular to the thickness direction, screws or nails will enter between the chips and break the chip and the gypsum-based matrix, causing the board to crack. Conversely, if the chips are more parallel to the plane perpendicular to the thickness of the gypsum board, there is a higher probability that screws or nails traversing the board will penetrate the plane of the chip, and the chips and screws or Screw and nail pull-out resistance increases due to frictional force with the nail.
  • the present invention clarifies the relationship between the existing angle of the chip and the screw / nail pull-out resistance in this operation, and in order to obtain a higher screw / nail pull-out resistance, the flat portion of the chip at the above specific angle is required. It was found that the existence of a
  • the angle distribution is the angle distribution of the plane portion of the chip with respect to the plane perpendicular to the thickness direction of the gypsum board.
  • FIG. 17 is a diagram showing the relationship between the average angle of the paper sheet in Table 1 and the nail pull-out resistance.
  • the gypsum board used in this example is made by laying back base paper in an acrylic mold, laying paper chips on it, pouring the gypsum slurry there once or three times, placing the front base paper on it, and curing it. Hold by a glass plate, then 60 °. And dried at 45 ° C for 2 days for 1 day.
  • the final size of the cured product was 10 cm in length ⁇ 2 O in width ⁇ 1.5 cm in thickness, and the specific gravity was 1.0 g / cc. Note that the angle distribution of the paper sheet can be easily controlled by adjusting the casting distance of the gypsum slurry.
  • the angle of the paper chip in the cured product was determined by cutting the cured product into 1.6 cm x 1.5 cm x 10 cm, and scanning the cross section with a scanner (Hewlett-Packard, product name scanjet4c). After clarifying the existence of the paper sheet by adjusting the contrast of the obtained image with image processing (Adobe Photoshop), the output diagram is further analyzed by an image analyzer (Nireco Co., Ltd.). No. LuzexIII).
  • Calcined gypsum (manufactured by San-es Gypsum Co., Ltd., special issue green, calcined gypsum) 100 parts by weight Polyvinyl alcohol (manufactured by Kuraray Co., Ltd., MSH 916) 0.3 parts by weight Water (tap water) 70 parts by weight
  • the nail pull-out resistance is set to 11.4 mm hole in the cured body, which is ⁇ 2.5 mm x 40 mm
  • the resistance (kgf) was measured when a 1.5 cm iron round nail was driven in and pulled out with a 2 mm crosshead using an Instron universal testing machine.
  • additives can be added to the gypsum board of the present invention as needed in order to improve desired properties.
  • additives (agents) used in the production of ordinary gypsum board include, for example, water reducing agents, foaming agents, retarding agents, and sizing agents.
  • various auxiliary materials such as aggregate, flame retardant, and binder can be added. Specific examples include reinforcing fibers, sawdust, wood chips, perlite, vermiculite, starch, PVA, and oxidized starch.
  • the compounding ratio of these additives is preferably, for example, about 0.1 to 3% by weight based on the gypsum material.
  • the specific gravity of the gypsum board thus obtained is usually 0.5 to 1.6 g / cm 3 , preferably 0.7 to 1. SgZcm 3 .
  • a method and apparatus capable of stably producing a gypsum board having excellent bending strength and resistance to pulling out screws and nails, and having improved various performances with high productivity. Even if it is manufactured by an arbitrary manufacturing method, a gypsum board capable of obtaining a desired bending strength and resistance to pulling out screws and nails is provided, and the following effects are particularly remarkable.
  • the supply of chips is unstable due to bulkiness.
  • chips flow in the supply path, for example, in the case of the natural drop type injection method, and the predetermined amount is not supplied to the continuous mixer. Probability is high. According to the present invention, such a problem is solved by premixing the chips and the gypsum material and supplying them to the continuous mixer.
  • fresh gypsum has attached moisture of several percent to several tens of percent, and when it is transferred to a continuous mixer as it is, it adheres strongly to the transfer path and requires a stable supply to the continuous mixer. It can be a hindrance.
  • the adhesiveness is reduced and stable supply to the continuous mixer is possible.
  • the structure of the gypsum board is homogenized.
  • the premix ensures a homogeneous mixing of the materials and significantly reduces the amount of chip agglomerates and gypsum material agglomerates.
  • gypsum board with improved product performance mechanical properties, durability, fire resistance, etc.
  • the premix forms a thin layer of gypsum hemihydrate on the surface of the chips.
  • hydrated reaction by thin layer portion (CaS0 4 - 1/2 H 2 0 ⁇ CaS0 4 - 2 H 2 0) produce but fine fine water
  • the hydrate crystals penetrate the chip microstructure, resulting in a strong interface (strong adhesion) between the chip and the gypsum material.
  • mechanical strength such as bending strength, and the pulling resistance of screws and nails are improved.
  • Chip adhesion in the continuous mixer is reduced.
  • Chips when used as a raw material for gypsum board, have a large flat surface area and a small thickness, so when kneaded with water, they can easily stick to the inner wall or rotor of a continuous mixer.
  • the premix forms a thin layer on the surface of the chips as described in 4 above, thereby reducing the adhesion of chips to the continuous mixer.
  • the gypsum board of the present invention can reliably increase bending strength and resistance to pulling out screws and nails.

Abstract

Raw gypsum dihydrate (11) is dried in a dryer (12), pulverized by a pulverizer (13), calcined in a calcinator (14), re-pulverized in a pulverizer (15), providing gypsum hemihydrate, which is then once stored in a gypsum hemihydrate silo (16), and then the gypsum hemihydrate and a chip (22) are premixed in a premixer (30). The resulting kneaded product, water and, if necessary, various additive materials (agents) are kneaded in a continuous mixer (31), providing a raw material slurry, which is then slip-cast by a slip casting means (32), providing a gypsum board. Further, the flat surface of the chip is set at 30° or less with respect to a plane perpendicular to the direction of the thickness of the gypsum board. According to this technique, a gypsum board considerably superior in bending strength and screw or nail pull-out resistance and having various improved performances can be produced with good productivity and stability.

Description

明 細 書 石膏ボード、 石膏ボードの製造方法および石膏ボードの製造装置 技術分野  Description Gypsum board, gypsum board manufacturing method and gypsum board manufacturing apparatus
本発明は、 石膏ボード、 石膏ボードの製造方法および石膏ボードの製造装置 に関するものである。 さらに詳しくは本発明は、 曲げ強度およびネジ，釘引き 抜き抵抗力が著しく優れ、 なおかつ各種性能が向上した石膏ボードを生産性よ く安定に製造することのできる方法および装置に関するものである。 また本発 明は、 任意の製造方法により製造されても、 所望の曲げ強度およびネジ ·釘引 き抜き抵抗力を獲得可能な石膏ボードに関するものである。 背景技術  The present invention relates to a gypsum board, a gypsum board manufacturing method, and a gypsum board manufacturing apparatus. More specifically, the present invention relates to a method and an apparatus capable of stably producing a gypsum board having remarkably excellent bending strength, resistance to pulling out screws and nails, and various performances with good productivity. Further, the present invention relates to a gypsum board capable of obtaining desired bending strength and screw / nail pull-out resistance even when manufactured by an arbitrary manufacturing method. Background art
近年、 建築物の多様化により、 建材に対しても様々な性能を改善することが 求められている。 安価且つ防火性に優れる無機質内装建材として広く使用され ている石膏ボードにおいても、 とくに曲げ強度およびネジ ·釘引き抜き抵抗力 の改善に対する要望が強く、 そのため、 例えば石膏材料に、 繊維材料を配合す ることが知られている。 その繊維材料としては、 繊維化したパルプが代表的で ある。  In recent years, with the diversification of buildings, it is required to improve various performances of building materials. Even for gypsum board widely used as an inorganic interior building material that is inexpensive and has excellent fire resistance, there is a strong demand for improvement in bending strength and screw / nail pull-out resistance. Therefore, for example, a fiber material is mixed with a gypsum material. It is known. A typical example of the fiber material is fiberized pulp.
石膏材料に繊維化したパルプを配合して複合化するには、 例えば、 パルプ原 料をハンマ—ミルなどの衝撃型粉砕機、 あるいはパルパ一などの湿式解繊機等 を用いて繊維化し、 これを石膏材料のマトリックス中に分散させることにより 行われている。 この方法は、 石膏ボードの補強には有効である。 しかしながら、 実際の製造工程において、 解繊された繊維は非常にかさ高となり、 このような. かさ高な繊維と石膏材料の粉体とを、 水と共に混練しょうとしても、 均一な混 合物を効率よく得るには技術的に困難である。 従来技術における繊維化したパ ルプは、 通常、 長さが約 0 . 1 ~ 3 mm、 幅が約 1 0〜 1 0 0〃m の微細繊維 であり、 このような繊維は、 原材料の混合時にスラリー中で互いに絡まり合い、 スラリーの流動性を著しく低下させる。 従って、 原料のスラリー化を経由して 製造される石膏ボードの製造ラインにおいては、 通常、 約 0 . 1〜2 %、 多く とも 3 %程度の繊維しか配合できない。 この程度の繊維の配合割合では、 得ら れる石膏ボードの特性、 とくに、 曲げ強度、 ネジ ·釘引き抜き抵抗力等の特性 は期待されるほど改善されるに至らず、 むしろ製造時に生じる材料の分離など によって、 繊維を配合してもかえってこの特性が損なわれる場合もあった。 そこで、 混練水の配合量を著しく増量させて石膏材料に大量の繊維を配合す ることが試みられているが、 この場合は、 後述する連続流し込み成形によると、 成形したボード中に残る水の量が多くなり、 得られる石膏ボードの比重が低下 し、 これに伴って強度低下も生じるという欠点がある。 また、 軽量化に伴うネ ジ ·釘引き抜き抵抗力の低下も明白である。 さらに混練水の増、大により、 余剰 水が増加するため、 これに伴い石膏ボードの乾燥エネルギーの増大も招くこと になる。 In order to compound the gypsum by mixing fiberized pulp with the gypsum material, for example, the pulp raw material is fiberized using an impact-type pulverizer such as a hammer mill or a wet defibration machine such as pulper. This is done by dispersing in a gypsum material matrix. This method is effective for reinforcing gypsum board. However, in the actual manufacturing process, the defibrated fiber becomes very bulky, and this is the case. Even if you try to knead the bulky fiber and the powder of the gypsum material together with water, a uniform mixture is obtained. It is technically difficult to obtain efficiently. The fiberized pulp in the prior art is usually fine fibers having a length of about 0.1 to 3 mm and a width of about 100 to 100 〃m. Entangled with each other in the slurry, It significantly reduces the fluidity of the slurry. Therefore, in a gypsum board production line produced through slurrying of raw materials, usually, only about 0.1 to 2%, at most about 3%, of fibers can be blended. At such a fiber mixing ratio, the properties of the resulting gypsum board, especially the properties such as bending strength and screw and nail pull-out resistance, are not improved as expected, but rather, the separation of materials that occurs during manufacturing. In some cases, this property may be impaired even if fibers are blended. Therefore, attempts have been made to significantly increase the mixing amount of the kneading water to mix a large amount of fibers into the gypsum material. In this case, according to the continuous casting method described later, the water remaining in the formed board is determined. There is a drawback that the amount of gypsum board increases, the specific gravity of the gypsum board obtained decreases, and the strength decreases accordingly. It is also evident that the resistance to pulling screws and nails has been reduced due to the weight reduction. In addition, the excess water increases due to the increase and increase of the mixing water, which leads to an increase in the drying energy of the gypsum board.
以上の点から、 繊維化したパルプと石膏材料とを複合化する方法には、 多く の問題点があり、 石膏ボードの曲げ強度や、 ネジ ·釘引き抜き抵抗力など、 各 種性能の有効な改善策とはなり得なかった。  In view of the above, there are many problems in the method of combining fiberized pulp with gypsum material, and effective improvements in various performances such as bending strength of gypsum board and resistance to pulling screws and nails It could not be a solution.
また、 現在わが国では情報化社会を迎え、 情報伝達の媒体となる新聞、 雑誌 および広告などの出版量は世界的にもますます増加しつつある。 さらに、 記録 用電子機器の普及に伴い、 カセットテープ、 フロッピ一ディスク等の磁性記録 材料が多く使用されるようになった。 また、 交通機関、 金融機関等の利用にお ける簡便化、 あるいは効率化のために、 財貨のプリペイ ド化が進展し、 切符、 テレホンカード等の記録用磁性材料の使用量は、 今や膨大な量に達している。 現在、 環境保全に対して人々の関心が高まってきており、 リサイクルへの取 り組みは、 各種産業においても本格化しつつある。 このため、 用済みとなった 新聞紙、 O A紙、 塩化ビニル樹脂シート、 テープ、 フロッピ一ディスク等の各 種材料の有効利用に注目が集まっている。 ところが、 例えば不要になった磁性 材料は有効に活用できる方策がないので、 そのままの形状で大量に廃棄されて いるのが現状である。 また、 塩化ビニル樹脂シートからなる農業用保温シート なども大量に使用されているが、 廃棄物を焼却する際有害なガスを発生するた め、 これらはほぼ使い捨てられている。 したがって、 省資源化、 環境保全、 ゴ ミ問題の観点から、 これらシート状材料を有効利用する技術の開発が強く望ま れている。 In Japan, the information society has now entered the world, and the volume of publication of newspapers, magazines, and advertisements, which serve as information transmission media, is increasing worldwide. Furthermore, with the widespread use of recording electronic devices, magnetic recording materials such as cassette tapes and floppy disks have been increasingly used. In addition, prepaid goods have been developed to make transportation and financial institutions easier or more efficient, and the amount of magnetic materials used for recording such as tickets and telephone cards is now enormous. Amount has been reached. At present, people's interest in environmental preservation is increasing, and recycling initiatives are also in full swing in various industries. For this reason, attention has been focused on the effective use of various materials such as used newspapers, office paper, vinyl chloride resin sheets, tapes, and floppy disks. However, for example, there is no way to effectively use unneeded magnetic materials, and at present, large quantities are discarded in their original shape. Agricultural insulation sheet made of vinyl chloride resin sheet Although they are used in large quantities, they are almost disposable because they generate harmful gases when incinerating waste. Therefore, from the viewpoints of resource saving, environmental conservation, and trash problems, there is a strong demand for the development of technology that effectively uses these sheet materials.
そこで本発明者らは、 W O 9 6 / 2 6 1 6 6号において、 上記のような従来 の課題を解決する複合石膏ボードとその製造方法を提案した。  In view of this, the present inventors have proposed a composite gypsum board and a method for producing the same in WO 96/26166, which solve the above conventional problems.
この複合石膏ボードは、 石膏材料に紙チップおよび/またはチップ体を配合 し、 且つ紙チップおよび/またはチヅプ体が、 複合石膏ボードの厚さ方向に対 して垂直な面とほぼ平行に配向しているものである。 またこのような複合石膏 ボードは、 石膏材料、 紙チップおよび/またはチップ体、 水、 必要に応じて各 種フイラー材を含む原料スラリ一を調製し、 これを移動可能なコンベア上に供 給し、 コンベアを移動させながら、 原料スラリーに含まれる紙チップおよび/ またはチップ体を配向手段により、 得られる複合石膏ボードの厚さ方向に対し て垂直な方向の面とほぼ平行に配向させることにより製造される。 さらに本発 明者らは、 W O 9 6 / 2 6 1 6 6号において石膏ボードにとくに好適な組成物 として、 石膏材料が、 半水石膏 1 0 0重量部および二水石膏 1 0〜2 5 0重量 部からなる石膏材料組成物も提案した。  This composite gypsum board is prepared by mixing paper chips and / or chips with a gypsum material, and the paper chips and / or chips are oriented substantially parallel to a plane perpendicular to the thickness direction of the composite gypsum board. Is what it is. In addition, such composite gypsum board prepares a raw material slurry containing gypsum material, paper chips and / or chips, water, and various types of filler materials as needed, and supplies them to a movable conveyor. While moving the conveyor, the paper chips and / or chips contained in the raw slurry are oriented by an orientation means so as to be substantially parallel to the plane perpendicular to the thickness direction of the composite gypsum board to be obtained. Is done. Furthermore, the present inventors have reported that, as WO 96/26616, a composition particularly suitable for gypsum board, the gypsum material is 100 parts by weight of hemihydrate gypsum and 100 to 25 gypsum. A gypsum material composition consisting of 0 parts by weight was also proposed.
しかしながら、 上記の複合石膏ボードの製造に従来の一般的な石膏ボードの 製造ラインを用いた場合には、 石膏材料、 紙チップおよび/またはチヅプ体、 水、 必要に応じて各種フイラー材を同時に連続ミキサーに入れて原料スラリー を調製することになるが、 該工程において紙チヅプぉよび/またはチップ体が かさ高なため連続ミキサーへの供給が不安定になるという問題点がある。 例え ば、 連続ミキサー内のローターが高速で回転しているため供給経路から流入し てくる紙チップおよび/またはチップ体が吹き上げられ供給経路内で舞ってし まい、 所定量の供給が困難となる。  However, when a conventional general gypsum board production line is used for the production of the composite gypsum board, the gypsum material, paper chips and / or chips, water, and, if necessary, various filler materials are continuously continuously used. Although the raw material slurry is prepared by putting the slurry in a mixer, there is a problem that the supply to the continuous mixer becomes unstable due to the bulk of the paper chips and / or chips in the process. For example, since the rotor in the continuous mixer is rotating at high speed, the paper chips and / or chip bodies flowing from the supply path are blown up and flutter in the supply path, making it difficult to supply a predetermined amount. .
また、 上記の石膏材料組成物を使用して石膏ボードを製造する際、 乾燥処理 していない二水石膏には、 通常数％から数十％の付着水分があり、 これを移送 したときに移送経路への付着が激しく連続ミキサ一への安定供給が困難となる 問題点もある。 In addition, when gypsum board is manufactured using the above-mentioned gypsum material composition, gypsum dihydrate that has not been dried usually has a water content of several% to several tens%. Adhesion to the path is severe, and stable supply to the continuous mixer becomes difficult. There are also problems.
図 1 8および図 1 9は、 従来の一般的な石膏ボードの製造ラインを用いて上 記の複合石膏ボードを製造する際の問題点を詳しく説明するための工程図であ る。 図 1 8では、 乾燥処理していない二水石膏 （以下、 生二水石膏という） を 石膏材料として用いている。 生二水石膏 1 1は、 乾燥機 1 2に移送され、 乾燥 後粉碎機 1 3により粉砕される。 続いてか焼炉 1 4でか焼されて水和硬化性を 有する半水石膏に変化し、 粉碎機 1 5によって所望のサイズに粉碎され、 半水 石膏サイロ 1 6に一旦貯蔵される。 そして、 混練水 2 1、 紙チップおよび/ま たはチップ体 2 2 (以下、 単に 「チップ」 と呼ぶ） 、 必要に応じて添加材 (剤） 2 3が、 半水石膏サイロ 1 6に貯蔵されていた半水石膏とともに連続ミ キサー 3 1に導入される。 続いて連続ミキサー 3 1で混練された材料は、 流し 込み成形手段 3 2に導入される。 図 1 8の態様では、 上記のように、 連続ミキ サー 3 1内の口一ターの高速回転によりチップが安定して導入されない場合が ある。  FIG. 18 and FIG. 19 are process drawings for explaining in detail the problems when the above-mentioned composite gypsum board is manufactured using a conventional general gypsum board manufacturing line. In Fig. 18, gypsum that has not been dried (hereinafter referred to as raw gypsum) is used as the gypsum material. The raw dihydrate gypsum 11 is transferred to a dryer 12, and after drying, is ground by a mill 13. Subsequently, it is calcined in a calciner 14 to be converted into hemihydrate gypsum having hydration-hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16. The kneading water 21, paper chips and / or chips 22 (hereinafter simply referred to as “chips”), and if necessary, additives (agents) 23, are stored in hemihydrate gypsum silos 16. It is introduced into the continuous mixer 31 together with the hemihydrate gypsum. Subsequently, the material kneaded in the continuous mixer 31 is introduced into the casting means 32. In the embodiment of FIG. 18, as described above, the chip may not be stably introduced due to the high-speed rotation of the mouth in the continuous mixer 31.
図 1 9は、 チップを含まず、 かつ上記の石膏材料組成物を使用して石膏ボー ドを製造する場合の工程図である。 生二水石膏 1 1を乾燥機 1 2で乾燥し、 粉 砕機 1 3により粉砕し、 か焼炉 1 4でか焼し、 得られた半水石膏を粉碎機 1 5 により粉碎し、 半水石膏サイロ 1 6に一旦貯蔵する工程は、 図 1 8と同じであ る。 また混練水 2 1、 必要に応じて添加材 （剤） 2 3が、 半水石膏サイロ 1 6 に貯蔵されていた半水石膏とともに連続ミキサー 3 1に導入される。 これとは 別に、 組成物の所定の配合割合を満たすように、 二水石膏 1 1の一部が連続ミ キサー 3 1に直接移送され、 混練される。 混練された材料は、 流し込み成形手 段 3 2に導入される。 図 1 9の態様では、 上記のように、 生二水石膏が連続ミ キサー 3 1に向かう移送経路に付着し、 連続ミキサー 3 1に安定して供給でき ないという問題点がある。  FIG. 19 is a process chart in the case of producing a gypsum board using no gypsum material composition and containing the above-described gypsum material composition. The fresh gypsum plaster 1 1 is dried with a dryer 1 2, pulverized with a pulverizer 13, calcined in a calciner 14, and the obtained hemihydrate gypsum is pulverized with a pulverizer 15 to obtain semi-hydrated water. The process of temporarily storing in gypsum silo 16 is the same as in FIG. Also, kneading water 21 and, if necessary, additives (agent) 23 are introduced into the continuous mixer 31 together with the hemihydrate gypsum stored in the hemihydrate gypsum silo 16. Apart from this, a part of the gypsum dihydrate 11 is directly transferred to the continuous mixer 31 and kneaded so as to satisfy a predetermined mixing ratio of the composition. The kneaded material is introduced into the casting means 32. In the embodiment of FIG. 19, as described above, there is a problem that the raw dihydrate gypsum adheres to the transfer path toward the continuous mixer 31 and cannot be stably supplied to the continuous mixer 31.
また、 上記のような製造方法により製造された複合石膏ボードでは、 その特 性にバラツキが生じ、 所望の曲げ強度およびネジ ·釘引き抜き抵抗力が得られ ない場合があるという欠点があった。 したがって本発明の目的は、 曲げ強度およびネジ ·釘引き抜き抵抗力が著し く優れ、 なおかつ各種性能が向上した石膏ボードを生産性よく安定に製造する ことのできる方法および装置を提供することにある。 Further, the composite gypsum board manufactured by the above-described manufacturing method has a disadvantage that the characteristics thereof vary, and a desired bending strength and screw / nail pull-out resistance may not be obtained. Accordingly, an object of the present invention is to provide a method and an apparatus capable of stably producing a gypsum board with remarkably excellent bending strength and resistance to pulling out screws and nails, and various performances with good productivity. .
また本発明の別の目的は、 任意の製造方法により製造されても、 所望の曲げ 強度およびネジ ·釘引き抜き抵抗力を獲得可能な石膏ボ一ドを提供することに ある。 発明の開示  Another object of the present invention is to provide a gypsum board capable of obtaining desired bending strength and screw / nail pull-out resistance even when manufactured by an arbitrary manufacturing method. Disclosure of the invention
本発明は、 生二水石膏、 乾燥二水石膏および水和硬化性を有する石膏からな る群から選択された少なくとも 1種の石膏と、 紙チップおよび/またはチップ 体とをプレミキサー内で混練するプレミックス工程と、 得られた混練物、 水お よび必要に応じて各種添加材 （剤） を含む原料を連続ミキサー内で混練し原料 スラリーを調製する工程と、 前記原料スラリーを流し込み成形する工程と、 を 含む石膏ボードの製造方法を提供するものである。 なお、 前記原料スラリーに は水和硬化性を有する石膏が必須成分として含まれている。  According to the present invention, at least one gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum, and paper chips and / or chip bodies are kneaded in a premixer. A premixing step, a step of kneading a raw material containing the obtained kneaded material, water and, as necessary, various additives (agents) in a continuous mixer to prepare a raw material slurry, and pouring and forming the raw material slurry. And a method for producing a gypsum board comprising: The raw material slurry contains hydration-hardening gypsum as an essential component.
また本発明は、 ブレミックス工程が、 生二水石膏または乾燥二水石膏と、 水 和硬化性を有する石膏と、 紙チップおよび/またはチップ体とをプレミキサー 内で混練するものである前記の石膏ボードの製造方法を提供するものである。 また本発明は、 プレミックス工程が、 生二水石膏または乾燥二水石膏と、 紙 チヅプおよび/またはチップ体とを第 1プレミキサ一内で混練する第 1プレミ ックス工程と、 得られた混練物と水和硬化性を有する石膏材料とを第 2プレミ キサー内で混練する第 2プレミックス工程とからなる前記の石膏ボードの製造 方法を提供するものである。  Further, in the present invention, the blending step comprises kneading a raw dihydrate gypsum or a dried dihydrate gypsum, a hydrate-curable gypsum, and a paper chip and / or a chip body in a premixer. A method for producing a gypsum board is provided. Further, in the present invention, the premixing step may include: a first premixing step of kneading the raw gypsum or the dried gypsum, and a paper chip and / or a chip body in the first premixer; And a gypsum material having hydration-hardening properties in a second premixer, and a second premixing step of kneading the same in a second premixer.
また本発明は、 プレミックス工程が、 生二水石膏または乾燥二水石膏と、 紙 チップぉよび/またはチップ体とをプレミキサー内で混練するものである前記 の石膏ボードの製造方法を提供するものである。  Further, the present invention provides the method for producing a gypsum board according to the above, wherein the premixing step comprises kneading the raw gypsum or the dried gypsum and the paper chips and / or chips in a premixer. Things.
また本発明は、 生二水石膏および乾燥二水石膏からなる群から選択された少 なくとも 1種の石膏と、 水和硬化性を有する石膏とをプレミキサー内で混練す る工程と、 得られた混練物、 水および必要に応じて各種添加材 （剤） を連続ミ キサー内で混練し原料スラリーを調製する工程と、 前記原料スラリーを流し込 み成形する工程と、 を含む石膏ボ一ドの製造方法を提供するものである。 また本発明は、 乾燥二水石膏を得るために生二水石膏を乾燥する工程と、 水 和硬化性石膏を得るために前記乾燥二水石膏を粉碎しか焼する工程と、 をさら に有する前記の石膏ボードの製造方法を提供するものである。 Also, the present invention provides a method of kneading at least one gypsum selected from the group consisting of fresh gypsum and dried gypsum, and gypsum having hydration-hardening property in a premixer. A step of kneading the obtained kneaded material, water and, as necessary, various additives (agents) in a continuous mixer to prepare a raw material slurry; and a step of pouring and forming the raw material slurry. And a method for producing a gypsum board containing the same. Further, the present invention further comprises a step of drying the raw dihydrate gypsum to obtain a dried gypsum, and a step of only grinding or burning the dried gypsum to obtain a hydrate-setting gypsum. And a method for producing a gypsum board.
また本発明は、 前記の製造方法により製造された石膏ボードを提供するもの である。  Further, the present invention provides a gypsum board manufactured by the above manufacturing method.
また本発明は、 生二水石膏、 乾燥二水石膏および水和硬化性を有する石膏か らなる群から選択された少なくとも 1種の石膏と、 紙チップおよび/またはチ ップ体とを混練することのできるプレミキサーと、 得られた混練物、 水および 必要に応じて各種添加材 （剤） を含む原料を連続的に供給し、 混練し、 得られ た原料スラリー （但し、 前記原料スラリーには水和硬化性を有する石膏が必須 成分として含まれている） を連続的に排出することのできる連続ミキサーと、 前記原料スラリーを流し込み成形することのできる手段と、 を備えてなる石膏 ボードの製造装置を提供するものである。  Further, the present invention comprises kneading at least one type of gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum with a paper chip and / or a chip body. And a raw material containing the obtained kneaded material, water, and, if necessary, various additives (agents) are continuously supplied and kneaded, and the obtained raw material slurry (provided that the raw material slurry Is a gypsum board having a hydration-hardening gypsum as an essential component), and a means capable of pouring and molding the raw material slurry. A manufacturing apparatus is provided.
また本発明は、 生二水石膏を乾燥し乾燥二水石膏を得る乾燥機と、 前記乾燥 二水石膏を粉砕する粉碎機と、 粉砕した乾燥二水石膏をか焼し水和硬化性石膏 を得るか焼炉と、 をさらに備えてなる前記の石膏ボードの製造装置を提供する ものである。  Further, the present invention provides a dryer for drying raw dihydrate gypsum to obtain dried dihydrate gypsum, a pulverizer for pulverizing the dried dihydrate gypsum, and a hydration-curable gypsum obtained by calcining the pulverized dry gypsum. An apparatus for producing a gypsum board, further comprising: a calcining furnace;
また本発明は、 石膏材料に紙チップおよび/またはチップ体が配合されてな る石膏ボードにおいて、 前記紙チップおよび/またはチップ体の平面部が、 前 記石膏ボードの厚さ方向に対する垂直な面に対して 3 0 ° 以下の平均角度を有 することを特徴とする石膏ボードを提供するものである。  Further, the present invention provides a gypsum board in which a paper chip and / or a chip body is blended with a gypsum material, wherein the plane part of the paper chip and / or the chip body is a plane perpendicular to the thickness direction of the gypsum board. The present invention provides a gypsum board characterized by having an average angle of 30 ° or less with respect to the gypsum board.
また本発明は、 紙チップおよび/またはチップ体の配合割合が、 石膏材料の 重量に対して、 0 . 2〜2 5重量％である、 前記の石膏ボードを提供するもの である。  Further, the present invention provides the gypsum board, wherein the mixing ratio of the paper chips and / or chips is 0.2 to 25% by weight based on the weight of the gypsum material.
また本発明は、 紙チップぉよび/またはチップ体が、 1 mm X 1 mm〜 5 0 mm x 5 0 mm の大きさの平面部を有する、 前記の石膏ボードを提供するもの である。 The present invention also provides a paper chip and / or a chip body having a size of 1 mm X 1 mm to 50 mm. It is an object of the present invention to provide the gypsum board having a plane portion having a size of mm × 50 mm.
また本発明は、 紙チップおよび/またはチップ体が、 1 ~ 1 0の長辺/短辺 比を有する、 前記の石膏ボードを提供するものである。 図面の簡単な説明  Further, the present invention provides the gypsum board, wherein the paper chip and / or the chip body has a long side / short side ratio of 1 to 10. BRIEF DESCRIPTION OF THE FIGURES
図 1は、 本発明の製造方法の一実施態様を説明するための工程図である。 図 2〜 8は、 本発明の製造方法の別の実施態様を説明するための工程図であ FIG. 1 is a process chart for explaining one embodiment of the production method of the present invention. 2 to 8 are process diagrams for explaining another embodiment of the production method of the present invention.
Ό o Ό o
図 9〜 1 5は、 本発明の製造装置に好適に用いられるプレミキサーを説明す るための断面図である。  9 to 15 are cross-sectional views for explaining a premixer suitably used in the production apparatus of the present invention.
図 1 6は、 連続ミキサーおよび流し込み成形手段を説明するための図である c 図 1 7は、 表 1における紙シートの平均角度と釘引き抜き抵抗力との関係を 示す図である。  FIG. 16 is a diagram for explaining the continuous mixer and the casting means. C FIG. 17 is a diagram showing the relationship between the average angle of the paper sheet in Table 1 and the nail pull-out resistance.
図 1 8〜 1 9は、 従来の一般的な石膏ボードの製造ラインを用いて複合石膏 ボードを製造する際の問題点を詳しく説明するための工程図である。 発明を実施するための最良の形態  FIGS. 18 to 19 are process diagrams for explaining in detail the problems in producing a composite gypsum board using a conventional general gypsum board production line. BEST MODE FOR CARRYING OUT THE INVENTION
以下、 具体的な実施態様により本発明をさらに説明するが、 本発明は、 下記 説明に限定されるものではない。  Hereinafter, the present invention will be further described by specific embodiments, but the present invention is not limited to the following description.
図 1は、 本発明の製造方法の一実施態様を説明するための工程図である。 生 二水石膏 1 1は、 乾燥機 1 2に移送され、 乾燥後粉碎機 1 3により粉砕される c 続いてか焼炉 1 4でか焼されて水和硬化性を有する半水石膏に変化し、 粉碎機 1 5によって所望のサイズに粉砕され、 半水石膏サイロ 1 6に一旦貯蔵される c 続いて、 この半水石膏サイ口 1 6内の半水石膏とチップ 2 2とがプレミキサー 3 0により混練 （プレミックス） される。 得られた混練物は、 連続ミキサー 3 1に送られ、 同時に混練水 2 1、 必要に応じて添加材 （剤） 2 3も、 連続ミキ サー 3 1に導入されて混練され、 得られた原料スラリーは、 流し込み成形手段 3 2に導入される。 この態様によれば、 半水石膏とチップ 2 2とがプレミキサ 一 3 0によりあらかじめ混練されているので、 チップを安定して連続ミキサー に導入することができる。 FIG. 1 is a process chart for explaining one embodiment of the production method of the present invention. The raw dihydrate gypsum 11 is transferred to the dryer 12 and dried and crushed by the pulverizer 13 c.Then, it is calcined in the calciner 14 to change to hydration-hardening gypsum. Then, it is ground to a desired size by a crusher 15 and temporarily stored in a hemihydrate gypsum silo 16 c. Subsequently, the hemihydrate gypsum in the hemihydrate gypsum rhinoceros 16 and the chips 22 are premixed. Kneaded (premixed) with 30. The obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded, and the obtained raw material is obtained. The slurry is cast Introduced in 32. According to this aspect, since the hemihydrate gypsum and the chips 22 are kneaded in advance by the premixer 130, the chips can be stably introduced into the continuous mixer.
図 2は、 本発明の製造方法の別の実施態様を説明するための工程図である。 生二水石膏 1 1は、 乾燥機 1 2に移送され、 乾燥後粉碎機 1 3により粉碎され る。 続いてか焼炉 1 4でか焼されて水和硬化性を有する半水石膏に変化し、 粉 砕機 1 5によって所望のサイズに粉砕され、 半水石膏サイロ 1 6に一旦貯蔵さ れる。 続いて、 この半水石膏サイロ 1 6内の半水石膏とチップ 2 2と、 さらに 生二水石膏 1 1とがプレミキサー 3 0により混練 （プレミックス） される。 得 られた混練物は、 連続ミキサー 3 1に送られ、 同時に混練水 2 1、 必要に応じ て添加材 （剤） 2 3も、 連続ミキサー 3 1に導入されて混練され、 得られた原 料スラリーは、 流し込み成形手段 3 2に導入される。 この態様によれば、 半水 石膏、 チップ 2 2および生二水石膏 1 1がプレミキサー 3 0によりあらかじめ 混練されているので、 チップを安定して連続ミキサーに導入することができる とともに、 生二水石膏 1 1の一部がプレミキサーに移送されることによって、 乾燥、 粉碎、 か焼に必要なエネルギーも節約できる。 なお、 生二水石膏の付着 水分による半水石膏の水和を防止するために、 半水石膏と生二水石膏が混練さ れてから連続ミキサ一に導入するまでの時間は短いほうが好ましい。  FIG. 2 is a process chart for explaining another embodiment of the production method of the present invention. The raw dihydrate gypsum 11 is transferred to a dryer 12 and is dried and ground by a mill 13. Subsequently, it is calcined in a calcining furnace 14 to be converted into hemihydrate gypsum having hydration hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16. Subsequently, the hemihydrate gypsum and the chips 22 in the hemihydrate gypsum silo 16 and the raw dihydrate gypsum 11 are kneaded (premixed) by a premixer 30. The obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded to obtain the raw material. The slurry is introduced into the casting means 32. According to this embodiment, since the hemihydrate gypsum, the chips 22 and the raw dihydrate gypsum 11 are kneaded in advance by the premixer 30, the chips can be stably introduced into the continuous mixer. By transferring part of the water plaster 11 to the premixer, the energy required for drying, milling and calcining can also be saved. In order to prevent hydration of hemihydrate gypsum due to moisture attached to the gypsum, it is preferable that the time from mixing of the gypsum hemihydrate and gypsum to the introduction of the gypsum to the continuous mixer is shorter.
図 3は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この製造方法は、 図 2の態様とほぼ同じであるが、 乾燥機 1 2により乾燥され た乾燥二水石膏が半水石膏サイ口 1 6内の半水石膏とチップ 2 2とともにプレ ミキサー 3 0により混練 （プレミックス） されている。 乾燥二水石膏の一部が プレミキサーに移送されることによって、 粉砕、 か焼に必要なエネルギーが節 約できる。  FIG. 3 is a process chart for explaining another embodiment of the production method of the present invention. This production method is almost the same as that of the embodiment of FIG. 2, except that the dried dihydrate gypsum dried by the dryer 12 is mixed with the gypsum in the hemihydrate gypsum syrup 16 and the chips 22 together with the premixer 30. Is kneaded (premixed). By transferring part of the dried gypsum to the premixer, the energy required for grinding and calcination can be saved.
図 4は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この製造方法は、 図 2の態様とほぼ同じであるが、 まず生二水石膏 1 1とチッ プ 2 2が第 1プレミキサー 3 0 1により混練され、 得られた混練物と半水石膏 サイロ 1 6内の半水石膏とが第 2プレミキサー 3 0 2により混練されている。 この態様によれば、 チップの表面が生二水石膏の付着水分で濡らされ石膏マト リックスと強固な界面を形成することができ、 曲げ強度、 ネジ ·釘引き抜き抵 抗カ等の一層優れた石膏ボードを提供することができる。 FIG. 4 is a process chart for explaining another embodiment of the production method of the present invention. This production method is almost the same as that of the embodiment shown in FIG. 2, but first, raw dihydrate gypsum 11 and chip 22 are kneaded by a first premixer 301, and the obtained kneaded material and hemihydrate gypsum silo The hemihydrate gypsum in 16 is kneaded by the second premixer 302. According to this aspect, the surface of the chip can be wet with the adhering moisture of the raw gypsum to form a strong interface with the gypsum matrix, and more excellent gypsum such as bending strength, screw and nail pull-out resistance, etc. Board can be provided.
図 5は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この製造方法は、 図 4の態様とほぼ同じであるが、 乾燥機 1 2により乾燥され た乾燥二水石膏とチップ 2 2が第 1プレミキサー 3 0 1により混練され （第 1 プレミックス） 、 得られた混練物と半水石膏サイロ 1 6内の半水石膏とが第 2 プレミキサー 3 0 2により混練されている （第 2プレミックス） 。  FIG. 5 is a process chart for explaining another embodiment of the production method of the present invention. This production method is almost the same as the embodiment of FIG. 4, except that the dried dihydrate gypsum dried by the dryer 12 and the chips 22 are kneaded by the first premixer 301 (first premix). The obtained kneaded material and the hemihydrate gypsum in the hemihydrate gypsum silo 16 are kneaded by the second premixer 302 (second premix).
図 6は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この製造方法は、 図 4の態様において、 半水石膏サイロ 1 6内の半水石膏がプ レミキサー 3 0を経ることなく直接連続ミキサー 3 1に導入されている。 なお 図示していないが、 プレミキサー 3 0には生二水石膏ではなく乾燥機 1 2によ り乾燥された乾燥二水石膏とチップ 2 2とを混練してもよい。  FIG. 6 is a process chart for explaining another embodiment of the production method of the present invention. In this production method, the hemihydrate gypsum in the hemihydrate gypsum silo 16 is directly introduced into the continuous mixer 31 without passing through the premixer 30 in the embodiment of FIG. Although not shown, the premixer 30 may be kneaded not with the fresh gypsum gypsum but with the dried gypsum gypsum dried by the dryer 12 and the chips 22.
図 7は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この態様はチップを使用しない製造方法に関するものである。 生二水石膏 1 1 は、 乾燥機 1 2に移送され、 乾燥後粉砕機 1 3により粉砕される。 続いてか焼 炉 1 4でか焼されて水和硬化性を有する半水石膏に変化し、 粉碎機 1 5によつ て所望のサイズに粉碎され、 半水石膏サイロ 1 6に一旦貯蔵される。 続いて、 この半水石膏サイ口 1 6内の半水石膏と生二水石膏 1 1とがプレミキサー 3 0 により混練される。 得られた混練物は、 連続ミキサー 3 1に送られ、 同時に混 練水 2 1、 必要に応じて添加材 （剤） 2 3も、 連続ミキサー 3 1に導入されて 混練され、 得られた原料スラリーは、 流し込み成形手段 3 2に導入される。 こ の態様によれば、 半水石膏およびおよび生二水石膏 1 1とがプレミキサー 3 0 によりあらかじめ混練されているので、 生二水石膏 1 1を安定して連続ミキサ —に導入することができるとともに、 生二水石膏 1 1の一部がプレミキサーに 移送されることによって、 乾燥、 粉碎、 か焼に必要なエネルギーも節約できる。 図 8は、 本発明の製造方法の別の実施態様を説明するための工程図である。 この製造方法は、 図 7の態様とほぼ同じであるが、 乾燥機 1 2により乾燥され た乾燥二水石膏が半水石膏サイ口 1 6内の半水石膏とともにプレミキサー 3 0 により混練されている。 乾燥二水石膏の一部がプレミキサーに移送されること によって、 粉碎、 か焼に必要なエネルギーが節約できる。 FIG. 7 is a process chart for explaining another embodiment of the production method of the present invention. This embodiment relates to a manufacturing method that does not use a chip. The raw dihydrate gypsum 11 is transferred to a dryer 12 and is dried and crushed by a crusher 13. Subsequently, it is calcined in a calciner 14 to change into hemihydrate gypsum having a hydration-hardening property, pulverized to a desired size by a pulverizer 15 and temporarily stored in a hemihydrate gypsum silo 16. You. Subsequently, the gypsum hemihydrate in the gypsum hemihydrate gypsum mouth 16 and the gypsum fresh dihydrate 11 are kneaded by the premixer 30. The obtained kneaded material is sent to the continuous mixer 31, and at the same time, the kneading water 21 and, if necessary, the additive (agent) 23 are also introduced into the continuous mixer 31 and kneaded, and the obtained raw material is obtained. The slurry is introduced into the casting means 32. According to this embodiment, the hemihydrate gypsum and the fresh dihydrate gypsum 11 are previously kneaded by the premixer 30, so that the raw dihydrate gypsum 11 can be stably introduced into the continuous mixer. As well as the transfer of part of the raw gypsum to the premixer, the energy required for drying, milling and calcining can be saved. FIG. 8 is a process chart for explaining another embodiment of the production method of the present invention. This manufacturing method is almost the same as that of the embodiment of FIG. 7, but is dried by the dryer 12. The dried dihydrate gypsum is kneaded with the hemihydrate gypsum in the gypsum hemihydrate gypsum 16 by the premixer 30. By transferring part of the dried gypsum to the premixer, the energy required for milling and calcination can be saved.
なお、 上記図 1〜図 8の説明においては、 生二水石膏を出発材料とし、 これ を乾燥、 粉砕、 か焼し、 半水石膏を得、 それに水その他の原料を加え原料スラ リーを調製する工程を一つの製造ラインとして記載しているが、 別な場所で製 造された水和硬化性を有する石膏材料 （例えば市販石膏材料） を用い、 これに チップをブレミックスすることもできる。 また、 水和硬化性を有する石膏も半 水石膏に制限されず、 下記で説明する様々な種類の石膏材料を利用できる。 さ らにまた、 図 1〜図 8の説明においては乾燥機 1 1および粉碎機 1 3を別々の 装置として示しているが、 必要に応じて高温ガスをミルに吹き込み乾燥および 粉砕を同時に行うことのできる装置を利用してもよい。  In the description of Figs. 1 to 8 above, raw dihydrate gypsum is used as a starting material, which is dried, crushed and calcined to obtain hemihydrate gypsum, and water and other raw materials are added thereto to prepare a raw material slurry. The process is described as one production line, but it is also possible to use a hydration-hardening gypsum material (for example, a commercially available gypsum material) manufactured at another location, and blend the chips with the gypsum material. Gypsum having hydration-hardening properties is not limited to hemihydrate gypsum, and various types of gypsum materials described below can be used. Further, in the description of FIGS. 1 to 8, the dryer 11 and the crusher 13 are shown as separate devices.However, if necessary, high-temperature gas is blown into the mill to simultaneously perform drying and crushing. A device capable of performing the above may be used.
また本発明の製造装置は、 上記で説明した本発明の製造方法を実施するため に、 プレミキサー 3 0と、 連続ミキサー 3 1と、 流し込み成形手段 3 2とを備 えてなる。 本発明の製造装置は従来の石膏ボードの製造装置に比べてブレミキ サー 3 0を備えていることに特徴を有している。 以下、 本発明の装置に好適に 使用できるプレミキサー 3 0について説明する。  Further, the production apparatus of the present invention includes a premixer 30, a continuous mixer 31, and a casting means 32 in order to carry out the production method of the present invention described above. The production apparatus of the present invention is characterized in that it is provided with a blender 30 as compared with a conventional gypsum board production apparatus. Hereinafter, the premixer 30 that can be suitably used in the apparatus of the present invention will be described.
本発明で使用されるプレミキサーの好適な例としては、 スクリューフィーダ 一、 パドルミキサー、 パグミキサー、 リボンミキサー、 プロシェア一ミキサー、 ヘンシェルミキサー、 スパイラル .ビンミキサー （商品名） 等が挙げられる。 これらのミキサーについて、 図面を用いて簡単に説明する。  Preferable examples of the pre-mixer used in the present invention include a screw feeder 1, a paddle mixer, a pug mixer, a ribbon mixer, a pro-share mixer, a Henschel mixer, a spiral bottle mixer (trade name) and the like. These mixers will be briefly described with reference to the drawings.
図 9は、 スクリユーフィーダ一の断面図である。 材料は投入口 1からケース 2内に導入され、 モー夕一 3により回転する回転軸 4に設けられたスクリュー 羽根 5 1により移動しながら混練され、 排出口 6から排出される。 スクリュー フィーダ一は、 小型で安価であり、 良好な混合効果も期待できる。 スクリユー フィーダ一は、 上記で説明した図 1、 3、 5、 6、 8の態様においてとくに好 適に使用できる。  FIG. 9 is a sectional view of the screw feeder. The material is introduced into the case 2 from the inlet 1, is kneaded while being moved by the screw blade 51 provided on the rotating shaft 4 rotated by the motor 1, and is discharged from the outlet 6. Screw feeders are small and inexpensive, and good mixing effects can be expected. The screw feeder can be particularly preferably used in the embodiments of FIGS. 1, 3, 5, 6, and 8 described above.
図 1 0は、 パドルミキサーの断面図である。 材料は投入口 1からケース 2内 に導入され、 モー夕一 3により回転する回転軸 4に設けられたパドル 5 2によ り移動しながら混練され、 排出口 6から排出される。 パドルミキサーは、 良好 な混合効果が期待できる。 パドルミキサーは、 上記で説明した図 1〜図 8のす ベての態様において好適に使用できる。 FIG. 10 is a cross-sectional view of the paddle mixer. Material is in case 2 from inlet 1 The mixture is kneaded while being moved by a paddle 52 provided on a rotating shaft 4 which is rotated by a motor 3, and is discharged from a discharge port 6. Paddle mixers can be expected to have good mixing effects. The paddle mixer can be suitably used in all the embodiments of FIGS. 1 to 8 described above.
図 1 1 ( a ) は、 バグミキサーの断面図であり、 （b ) は A— A線断面図で ある。 材料は投入口 1からケース 2内に導入され、 モーター 3により回転する 2軸の回転軸 4、 4， に設けられたスクリュー羽根 5 1およびパドル 5 2によ り移動しながら混練され、 排出口 6から排出される。 パドルミキサーは、 良好 な混合効果が期待できる。 パグミキサーは、 上記で説明した図 1〜図 8のすベ ての態様において好適に使用できる。  Fig. 11 (a) is a cross-sectional view of the bag mixer, and (b) is a cross-sectional view taken along line AA. The material is introduced into the case 2 from the inlet 1 and is kneaded while being moved by the screw blades 51 and the paddles 52 provided on the two rotating shafts 4, 4, which are rotated by the motor 3, and is discharged. Exhausted from 6. Paddle mixers can be expected to have good mixing effects. The pug mixer can be suitably used in all the embodiments of FIGS. 1 to 8 described above.
図 1 2は、 リボンミキサーの断面図である。 材料は投入口 1からケース 2内 に導入され、 モータ一 3により回転する回転軸 4に設けられたリボン羽根 5 3 により移動しながら混練され、 排出口 6から排出される。 リボンミキサーは、 比較的安価であり、 大量の処理が可能であり、 また良好な混合効果が期待でき る。 リボンミキサーは、 上記で説明した図 1、 3、 5、 6、 8の態様において とくに好適に使用できる。  FIG. 12 is a cross-sectional view of the ribbon mixer. The material is introduced into the case 2 from the input port 1, kneaded while moving by the ribbon blade 5 3 provided on the rotating shaft 4 rotated by the motor 13, and discharged from the discharge port 6. Ribbon mixers are relatively inexpensive, can process large quantities, and have good mixing effects. The ribbon mixer can be particularly preferably used in the embodiments of FIGS. 1, 3, 5, 6, and 8 described above.
図 1 3 ( a ) は、 プロシェア一ミキサーの断面図であり、 （b ) は B— B線 断面図である。 材料は投入口 1からケース 2内に導入され、 モー夕一 3により 回転する回転軸 4に設けられたフラットショベル羽根 5 4と、 これとは別にケ —ス 2の下部に設けられモータ一 （図示せず） により回転するチョッパー 5 5 により移動しながら混練され、 排出口 6から排出される。 プロシェア一ミキサ 一は、 比較的小型であり、 一層良好な混合効果が期待できる。 プロシェアーミ キサ一は、 上記で説明した図 2、 4、 7の態様においてとくに好適に使用でき る。  Fig. 13 (a) is a cross-sectional view of a pro-share mixer, and (b) is a cross-sectional view taken along line BB. The material is introduced into the case 2 from the inlet 1 and the flat shovel blades 54 provided on the rotating shaft 4 which is rotated by the motor 3, and the motor 1 provided separately below the case 2. It is kneaded while being moved by a chopper 55 rotating by a rotating (not shown), and is discharged from a discharge port 6. Proshare mixers are relatively small and can be expected to have better mixing effects. The pro-share mixer can be particularly preferably used in the embodiments of FIGS. 2, 4, and 7 described above.
図 1 4 ( a ) は、 ヘンシェルミキサーの断面図であり、 （b ) は C— C線断 面図である。 材料は投入口 1からケース 2内に導入され、 モーター 3により回 転する回転軸 4に設けられた混合羽根 5 6により混練され、 混練された材料は モータ一 3， により回転する回転軸 4， に設けられたスクリュー羽根 5 1によ り移動し、 排出口 6から排出される。 ヘンシェルミキサーは、 良好な混合効果 が期待できる。 Fig. 14 (a) is a cross-sectional view of the Henschel mixer, and (b) is a cross-sectional view taken along line CC. The material is introduced into the case 2 from the inlet 1 and is kneaded by the mixing blades 56 provided on the rotating shaft 4 rotated by the motor 3. The kneaded material is rotated by the rotating shaft 4 by the motor 1, 3. Screw blades 5 And is discharged from outlet 6. The Henschel mixer can be expected to have a good mixing effect.
図 1 5は、 スパイラル · ビンミキサーの断面図である。 材料は投入口 1から ケース 2内に導入され、 モーター 3により回転するローター 5に設けられた分 散ピン 5 7により混練され、 排出口 6から排出される。 スパイラル · ピンミキ サ一は、 良好な混合効果が期待できる。  FIG. 15 is a sectional view of a spiral bin mixer. The material is introduced into the case 2 from the inlet 1, kneaded by the dispersing pins 57 provided on the rotor 5 rotated by the motor 3, and discharged from the outlet 6. Spiral pin mixer can be expected to have a good mixing effect.
また、 本発明の製造装置において連続ミキサー 3 1は、 従来から石膏ボード の連続流し込み成形による製造に用いられていたもの、 すなわち、 高速混練が 可能で、 かつ、 ミキサー内での原料スラリー 4 1の滞留時間が短いものを使用 することもできるが、 チップ 2 2を配合する場合には、 チップ 2 2が内部に付 着し難いものが好ましい。 また、 流し込み成形手段 3 2は、 従来から石膏ボー ドの連続流し込み成形による製造に用いられていた公知のものを使用すること ができ、 とくに制限されない。  Further, in the production apparatus of the present invention, the continuous mixer 31 has been conventionally used for the production by continuous casting of gypsum board, that is, capable of high-speed kneading, and of the raw material slurry 41 in the mixer. It is possible to use a material having a short residence time, but when compounding the chip 22, it is preferable that the chip 22 does not easily adhere to the inside. The casting means 32 may be a known one which has been conventionally used for continuous gypsum board production by continuous casting, and is not particularly limited.
図 1 6は、 連続ミキサーおよび流し込み成形手段を説明するための図である c 例えば、 連続ミキサー 3 1は、 容器 3 1 1と容器 3 1 1内部に設けられるとと もにロー夕一により回転する攪拌羽根 3 1 2とを有し、 容器 3 1 1にチップ 2 2を含む各種材料が導入され、 混練 （撹拌混合） により原料スラリーを得るこ とができるものであり、 各種材料は連続的に容器 3 1 1に導入され得、 また混 練により得られた原料スラリーが連続的に排出口 3 1 3から排出されるもので ある。 流し込み成形手段は、 原料スラリー 4 1が、 容器 3 1 1の出口 3 1 3か らボード用原紙 4 2の載置された移動コンベア 4 3上に連続的に流し出された 後、 均しローラ一 4 4を経て所定の厚さに均され、 かつ鉛直方向から供給され るボード用原紙 4 2 ' により挟まれ、 所定時間 （例えば 2分） このまま走行し てある程度固化、 養生された後、 所望のサイズに切断機 4 5により切断され、 乾燥工程を経て、 石膏ボード 5 0を得るというものである。  Fig. 16 is a diagram for explaining the continuous mixer and the casting means.c For example, the continuous mixer 31 is provided inside the container 311 and the container 311 and is rotated by the low speed and the low speed. Various materials including chips 22 are introduced into the container 311 and a raw material slurry can be obtained by kneading (stirring and mixing). The raw material slurry obtained by kneading can be continuously discharged from the discharge port 311. After the raw material slurry 41 is continuously poured out from the outlet 313 of the container 311 onto the moving conveyor 43 on which the base paper for board 42 is placed, the leveling roller is used. After passing through 44, it is leveled to a predetermined thickness, sandwiched between board base papers 4 2 ′ supplied from the vertical direction, travels for a predetermined time (for example, 2 minutes), and is solidified and cured to some extent. The gypsum board 50 is obtained by being cut by a cutting machine 45 into the size shown in FIG.
本発明で使用される各種材料は、 W 0 9 6 / 2 6 1 6 6に記載のものを好適 に利用することができるが、 以下、 簡単に説明する。  As the various materials used in the present invention, those described in WO96 / 26616 can be suitably used, and will be briefly described below.
本発明で使用できる生二水石膏、 乾燥石膏、 水和硬化性石膏材料は、 チップ を分散 ·保持できるマトリックスとなり得る石膏質の材料であればとくに制限 されない。 例えば水和硬化性石膏は、 焼き石膏、 ひ型半水石膏、 III型無水石 膏、 II 型無水石膏等が挙げられる。 これらは、 水の存在下で水和反応によつ て二水石膏に変化し硬化する石膏である。 なお、 本発明でいう生二水石膏とは、 上記のように未乾燥の通常数％から数十％の付着水分を有する石膏材料であり、 例えば天然石膏や、 排脱石膏、 リン酸石膏等の副産化学石膏が挙げられる。 乾 燥二水石膏とは、 この付着水分を除去する程度の加熱乾燥を行った石膏材料で あって、 水和硬化性を得るための焼成温度まで加熱するものではない。 The raw gypsum, dried gypsum, and hydration-hardening gypsum material that can be used in the present invention are chips The material is not particularly limited as long as it is a gypsum-like material that can serve as a matrix capable of dispersing and holding the material. For example, the hydration setting gypsum includes calcined gypsum, cast hemihydrate gypsum, type III anhydrous gypsum, type II anhydrous gypsum, and the like. These are gypsum which changes to gypsum by the hydration reaction in the presence of water and hardens. Note that the raw dihydrate gypsum in the present invention is a gypsum material having an attached moisture of usually several percent to several tens percent, as described above, such as natural gypsum, drainage gypsum, phosphate gypsum, and the like. By-product gypsum. The dried dihydrate gypsum is a gypsum material that has been heated and dried to remove the attached moisture, and is not heated to a firing temperature for obtaining hydration curability.
石膏材料に対するチップの配合割合は、 目的とする石膏ボードのサイズや用 途等により適宜選択することができるが、 例えば、 石膏ボードの曲げ強度およ びネジ ·釘引き抜き抵抗力を大幅に改善するためには、 石膏材料に対して、 チ ップを 0 . 2〜 2 5重量％、 好ましくは 2〜 1 0重量％、 さらに好ましくは 5 〜 8重量％配合することが好ましい。  The mixing ratio of the chips to the gypsum material can be appropriately selected according to the target gypsum board size and intended use.For example, it greatly improves the bending strength of the gypsum board and the resistance to pulling out screws and nails. For this purpose, it is preferable to add the chip in an amount of 0.2 to 25% by weight, preferably 2 to 10% by weight, more preferably 5 to 8% by weight, based on the gypsum material.
チップの原料としては、 例えば新聞紙、 折り込み広告用紙、 雑誌 ·文庫等の 書籍用紙、 コピー用紙、 ダンボール紙、 包装用紙、 工作用紙、 これらの廃棄物、 建材 （例えば板紙を用いた石膏ボード等） の端材、 発生材およびロス材等から 分離された紙等が挙げられる。 このほか、 フロッピ一ディスク、 録音用テープ、 映像用磁気テープ、 切符、 馬券、 農業用シート、 不織布、 織布等やこれらの廃 棄物等を原料にすることもできる。  Raw materials for chips include, for example, newspaper paper, insert advertising paper, book paper such as magazines and paperbacks, copy paper, cardboard paper, packaging paper, work paper, these wastes, and building materials (eg, gypsum board using paperboard). Examples include paper separated from offcuts, generated materials, loss materials, and the like. In addition, floppy disks, recording tapes, video magnetic tapes, tickets, betting tickets, agricultural sheets, non-woven fabrics, woven fabrics, etc., and their waste can also be used as raw materials.
チップのサイズは、 目的とする石膏ボードの強度やその種類等を考慮して適 宜選択されるものではあるが、 例えば、 1 mm x 1 mn！〜 5 O mm X 5 0 mm の平面部を有するものがよい。 また厚さは、 例えば 0 . 0 5〜2 mm程度が 好ましい。 チップの形状は、 例えば正方形、 長辺/短辺比として 1〜1 0を有 する長方形、 円形、 三角形あるいは異形なものであることができる。  The size of the chip is appropriately selected in consideration of the strength and the type of the target gypsum board, for example, 1 mm x 1 mn! It is preferable to have a flat part of up to 5 O mm X 50 mm. The thickness is preferably, for example, about 0.05 to 2 mm. The shape of the chip can be, for example, a square, a rectangle having a long side / short side ratio of 1 to 10, a circle, a triangle, or an irregular shape.
チップは、 公知である乾式粉砕法および湿式粉砕法等により製造でき、 所望 によりチップの表面処理、 毛羽立ち加工等を組み合わせることもできる。 また、 チップとして磁性材料およびプラスチック製材料を採用する場合は、 石膏材料 に水性接着剤を配合し、 さらにチップにカツプリング剤をコーティングするの が好ましい。 水性接着剤およびカップリング剤を配合する場合は、 これらの配 合割合も、 目的とする複合石膏ボードのサイズや用途、 使用する薬剤の種類等 により適宜選択することができるが、 例えば、 水性接着剤は石膏材料に対してThe chip can be manufactured by a known dry pulverization method, wet pulverization method, or the like. If desired, surface treatment of the chip, fluffing, and the like can be combined. When magnetic and plastic materials are used for the chips, a plaster material is mixed with an aqueous adhesive, and the chips are coated with a coupling agent. Is preferred. When a water-based adhesive and a coupling agent are blended, the mixing ratio thereof can be appropriately selected according to the size and application of the target composite gypsum board, the type of the chemical used, and the like. The agent is for the gypsum material
3〜2 0重量％、 好ましくは 3〜 1 0重量％、 カップリング材料は、 石膏材料 に対して 0 . 0 1 ~ 3重量％、 好ましくは 0 . 1〜 1重量％であることができ る。 3 to 20% by weight, preferably 3 to 10% by weight, the coupling material can be 0.01 to 3% by weight, preferably 0.1 to 1% by weight, based on the gypsum material. .
本発明によれば、 チップの平面部が、 石膏ボードの厚さ方向に対する垂直な 面に対して 3 0 ° 以下、 好ましくは 2 0 ° 以下の平均角度を有することにより、 任意の製造方法により製造されても、 所望の曲げ強度およびネジ '釘引き抜き 抵抗力を獲得可能な石膏ボードとなる。 なお、 従来の複合石膏ボードは、 チッ プの存在角度について全く考慮されておらず、 上記角度の範囲外になると曲げ 強度およびネジ ·釘引き抜き抵抗力が十分に発現しなかった。 チップが厚さ方 向に対して垂直な方向に存在する場合、 チップ間にネジまたは釘が入り込み、 チップと石膏を主成分とするマトリックスを分断することによって、 ボードに 割れ生ずることとなる。 逆に、 チップが石膏ボードの厚さ方向に対する垂直な 面に対してより平行に存在する場合、 ボード中を横断するネジまたは釘がチッ プの平面部を突き抜ける確率が高くなり、 チップとネジまたは釘との摩擦力に よってネジ ·釘引き抜き抵抗力が増大する。 本発明は、 この作用におけるチッ プの存在角度とネジ ·釘引き抜き抵抗力との関係を明確化し、 より高度にネ ジ ·釘引き抜き抵抗力を得るためには、 上記特定角度でチップの平面部が存在 することが必須であることを見出したものである。  According to the present invention, the chip has an average angle of 30 ° or less, preferably 20 ° or less with respect to a plane perpendicular to the thickness direction of the gypsum board, so that the chip can be manufactured by any manufacturing method. Even if it is, it becomes a gypsum board that can obtain the desired bending strength and screws' nail pull-out resistance. In addition, in the conventional composite gypsum board, the angle at which the chip exists was not considered at all, and when the angle was out of the above range, the bending strength and the screw / nail pull-out resistance were not sufficiently exhibited. If the chips are present in a direction perpendicular to the thickness direction, screws or nails will enter between the chips and break the chip and the gypsum-based matrix, causing the board to crack. Conversely, if the chips are more parallel to the plane perpendicular to the thickness of the gypsum board, there is a higher probability that screws or nails traversing the board will penetrate the plane of the chip, and the chips and screws or Screw and nail pull-out resistance increases due to frictional force with the nail. The present invention clarifies the relationship between the existing angle of the chip and the screw / nail pull-out resistance in this operation, and in order to obtain a higher screw / nail pull-out resistance, the flat portion of the chip at the above specific angle is required. It was found that the existence of a
下記の表は、 本発明の石膏ボードが釘引き抜き抵抗力に優れることを示すも のである。 表 1 The following table shows that the gypsum board of the present invention has excellent nail pull-out resistance. table 1
試験例 Test example
角度分布 (° ) 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 Angle distribution (°) 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14
0〜10 100 96.1 78.3 84.8 66.6 71.4 48.1 45 29.6 15.2 18.5 0 0 00 to 10 100 96.1 78.3 84.8 66.6 71.4 48.1 45 29.6 15.2 18.5 0 0 0
10〜20 0 3.8 16.2 13.1 30.8 20 31. ί 31.5 1 1.1 15.1 1 1.1 0 0 010-20 0 3.8 16.2 13.1 30.8 20 31.ί 31.5 1 1.1 15.1 1 1.1 0 0 0
20~30 0 0 5.4 0 2.6 2.9 1 .8 12.2 14.8 9.1 3.7 0 0 020 ~ 30 0 0 5.4 0 2.6 2.9 1.8 .2 12.2 14.8 9.1 3.7 0 0 0
30〜40 0 0 0 0 0 5.7 4.81 6.86 3.7 18.2 18.5 0 0 0 頻度 40〜50 0 0 0 2.2 0 0 0 2.1 7.4 9.1 22.2 0 0 030 ~ 40 0 0 0 0 0 5.7 4.81 6.86 3.7 18.2 18.5 0 0 0 Frequency 40 ~ 50 0 0 0 0 2.2 0 0 0 2.1 7.4 9.1 22.2 0 0 0
(%) 50-60 0 0 0 0 0 0 0.34 0.97 7.4 3 0 0 0 0 (%) 50-60 0 0 0 0 0 0 0.34 0.97 7.4 3 0 0 0 0
60-70 0 0 0 0 0 0 0 0.56 14.8 21.2 3.7 0 0 0 60-70 0 0 0 0 0 0 0 0.56 14.8 21.2 3.7 0 0 0
70〜80 0 0 0 0 0 0 0 0 3.7 3 14.8 4.8 0 070-80 0 0 0 0 0 0 0 0 3.7 3 14.8 4.8 0 0
80-90 0 0 0 0 0 0 0.86 0.89 7.4 6.1 7.4 95.2 100 100 紙シ - -卜の平均角度 5.0 5.4 7.7 7.2 8.6 9.3 13 4 15.0 34.2 38.6 39.8 84.5 85.0 85.0 釘引き抜き抵抗力 16.3 14.2 16 2 15.2 16.3 16.4 14.2 12.6 10.7 10.4 1 1.5 6.85 7.15 3.5 80-90 0 0 0 0 0 0 0.86 0.89 7.4 6.1 7.4 95.2 100 100 Average paper sheet angle 5.0 5.4 7.7 7.2 8.6 9.3 13 4 15.0 34.2 38.6 39.8 84.5 85.0 85.0 Nail pull-out resistance 16.3 14.2 16 2 15.2 16.3 16.4 14.2 12.6 10.7 10.4 1 1.5 6.85 7.15 3.5
上記表 1において、 角度分布とは石膏ボードの厚さ方向に対する垂直な面に 対するチップの平面部の角度分布である。 また、 図 17は、 表 1における紙シ —トの平均角度と釘引き抜き抵抗力との関係を示す図である。 In Table 1 above, the angle distribution is the angle distribution of the plane portion of the chip with respect to the plane perpendicular to the thickness direction of the gypsum board. FIG. 17 is a diagram showing the relationship between the average angle of the paper sheet in Table 1 and the nail pull-out resistance.
表 1および図 17から、 チップの平面部が 30° 以下の角度である石膏ボー ドは、 釘引き抜き抵抗力に優れていることが分かる。  From Table 1 and Fig. 17, it can be seen that the gypsum board with the tip flat at an angle of 30 ° or less has excellent nail pull-out resistance.
なお、 本例で用いた石膏ボードは、 アクリル型枠中に裏原紙を敷き、 この上 に紙チップを並べ、 石膏スラリーをそこに 1回ないし 3回流し込んだ後表原紙 を乗せ、 硬化するまでガラス板で押さえ、 その後、 60°。で 1日、 45°Cで 2 日乾燥し、 硬化体としたものである。 最終的な硬化体サイズは縦 10 cmx横 2 O x厚さ 1. 5 cmとし、 比重は 1. 0 g/c cとした。 なお、 紙シートの 角度分布は、 石膏スラリ一の流し込み距離を調節することにより簡単に制御す ることができる。 また、 硬化体における紙チップの角度は、 硬化体を 1. 6 c mx 1. 5 cmx 10 cmに切断し、 その断面をスキャナ一 （ヒューレットパ ッカード社製、 商品名 scanjet4c) でスキャンし、 得られたデ一夕を画像処理 (アドビ （株） photoshop) にてコントラスト調整することで紙シートの存在 を明確化した後、 さらにこの出力図を画像解析装置 （ （株） 二レコ社製、 商品 名 LuzexIII) で処理することにより測定した。  The gypsum board used in this example is made by laying back base paper in an acrylic mold, laying paper chips on it, pouring the gypsum slurry there once or three times, placing the front base paper on it, and curing it. Hold by a glass plate, then 60 °. And dried at 45 ° C for 2 days for 1 day. The final size of the cured product was 10 cm in length × 2 O in width × 1.5 cm in thickness, and the specific gravity was 1.0 g / cc. Note that the angle distribution of the paper sheet can be easily controlled by adjusting the casting distance of the gypsum slurry. The angle of the paper chip in the cured product was determined by cutting the cured product into 1.6 cm x 1.5 cm x 10 cm, and scanning the cross section with a scanner (Hewlett-Packard, product name scanjet4c). After clarifying the existence of the paper sheet by adjusting the contrast of the obtained image with image processing (Adobe Photoshop), the output diagram is further analyzed by an image analyzer (Nireco Co., Ltd.). No. LuzexIII).
使用した材料を下記に示す。  The materials used are shown below.
-石膏スラリー  -Gypsum slurry
焼き石膏 （サンエス石膏 （株） 製、 特号緑、 焼き石膏） 100重量部 ポリビニルアルコール （ （株） クラレ製、 MSH 9 16) 0. 3重量部 水 （水道水） 70重量部 Calcined gypsum (manufactured by San-es Gypsum Co., Ltd., special issue green, calcined gypsum) 100 parts by weight Polyvinyl alcohol (manufactured by Kuraray Co., Ltd., MSH 916) 0.3 parts by weight Water (tap water) 70 parts by weight
•紙チヅプ • Paper chip
十條板紙 （株） 製、 坪量 160 g/m2を 1 X 20 cmに力ットした短冊状 のもの Manufactured by Jujo Paperboard Co., Ltd., in the form of a strip with a basis weight of 160 g / m 2 and a force of 1 X 20 cm
•表原紙  • Table paper
十条板紙 （株） 製、 ボード用板紙、 坪量 210 g/m2) Jujo Paperboard Co., Ltd., board paperboard, basis weight 210 g / m 2 )
•裏原紙 十条板紙 （株） 製、 ボ一ド用板紙、 坪量 220 g/m2) また、 釘引き抜き抵抗力は、 硬化体に 01. 4mmの孔部を設け、 これに^ 2. 5mmx 40 mmの鉄丸釘を 1. 5 cm打ち込み、 これをインストロン万 能試験機にてクロスヘッド 2mmで引き抜いたときの抵抗力 （kgf) を測定 したものである。 • Backing paper Made of Jujo Paperboard Co., Ltd., board paperboard, basis weight 220 g / m 2 ) Also, the nail pull-out resistance is set to 11.4 mm hole in the cured body, which is ^ 2.5 mm x 40 mm The resistance (kgf) was measured when a 1.5 cm iron round nail was driven in and pulled out with a 2 mm crosshead using an Instron universal testing machine.
なお本発明の石膏ボードには、 所望の特性を改善するために、 必要に応じて 各種添加材 （剤） を配合することができる。 例えば、 通常の石膏ボードの製造 に用いられている添加材 （剤） 、 例えば減水剤、 泡剤、 遅延剤、 あるいは糊剤 等が挙げられる。 さらに、 軽量化、 不燃化、 高強度化等を望む場合には、 骨材、 難燃材、 バインダー等の各種副資材を配合することができる。 具体的には、 補 強繊維、 おがくず、 木質チップ、 パーライ ト、 ひる石、 でん粉、 PVA、 酸化 でん粉等が挙げられる。  Various additives (agents) can be added to the gypsum board of the present invention as needed in order to improve desired properties. For example, additives (agents) used in the production of ordinary gypsum board include, for example, water reducing agents, foaming agents, retarding agents, and sizing agents. Furthermore, if it is desired to reduce the weight, make it non-flammable, or increase the strength, various auxiliary materials such as aggregate, flame retardant, and binder can be added. Specific examples include reinforcing fibers, sawdust, wood chips, perlite, vermiculite, starch, PVA, and oxidized starch.
これらの添加材 （剤） の配合割合は、 例えば石膏材料に対して、 0. 1〜3 重量％程度がよい。  The compounding ratio of these additives (agents) is preferably, for example, about 0.1 to 3% by weight based on the gypsum material.
このようにして得られる石膏ボードの比重は、 通常 0. 5〜1. 6g/cm3、 好ましくは 0. 7〜1. SgZcm3がよい。 産業上の利用の可能性 The specific gravity of the gypsum board thus obtained is usually 0.5 to 1.6 g / cm 3 , preferably 0.7 to 1. SgZcm 3 . Industrial applicability
本発明によれば、 曲げ強度およびネジ ·釘引き抜き抵抗力が著しく優れ、 な おかつ各種性能が向上した石膏ボードを生産性よく安定に製造することのでき る方法および装置が提供され、 また、 任意の製造方法により製造されても、 所 望の曲げ強度およびネジ ·釘引き抜き抵抗力を獲得可能な石膏ボードが提供さ れ、 とくに次の事項について特筆すべき効果が奏される。  According to the present invention, there is provided a method and apparatus capable of stably producing a gypsum board having excellent bending strength and resistance to pulling out screws and nails, and having improved various performances with high productivity. Even if it is manufactured by an arbitrary manufacturing method, a gypsum board capable of obtaining a desired bending strength and resistance to pulling out screws and nails is provided, and the following effects are particularly remarkable.
1. チップの供給が安定化する。  1. The supply of chips is stabilized.
チップ単味では、 かさ高のため供給が不安定である。 とくに連続ミキサー内 の口一夕一は高速で回転しているため、 例えば自然落下方式の投入法では供給 経路内でチップが舞ってしまい、 連続ミキサー内に所定量が供給されなくなる 可能性が高い。 本発明によれば、 チップと石膏材料とをプレミックスして連続 ミキサーに供給することにより、 こうした問題は解決される。 The supply of chips is unstable due to bulkiness. In particular, since the mouth of the continuous mixer is rotating at high speed, chips flow in the supply path, for example, in the case of the natural drop type injection method, and the predetermined amount is not supplied to the continuous mixer. Probability is high. According to the present invention, such a problem is solved by premixing the chips and the gypsum material and supplying them to the continuous mixer.
2. 二水石膏の供給が安定化する。  2. The supply of gypsum is stabilized.
生二水石膏には、 通常数％から数十％の付着水分があり、 これをそのまま連 続ミキサ一に移送する際には、 移送経路への付着が激しく連続ミキサ一への安 定供給を妨げる原因となる。 生二水石膏を半水石膏やチップとプレミックスす ることにより、 付着性は低減されるので連続ミキサ一への安定供給が可能とな る。  Normally, fresh gypsum has attached moisture of several percent to several tens of percent, and when it is transferred to a continuous mixer as it is, it adheres strongly to the transfer path and requires a stable supply to the continuous mixer. It can be a hindrance. By premixing raw dihydrate gypsum with hemihydrate gypsum and chips, the adhesiveness is reduced and stable supply to the continuous mixer is possible.
3. 石膏ボードの組織が均質化する。  3. The structure of the gypsum board is homogenized.
プレミックスによって、 材料の均質混合が図られ、 チップの凝集物や石膏材 料の凝集物の発生量が著しく低減する。 その結果、 製品性能 （機械的性質、 耐 久性、 耐火性等） の向上した石膏ボードが安定して得られる。  The premix ensures a homogeneous mixing of the materials and significantly reduces the amount of chip agglomerates and gypsum material agglomerates. As a result, gypsum board with improved product performance (mechanical properties, durability, fire resistance, etc.) can be obtained stably.
4. 機械的強度、 ネジ ·釘引き抜き抵抗力が向上する。  4. Improved mechanical strength, screw and nail pull-out resistance.
プレミックスによって、 チップの表面には例えば半水石膏粉末の薄層が形成 される。 連続ミキサーでこれらと水、 その他の原料が混練される際、 薄層部で は水和反応 （CaS04 - 1/2 H20→CaS04 - 2 H20) を生じるが微 細な水和物結晶はチップの微細組織に入り込み、 結果としてチップと石膏材料 間で強力な界面 （強固な付着） を形成する。 このことにより、 曲げ強度等の機 械的強度ゃネジ ·釘引き抜き抵抗力が向上する。 The premix forms a thin layer of gypsum hemihydrate on the surface of the chips. Thereof with water in a continuous mixer, when the other ingredients are kneaded, hydrated reaction by thin layer portion (CaS0 4 - 1/2 H 2 0 → CaS0 4 - 2 H 2 0) produce but fine fine water The hydrate crystals penetrate the chip microstructure, resulting in a strong interface (strong adhesion) between the chip and the gypsum material. As a result, mechanical strength such as bending strength, and the pulling resistance of screws and nails are improved.
5.連続ミキサー内におけるチップの付着が軽減される。  5. Chip adhesion in the continuous mixer is reduced.
チップは、 石膏ボードの原料として用いられるには、 平面部の面積が広く、 かつ厚さも薄いので、 水と混練すると連続ミキサーの内壁やローターに貼り付 きやすい。 プレミックスにより、 チップの表面に上記 4. に記した薄層部が形 成され、 その結果連続ミキサー内へのチップの付着が軽減される。  Chips, when used as a raw material for gypsum board, have a large flat surface area and a small thickness, so when kneaded with water, they can easily stick to the inner wall or rotor of a continuous mixer. The premix forms a thin layer on the surface of the chips as described in 4 above, thereby reducing the adhesion of chips to the continuous mixer.
6. 本発明の石膏ボードは、 曲げ強度およびネジ ·釘引き抜き抵抗力を確実に 高めることができる。  6. The gypsum board of the present invention can reliably increase bending strength and resistance to pulling out screws and nails.
チップの平面部を、 石膏ボードの厚さ方向に対する垂直な面に対して 30° 以下にすることにより、 ボード中を横断するネジまたは釘がチップの平面部を 突き抜ける確率が高くなり、 チップとネジまたは釘との摩擦力によってネジ · 釘引き抜き抵抗力が増大する。 したがって、 任意の製造方法により製造されて も、 所望の曲げ強度およびネジ ·釘引き抜き抵抗力を得ることができる。 By making the plane of the chip no more than 30 ° to the plane perpendicular to the thickness direction of the gypsum board, screws or nails traversing the board will cut the plane of the chip. The probability of penetration increases, and the frictional force between the tip and the screw or nail increases the screw / nail pull-out resistance. Therefore, even if it is manufactured by an arbitrary manufacturing method, it is possible to obtain desired bending strength and screw / nail pull-out resistance.

Claims

請 求 の 範 囲 The scope of the claims
1 . 生二水石膏、 乾燥二水石膏および水和硬化性を有する石膏からなる群 から選択された少なくとも 1種の石膏と、 紙チップおよび/またはチップ体と をプレミキサー内で混練するプレミックス工程と、 1. Premix in which at least one gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum, and paper chips and / or chip bodies are kneaded in a premixer. Process and
得られた混練物、 水および必要に応じて各種添加材 （剤） を含む原料を連続 ミキサー内で混練し原料スラリーを調製する工程と （但し、 前記原料スラリー には水和硬化性を有する石膏が必須成分として含まれている） 、  A step of kneading the raw material containing the obtained kneaded material, water and, if necessary, various additives (agents) in a continuous mixer to prepare a raw material slurry (provided that the raw material slurry has hydration-hardening gypsum; Is included as an essential ingredient),
前記原料スラリーを流し込み成形する工程と、  Casting and casting the raw material slurry;
を含む石膏ボードの製造方法。 A method for producing a gypsum board.
2 . プレミックス工程が、 生二水石膏または乾燥二水石膏と、 水和硬化性 を有する石膏と、 紙チップおよび/またはチップ体とをプレミキサー内で混練 するものである請求の範囲第 1項に記載の石膏ボードの製造方法。 2. The premixing step wherein the premixing step comprises kneading, in a premixer, raw gypsum or dried gypsum, hydration-hardening gypsum, and paper chips and / or chips. A method for producing a gypsum board according to the above item.
3 . プレミックス工程が、 生二水石膏または乾燥二水石膏と、 紙チップお よび/またはチップ体とを第 1プレミキサー内で混練する第 1プレミックスェ 程と、 得られた混練物と水和硬化性を有する石膏材料とを第 2プレミキサー内 で混練する第 2プレミックス工程とからなる請求の範囲第 2項に記載の石膏ボ ードの製造方法。 3. The premixing step comprises: a first premixing step of kneading the raw or dried gypsum, paper chips and / or chips in a first premixer, and a kneaded material obtained. 3. The method for producing a gypsum board according to claim 2, comprising a second premixing step of kneading a hydration-hardening gypsum material in a second premixer.
4 . プレミックス工程が、 生二水石膏または乾燥二水石膏と、 紙チップお よび/またはチップ体とをプレミキサー内で混練するものである請求の範囲第 1項に記載の石膏ボードの製造方法。 4. The production of the gypsum board according to claim 1, wherein the premixing step is a step of kneading the raw dihydrate gypsum or the dried dihydrate gypsum and the paper chips and / or chips in a premixer. Method.
5 . 生二水石膏および乾燥二水石膏からなる群から選択された少なくとも 1種の石膏と、 水和硬化性を有する石膏とをプレミキサー内で混練する工程と、 得られた混練物、 水および必要に応じて各種添加材 （剤） を連続ミキサー内 で混練し原料スラリーを調製する工程と、 5. a step of kneading at least one kind of gypsum selected from the group consisting of raw gypsum and dried gypsum and a gypsum having hydration-hardening property in a premixer; And, if necessary, various additives (agents) in a continuous mixer Preparing a raw material slurry by kneading with
前記原料スラリーを流し込み成形する工程と、  Casting and casting the raw material slurry;
を含む石膏ボードの製造方法。 A method for producing a gypsum board.
6 . 乾燥二水石膏を得るために生二水石膏を乾燥する工程と、 水和硬化性 石膏を得るために前記乾燥二水石膏を粉砕しか焼する工程と、 をさらに有する 請求の範囲第 1項ないし第 5項のいずれか 1項に記載の石膏ボードの製造方法 c 6. The method according to claim 1, further comprising: a step of drying the raw gypsum to obtain dried gypsum; and a step of only pulverizing and calcining the dried gypsum to obtain a hydration-hardening gypsum. Method for producing gypsum board according to any one of paragraphs 5 to 5 c
7 . 請求の範囲第 1項ないし第 6項のいずれか 1項に記載の製造方法に より製造された石膏ボード。 7. A gypsum board manufactured by the manufacturing method according to any one of claims 1 to 6.
8 . 生二水石膏、 乾燥二水石膏および水和硬化性を有する石膏からなる群 から選択された少なくとも 1種の石膏と、 紙チヅプおよび Zまたはチップ体と を混練することのできるプレミキサ一と、 8. A premixer capable of kneading at least one gypsum selected from the group consisting of fresh gypsum, dried gypsum and hydration-hardening gypsum, and paper chips and Z or chip bodies. ,
得られた混練物、 水および必要に応じて各種添加材 （剤） を含む原料を連続 的に供給し、 混練し、 得られた原料スラリー （但し、 前記原料スラリーには水 和硬化性を有する石膏が必須成分として含まれている） を連続的に排出するこ とのできる連続ミキサーと、  The raw material containing the obtained kneaded material, water and, if necessary, various additives (agents) is continuously supplied and kneaded, and the obtained raw material slurry (provided that the raw material slurry has hydration curability. Mixer that can continuously discharge gypsum as an essential ingredient)
前記原料スラリ一を流し込み成形することのできる手段と、  Means capable of casting and molding the raw material slurry,
を備えてなる石膏ボードの製造装置。 A gypsum board manufacturing apparatus comprising:
9 . 生二水石膏を乾燥し乾燥二水石膏を得る乾燥機と、 前記乾燥二水石膏 を粉碎する粉砕機と、 粉砕した乾燥二水石膏をか焼し水和硬化性石膏を得るか 焼炉と、 をさらに備えてなる請求の範囲第 8項に記載の石膏ボードの製造装置 c 9. Dryer for drying raw gypsum to obtain dried gypsum, pulverizer for grinding the dried gypsum, and calcining the dried gypsum to obtain hydration-hardening gypsum A gypsum board manufacturing apparatus c according to claim 8, further comprising: a furnace.
1 0 . 石膏材料に紙チップおよび/またはチップ体が配合されてなる石膏ボ ードにおいて、 前記紙チップおよび/またはチップ体の平面部が、 前記石膏ボ ードの厚さ方向に対する垂直な面に対して 3 0 ° 以下の平均角度を有すること を特徴とする石膏ボード。 10. In a gypsum board in which a paper chip and / or a chip body is blended with a gypsum material, a plane portion of the paper chip and / or the chip body has a plane perpendicular to a thickness direction of the gypsum board. Have an average angle of less than 30 ° Gypsum board.
1 1. 紙チップおよび/またはチップ体の配合割合が、 石膏材料の重量に対 して、 0.2〜25重量％である、 請求の範囲第 10項に記載の石膏ボード。 11. The gypsum board according to claim 10, wherein the mixing ratio of the paper chips and / or chips is 0.2 to 25% by weight based on the weight of the gypsum material.
12. 紙チップおよび/またはチップ体が、 lmmx lmn！〜 5 Ommx 5 Omm の大きさの平面部を有する、 請求の範囲第 10項または第 1 1項に記 載の石膏ボード。 12. The paper chips and / or chips are lmmx lmn! The gypsum board according to claim 10 or 11, wherein the gypsum board has a plane portion having a size of 5 to 5 Omm x 5 Omm.
13. 紙チップおよび/またはチップ体が、 1〜 10の長辺/短辺比を有す る、 請求の範囲第 10項ないし第 12項のいずれか 1項に記載の石膏ボード。 13. The gypsum board according to any one of claims 10 to 12, wherein the paper chip and / or the chip body has a long side / short side ratio of 1 to 10.
PCT/JP2000/001790 1999-03-30 2000-03-23 Gypsum board, gypsum board producing method and gypsum board producing device WO2000059698A1 (en)

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EP3984977B1 (en) 2020-10-19 2022-11-09 Lindner NORIT GmbH & Co. KG Method for recycling gypsum wallboard material

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