JPS6018536B2 - Lightweight reinforced gypsum cured product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight reinforced gypsum cured product,
Especially when molding lightweight hardened gypsum by pouring or pouring and gluing, warm water soil with 0. The present invention relates to a method for manufacturing a reinforced laminated cured gypsum product by using Q gypsum under the granite wall and molding it with a loam foam board or the like in the core, and to such a lightweight reinforced hardened gypsum product.

Gypsum board is originally an inorganic material and is nonflammable, but it has poor water resistance and when it comes into contact with water, its mechanical strength is reduced to about half. Indicates the proportion of water added when

This includes the standard amount of mixed water and the amount of water added, but when simply written as the amount of overflowing water, both are meant. ) or when using 81 gypsum with a standard leakage rate of 0.7, the strength of the board after forming and drying is also low. Therefore, the mechanical strength is insufficient during wheel transportation or work, and the paper may break or break, so the surface is protected using relatively thick paper for the purpose of reinforcement. Therefore, although conventional gypsum board is not necessarily a non-combustible material due to its surface paper quality, it is highly productive and excellent as an inexpensive building material. The inventor of the present invention hopes that by using not only the three conventional types of gypsum board but also Q type gypsum, the highly hard gypsum will become a useful industrial material as a building material. We considered and came to a decision. However, even though the strength increases, the specific gravity also increases, so in terms of strength per weight, it may not be said that Q-gypsum is particularly superior even when used.
However, in the case of hardened gypsum products using Q-gypsum, such as gypsum board, even 0.5% of dry water may not be sufficient for the surface strength when the amount of hot water is low or when glass fiber or asbestos fiber adjuvants are used. Therefore, it was determined that if it were made into a lightweight composite structure, its practicality would be greatly expanded and it could be used as a building material.

As is clear from the above description, an object of the present invention is to provide a novel and improved gypsum hardened body having a core.

Another object is to provide a new and simple method for producing the cured product. The present invention is a lightweight gypsum cured product formed by pouring and/or gluing using a lightweight foam board or lightweight inorganic fiberboard as a core, and Q gypsum containing 2 to 8% by weight of glass fiber. By adding not more than 1% by weight of a vinyl resin emulsion to the plaster, it is mixed and hardened at a rate of not more than 0.5% by weight, so that it can be applied through the penetration part provided in the lightweight foam board or the lightweight inorganic fiberboard. A lightweight reinforced hardened gypsum product made by fixing matching Q gypsum layers with a Q gypsum hardened product.

■ The lightweight reinforced gypsum cured product according to item ``1'' above, wherein the material of the lightweight foam board or lightweight inorganic fiberboard is foamed polystyrene, foamed polyurethane, foamed polyolefin, foamed polypynyl chloride, rock wire board, or glass wool board. .
It is. In an exemplary embodiment of the present invention, a 2 to 3 layer thick gypsum layer, preferably 2.5 to 3 layers, is formed on the surface layer, and a lightweight foam layer is interposed in the middle layer, thereby creating a lightweight gypsum hardened body as a whole. However, if the gypsum layer on the surface of the hardened body is made thin, the mechanical strength will be insufficient unless it is reinforced to withstand external forces. The surface layer is not just a hardened gypsum, but a hardened gypsum reinforced with vinyl resin, a hardened gypsum reinforced with glass fiber, and a reinforced gypsum reinforced with both. At the same time, when manufacturing such a gypsum surface layer by pouring or pouring and laminating, the core layer of lightweight foam board or lightweight inorganic fiberboard (hereinafter both referred to as lightweight foam board, etc.) is punched circularly or linearly. When using a board (hereinafter referred to as a lightweight effective board, etc.), the poured gypsum slurry will flow into the punched holes or linear parts, or the gypsum slurry will flow into the punched holes or linear parts.
When a lightweight foam board or the like is inserted into the mold, the slurry floats up in the punched holes or linear punched parts, filling the inside of the holes or punched parts with the slurry.Then, an upper layer or surface layer is formed by pouring or laminating, and the plaster is hardened. The gypsum hardens as a unit, and the upper and lower layers or between the inner and outer layers are molded as an integral hardened body in which punched holes or linear punched holes or the surrounding side walls are connected by the gypsum. The hardened gypsum body is molded by pouring slurry, but at this time, the layers facing each other, such as the top and bottom or the inside and outside of the gypsum, are connected through holes, with a perforated board being embedded as the lightweight foam board or interposed as a core. Preferably, the structure is as follows.

To explain the present invention using the drawings, reference numeral 1 in FIG. 1 is a schematic representation of a lightweight foam, and the outer side 2 indicates the inner periphery of the formwork.

Put 1 in 2. 1 has punched holes 3 and linear punched holes 4.
is cut or punched in advance.

The diameter, number, and installation location of 3 can be arbitrarily determined depending on the purpose.

4 is a linear punched hole, and the length and length of the hole into which the plaster enters by pouring or press-fitting can be arbitrarily selected.

Gypsum slurry enters the gap between 1 and 2 by molding, and becomes the outer wall of the molded body.

3 and 4, by press-fitting the lightweight foam 1 into the gypsum slurry, the uncured gypsum slurry enters and becomes columnar or wall-like objects that connect the upper and lower gypsum layers.

The bran-like punched holes are used to handle a lightweight foam board connected at points close to four circumferences instead of handling several lightweight foam boards, and are used instead of handling multiple foam boards, as shown in the example. In some cases, multiple pieces of lightweight foam board punched out in different shapes are used. Figure 2 corresponds to the A-A sectional view after inserting and molding the lightweight foam board in Figure 1, and Figure 3 corresponds to the sectional view taken along B-B, where 5 is a gypsum layer and 6 is a sectional view. It is a lightweight foam. The foamed lightweight perforated board used for the lightweight reinforced gypsum cured product of the present invention is a thin layer slice (from the 3rd side to the 3rd side) of a foamed polystyrene block.
3) or by foam molding of expanded polystyrene, but may also be a plate of flexible or rigid polyurethane foam.

Also usable are polyethylene foam, polypropylene foam, polyvinyl chloride foam, and rock wool and glass wool boards. The density of the lightweight foam used can be as low as 0.008~ as long as it maintains a constant volume during molding.
Light foams of 0.08 and relatively high specific gravity foams of 0.05 to 0.5 are also used. The density of the rock wool board and the glass wool board is also similar to that of the lightweight foam. Q1 gypsum is used as the gypsum slurry that forms the gypsum layer.

When the lightweight hardened gypsum product of the present invention is molded with a water content of 0.5, the strength is somewhat insufficient, but it can still be used. Although it is preferable to use Q-gypsum with a hot water amount of 0.4 or less, the fluidity of the slurry becomes poor and the molding process becomes difficult. 5 for the purpose of lowering the viscosity for practical use.
By adding 0% vinyl resin emulsion at 10% or less (resin 5% or less) of the weight of the gypsum, it is possible to reduce the amount of hot water used, and the amount of addition is also preferably 3 to 6. % addition. Furthermore, in order to improve adhesion to paper, wood or lauan material, a slurry obtained by adding 40% vinyl emulsion in an amount of 3 to 10% of the weight of the plaster can also be used. The vinyl emulsions used are mainly polyacrylic esters, polymethacrylic esters, and polyvinyl acetate, and vinyl emulsions obtained by copolymers or polymer blends of these and polystyrene are also used. Partly A.
B. It is also possible to use a mixture of Semulsion latex. Furthermore, fibrous material such as glass fiber can be added to increase the strength of the song.

Especially 1 to 3 ships, preferably 2 to 15 willow glass fibers per 1
By adding ~10% preferably 2-8% by weight,
Lighter boards have higher strength and impact strength, but
An added feature is that nailing is also available for installation. Lightweight gypsum cured products made using glass fiber-reinforced slurry made in this way can be made from lightweight to relatively heavy depending on the proportion (volume ratio) of lightweight foam used, and are mainly used for insulation. It is used as wall material, partition board, and ceiling board for soundproofing, soundproofing, and noncombustibility. The obtained lightweight gypsum cured product has a specific gravity of 0, although it varies depending on the occupied volume ratio of the lightweight foam.
．． It is possible to make one with a room temperature of 45 to 1.0. The higher the specific gravity, the higher the strength. Although the ratio of the inorganic component to the organic component can be approximately 5% or less by weight, the degree of non-combustibility and combustibility of the structure becomes a problem. 1 to the foamed polystyrene that has formed on the surface of the lightweight cut piece of the present invention, which is partitioned from above and below and in three directions by a gypsum structure.
Even if an oxidizing flame of 000q○ was applied, when the flame was removed, the polystyrene stopped burning (self-extinguishing property), and the portions hit by the flame were partially melted and solidified.

When the surface of the entire lightweight board is heated by an oxidizing flame, the surface of the gypsum board cracks and structural failure occurs, but a layer of melted and carbonized polystyrene remains inside, and it has been found that the insulation properties vary depending on the thickness of the lightweight board. The diameter of the punched holes and the number of punched holes per square surface in the lightweight foam board used in the present invention, the thickness of the bran-like punched holes that make up the wall structure, the length per square surface, etc. can be determined to preferred values, respectively. The greater the number and the longer the length, the greater the strength, and conversely, the weight per product increases.

The four walls of the lightweight hardened gypsum of the present invention form the connection between the linear punched holes forming the wall structure and the upper and lower gypsum surfaces of the machine, and have the effect of reinforcing the lightweight board. You can also enter

Furthermore, the lightweight hardened gypsum product of the present invention can be made by integral molding not only into plate-like objects but also box-like or tubular objects such as air-conditioning, heating and ventilation ducts, etc., and can be used as a semi-noncombustible lightweight structure with insulation and sound insulation. Ru. Examples are shown below. Example
1 Q gypsum (Chisso ■Product name K) with a standard water content of 0.40
Q) After pre-mixing 12 kg and 240 kg of glass fiber (2% by weight of the gypsum weight), 2.4 kg of sodium citrate, methyl cellulose (molecular weight 9000-1
5000 (trade name Hymetrose) 12 times dissolved 4.
8 Mix it in water to make a gypsum slurry containing glass fibers, pour about 2/3 of the gypsum slurry into a formwork with a medium length of 60 degrees and 180 degrees, and after flattening the surface, use it as a baser. After placing strips of gypsum hardened material (5×low/skin) with a thickness of 300 cm in places, a polystyrene foam of 1 having the shape shown in FIG.
5.5 thickness 895.5 skin, 3: 12 hole diameter, 3 ribs in the cut line of 4, 4 pieces of foam with a thickness of 14 feet are installed and held down from above, and excess gypsum slurry is drained from the four sides and the hole. After floating (in other words, after sinking the porous polystyrene into the gypsum slurry), approximately one-third of the gypsum slurry remains.
The surface was smoothed with a trowel to a thickness of 2 mm, the excess gypsum slurry was removed, and after 4 hours, the mold was removed from the formwork, and a flat plate was placed on the top and bottom, and a load of 50k9 was applied.
18 x 60 skins left for a long time to completely harden
After a molded board with a thickness of 0.2 mm was left to dry for one month, it was a lightweight gypsum board with a weight of 13.52k9 and a specific gravity of 0.626.

After cutting out the plate into 40 x 50 pieces, the bending failure load was measured at a distance of 40 pieces between supporting points and found to be 56.4k9. Example 2 Commercially available Q gypsum (Chisso ■ commercial name KQ) 16k9 and 7-promoting glass fiber 32 showing standard water leakage rate of 0.40
50% acrylic resin emulsion (commercial name: Dainippon Ink Boncoat) 8009 (5% of the weight of gypsum), methyl cellulose (molecular weight 9000 ~
15,000 (trade name Hymetrose) 10 days and 6 days of sodium citrate were mixed and dissolved in 4.72 hours of water (the amount of water used for the plaster, including the water in the emulsion, the amount of water mixed is 0.32). A slurry was made by mixing.

Approximately two-thirds of the slurry was poured into a formwork with a diameter of 60 mm and a length of 180 mm, and three thick pieces of plaster (5 skins x 1 cape) were restaged here and there to form a smooth surface. Then, four foamed polystyrene plates with an effective thickness of 24 mm and the same dimensions as those shown in Example 1 were installed (only the thickness differs), and the foamed polystyrene plates were submerged in the slurry by holding them down from above, and the voids and punched holes were placed around the four sides. ,
Lift up the excess gypsum slurry on the linear parts, and then add the remaining 1/3 of the gypsum slurry to the missing part and the upper layer, making the top flat and making a total thickness of 3 cm, and remove the excess slurry. , After 4 hours, take it out from the formwork and put a flat plate on it for 50k
The gypsum was sufficiently hardened by applying a load of 1.5 g and left to dry indoors for one month. The weight of the dry product was 18.9k9 and the specific gravity was 0.575. This cured product was cut into a size of 40 x 5 pieces, and the bending fracture load was measured at a ratio of 4 pieces to 4 pieces with a distance between fulcrums, and it was found to be 135 k9. This item could be fixed by nailing, and the surface was hard enough that it did not break easily even when exposed to water.

[Brief Description of the Drawings] Figures 1 to 3 are explanatory diagrams of the lightweight reinforced gypsum cured product of the present invention. It is an AA or BB sectional view after completion of a cured product. In these figures, 1, 2, 3 and 4 are the lightweight foam, the inner periphery of the formwork, and circular and linear perforations, respectively. Further, 5 and 6 indicate a gypsum layer and a lightweight foam, respectively. *
JI8 Mizootaka *3' mother

Claims (1)

[Scope of Claims] 1. In a lightweight gypsum cured product formed by casting and/or gluing using a lightweight foam board or lightweight inorganic fiberboard as a core, α containing 2 to 8% by weight of glass fiber.
By adding 10% by weight or less of vinyl resin emulsion to alpha gypsum, the gypsum is kneaded and cured in a mixed water amount of 0.5 or less, and then the gypsum is oriented through the penetration part provided in the lightweight foam board or the lightweight inorganic fiberboard. The matching α gypsum layer is α
Lightweight reinforced hardened gypsum material fixed with hardened gypsum material. 2. Lightweight reinforced gypsum hardening according to claim 1, wherein the material of the lightweight foam board or lightweight inorganic fiber board is foamed polystyrene, foamed polyurethane, foamed polyolefin, foamed polyvinyl chloride, rock wool board, or glass wool board. thing.