JP3857442B2 - Manufacturing method of veneered inorganic board - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a veneered inorganic board that is curved to form a curved surface.
[0002]
[Prior art and problems to be solved by the invention]
Conventionally, when making a wooden decorative finish on a curved surface part that requires fire resistance, after spraying water on an inorganic board such as a calcium silicate board or fiber reinforced gypsum board and letting it stand for several minutes, Molded into a desired curvature with a mold material, etc., dried to an appropriate moisture content, fixed to the curved surface with screws or adhesive, and then a rubber plate with a veneer backed with a nonwoven fabric etc. on the surface of the inorganic board A method of bonding with an adhesive having a strong tackiness is generally used.
[0003]
In this method, water is sprinkled on an inorganic board at the construction site, and the veneer is pasted after drying to form a curved surface. Therefore, it takes a lot of labor and time, and then the veneer is bonded to the site using a highly tacky adhesive. For this reason, it is difficult to uniformly apply the adhesive, and the surface of the veneer may be uneven or may be partially peeled off.
[0004]
In view of the above-described problems, the present invention is intended to provide a method for manufacturing a veneered inorganic board with high productivity while the veneer can be stuck smoothly and the occurrence of peeling can be prevented.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, a method for producing a veneered inorganic board according to the present invention includes a front and back layer comprising mineral fibers, an inorganic powder, and a reactivating binder, an inorganic foam, After heating a three-layered inorganic plate in which a core layer containing an activatable binder as an essential component is integrated and imparting flexibility, at least one surface of the inorganic plate is protruded through a thermosetting adhesive. And pressing in a heated state to form a curved surface, curing the thermosetting adhesive, and then cooling the inorganic plate to cure the reactivating binder.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the present invention will be described with reference to FIG.
The veneered inorganic board A shown in FIG. 1 is required to have front and back layers 1a and 1c containing mineral fibers, inorganic powders, and a reactivating binder as essential components, an inorganic foam and a reactivating binder. The inorganic plate 1 having a three-layer configuration in which the core layer 1b as a component is laminated and integrated is formed into a curved surface, and the projecting plate 3 is pasted through a thermosetting adhesive 2.
[0007]
The production method of the present invention will be specifically described. First, the inorganic plate 1 is heated in advance with a hot press or a dryer to impart flexibility. The heating conditions vary depending on the thickness of the plate and the type of the reactivatable binder, but are usually within a few minutes at a temperature of 100 to 150 ° C. Next, the thermosetting adhesive 2 is applied onto the inorganic plate 1 and the protruding plate 3 is disposed. As the thermosetting adhesive, urea, melamine, urea-melamine, phenol, epoxy or the like can be used. Next, as shown in FIG. 2, it is inserted into a curved mold 11 and pressed by a press 10 to integrally mold the inorganic plate 1 and the projecting plate 3 into a curved surface, cure the thermosetting adhesive 2, and re-cool after cooling. After the activatable binder was cured, it was taken out from the mold 11 to obtain a curved veneered inorganic board A as shown in FIG.
[0008]
Next, a specific composition and manufacturing method of the inorganic plate 1 will be described.
Rock mineral, slag wool, glass wool, etc. can be used as the mineral fiber that forms the front and back layers 1a, 1b and develops strength, and the added amount is 20 to 80% by weight. The inorganic powder is for increasing the surface hardness and smoothness, and aluminum hydroxide, calcium carbonate, silica sand and the like can be used, and the addition amount is 10 to 65% by weight. The reactivating binder that binds and integrates them is a binder that softens when heated in the presence of moisture and hardens again when cooled. Starch, polyvinyl alcohol, and the like can be used. Usually, when heated by the moisture contained in the plate material, flexibility is exhibited, but it is preferable to add more moisture. In addition, it is preferable to add a water-resistant binder such as a phenol resin or an acrylic resin in order to impart water resistance. The combined amount of these binders is 5 to 30% by weight. In order to increase the strength, 3 to 15% by weight of organic fibers such as pulp and polypropylene can be added. A slurry obtained by adding and stirring these into water was made into a paper to obtain a wet mat serving as front and back layers.
[0009]
On the other hand, pearlite, shirasu foam, glass foam or the like can be used as the inorganic foam which is the main component of the core layer 2 and is effective in reducing the weight of the plate material. The addition amount is 40 to 80% by weight. The binder for binding the inorganic foam can be the same as that of the front and back layers, and the addition amount is 5 to 30% by weight including the reactivating binder and other water-resistant binder. . In order to increase the strength, 5 to 30% by weight of organic fibers such as pulp and polypropylene can be added. Moreover, you may add an inorganic powdery body as needed. These are mixed by atomization of water, sprayed and deposited on the wet mat on the back layer, and the wet mat on the surface layer is placed on it, dried by a dryer after being heated and pressed with a continuous press, and the specific gravity of the front and back layers. Is 0.8 to 1.2, the core layer has a specific gravity of 0.4 to 0.7, and an overall specific gravity of 0.6 to 0.9 is obtained.
[0010]
Since the inorganic board 1 is mainly composed of mineral fibers in the front and back layers, it is easily deformed along the curved surface during curved molding, and the reactivating binder is mainly used as the binder. It can be easily deformed and curved surface processing becomes possible. In addition, since the curved plate is formed immediately after placing the protruding plate 3 through the thermosetting adhesive 2 after the inorganic plate 1 is heated, the thermosetting adhesive 2 is cured simultaneously with the curved forming so that the protruding plate is stuck smoothly and peeled off. Occurrence can also be prevented. Moreover, curved surface molding and veneering can be performed simultaneously, and productivity can be improved.
[0011]
【Example】
65% by weight of rock wool as mineral fiber, 20% by weight of aluminum hydroxide as inorganic powder, 5% by weight of pulp as organic fiber, 5% by weight of starch as reactivating binder, 5% of powdered phenol as water-resistant binder About 2% of the slurry obtained by adding and stirring the weight percent in water was made with a long net paper machine to obtain a wet mat for the surface layer portion and the back layer portion.
On the other hand, as the core layer part, 65% by weight of pearlite as an inorganic foam, 20% by weight of aluminum hydroxide as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as a reactivating binder, water resistance Formed from a mixture obtained by mixing 5% by weight of powdered phenol as a water-soluble binder by atomization of water, sprayed and deposited on the wet mat serving as the back layer portion, and the wet mat serving as the surface layer portion on the upper surface Lamination was performed to obtain a laminate. This laminate was pressed with a hot press at 100 ° C. for 5 minutes, then dried with a dryer at 200 ° C. for 60 minutes, cooled to room temperature, and an inorganic plate 1 having a specific gravity of 0.7 and a thickness of 6 mm (Daiken Industry Co., Ltd.) Product name: Dielite).
[0012]
Next, the inorganic plate 1 is heated in a hot press at 130 ° C. for about 1 minute to be flexible, and then the urea / melamine adhesive 2 is quickly applied on one surface thereof, and the projecting plate 3 is disposed thereon. Then, as shown in FIG. 2, it was placed on the lower frame 11a mounted on the press 10 and pressed with the upper frame 11b to form a curved surface. Cooling while sandwiched between the molds 11, the reactivating binder of the inorganic plate was cured to obtain a veneered inorganic plate A having a desired curved surface as shown in FIG. As the veneer plate 3, those conventionally attached to plywood or MDF (medium fiber board) can be used as they are, and are not particularly limited.
In addition, flexibility is further increased by adding water to the inorganic plate 1 by spraying water or using a press machine that generates steam.
Further, the heating means for the inorganic plate 1 is not limited to the hot press but may be a dryer. The curved surface forming means can be used only for the mold 11 as shown in this embodiment as long as the plate can be bent and held in that state. Not limited.
[0013]
The heating temperature and time for imparting flexibility are appropriately selected depending on the thickness of the inorganic plate 1 and the type of the reactivating binder used. Moreover, the temperature of the hot press at the time of curved surface molding is appropriately selected depending on the type of the thermosetting adhesive on which the veneer is pasted, and if the inorganic board 1 retains sufficient heat to cure the thermosetting adhesive, Curved molding by pressing may be used.
[0014]
Since the obtained protruding plate-attached inorganic plate A is formed into a curved surface with a desired curvature, it can be directly fixed to the curved portion with an adhesive, a nail or the like, and has excellent workability. In addition, about the flat board sticking inorganic board applied to a plane part, just sticking the stick board 3 via an adhesive like the sticking board to a plywood or MDF to the inorganic board 1 used for the present invention, At this time, it is not necessary to use a thermosetting adhesive as the adhesive.
[0015]
【The invention's effect】
As described above, according to the present invention, immediately after heating the inorganic plate formed using the reactivatable binder to impart flexibility, the veneer is disposed via the thermosetting adhesive, and the curved surface Thus, the protruding plate can be bonded and integrated with the inorganic plate simultaneously with the curved surface forming, the protruding plate can be applied smoothly and peeling can be prevented, and productivity can be increased.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a veneered inorganic board showing an embodiment of the present invention.
FIG. 2 is a production explanatory view of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Inorganic board 2 ... Thermosetting adhesive 3 ... Veneer board 11 ... Formwork A ... Veneer board inorganic board

Claims (1)

A three-layer structure in which mineral fibers, inorganic powders, and a reversible binder as essential components, and a core layer that includes inorganic foam and a reactivating binder as essential components are laminated and integrated. After imparting flexibility by heating the inorganic plate, a projecting plate is disposed on at least one surface of the inorganic plate via a thermosetting adhesive, pressed in a heated state and molded into a curved surface, and a thermosetting adhesive And then cooling the inorganic plate to cure the reactivating binder, and a method for producing a veneered inorganic plate.

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