JPS6056117B2 - Manufacturing method of composite board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a composite plate using a curable aqueous slurry that exhibits expandability upon curing.

The present inventors have already discovered that when a perforated plate is laminated with an aqueous slurry that expands upon hardening and the slurry is hardened, the slurry that enters the holes expands and hardens, forming a kind of wedge. found that a composite plate with excellent integrity could be obtained, and proposed a method for manufacturing a composite plate (Patent Application No. 14212 (1978) (Japanese Patent Application Laid-Open No. 109284/1984)).

The present invention relates to an improvement in the method for manufacturing the above-mentioned composite plate.

In other words, in the case of using the above method, if the perforated plate is made of a wood-based material with strong water absorption, or if a gypsum perforated raspod which is sensitive to water is used, water absorption expansion due to contact with the aqueous slurry and drying shrinkage may occur. As a result, various types of shear stress and bending stress occur, causing dimensional deformation or warping of the composite plate.
As a result of further research to solve the above-mentioned problem, the present inventors discovered that it is very effective to provide a water barrier layer (bond breaker) on the surface of the perforated plate that comes into contact with the aqueous slurry. We have arrived at the present invention.

That is, the method for manufacturing a composite board of the present invention is to prepare a perforated laminate in which a water-blocking layer is provided on one surface of a water-absorbing perforated board except for the pores, and a perforated laminate with a property of expanding upon curing through the water-blocking layer. The slurry is layered on a curable aqueous slurry having a porous laminate and allowed to penetrate into the pores of the porous laminate, and then the slurry is cured and the cured slurry and the porous laminate are integrated by expansion during curing. There are things. Hereinafter, the present invention will be explained in more detail with reference to the drawings as necessary.

In the following description, "%" and "part" are used unless otherwise specified.
All are based on weight. As shown in FIG. 1, a perforated laminate 1 used in the present invention includes a water-absorbing perforated plate 2 having holes 2a.
A water blocking layer 3 is formed on one surface of J except for the area where the holes 2a are formed.

The water-absorbing perforated board 2 may be a wood veneer, plywood, gypsum board, asbestos slate board, wood wool cement board, cement board, glass-reinforced concrete board, particle board, asbestos-cement board, or other water-absorbing composite board. A type with a through hole 2a provided therein is used.

The greater the water absorption, the greater the effect of the present invention, but those with relatively low water absorption can also be used. The wall thickness of the perforated plate 2 is generally about 3 to 45 wn. The dimensions, pitch, and depth of the holes 2 vary depending on the viscosity of the expandable slurry used for lamination (splicing) and the tensile strength of the cured product. For example, if the viscosity is low and the tensile strength is low, the pore diameter is 1 to 5 m and the pitch is designed to be dense, and if the viscosity is high, the pore diameter is generally increased.
In principle, the shape and pitch of the holes 2 must be such that they push out the air bubbles formed on the upper surface of the expandable slurry and do not prevent the expandable slurry from entering the holes and expanding. Generally, a through hole is preferable, but a hollow hole may be used as long as the above conditions are satisfied. The water blocking layer 3 provided on one surface of the perforated plate 2 may be paper coated with resin or a release agent, synthetic paper, plastic sheet, plastic foam, non-woven fabric, resin coating, or cloth-like material made of silica fiber. , metal foil such as aluminum, inorganic powder, rubber, coating film of silicone oil or other oil, etc. are used.

These water blocking layers 3 do not necessarily have to absolutely block water, but only need to be able to substantially prevent the adverse effects of water permeation into the water-absorbing substrate 2. It is preferable that the water barrier layer 3 also has a releasing effect on the expandable slurry. This makes it possible to alleviate the shear stress that acts in the direction of the contact surface with the water barrier layer 3 during curing of the expandable slurry and directly affects the water absorbent substrate 1. The thickness of the water barrier layer varies greatly depending on the type of material, but is usually 50 μm or more.
There is a range of 3wn. In order to form the perforated laminate 1 as described above, there are two methods: forming a water barrier layer on a water-absorbing substrate and then forming holes; selectively removing the holes on the perforated plate;
For example, the water blocking layer may be formed by coating, or the water blocking layer may be formed on the entire surface and then the pores may be selectively removed, and the formation order may be arbitrary.

3. Next, this perforated laminate 1 is poured into a suitable formwork 4, for example, as shown in FIG. 2, through the water barrier layer 3 to form an expandable slurry (that is, an aqueous slurry having the property of expanding upon curing) 5. layer on top. As a result, the slurry 5 enters the holes 243a of the perforated plate 2. When the slurry 5 is cured in this state, as shown in FIG. The slurry is impregnated into the side wall 2b and hardened, acting as a kind of wedge. Therefore, excellent integrity is provided between the slurry cured product 5 and the perforated laminate 1. As described above, when the water barrier layer 3 has a mold release effect on the slurry 5, the shearing force due to hardening and expansion of the slurry 5 will not reach the perforated plate 2.
Causes of dimensional changes such as warpage are more effectively eliminated. Here, the expandable slurry is, for example, cement concrete or cement mortar.
l2O32~10%, CaO5O~70%, SO2l8
~32%, SiO23~12%, etc. Expanding agent for cement is added at 10% to 100 parts of cement.
Above, preferably 10 to 15% is used. Examples of cement here include air-hard cements such as slaked lime, dolomite plaster, calcined gypsum, and magnesia cement, natural boltland cement, ordinary boltland cement, early-strength boltland cement, white boltland cement, iron cement, alumina cement, and silica cement. Cement Hydraulic cements such as pozzolanic cement, blast furnace cement, iron boltland cement, fly ash cement, solid cement, and slag cement are used. In addition, aluminum powder (for example, product name P-200, 300 manufactured by Yamaishi Kinzoku Co., Ltd.) is used as an expanding agent for cement,
By adding 0.02 part or more to the cement opening (4), it can also be used as a mortar for prepact. In addition, the expandable slurry has an expansion coefficient of 0.05 to 1. A 50% by volume gypsum slurry is also used. Here, gypsum hemihydrate is a hydration-hardening substance whose main component is calcium sulfate 112 hydrate, which is expressed by the chemical formula CasOl・1-2H20, and includes calcined gypsum, gypsum plaster, etc., as well as industrial by-product gypsum, A product made by baking mirabilite gypsum etc. to form hemihydrate gypsum is also used. In these expandable slurries, chopped strands of inorganic fibers such as glass fiber, rock wool, asbestos, slag wool, etc., or organic fibers such as polypropylene and nylon are used as reinforcing materials, for example, at a concentration of 0.2 to 20%.
% can also be added.

The thickness of the cured slurry layer formed according to the present invention is not particularly limited, but a range of 3 to 12 wOn is generally suitably used. After curing the slurry as described above, the integrated product of the hardened slurry 5 and the perforated plate 2 is taken out from the mold 4 to obtain a composite plate according to the present invention.

As described above, according to the present invention, when a water-absorbing perforated plate and an expandable slurry are spliced together to produce a composite plate with excellent integrity, contact of the water-absorbing perforated plate with the expandable slurry is prevented. By forming a water barrier layer on the surface, unnecessary migration of water from the slurry to the water-absorbing perforated plate is prevented, and dimensional changes such as warping due to water absorption and subsequent drying of the perforated plate are prevented. A decrease in strength is also prevented. Furthermore, by providing the water barrier layer with mold releasability, it is possible to effectively prevent shearing force due to the curing and expansion force of the slurry from acting on the perforated plate. In this way, conventionally, when forming a composite board from wood perforated boards, the size limit was about 45 cm square, but according to the present invention, dimensional changes such as warping do not occur even at 90 G square. was confirmed. In addition, in the above description, the mode in which a perforated laminate is stacked on top of the slurry was mainly explained, but the present invention can also adopt a method in which the slurry is stacked on a perforated laminate and then cured.

In this case, the side frame is somewhat more complicated than in the above method. It is of course possible to provide the composite plate according to the invention with any desired cosmetic effect.

It has been recognized that by applying such a composite board as a surface material to a wooden house, it is possible to make it non-combustible, and it also has the advantage of being able to be installed using conventional nailing methods. In addition, as a method of imparting a decorative pattern to the surface of such a composite board, especially the slurry cured material layer,
The techniques described in Japanese Patent Application Laid-Open Nos. 52-52965 to 53-168115, or Japanese Patent Applications No. 54-106500 (Japanese Patent Application Laid-Open No. 56-30889), Kaisho 56-64816
No. 54-10882 Gin (Japanese Patent Publication No. 56-3236) and No. 65-112 Rei (Japanese Patent Publication No. 56-10978)
The technique described in the specification of No. 1) can be suitably employed.

The present invention will be explained in more detail with reference to Examples below.

Example 1 On a cement-wood mixed perforated board (manufactured by Mitsui Mokuzai Co., Ltd., trade name: Centurion Board) having through holes with a pitch of 50 wm and an effective diameter of 10 WL, a board with dimensions of 12 x 910 x 91 - was placed. A masking plate made of 0.3 TmIn galvanized iron was placed to cover the hole, and then a vinyl paint (trade name: Vinylol 9-Kin) manufactured by Showa Kobunshi Co., Ltd. was applied, and the masking plate was removed. The paint was sufficiently cured to form a water-blocking layer consisting of a coating film with a thickness of 200 μm.

Next, a transfer printing sheet was laid on a flat plate form made of alloy, and then an outer frame with dowel pins for determining the thickness was fixed.

On the other hand, α-type hemihydrate gypsum 1 with a plain value of 3200 cILIV (
1) Mix 0.3 parts of water-soluble dispersion type E-glass, 2 parts of transfer stabilizer, and 0.1 part of viscosity modifier with a forced stirring mixer for 3 minutes, then add 1 part of water-resistant reinforced emulsion, 1 part of water-resistant emulsion, and 0.1 part of viscosity modifier. 0.01 part of the agent was added and kneaded for an additional 1 minute to obtain an expandable slurry.

Pour this slurry into the above formwork to a thickness of 6w! After that, the perforated plate was pressed so that the water barrier layer was facing down, and after fixing with the dowel pin to determine the thickness, a vibrator was applied for 3 seconds to spread it. After pouring, it was left in a room at 20 ± 10°C for 9 minutes, then removed from the mold, the transfer sheet was removed, placed on a pallet, dried in a drying oven at 45°C ± 5°C for 1 full hour, and then acrylic urethane was spray-painted. As a result, a composite board with a very beautiful decorative surface, excellent integrity, and virtually no warping was obtained. Example 2 Pitch 60Tn as base material! A perforated gypsum lath board with a wall thickness of 9Tr$t and having through holes with a diameter of n1 of 3wr1n was used, and a 0.17wt polyethylene sheet with adhesive on one side was pasted as a water barrier layer, and the holes were burned off to form the perforated board. A laminate was obtained.

When this laminated perforated plate was molded in the same manner as in Example 1, a decorative composite plate of the same high quality could be obtained. Example 3 Using the method of Example 1, a perforated gypsum sheathing board with a wall thickness of 97 m was used, and paper treated with silicone water repellent and glued on one side was used, and it was successfully bonded to the gypsum layer.

This perforated laminate was then molded in the same manner as in Example 1. Example 4 9×910×9107177! Solid silicone was melted in a hot water bath in a perforated flexible bond having dimensions of , and this was applied with a brush to form a water barrier layer with a thickness of 50 μm.

Next, 1 (1) part of white Voltland cement manufactured by Onoda Cement Co., Ltd., 0.1 part of aluminum stearate, 2 (1) parts of Tagawa Kansui stone, and 1 part of CSA expansive material manufactured by Mitsui Denka Co., Ltd.
An expandable slurry obtained by mixing and kneading 5 parts of water and 50 to (9) parts of water was poured into a matrix form made of heat-resistant silicone resin made of a cracked firebrick pattern, and the above-mentioned A perforated flexible board with a water barrier layer was spliced and slurry cured to obtain a composite board. After curing, this cracked skin pattern was sprayed with 180 μm of epoxy primer and then brown acrylic paint to obtain a beautiful exterior wall decorative board without warping.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of a perforated laminate used in the method of the present invention, Fig. 2 is a schematic cross-sectional view showing the state before lamination of the perforated laminate and expandable slurry, and Fig. 3 is a perspective view of the perforated laminate used in the method of the present invention. FIG. 4 is a cross-sectional view showing the laminated state with the expandable slurry, and is an enlarged view of the section ■ in FIG. 3. 1... Perforated laminate board, 2... Perforated board (2
a...hole), 3...water barrier layer, 4...
Formwork, 5... Expandable slurry.

Claims (1)

[Claims] 1. A perforated laminate having a water-blocking layer provided on one side of a water-absorbing perforated plate, excluding the holes, is layered with a curable aqueous slurry that has the property of expanding upon curing via the water-blocking layer. A method for manufacturing a composite board, which comprises: infiltrating a slurry into the holes of a perforated laminate, then curing the slurry, and integrating the cured slurry with the perforated laminate through expansion during curing.