JP6605898B2 - Humidity control panel and manufacturing method thereof - Google Patents

Description

  The present invention relates to a humidity control panel and a manufacturing method thereof.

Conventionally, building materials using gypsum as a raw material are known. For example, a humidity control gypsum board in which a porous filler such as silica gel or diatomaceous earth that absorbs and releases water vapor in a specific humidity range is poured between gypsum board base paper and cured is proposed. (Patent Document 1)
Patent Document 2 discloses a humidity control material that has a humidity control performance and is lightweight and capable of improving the construction efficiency. The total amount of calcium carbonate and silica gel is 3 to 80 weights with respect to 100 parts by weight of gypsum. Humidity-conditioning gypsum board contained in parts is disclosed.
Furthermore, Patent Document 3 discloses a humidity control gypsum board formed by mixing a calcined hemihydrate gypsum with silica gel and, if necessary, an admixture composed of a bulking agent, a strength reinforcing agent, and the like, into a plate shape. .

JP-A-1-230456 JP-A-8-12408 JP-A-9-59052

However, in the prior art, it is necessary to arrange the base paper for gypsum board on the front and back sides to secure the physical properties as a board, and the thickness is as thick as 12 to 21 mm in order to ensure the strength in use. In addition, it is not designed to be used as a home interior material, and it is necessary to paint the surface of the base paper, and the coated material is required to have humidity control. It was.
In addition, humidity control tiles that are baked by mixing humidity control fillers and clay that are distributed in the market are excellent in design, but require special tools for cutting at construction sites and require skill. Met.

  The present invention has been studied in view of such circumstances, and is an invention that is easy to manufacture, is a lightweight finished product, and is an invention aimed at obtaining a moisture-controllable panel that is easy to construct, gypsum, inorganic filler, silica gel, Humidity control panels characterized by containing hollow bodies and fibrous substances as essential components, and also containing gypsum, inorganic filler, silica gel, hollow bodies, fibrous substances, and appropriate amounts of water, kneading and molding Is a method for producing a humidity control panel.

The humidity control panel of the present invention has a strength capable of handling even when the thickness is 6 mm, and has excellent humidity control performance. Moreover, an embossed pattern can be easily and freely given to the design properties.
The production method does not require the base paper used in the conventional gypsum board humidity control panel as in the casting method.
Further, by blending the resin hollow body, the humidity control panel can be easily cut. This has the advantage that the dimensions can be easily adjusted and simple construction can be performed without using a dedicated tool on site during actual construction.
Furthermore, the humidity control panel of the present invention obtained by the vacuum extrusion method has a dense structure and excellent mechanical strength.

As the gypsum according to the present invention, α-type hemihydrate gypsum, β-type hemihydrate gypsum, and type III anhydrous gypsum obtained by heat-treating dihydrate gypsum or dihydrate gypsum by a known method can be used. In addition, type II anhydrous gypsum with a slow hydration reaction can be used by using a curing accelerator such as potassium sulfate, aluminum sulfate, sodium salts and the like. Among these gypsums, α-type hemihydrate gypsum and β-type hemihydrate gypsum are called calcined gypsum (CaSO ₄ · 1 / 2H ₂ O), which reacts quickly with water and is stable dihydrate gypsum (CaSO ₄ · 2H _2). O) is preferable because it becomes a coagulated hardened material that is hardly soluble in water, and in the present invention, a β-type hemihydrate gypsum having an average particle diameter of 10 to 20 μm by a laser diffraction / scattering method (microtrack method) is particularly preferable. .

  In the present invention, 40 to 250 parts by weight of the inorganic filler is blended with 100 parts by weight of gypsum. Examples of the inorganic filler include silica, calcium carbonate, calcium sulfate, magnesium silicate, diatomaceous earth, talc, fly ash, zeolite, wollastonite, mica, and the like.

There are no particular restrictions on calcium carbonate, and heavy calcium carbonate, light calcium carbonate (precipitated calcium carbonate), etc. are used, and the average particle size (particle size distribution (volume) detected by the laser diffraction / scattering method (microtrack method) If the arithmetic mean diameter calculated from the distribution) is in the range of 1 to 20 μm, the strength and machinability of the panel are excellent. In particular, calcium carbonate having a specific surface area value of 2,500 to 23,000 cm ² / g is preferable.

  In the present invention, silica gel is used as the humidity control material. A particularly preferred silica gel is B-type silica gel, which has larger pores than the A-type silica gel and has an excellent moisture absorption / release function. The B-type silica gel preferably has an average particle diameter in the range of 12 to 27 μm by the laser diffraction / scattering method (microtrack method), and within this range, it can be dispersed uniformly and has a moisture absorption / release function. Excellent. If the particle diameter is less than the lower limit, the specific surface area is increased, so a large amount of binder is required for curing, and if the upper limit is exceeded, the distribution in the material becomes non-uniform, and adjustment at each position is not possible. Variations in humidity performance are likely to occur. Silica gel is blended in an amount of 40 to 80 parts by weight per 100 parts by weight of gypsum. If it is in this range, a sufficient moisture absorbing / releasing function is exhibited, and if the lower limit is not reached, the moisture absorbing / releasing function tends to decrease, and if the upper limit is exceeded, the bending strength of the humidity control panel tends to decrease.

  In the present invention, for the purpose of weight reduction, a hollow body such as an inorganic hollow body or a synthetic resin hollow body may be used. Examples of the inorganic hollow body include silica balloon, shirasu balloon, fly ash balloon, foamed pearlite, foamed vermiculite, and foamed glass beads. Examples of the synthetic resin hollow body include acrylonitrile (co) polymer resin, phenol resin, urea resin, Examples thereof include a foamed resin hollow body made of polystyrene, polypropylene, polyvinylidene chloride, or the like. The blending ratio of the hollow body is 5 to 15 parts by weight based on 100 parts by weight of gypsum. If the lower limit is not reached, it is difficult to reduce the weight of the humidity control panel, and if the upper limit is exceeded, the bending strength of the humidity control panel tends to decrease.

  In the present invention, the hollow body is used for the purpose of reducing the weight, but the thermoplastic resin foam hollow body is particularly preferable because it has been found that it is superior in cutting workability. This is considered because the thermoplastic resin foam hollow body is melted by heat at the time of cutting. Among these, a thermoplastic foam hollow body having an average particle diameter of 35 to 55 μm by a laser diffraction / scattering method (microtrack method) and a specific gravity of 0.08 to 0.18 g / cm 3 is preferable.

Furthermore, you may mix | blend the thermoplastic resin emulsion which improves water resistance and acts also as a binder component. The thermoplastic resin Emarujiyon, such as vinyl acetate-based polymer Emarujiyon, acrylic polymer Emarujiyon vinyl polymer Emarujiyon chloride, vinylidene chloride polymer Emarujiyon, there may be mentioned a urethane-based polymer Emarujiyon etc. Especially acrylic resin Emulsions are preferable, and acrylic resin emulsions having ethyl acrylate and methyl methacrylate as main monomers and having an average particle size of 200 to 300 nm are more preferable in terms of dispersibility. The average particle diameter is a value calculated based on scattered light detected at the time of laser irradiation using a laser light diffraction / scattering particle diameter measuring apparatus (ELS-8000 manufactured by Otsuka Electronics Co., Ltd.). If the blending ratio of the thermoplastic resin emulsion is 10 to 25 parts by weight with respect to 100 parts by weight of gypsum as a solid content, it functions as a binder.

  Furthermore, fibrous materials such as hemp, cotton, pulp and other natural fibers, rock wool fibers, ceramic fibers, carbon fibers, glass fibers, boron fibers and other inorganic fibers, rayon, polypropylene, polyethylene, vinylon, nylon, polyester, In addition, synthetic fibers such as acrylic may be blended, and by blending, the impact resistance of the humidity control panel is improved. The fiber length is 3 to 13 mm, and the blending ratio is 1 to 10 parts by weight per 100 parts by weight of gypsum. If the fiber length is within this range, the dispersibility is good, there is no occurrence of pinholes in the humidity control panel, and if the blending is less than the lower limit, the effect of impact resistance is small. It tends to be inferior.

  In the present invention, the shape retention is improved by adding a thickener. Thickeners include inorganic thickeners such as bentonite, kaolinites, wax, silica aerosil, and organic thickeners such as methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, acrylamide polymer, and polyvinyl alcohol. , Natural thickeners such as glue, casein and starch. By adding a thickener, the viscosity becomes suitable for extrusion molding, and it becomes easy to mold into a plate shape. The blending ratio is 0.5 to 5 parts by weight based on 100 parts by weight of gypsum.

  The above substances are made into a kneaded paste by adding an appropriate amount of water. After kneading, it is molded into a desired shape with a cast molding, screw type or piston type vacuum extrusion molding machine. In the case of a screw type, it may be uniaxial or multiaxial. In particular, it can be mass-produced continuously by vacuum extrusion molding, and a thin product having a thickness of 6 to 12 mm can be easily manufactured by appropriately changing the shape of the die. Moreover, the base paper for gypsum board is not required unlike the pouring method.

  The degree of vacuum is formed at 700 to 750 mmHg, conveyed by a belt conveyor, and cured and cured at a temperature of room temperature to 60 ° C. to obtain a humidity control panel. When a pattern is applied with an embossing roll after extrusion molding, the design is improved, and it looks better than a product without embossing and increases the commercial value.

Hereinafter, the present invention will be described in detail with reference to examples.
In a double-arm kneader, 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g, 56 parts by weight of B-type silica gel with an average particle diameter of 19 μm, and 50 parts by weight of calcium carbonate with an average particle diameter of 5 μm 8 parts by weight of a foamed acrylic resin hollow body having an average particle diameter of 45 μm, 15 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 4 parts by weight of glass fibers having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 2 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.

  Next, after extrusion molding from a slit having a vacuum degree of 735 mmHg, a width of 330 mm and a height of 6 mm, a pattern is applied with a block-like embossing roll, curing at 40 ° C. for 12 hours and 105 ° C. for 5 hours, The target panel was obtained by cutting the periphery to 300 × 300 mm.

In a double-arm kneader, 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g, 75 parts by weight of B-type silica gel with an average particle diameter of 19 μm, and 100 parts by weight of calcium carbonate with an average particle diameter of 5 μm 11 parts by weight of hollow acrylic resin foam having an average particle size of 45 μm, 20 parts by weight of acrylic resin emulsion having an average particle size of 230 μm, 5 parts by weight of glass fiber having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 3 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

In a double-arm kneader machine, 43 parts by weight of B-type silica gel with an average particle diameter of 19 μm and 46 parts by weight of calcium carbonate with an average particle diameter of 5 μm per 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g , 6 parts by weight of a foamed acrylic resin hollow body having an average particle diameter of 45 μm, 12 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 2 parts by weight of vinylon fiber having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 1 part by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

In a double-arm kneader, 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g, 56 parts by weight of B-type silica gel with an average particle diameter of 19 μm, and 50 parts by weight of calcium carbonate with an average particle diameter of 5 μm 8 parts by weight of a foamed acrylic resin hollow body having an average particle diameter of 45 μm, 15 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 2 parts by weight of vinylon fibers having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 2 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

In a double-arm kneader machine, 75 parts by weight of B-type silica gel with an average particle diameter of 19 μm and 100 parts by weight of calcium carbonate with an average particle diameter of 5 μm per 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g , 6 parts by weight of a hollow foamed acrylic resin having an average particle diameter of 45 μm, 20 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 5 parts by weight of glass fibers having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 3 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

In a double-arm kneader, 100 parts by weight of B-type silica gel with an average particle diameter of 19 μm and 100 parts by weight of calcium carbonate with an average particle diameter of 5 μm per 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g 3 parts by weight of a foamed acrylic resin hollow body having an average particle diameter of 45 μm, 13 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 3 parts by weight of glass fiber having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 3 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

In a double-arm kneader, 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g, 77 parts by weight of B-type silica gel with an average particle diameter of 19 μm, and 223 parts by weight of calcium carbonate with an average particle diameter of 5 μm , 6 parts by weight of a foamed acrylic resin hollow body having an average particle diameter of 45 μm, 21 parts by weight of an acrylic resin emulsion having an average particle diameter of 230 μm, 5 parts by weight of glass fiber having an average fiber length of 6 mm, an appropriate amount of water, and hydroxy as a thickener 3 parts by weight of propylmethylcellulose was added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

Reference example 1
10 parts of an acrylic resin emulsion having an average particle diameter of 230 μm and 25 parts by weight of B-type silica gel and an average particle diameter of 230 μm per 100 parts by weight of β-type hemihydrate gypsum having a specific surface area of 18,800 cm ² / g. 5 parts by weight of glass fiber having an average fiber length of 6 mm, an appropriate amount of water, 1 part by weight of hydroxypropylmethylcellulose as a thickener, kneaded for 15 minutes, and the mold thickness after drying is 6 mm It was cast to be

Comparative Example 1
Into a double-arm kneader, 100 parts by weight of β-type hemihydrate gypsum with a specific surface area of 18,800 cm ² / g, 23 parts by weight of B-type silica gel with an average particle diameter of 19 μm, and 8 acrylic resin emulsions with an average particle diameter of 230 μm 1 part by weight of vinylon fiber having an average fiber length of 6 mm, 1 part by weight of water and 1 part by weight of hydroxypropylmethylcellulose as a thickener were added and kneaded for 15 minutes.
Subsequently, it manufactured similarly to Example 1.

Comparative Example 2
In Example 1, it implemented similarly except not having mix | blended glass fiber.

The evaluation results are shown in Table 1.

The evaluation method is shown below.
(1) Strength: Measured in accordance with a bending test method for JIS A 1408 building boards.
(2) Humidity adjustment performance is 23 ° C 50% until the weight is stabilized, then water vapor adsorption when left at 23 ° C 75% for 12 hours, water vapor when humidity is 50% The amount released was measured.
(3) Machinability: The machinability with a tip saw was confirmed.
(4) Impact resistance: A case where a 320 g steel ball was dropped from a height of 500 mm and no cracks were generated on the surface was indicated as “◯”, and a case where it occurred was indicated as “X”.

Claims (9)

Gypsum, inorganic filler, silica gel, hollow bodies, comprising a fibrous material, wherein the hollow body is a synthetic resin hollow bodies, tone, characterized in including Mukoto 3-15 parts by weight with respect to the plaster 100 parts by weight Moist panel. The humidity control panel according to claim 1, further comprising a thermoplastic resin emulsion . The humidity control panel according to claim 2, wherein the thermoplastic resin emulsion includes 10 to 25 parts by weight with respect to 100 parts by weight of the gypsum. The thermoplastic resin emulsion is an acrylic resin emulsion.
The humidity control panel according to claim 2. Gypsum, inorganic filler, silica gel, hollow body, fibrous substance, and appropriate amount of water, the hollow body is a synthetic resin hollow body, and 3 to 15 parts by weight with respect to 100 parts by weight of the gypsum, kneaded And forming the humidity control panel. 6. The method of manufacturing a humidity control panel according to claim 5, wherein the molding is vacuum extrusion molding. Furthermore, a thermoplastic resin emulsion is included , The manufacturing method of the humidity control panel in any one of Claim 5 or 6 characterized by the above-mentioned. The said thermoplastic resin emulsion contains 10-25 weight part with respect to 100 weight part of said gypsum, The manufacturing method of the humidity control panel of Claim 7 characterized by the above-mentioned. The thermoplastic resin emulsion is an acrylic resin emulsion.
The manufacturing method of the humidity control panel in any one of Claim 7 or 8.