JPS5957B2 - Manufacturing method of composite board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a novel composite board consisting of a raw material composition of artificial lightweight aggregate, coarse fly ash, thermosetting resin, and inorganic fiber.

Hereinafter, details of the manufacturing method according to the present invention will be explained with reference to the drawings. In the present invention, first, mixtures for the front and back layers and the core layer of the composite plate are individually prepared.

That is, for the mixture for the front and back layers, the particle size is from 0.1 to
15 to 20 parts by weight of coarse fly ash and 10 parts by weight of thermosetting resin to 100 parts by weight of 1.0 mm artificial lightweight aggregate.
Add ~30 parts by weight and mix uniformly. In addition, the mixture for the core layer is an artificial lightweight aggregate with a particle size of 0.1 to 2.5 mm.
5 to 25 parts by weight of coarse fly ash and 10 to 30 parts by weight of thermosetting resin are added and mixed to 0 parts by weight. Next, the mixture for the front and back layers is spread on the caul board in a thin layer with no uneven thickness, and then an inorganic fiber layer is formed thereon to form the back layer of the composite board. Subsequently, the mixture for the core layer is uniformly spread on this back layer to a desired thickness, and then the inorganic fiber/front and back layer mixture is further spread on top of this in this order to the same thickness as the back layer formed first. Laminate them in thin layers to form the surface layer. Then, as it is, it is heated under a pressure of 10 to 30 to 9/1 to polymerize and harden the entire thermosetting resin as a binder. The raw materials used in the present invention will be explained.

Artificial lightweight aggregate - Refers to structural lightweight concrete aggregate (JISA5002) manufactured by firing expanded shale, clay, slate, fly ash, etc. In the present invention, depending on whether the aggregate is divided as it is or by crushing, the particle size of the aggregate for the surface layer is 0.1 to 0.1.
In the range of 1.0 mm, and 0.1 to 2.5 m in the middle core layer
It is used after adjusting to the range of wL. Coarse fly ash ~ Coal ash collected in pulverized coal-burning thermal power plants, etc., with a specific surface area (plain value) of 1000 to 1600 cwL/
gr, and 90 parts by weight or more of the total weight is 0.06 to 0
．． Refers to particles adjusted to a particle size of up to 3 mm.
It is completely different from fine-grained fly ash in terms of specific surface area and particle size composition.

Thermosetting resin - In the present invention, a thermosetting resin that is in the form of a fine powder and has a curing temperature in the range of 80 to 200°C is mainly used.

These include elia, elia melamine, melamine, phenol, and lignin resin. In addition, the above synthetic resins dissolved in a solvent or mixed with water can also be used. Inorganic fibers - In the present invention, mainly roping/chopped strand glass fibers are used, but matte or net-like glass fibers and organic fibers such as vinylon and polyester can also be used.

The present invention aims to provide an economical composite board that uses only a small amount of plastic, which is a petroleum product used as a binder, and has excellent performance such as strength, lightness, workability, and fire resistance, and is as follows: The details of the embodiment will be explained.

Example 1 12 parts by weight of coarse fly ash and 2 parts by weight of powdered Funiol resin were added to 100 parts by weight of artificial lightweight aggregate (raw material: expanded shale, trade name: Mesalite) with a particle size of 0.125 to 1.0 m1L.
0 parts by weight was added and mixed, and 1.620g of the mixture was sprinkled on a coal board in an area of 1m x 1m to form a uniform thin layer, and then spread on it in a length of 2.5mm. 265 g of chopped strand glass fibers were uniformly scattered to form a back layer.

Next, on this back layer, a particle size of 0.125 to 2.38 mm is added.
To 100 parts by weight of the above-mentioned artificial lightweight aggregate, 3750 gr of a mixture of 18 parts by weight of coarse fly ash and 20 parts by weight of powdered phenolic resin was sprinkled evenly to form a core layer. Subsequently, the same raw materials as those for the first back layer were uniformly sprinkled thereon in the same weight in the order of glass fibers and mixture to form the other surface layer. The laminate obtained by this operation was inserted into a hot press at a temperature of 150°C and a pressure of 20kg/C7 without a stopper. It was pressed at i for 10 minutes. The composite board obtained in this way is
It has the following performance. Thickness ratio, weight bending strength, fire resistance 6m7! L l. 25 36Ol<9/Cril Corresponds to semi-noncombustible material stipulated in the Building Standards Act.

Workability: Can be nailed and cut with a saw.In addition to increasing the heat resistance of the composite board in the above example, if higher hot strength is required at high temperatures, commonly used flame retardants, such as , aluminum hydroxide, calcium carbonate, magnesium carbonate, boric acid, borax, tricalcium, aluminate hydrate, etc. may be added in appropriate amounts.

Comparative Example 1 (When the minimum particle size of the artificial lightweight aggregate exceeds the range of the present invention) The weight ratio of each raw material and the manufacturing operation were the same as in the example, and only the particle size of the artificial lightweight aggregate was changed in the surface layer. 0-1.0m
In TIL, the performance of the composite plate obtained by setting the core layer to 0 to 2.38 mm was as follows.

Thickness: 5.5 Specific gravity: 1.37 Bending strength: 210kg/CTil Fire resistance: Equivalent to quasi-noncombustible material stipulated in the Building Standards Act.

Workability: Easy to crack when nailing.

Comparative Example 2 (When the maximum particle size of the artificial lightweight aggregate exceeds the range of the present invention) The weight ratio of each raw material and the manufacturing operation were the same as in the example, and only the particle size of the artificial lightweight aggregate was changed to the front and back layers. Then 0.125~
2.38 mm, and 0.125 to 5 in the middle core layer.

The composite plate obtained at 0 m did not have a smooth surface layer, and many large voids were formed in the core layer, making it impossible to test the performance.

Comparative Example 3 (When coarse fly ash is not used) The particle size of the artificial lightweight aggregate, the amount of phenolic resin, and the amount of glass fiber used, and the manufacturing operation are the same as in the example, but the coarse fly ash is not used, and only that amount is used. The performance of the composite board obtained by increasing the weight of the artificial lightweight aggregate was as follows.

Thickness 6.5m1L Specific gravity 1.16 Bending strength 230kg/(-d Fire resistance A quasi-noncombustible material stipulated by the Building Standards Act.

Therefore, the reason for regulating the use, particle size, and blending ratio of each raw material in the present invention will be explained. Artificial lightweight aggregate is a type of inorganic foam that is lightweight, strong, and inexpensive compared to other inorganic foams such as shirasu balloons and perlite, so it can be used to manufacture lightweight composite boards. It is a material suitable for use on top. In addition, as is clear from Examples and Comparative Examples (1, 2), the particle size of the artificial lightweight aggregate is regulated when the particle size is 0.1 to 0.1 in the front and back layers.
1.0m7! L, 0.1-2.5 m1 in the central layer
This is because if the value L exceeds the range, the mechanical strength of the composite plate will significantly decrease and the workability will also deteriorate.

Coarse fly ash has various advantages as a fine powder used in the manufacture of composite plates.

That is, its shape is spherical (average particle size is approximately 0.1 mm).
), the specific surface area is small, and only a small amount of binder is required. Also, since it includes some hollow spheres, it is lightweight and strong. Therefore, the particle size is 0.1
As is clear from Comparative Example 3, by using coarse-grained fly ash with such characteristics instead of artificial lightweight aggregate with a size of less than mm, it is possible to create a composite board with high strength and good workability. You will get it. The reason why the blending ratio of coarse fly ash is regulated is as follows. The composite board according to the present invention has a dense internal structure in which the voids between the particles of the artificial lightweight aggregate are filled with coarse-grained flyash bonded with a binder. The blending ratio of coarse fly ash is 5 to 20 parts by weight for the front and back layers, and 15 to 2 parts by weight for the middle core layer.
If it exceeds 5 parts by weight, it will not be possible to obtain a dense structure in the surface layer and core layer during pressure molding, and as a result, a high-strength composite plate will not be obtained. The compounding ratio of the thermosetting resin as a binder is regulated because if the compounding ratio is less than 10 to 30 parts by weight, the mechanical strength will drop significantly, and if it is more than that, a high-strength composite plate will not be obtained. However, it has the disadvantage of poor fire resistance. Since the method of the present invention is configured as described above,
A. As raw materials, we use only a small amount of expensive petroleum products and glass products, and use inexpensive artificial lightweight aggregate as the main raw material, as well as industrial waste, so we can economically provide high-performance composite boards.

B. In terms of quality and performance, it is possible to manufacture high-strength thin-layer composite boards with excellent lightness, fire resistance, workability, and construction ease.

C. In the manufacturing method of the present application, the raw materials are laminated into thin layers and then pressurized and heat-formed as they are, so that a high-performance composite plate can be manufactured by a simple method.

In addition, in the figure, 1 is a composite board, 2 is a surface layer, 3 is a back layer, 4
5 is a core layer, 5 is a coarse flyash, 6 is an artificial lightweight aggregate, and 7 is an inorganic fiber.

[Brief explanation of the drawing]

The drawings show one embodiment of the present invention, and FIG. 1 is a partially enlarged sectional view of a composite plate. 1...Composite board, 2...Surface layer, 3...
... Back layer, 4 ... Middle core layer, 5 ...
・Coarse fly ash 6...Artificial lightweight aggregate,
7... Inorganic fiber.

Claims (1)

[Claims] 1 A mixture consisting of 100 parts by weight of artificial lightweight aggregate with a particle size of 0.1 to 2.5 mm, 15 to 25 parts by weight of coarse fly ash, and 10 to 30 parts by weight of a thermosetting resin is added to the core layer. .1 to 1.0 mm artificial lightweight aggregate 100 parts by weight, coarse fly ash 5 to 20 parts by weight, and thermosetting resin 1
A method for producing a composite board, comprising: a mixture comprising 0 to 30 parts by weight, and inorganic fibers, which are arranged as front and back layers, and then the front and back layers and the core layer are formed by pressure and heat molding as they are.