WO2008016011A1 - Inorganic plate and method for producing the same - Google Patents

Abstract

In order to efficiently produce an inorganic plate having high surface smoothness and a good decorative layer, an inorganic plate A is produced by integrally forming a front surface layer (1), which contains 10-70% by weight of a fine inorganic fiber having a length of not more than 1 mm, 10-50% by weight of a light-weight aggregate having a particle size of not more than 500 μm, 10-70% by weight of an inorganic powder and 3-10% by weight of a binder, on a back surface layer (2), which contains 1-10% by weight of an inorganic fiber having a length of 3-15 mm, 10-70% by weight of a light-weight aggregate, 10-70% by weight of an inorganic powder and 5-15% by weight of a binder.

Description

 Specification

 Inorganic board and method for producing the same

 Technical field

 [0001] The present invention relates to a cosmetic inorganic board suitable for use as a base material for interior materials, ceiling materials, eave roof materials, etc. of buildings such as houses, and a method for producing the same.

 Background art

 [0002] Conventionally, as an interior finishing material of a building such as a house, a board for a decorative surface material such as furniture, there is a wood board such as plywood or MDF, and an inorganic board such as a plaster board or calcium silicate board. In order to satisfactorily provide a decorative layer on these surfaces, it is conceivable to obtain smoothness by sanding or the like, or to apply a coating with a thick layer of paint.

 [0003] And, when trying to form a smooth decorative layer such as a mirror-like finish by painting or printing, force sanding that requires a higher level of smoothness on the substrate surface is always sufficient. Smoothness was not obtained. Also, when applying paints that are thickly layered, the coating process reduces productivity and increases costs.

 [0004] Therefore, for example, as shown in Patent Document 1, a wet material obtained by mixing and dispersing a raw material containing mineral fibers, an inorganic powder, and a binder as essential components to form a slurry and wet papermaking There has been proposed a method for producing an inorganic board that can obtain a decorative layer satisfactorily by drying a mat and sanding it, followed by heating and compression to cure the binder.

 Patent Document 1: Japanese Patent Laid-Open No. 2005-289784

 Disclosure of the invention

 Problems to be solved by the invention

 [0005] However, in the above-mentioned conventional Patent Document 1, since the dry board is sanded and smoothed before heating and compression! /, Mineral fibers and inorganic powders are resistant to the binder. There is a problem that the base material is easily peeled off completely or partially during sanding because it is not hardened and fixed firmly. Therefore, it is difficult to obtain an inorganic plate having a desired thickness, and there is room for improvement in which the material yield tends to be low and the production efficiency is high.

[0006] In order to obtain more smoothness, fine inorganic fibers or fine inorganic powders are used. It is also possible to use it. However, in this case, a large amount of binder is required, which causes a problem that nonflammability is reduced.

[0007] The present invention has been made in view of such points, and an object of the present invention is to make it possible to produce with high productivity an inorganic board from which a good decorative layer having high smoothness can be obtained.

 Means for solving the problem

[0008] In order to achieve the above object, the inorganic board of the first invention comprises an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight; a lightweight aggregate of 10 to 70% by weight; and an inorganic powder. 10 to 70% by weight of a solid body, 5 to 15% by weight of a binder, and 10 to 70% by weight of inorganic fibers having a length of 1 mm or less and a lightweight aggregate having a particle size of 500 ^ 111 or less 10 It is characterized in that a surface layer having ˜50 wt%, inorganic powder 10-70 wt%, and binder 3˜; 10 wt% is integrally formed.

 [0009] According to the configuration of the first invention, fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer of the inorganic board. A force S to obtain a good surface layer.

 [0010] Further, the back layer is made of an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powdery material of 10 to 70% by weight, and a binder. Since this is a layer having 5 to 15% by weight, this back layer is stronger as a plate than the front layer. As a result, the surface layer can be supported by the back surface layer (by integrating the back surface layer with the surface layer, the relatively low strength surface layer can be reinforced and supplemented). A strong inorganic plate can be obtained by integrating the above.

 [0011] This back layer uses inorganic fibers with a length of 3 to 15 mm, and therefore has a good mixing balance with other components such as lightweight aggregates, inorganic powders and binders. It is possible to uniformly disperse and mix inorganic fibers that do not easily become lumps (fiber lump). For this reason, a back layer having higher strength and hardness can be obtained, and the surface layer can be supported and supported.

 [0012] By these synergistic actions, it is possible to obtain a high-strength inorganic plate that is excellent in incombustibility, handleability, workability, and workability as a whole.

In the second invention, the sheet-like material is integrated with the back surface of the inorganic board according to the first invention. According to this configuration, since the sheet-like material is integrated with the back surface layer, it is difficult to break and is strong. An inorganic plate with a thickness of 10 mm is obtained.

 [0014] The third and fourth inventions relate to a method for producing an inorganic plate. In the method for producing an inorganic board of the third invention, the length of 3 to 15 mm of inorganic fibers;! To 10 wt%, lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% And forming a back surface layer mat by forming a mixture having a binder of 5 to 15% by weight and water added to adjust the water content to 5 to 15%, Furthermore, 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ^ 111 or less, 10 to 70% by weight of an inorganic powder, and a binder of 3 to Forming a surface layer mat by forming a mixture having a water content of 5 to 10% and having a water content of 5 to 15% adjusted to 15%, and two layers of the back layer and the surface layer. It is characterized by comprising a step of forming the mat integrally by hot pressing.

 [0015] According to the configuration of the third aspect of the invention, the back surface layer of the inorganic board manufactured through the above steps uses inorganic fibers having a length of 3 to 15 mm. The inorganic fiber, which has a good mixing balance with the material, the inorganic powder, and the binder and does not easily become a lump (fiber lump), is uniformly dispersed and mixed. For this reason, an inorganic board with higher strength and hardness can be obtained.

 [0016] Further, since the mats of the back layer and the surface layer are adjusted to a moisture content of 5 to 15%, the binder can be reacted by performing heat compression at a high temperature for a short time. Moreover, since it is under high temperature and high pressure, the fluidity | liquidity of a binder can go up and it can spread over the whole, and a water | moisture content can be evaporated in a short time. As a result, the amount of the binder can be made relatively small in order to maximize the performance of the binder, and a strong inorganic board excellent in incombustibility can be obtained in a short time.

 [0017] Further, the moisture content of each mat of the back surface layer and the front surface layer is adjusted to 5 to 15%, so that the productivity in which puncture hardly occurs at the time of hot press is good.

[0018] In the method for producing an inorganic plate of the fourth invention, the length of 3 to 15 mm inorganic fiber;! To 10 wt%, light aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% And forming a back surface mat by forming a mixture adjusted to a water content of 5 to 15% by adding water and forming a mixture on a sheet-like material. On the back layer mat, 10 to 70% by weight of inorganic fibers with a length of 1 mm or less and lightweight aggregate with a particle size of 500 m or less 10 to 50% Surface layer by forming a mixture of 10% to 70% by weight of inorganic powder, 10% to 70% by weight of binder, and 10% by weight of water and adjusted to a water content of 5 to 15% by adding water. The step of forming the mat and the step of hot pressing the two mats of the back layer and the front layer and the sheet-like material to form them together.

 [0019] According to the configuration of the fourth invention, in addition to the effect of the third invention, the sheet-like material is also formed by hot-pressing integrally with the two-layer mat, so that it is difficult to break and is a strong inorganic material. A board is obtained. Further, it can be manufactured with good productivity with fewer steps than when a sheet-like material is pasted later. Furthermore, in the manufacturing process, the mat-like material, which is a mixture, can be transported more easily because the sheet-like material is laid underneath.

 [0020] An inorganic plate according to a fifth invention comprises a core layer, a surface layer integrated on the surface of the core layer, and a back layer integrated on the back surface of the core layer. 10 to 70% by weight of inorganic fiber with a length of lmm or less, 10 to 50% by weight of light-weight aggregate with a particle size of 500 111 or less, 10 to 70% by weight of organic powder, and binder 3 10% by weight, and the core layer is an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, lightweight aggregate 10 to 70% by weight, and inorganic powder 10 to 70% by weight And 5 to 15% by weight of a binder.

 [0021] According to the configuration of the fifth aspect of the invention, fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer and the back layer, respectively. And can gain the back layer.

 [0022] Further, the core layer between the surface layer and the back layer is composed of 3 to 15 mm in length of inorganic fiber 1 to 10% by weight, light aggregate 10 to 70% by weight, and inorganic powder 10 to 10%. Since the layer has 70% by weight and a binder of 5 to 15% by weight, the core layer is stronger as a plate than the surface layer and the back layer. Supports the layer (by integrating the core layer with the back layer and the surface layer, the relatively low strength surface layer and back layer can be reinforced and supplemented), and the core layer, the surface layer and the back layer are integrated. Thus, a strong inorganic plate can be obtained.

[0023] Since the core layer uses inorganic fibers with a length of 3 to 15 mm, the mixing balance with other components such as lightweight aggregates, inorganic powders, and binders is good. Inorganic fibers that are difficult to become (fiber aggregates) can be uniformly dispersed and mixed. For this reason, a core layer having higher strength and hardness can be obtained, and the surface layer and the back layer can be further supported and supported. [0024] By these synergistic actions, it is possible to obtain a high-strength inorganic board that is excellent in nonflammability, handleability, workability, and workability as a whole.

 [0025] The sixth invention is characterized in that in the inorganic plate according to the fifth invention, a sheet-like material is bonded and integrated on at least one (at least one side) of the front and back surfaces. According to this configuration, since the sheet-like material is adhered to at least one of the front and back surfaces, an inorganic plate that is hard to break and strong is obtained.

 [0026] The seventh and eighth inventions relate to a method for producing an inorganic plate. In the method for producing an inorganic board of the seventh invention, 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 μm or less, and 10 to Forming a back layer mat by forming a mixture having 70% by weight and a binder of 3 to 10% by weight and water added to adjust the water content to 5 to 15%, the back layer On a mat, 3 to 15 mm in length, 1 to 10% inorganic fiber, 10 to 70% light-weight aggregate, 10 to 70% inorganic powder, and 5 to 15% binder Forming a second-layer core mat by forming a mixture adjusted to a water content of 5 to 15% by adding water to 15%, and on the two-layer mat, 10 to 70% by weight of inorganic fibers with a length of lmm or less, 10 to 50% by weight of light aggregate with a particle size of 500 m or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder And have water And forming a third layer mat by forming a mixture adjusted to a moisture content of 5 to 15% and forming the third layer mat integrally with a hot press. It is characterized by that.

 [0027] According to the structure of the seventh invention, the core layer of the inorganic board manufactured through the above steps uses inorganic fibers having a length of 3 to 15 mm, so that lightweight bone which is another component is used. The inorganic fibers, which have a good mixing balance with materials, inorganic powders, and binders and do not easily become lumps (fiber lump), are uniformly dispersed and mixed. Therefore, a core layer having higher strength and hardness can be obtained, and the surface layer and the back layer can be supported and supported.

[0028] Further, since the moisture content of each mat is adjusted to 5 to 15%, the binder can be reacted by heating and compressing at a high temperature in a short time. In addition, because of high temperature and high pressure, the fluidity of the binder can be increased and distributed throughout, and the water can be evaporated in a short time. This maximizes the performance of the binder. As a result, the amount of the binder can be made relatively small, and a strong inorganic board excellent in incombustibility can be obtained in a short time.

 [0029] Further, by adjusting the moisture content of the mat of each layer to 5 to 15%, puncture hardly occurs at the time of hot press, and productivity is improved.

 [0030] The method for producing an inorganic board according to the eighth invention comprises 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ^ 111 or less, and an inorganic powder. 10% to 70% by weight of a compact and 3% to 10% by weight of a binder, and a mixture adjusted to a water content of 5% to 15% by adding water is formed on a sheet and back. Step of forming a layer mat, on this back layer mat, 3 to 15 mm long inorganic fiber;! To 10 wt%, lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 Forming a second core layer mat by forming a mixture having 5% by weight and a binder of 5 to 15% by weight and water added to adjust the water content to 5 to 15% And 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ^ 111 or less, and inorganic powders 10 to 70 on these two-layer mats. % By weight and binder 3 Forming a third-layer surface mat by forming a mixture having a water content of 5 to 10% by weight and having a water content of 5 to 15%; 15%, and the three-layer mat And a step of integrally forming the sheet-like material with a hot press.

 [0031] According to the configuration of the eighth invention, in addition to the effect of the seventh invention, since the sheet-like material is also integrally formed by hot-pressing together with the three-layer mat, it is hard to break and is a strong inorganic material. A board is obtained. Further, it can be manufactured with good productivity with fewer steps than when a sheet-like material is pasted later. Furthermore, in the manufacturing process, the mat-like material, which is a mixture, can be transported more easily because the sheet-like material is laid underneath.

 The invention's effect

[0032] As described above, according to the first invention, it is assumed that the inorganic plate is formed by combining two layers of the back surface layer and the surface layer, and the back surface layer has a length of 3 to; ~; 10% by weight, lightweight aggregate 10-70% by weight, inorganic powder 10-70% by weight, binder 5 ~; 15% by weight, and the surface layer has a length of lmm or less 10 to 70% by weight of fine inorganic fibers, 10 to 50% by weight of light-weight aggregate having a particle size of 500 ^ 111 or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder By adopting, surface smoothness, nonflammability, handleability, processing A high-strength inorganic plate excellent in workability and workability is obtained.

 [0033] According to the second invention, in addition to the effects of the first invention, the sheet-like material integrated with the back surface layer provides an inorganic plate that is hard to crack.

 [0034] According to the third invention, a length of 3 to 15 mm inorganic fiber;! To 10 wt%, lightweight aggregate 10 to 70 wt%, and inorganic powder 10 to 70 wt% Agent 5 ~; Add water to 15% by weight and form a mixture adjusted to a moisture content 5 ~; 15% to form a back surface layer mat. On this back surface layer mat, a fine lmm or less in length Add water to 10 to 70% by weight of inorganic fiber, 10 to 50% by weight of light aggregate with particle size of 500 m or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder. Surface smoothness is achieved by forming a surface layer mat by forming a mixture adjusted to a moisture content of 5 to 15%, and forming the back layer and the surface layer in one piece by hot pressing. High-strength inorganic plates with excellent nonflammability, handleability, workability and workability can be obtained with high productivity.

 [0035] According to the fourth invention, the mixture for the back surface layer mat is formed on a sheet to form a back surface layer mat, and the mixture for the surface layer mat is formed on the back surface layer mat. By forming a surface layer mat and integrally forming the back surface layer and the two surface layer mats with a sheet-like material by a hot press, in addition to the effects of the third invention, the surface layer mat is hard to crack and has a high strength. A certain inorganic board is obtained. In addition, the number of processes is less than when sheet-like materials are attached later, and the inorganic board can be manufactured with high productivity, and the carrying power of the mat becomes easy in the manufacturing process.

 [0036] According to the fifth invention, the inorganic plate is formed by integrating three layers of a back layer, a surface layer, and a core layer located between them, and the core layer has an inorganic fiber length of 3 to 15 mm. ~; 10% by weight, lightweight aggregate 10 ~ 70% by weight, inorganic powder 10 ~ 70% by weight, binder 5 ~; 15% by weight, surface and back layers are length 10 to 70% by weight of fine inorganic fibers of lmm or less, 10 to 50% by weight of light aggregate having a particle size of 500 ^ 111 or less, 10 to 70% by weight of inorganic powder, and 3 to 10% by weight of binder Therefore, a high-strength inorganic board excellent in surface smoothness, non-flammability, handleability, workability and workability can be obtained.

[0037] According to the sixth invention, in addition to the effects of the fifth invention, an inorganic plate having strength that is difficult to break can be obtained by the sheet-like material integrated with at least one of the front and back surfaces. [0038] According to the seventh invention, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of light aggregate having a particle size of 500 ^ 111 or less, and an inorganic powder 10 to 70% The mixture was adjusted to a water content of 5% to 15% by adding water to 3% by weight; a binder of 3 to; 10% by weight to form a back layer mat. 3 ~; 15mm inorganic fiber 1 ~; 10% by weight, light aggregate 10 ~ 70% by weight, inorganic powder 10 ~ 70% by weight, binder 5 ~; A mixture adjusted to a moisture content of 5 to 15% is formed to form a core layer mat. On the core layer mat, a surface layer mat similar to the back layer mat is formed, and these three layer mats are hot-pressed. By integrally forming with a press, a high-strength inorganic plate excellent in surface smoothness, incombustibility, handleability, workability and workability can be obtained with high productivity.

 [0039] According to the eighth invention, a mixture for a back layer mat similar to that of the above seventh invention is formed on a sheet to form a back layer mat, and the seventh invention is formed on the back layer mat. A core layer mat is formed by forming a core layer mat similar to the above, and a surface mat is formed on the core layer mat by forming the same surface mat mixture as the back layer mat. In addition to the effects of the seventh invention, an inorganic plate that is hard to break and strong is obtained by integrally molding these three-layer mat and sheet-like material with a hot press. In addition, the number of steps is smaller than when a sheet-like material is attached later, and the inorganic board can be manufactured with high productivity, and the mat can be transported more easily in the manufacturing process.

 Brief Description of Drawings

 FIG. 1 is a cross-sectional view of an inorganic plate according to Embodiment 1 of the present invention.

 FIG. 2 is a cross-sectional view of an inorganic plate according to Embodiment 2.

 FIG. 3 is a cross-sectional view of an inorganic plate according to Embodiment 3.

 FIG. 4 is a cross-sectional view of an inorganic plate according to Embodiment 4.

 FIG. 5 is a diagram showing various characteristics of Examples;! To 6 and Comparative Example;! To 4;

 FIG. 6 is a graph showing various characteristics of Examples 7 and 8 and Comparative Examples 5 to 8.

 Explanation of symbols

[0041] A inorganic board

 1 Surface layer

2 Back layer 3 core layer

 4 Sheet

 11 Surface

 12 Back layer

 BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The following description of preferred embodiments is merely exemplary in nature and is not intended to limit the present invention, its application, or its use.

[0043] [Embodiment 1]

 FIG. 1 shows an inorganic plate A according to Embodiment 1 of the present invention. This inorganic plate A is formed by integrating a surface layer 1 located on the front surface side (upper side in FIG. 1) and a back surface layer 2 located on the rear surface side (lower side in FIG. 1). .

[0044] (Surface layer)

 The surface layer 1 is composed of 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 m or less, and 10 to 70% by weight of an inorganic powder. 3 to 10% by weight of the agent.

 [0045] (1) Fine inorganic fibers

 The fine inorganic fibers are added to form a mat and have high stickiness and strength while obtaining high surface properties. For example, pulverized rock wool, slag wool, glass fibers, etc. Can be mentioned. The fine inorganic fibers are added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the entire solid component. If the added amount of the inorganic fiber is less than 10% by weight, it becomes difficult to form a mat and the stickiness is lost. On the other hand, if the added amount exceeds 70% by weight, other lightweight aggregates and inorganic powders are relatively reduced. This is because the desired strength cannot be obtained. In addition, it is desirable that the length of the fiber is as fine as 1 mm or less. This is because if it exceeds lmm, it will adversely affect the surface properties that tend to become lumps (fiber lump). The “fine inorganic fibers” added to the surface layer 1 are those having a small size while retaining the properties and functions of the fibers.

[0046] (2) Lightweight aggregate The lightweight aggregate is added to increase the bulk while securing the compressive strength, and examples thereof include perlite, shirasu foam, silica flour, and glass foam. The size of the lightweight aggregate used is 500 Hm or less, preferably 10 to 500 m (10 m or more and 500 m or less). This lightweight aggregate is less than 10 m in size! On the other hand, when the size of the lightweight aggregate is larger than 500 m, the workability of the inorganic board A is deteriorated as well as the surface property is deteriorated.

 [0047] This lightweight aggregate is added in an amount of 10 to 50% by weight (more than 10% by weight and less than 50% by weight) of the total solid components. If the amount of light aggregate added is less than 10% by weight, the bulk will be low and it will be difficult to spread uniformly during spraying, while if it exceeds 50% by weight, the pressure during pressing will be too high and production will occur. This is because the property decreases.

 [0048] (3) Inorganic powder

 The inorganic powder is added in order to ensure fire resistance and hardness, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash, mic port silica, and slag. This inorganic powder is added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the entire solid component. If the added amount of the inorganic powder is less than 10% by weight, the desired surface hardness cannot be obtained. On the other hand, if the added amount exceeds 70% by weight, the addition rate of other materials becomes relatively small, and the desired amount of the desired surface hardness is reduced. It is difficult to obtain the strength of

[0049] (4) Binder

 The binder is added to bind the fine inorganic fibers, lightweight aggregates, and inorganic powders. For example, melamine resin, phenol resin, MDI, urethane resin, attal resin, epoxy resin, Examples include poval and starch, which can be used alone or in combination. The amount of the binder that satisfies both the strength and nonflammability of the inorganic board A is 3 to 10% by weight (more than 3% by weight and less than 10% by weight) of the total solid components. That is, if the added amount of the binder is less than 3% by weight, the strength is insufficient, whereas if it exceeds 10% by weight, the nonflammability is impaired.

[0050] When the inorganic plate A is used for an exterior, it is preferable to select a binder having high water resistance. [0051] (5) Auxiliary additive

 As an auxiliary additive, a sizing agent, a coupling agent and the like may be added as necessary.

[0052] (Back layer)

 The back layer 2 is composed of an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powdery material of 10 to 70% by weight, and a binder of 5 to; 15% by weight.

 [0053] (1) Inorganic fiber

 The inorganic fiber is added in order to form a mat and to have stickiness and strength, and examples thereof include glass fiber and wollastonite. This inorganic fiber is added from! To 10 wt% (1 wt% or more and 10 wt% or less) of the total solid components. If the added amount of the inorganic fiber is less than 1% by weight, it becomes difficult to form a mat and the stickiness is lost. On the other hand, if it exceeds 10% by weight, separation occurs during mixing. For example, in the case of glass fibers, it is preferable to use bundles such as chopped strands for easy handling.

 [0054] The thickness of the fiber is preferably 6 to 13 m (6 m or more and 13 m or less). If the thickness is less than 6 mm, the fiber becomes too thin and the viscosity becomes low, and the strength is lowered. On the other hand, if it exceeds 13 ^ 111, the surface property is deteriorated.

 [0055] The length of the fiber is preferably 3 to 15 mm (3 mm or more and 15 mm or less). If the length is shorter than 3 mm, the fiber will become less sticky, and if it exceeds 15 mm, it will be detrimental (fiber lump) and adversely affect the surface properties. Further, when the fiber length is 3 to 15 mm, the balance during mixing with the lightweight aggregate, the inorganic powder, and the binder does not become dull and can be uniformly dispersed and mixed. For this reason, the back layer 2 having higher strength and hardness can be obtained.

 [0056] (2) Lightweight aggregate

 The lightweight aggregate is added to increase the bulk while securing the compressive strength, and examples thereof include perlite, shirasu foam, silica flour, and glass foam. The size of this light aggregate is preferably 2000,1 m or less! /. This is because when the size force is larger than 000 μm, the processability of the inorganic plate A is lowered.

[0057] The lightweight aggregate is added in an amount of 10 to 70% by weight (not less than 10% by weight and not more than 70% by weight) of the total solid components. If this amount is less than 10% by weight, the bulk will be low and even when spraying. On the other hand, when it exceeds 70% by weight, the pressure at the time of compression becomes too high and productivity is lowered.

 [0058] (3) Inorganic powder

 The inorganic powder is added in order to ensure fire resistance and hardness, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash, mic port silica, and slag. This inorganic powder is added in an amount of 10 to 70% by weight (10% by weight or more and 70% by weight or less) of the total solid components. If the amount added is less than 10% by weight, the desired surface hardness cannot be obtained, and if it exceeds 70% by weight, the addition rate of other materials becomes relatively small, making it difficult to obtain the desired strength. It is.

 [0059] (4) Binder

 The binder is added to bind the above-mentioned lightweight aggregate, inorganic fiber, and inorganic powder. For example, melamine resin, phenol resin, MDI, urethane resin, acrylic resin, epoxy resin, poval, starch, etc. These can be used alone or in combination. As an addition amount satisfying both the strength and nonflammability of the inorganic board A, 5 to 15% by weight (5% by weight or more and 15% by weight or less) of the whole solid component is added. This is because if the amount added is less than 5% by weight, the strength is insufficient, while if it exceeds 15% by weight, the nonflammability is impaired.

 [0060] (5) Auxiliary additive

 As an auxiliary additive, functional materials such as silica gel or diatomaceous earth can be mixed to impart moisture absorption and desorption, or a deodorant or VOC adsorbent can be added.

 [0061] (Method for producing inorganic board)

 The manufacturing method of the inorganic board A having the above configuration will be described below. This method includes a back surface layer mat forming step, a surface layer mat forming step, and a molding step.

 [0062] (1) Back surface layer mat forming step

In the first back surface layer mat forming step, the material for the back surface layer 2, that is, inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, lightweight aggregate 10 to 70% by weight, and inorganic powder 10 ~ 70 wt%, binder 5 ~; 15 wt% and auxiliary additives are put into a mixer and mixed while spraying water to obtain a mixture adjusted to water content 5 ~; 15% . Formin this mixture To form a back layer mat.

 [0063] The water added when mixing these materials is preferably 5 to 15 wt% (5 wt% or more and 15 wt% or less) of the solid component. The reason for this is that if it is less than 5% by weight, the powder is scattered during mixing and molding, resulting in poor workability. It is because it becomes easy to do.

 [0064] (2) Surface layer mat forming step

 In the next surface layer mat forming step, the material for the surface layer 1, that is, 10 to 70% by weight of fine inorganic fibers having a length of lm m or less and a lightweight aggregate having a particle size of 500 m or less and 10 to 50% by weight. , 10 to 70% by weight of an inorganic powder, 3 to 10% by weight of a binder, and mixed with spraying water to adjust the water content to 5 to 15%. Get. The mixture is formed on the back surface layer mat formed in the back surface layer mat forming step to form a surface layer mat.

 [0065] Even when these materials are mixed, the added water is preferably 5 to 15% by weight of the solid component. The reason for this is the same as in the backside layer mat forming step. When the amount is less than 5% by weight, the powder scatters much during mixing and molding, and the workability deteriorates. 'This is because it takes time to press and it becomes easy to puncture.

 [0066] (3) Molding process

 In the molding step, the two mats for the back layer 2 and the front layer 1 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C.) to be integrally molded. This hot press machine can be either a continuous press machine or a multi-stage press machine!

[0067] Through such steps, an inorganic plate A having a density of 0.3 to 1.5 g / cm ³ is formed. If this density is lower than 0.3 g / cm ³ , the desired strength cannot be obtained. On the other hand, if it exceeds 1.5 g / cm ³ , the workability and workability are deteriorated. Equipment is required and productivity is poor

<Effect of Embodiment 1>

Therefore, in this embodiment, fine inorganic fibers having a length of 1 mm or less and lightweight aggregates having a particle diameter of 500 m or less are used for the surface layer 1 of the inorganic plate A. Therefore, the dense surface layer 1 Is obtained. On the other hand, the back layer 2 has a length of 3 to; 15 mm of inorganic fiber 1 to 10% by weight Since it is a layer having 10 to 70% by weight of lightweight aggregate, 10 to 70% by weight of an inorganic powder, and 5 to 15% by weight of a binder, the surface layer 1 can be supported. Moreover, since the back layer 2 uses inorganic fibers with a length of 3 to 15 mm, it has a good mixing balance with other lightweight aggregates, inorganic powders, and binders, making it difficult to become lumps (fiber clumps). Can be uniformly dispersed and mixed. For this reason, the back layer 2 having higher strength and hardness can be obtained, and the force S for firmly supporting the front surface layer 1 can be obtained. As a result, it is possible to obtain a high-strength inorganic board A that is excellent in nonflammability, handling, workability, and workability as a whole.

 [0069] Further, in the production of the inorganic board A, the back layer and the surface layer mat are adjusted to a moisture content of 5 to 15%! /. Therefore, the binder is reacted by performing heat compression for a short time and at a high temperature. You can force S. In addition, because of the high temperature and high pressure, the flowability of the binder can be increased so that it can spread throughout, and the moisture can be evaporated in a short time, thus maximizing the performance of the binder. As a result, the amount of the binder that can be pulled out to a relatively low level can be made relatively small, and a strong inorganic board A excellent in incombustibility can be obtained in a short time.

 [0070] Further, since the back surface layer and the surface layer mat are adjusted to have a water content of 5 to 15%, the productivity that puncture hardly occurs at the time of hot press is good.

 [0071] [Embodiment 2]

 FIG. 2 shows an inorganic plate A according to Embodiment 2 of the present invention (in the following embodiments, the same parts as those in FIG. 1 are denoted by the same reference numerals and detailed description thereof is omitted).

 In this embodiment, the sheet-like material 4 is integrated on the back surface of the inorganic plate A. Others are the same as in the first embodiment.

 [0073] The sheet-like material 4 is not particularly limited, and may be a non-woven fabric, a veneer, an impregnated paper, a resin sheet, a fiber sheet or the like, and may be a cosmetic one.

[0074] A method for manufacturing the inorganic plate A of Embodiment 2 will be described. First, a sheet-like material 4 is prepared. And like the back surface layer mat formation process of Embodiment 1, length 3 ~; 15mm inorganic fiber;! ~ 10wt%, lightweight aggregate 10 ~ 70wt%, inorganic powder 10 ~ 70 and weight% binder 5; was charged with 15 wt% to the mixer, and mixed with spraying water to obtain a mixture which is adjusted to hydrous rate _{of 5} to 15 percent, the sheet material and the mixture ₄ Form on top to form the back layer mat. [0075] Next, similarly to the surface layer mat forming step of Embodiment 1, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less and 10 to 50% by weight of lightweight aggregate having a particle size of 500 111 or less. A mixture of 10 to 70% by weight of organic powder and 3 to 10% by weight of binder and mixed with water spray while mixing to adjust the water content to 5 to 15% The mixture is formed on the back layer mat to form a surface layer mat.

 [0076] Then, the two-layer mat of the back layer and the front layer and the sheet-like material 4 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C) to be integrally formed.

[0077] In the case where the sheet-like material 4 is integrated with a hot-press press at the same time as the formed mat, an adhesive is applied to the sheet-like material 4 in advance in order to improve the adhesion of the sheet-like material 4. It is also possible. Examples of the adhesive include phenol resin, melamine resin, urethane resin, acrylic resin, MDI, and butyl acetate resin, but it is desirable to select one having high water resistance when used for exterior use. The coating amount is preferably 50 g / m ² or less for solid formation! /. This is because if the solid component exceeds 50 g / m ² , the nonflammability decreases.

 <Effect of Embodiment 2>

 Therefore, in the case of this embodiment, since the sheet-like material 4 is physically hot-pressed and adhered to the back surface layer 2 of the inorganic plate A, an inorganic plate A having a strength that is difficult to break is obtained.

[0079] Further, since the sheet-like material 4 is also integrally molded by hot-pressing, it can be produced with high productivity with fewer steps than when the sheet-like material 4 is attached later. Further, in the manufacturing process, the mat 4 as a mixture can be more easily transported because the sheet-like material 4 is laid underneath.

 [0080] [Embodiment 3]

 FIG. 3 shows an inorganic plate A according to Embodiment 3 of the present invention. The inorganic plate A has a surface layer 11 located on the front surface side (upper side in FIG. 3) and a back surface located on the back side (lower side in FIG. 3). The layer 12 and the core layer 3 positioned between the surface layer 11 and the back layer 12 are integrally formed. In other words, the inorganic plate A includes the core layer 3, the surface layer 11 integrated on the surface of the core layer 3, and the back layer 12 integrated on the back surface of the core layer 3.

[0081] (surface layer and back layer) The surface layer 11 and the back layer 12 are the same, and are the same as the surface layer 1 in the first embodiment. That is, each of the surface layer 11 and the back layer 12 is composed of 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 111 or less, 10 to 70% by weight of body and 3 to 10% by weight of binder.

[0082] (1) Fine inorganic fiber

 The fine inorganic fibers are the same as the “fine inorganic fibers” in the surface layer 1 of the first embodiment.

[0083] (2) Lightweight aggregate

 The lightweight aggregate is the same as the “lightweight aggregate” in the surface layer 1 of the first embodiment (see the description of “lightweight aggregate” in the surface layer 1 of the first embodiment).

[0084] (3) Inorganic powder

 The inorganic powder is the same as the “inorganic powder” in the surface layer 1 of the first embodiment (see the description of “inorganic powder” in the surface layer 1 of the first embodiment).

[0085] (4) Binder

 The binder is the same as the “binder” in the surface layer 1 of the first embodiment (see the description of the “binder” in the surface layer 1 of the first embodiment).

[0086] (5) Auxiliary additive

 As an auxiliary additive, a sizing agent, a coupling agent and the like may be added as necessary.

[0087] (Core layer)

 The core layer 3 is the same as the back layer 2 in Embodiment 1, and has a length of 3 to; 15 mm of inorganic fiber;! To 10% by weight, lightweight aggregate of 10 to 70% by weight, and an inorganic powder. 10 to 70% by weight and 5 to 15% by weight of binder.

[0088] (1) Inorganic fiber

 The inorganic fiber is the same as the “inorganic fiber” in the back layer 2 of Embodiment 1 (see the description of “Inorganic fiber” in the back layer 2 of Embodiment 1).

[0089] (2) Lightweight aggregate

The lightweight aggregate is the same as the “lightweight aggregate” in the back surface layer 2 of Embodiment 1 (see the description of “Lightweight aggregate” in the back surface layer 2 of Embodiment 1). [0090] (3) Inorganic powder

 The inorganic powder is the same as the “inorganic powder” in the back layer 2 of Embodiment 1 (see the description of “Inorganic powder” in the back layer 2 of Embodiment 1).

[0091] (4) Binder

 The binder is the same as the “binder” in the back layer 2 of Embodiment 1 (see the description of the “binder” in the back layer 2 of Embodiment 1).

[0092] (5) Auxiliary additive

 As an auxiliary additive, functional materials such as silica gel or diatomaceous earth can be mixed to impart moisture absorption and desorption, or a deodorant or VOC adsorbent can be added.

[0093] (Method for producing inorganic plate)

 A method for manufacturing the inorganic plate A according to Embodiment 3 having the above configuration will be described. This method comprises a back layer mat forming step, a core layer mat forming step, a surface layer mat forming step, and a forming step.

[0094] (1) Back layer mat forming process

 In the first back layer mat forming step, the composition material for the back layer 12, that is, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less and a lightweight aggregate having a particle size of 500 Hm or less 10 to 50 10% by weight, 10 to 70% by weight of an inorganic powder, 3 to 10% by weight of binder, 10% by weight and auxiliary additives are added to the mixer and mixed while spraying water to obtain a water content of 5 to 5%; A mixture adjusted to 15% is obtained. This mixture is formed to form a backing mat.

[0095] The water added when mixing these materials is preferably 5 to 15% by weight of the solid component (more than 5% by weight and not more than 15% by weight) (moisture content 5 to 15%). ). The reason for this is that if it is less than 5% by weight, the scattering of the powder during mixing or molding deteriorates the workability, and if it exceeds 15% by weight, it takes time for heating and pressing, and puncture is caused. Because it becomes easier to do

[0096] (2) Core layer mat forming step

In the next core layer mat forming step, the material for the core layer 3, that is, the inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, lightweight aggregate 10 to 70% by weight, and inorganic powder 10 to 70% by weight, binder 5 to 5%; 15% by weight and auxiliary additives are put into a mixer and sprayed with water. To obtain a mixture adjusted to a water content of 5 to 15%. This mixture is formed on the back layer mat formed in the back layer mat forming step to form a second core layer mat.

 [0097] When mixing these materials, the added water is preferably 5 to 15% by weight of the solid component (water content 5 to 15%). The reason for this is the same as in the above-mentioned back layer mat forming process. If the amount is less than 5% by weight, the scattering of the powder during mixing or molding deteriorates the workability, while if it exceeds 15% by weight. This is because it takes time to heat and press, and it becomes easy to puncture.

 [0098] (3) Surface mat forming process

 In the next surface mat forming step, the same material as that for the surface layer 11, that is, the material for the back layer 12, is 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less and a particle size of 500 m or less. Light weight aggregate 10-50% by weight, inorganic powder 10-70% by weight, binder 3-10% by weight, auxiliary additives are added to the mixer and mixed while spraying water, moisture content A mixture adjusted to 5-15% is obtained. This mixture is formed on the core layer mat formed in the core layer mat forming step to form a third surface mat.

 [0099] When these materials are mixed, the added water is preferably 5 to 15% by weight of the solid component (moisture content 5 to 15%). The reason for this is the same as the mat forming process for each layer described above. When the amount is less than 5% by weight, powder scattering is large at the time of mixing or molding, while workability is deteriorated. 'It takes time to press and it becomes easy to puncture.

 [0100] (4) Molding process

 In the molding step, the three layers of mats laminated for the back layer 12, the core layer 3, and the surface layer 11 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C.) to be integrally molded. This hot press machine can be a continuous press machine or a multi-stage press machine!

[0101] Through these steps, an inorganic sheet A having a density of 0.3 to 1.5 g / cm ³ is formed. If this density is lower than 0.3 g / cm ³ , the desired strength cannot be obtained. On the other hand, if it exceeds 1.5 g / cm ³ , the workability and workability are deteriorated. Equipment is required and productivity is poor

[0102] <Effects of Embodiment 3> Therefore, in this embodiment, fine inorganic fibers having a length of 1 mm or less and lightweight aggregate having a particle size of 500 in or less are used for both the surface layer 11 and the back layer 12 of the inorganic plate A. Thus, a dense surface layer 11 and back layer 12 are obtained. On the other hand, the core layer 3 comprises an inorganic fiber having a length of 3 to 15 mm;! To 10% by weight, a lightweight aggregate of 10 to 70% by weight, an inorganic powder 10 to 70% by weight, and a binder 5 Since the layer has 15 wt%, the force S can be supported to support the surface layer 11 and the back layer 12. However, the core layer 3 uses a length of 3 to 15 mm of inorganic fibers, so it has a good mixing balance with other lightweight aggregates, inorganic powders and binders (fiber lump). Can be uniformly dispersed and mixed. Therefore, the core layer 3 having higher strength and hardness can be obtained, and the surface layer 11 and the back layer 12 can be supported and supported. As a result, it is possible to obtain a high-strength inorganic board A that is excellent in incombustibility, handling, workability, and workability as a whole.

 [0103] Further, in the production of the inorganic board A, the mats of the back layer, the core layer, and the surface layer are adjusted to a moisture content of 5 to 15%. Power to react S. In addition, because it is under high temperature and high pressure, the fluidity of the binder can be increased and distributed throughout, and the water can be evaporated in a short time, so that the performance of the binder can be maximized. As a result, the amount of the binder can be made relatively small, and a strong inorganic board A having excellent nonflammability can be obtained in a short time.

 [0104] Furthermore, since the mat of each layer is adjusted to a moisture content of 5 to 15%, the productivity is low because it is difficult for the tank to occur during hot press.

 [Embodiment 4]

 FIG. 4 shows an inorganic board A according to Embodiment 4 of the present invention. In this embodiment, the sheet-like material 4 is integrated on the back surface of the inorganic plate A. Others are the same as in the third embodiment.

 [0106] The sheet-like material 4 is not particularly limited, and may be a non-woven fabric, a veneer, an impregnated paper, a resin sheet, a fiber sheet, or the like, and may be a cosmetic one.

[0107] The method for producing the inorganic plate A of Embodiment 4 will be described. A sheet 4 is prepared. And, similarly to the back layer mat forming step of Embodiment 3, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 111 or less, 10 to 70% by weight of powdery substance and 3 to 10% by weight of binder are put into a mixer and water is injected. Mix with mist to obtain a mixture adjusted to a moisture content of 5 to 15%, and form the mixture on the sheet 4 to form a back layer mat.

 [0108] Next, in the same manner as in the core layer mat forming step of Embodiment 3, inorganic fiber 1 to 10% in length 3 to 15 mm, light aggregate 10 to 70% by weight, inorganic powder 10 ~ 70 wt% and binder 5 ~; 15 wt% are put into a mixer and mixed while spraying water to obtain a mixture adjusted to a water content of 5 ~; 15%. Form on the mat to form the second core mat.

 [0109] Next, similarly to the surface mat forming step of Embodiment 3, 10 to 70% by weight of fine inorganic fibers having a length of 1 mm or less, and 10 to 50% by weight of light-weight aggregate having a particle size of 500 111 or less, 10 to 70% by weight of an inorganic powder and 3 to 10% by weight of a binder are put into a mixer and mixed while spraying water to obtain a mixture adjusted to a moisture content of 5 to 15%. This mixture is formed on the core layer mat to form a surface mat.

 [0110] Then, the three-layer mat of the back layer, the core layer and the surface layer and the sheet-like material 4 are hot-pressed at a predetermined pressure and temperature (150 to 250 ° C) to be integrally formed.

[0111] When the formed mat and the sheet-like material 4 are integrated by a hot press, an adhesive may be applied to the sheet-like material 4 in advance in order to improve the adhesion of the sheet-like material 4. Is possible. Examples of the adhesive include phenol resin, melamine resin, urethane resin, acrylic resin, MDI, and butyl acetate resin. However, it is desirable to select one having high water resistance when used for exterior use. The coating amount is preferably 50 g / m ² or less as a solid component! /. This is because non-flammability decreases when the solid component exceeds 50 g / m ² .

 <Effect of Embodiment 4>

 Therefore, in this embodiment, since the sheet-like material 4 is physically hot-pressed and adhered to the back layer 12 of the inorganic plate A, an inorganic plate A having a strength that is difficult to break is obtained.

[0113] Further, since the sheet-like material 4 is also integrally formed by hot-pressing, it can be manufactured with less productivity than the case where the sheet-like material 4 is attached later. Further, in the manufacturing process, the mat 4 as a mixture can be more easily transported because the sheet-like material 4 is laid underneath. [0114] [Other Embodiments]

 In the second embodiment, the sheet-like material 4 is molded and integrated together with the mats of the back surface layer and the surface layer. However, after the mats of the back surface layer and the surface layer are molded as in the first embodiment, You may make it stick and integrate a sheet-like material on the back.

 [0115] Further, in Embodiment 4 described above, the sheet-like material 4 is formed and integrated together with the mats of the back layer, the core layer, and the surface layer. However, as in Embodiment 3, the back layer, the core layer, and the surface layer are integrated. After forming each mat, a sheet-like material may be bonded and integrated on the back surface thereof.

 [0116] In Embodiment 4, the sheet-like material 4 is molded and integrated only using the lower side of the back layer mat. However, the sheet-like material is placed on the upper side of the surface layer mat, and this sheet-like material 3 Simultaneously with the formation of the mat of the layer and the lower sheet-like material 4, it can be formed by hot-pressing integrally. It is also possible to apply an adhesive to the sheet-like material used on the upper side. In this way, when the sheet-like materials are integrated up and down, an inorganic plate A having higher strength and balance can be obtained.

 [0117] Furthermore, the sheet-like material can be molded and integrated only by using it on the upper side of the three-layer mat.

 That is, it is only necessary that the sheet-like material is attached to at least one of the front and back surfaces of the inorganic plate (at least one surface).

 Example

 [0118] Next, a specific example will be described. The following Examples;! To 6 and Comparative Examples;! To 4 relate to Embodiments 1 and 2 above, and Examples 7, 8 and Comparative Examples 5 to 8 relate to Embodiments 3 and 4 above. Is. The characteristics of Examples ;! to 6 and Comparative Examples ;! to 4 are shown in FIG. 5, and the characteristics of Examples 7 and 8 and Comparative Examples 5 to 8 are shown in FIG.

 [Example 1]

Mix 7% by weight of glass fiber with a fiber length of 6mm and fiber diameter lO ^ m as inorganic fiber, 63% by weight of calcium carbonate as inorganic powder, and 2% by weight of polyester fiber as an auxiliary agent in a mixer 1 Stirring and defibration for 30 minutes, add 20% by weight of shirasu foam with a size (particle size) of 1mm or less as a lightweight aggregate, 8% by weight of powdered phenol as a binder, and water for 30 seconds The mixture was stirred to obtain a mixture having a water content of 7%. This is uniformly formed and the back layer A mold was formed.

[0120] Separately, 50% by weight of rock wool crushed to a length of 850 Hm or less as a fine inorganic fiber, and a shirasu foam with a size (particle size) of 500 am or less as a lightweight aggregate 30 weight %, Aluminum hydroxide 10% by weight as an inorganic powder, and powder phenol 10% by weight as a binder were mixed with water to obtain a mixture having a water content of 7%. This was formed on the back surface layer mat to form a surface layer mat. Then, the two-layer mat was hot-pressed at 220 ° C. for 120 seconds to obtain an inorganic plate having a thickness of 3 mm and a density of 1.2 g / cm ³ .

 [0121] (Example 2)

Mix 7% by weight of glass fiber with a fiber length of 6mm and fiber diameter lO ^ m as inorganic fiber, 63% by weight of calcium carbonate as inorganic powder, and 2% by weight of polyester fiber as an auxiliary agent in a mixer 1 Stir for minutes and defiltrate, add 20% by weight of glass foam with a size of lmm or less as a lightweight aggregate, 8% by weight of powdered phenol as a binder, and water and stir for 30 seconds to contain water A mixture with a rate of 7% was obtained. This mixture was uniformly formed on a glass nonwoven fabric (sheet-like material) having a basis weight of 50 g / m ² coated with acrylic resin 30 g / m ² (solid component) to form a back layer mat.

[0122] Separately, 50% by weight of rock wool ground to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam having a size of 500 ^ 111 or less as a lightweight aggregate, and an inorganic powder As a binder, 10% by weight of aluminum hydroxide and 10% by weight of powdered phenol as a binder were mixed with water to obtain a mixture having a water content of 7%. This is formed on the back surface layer mat to form a surface layer mat, and these two layer mats are hot-pressed at 220 ° C for 120 seconds, with a thickness of 3 mm and a density of 1.2 g / cm ³ An inorganic plate was obtained.

 [0123] (Example 3)

 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10m as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and 16% by weight of calcium carbonate as inorganic powder. Then, 7% by weight of powdered phenol as a binder was stirred with a mixer for 2 minutes while spraying water to obtain a mixture having a water content of 10%. This was uniformly formed to form a back surface layer mat.

[0124] Separately, 50% by weight of rock wool crushed to a length of 850 Hm or less as fine inorganic fibers And 30% by weight of shirasu foam with a size of δΟΟ ^ ιη or less as a lightweight aggregate, 10% by weight of aluminum hydroxide as an inorganic powder, 10% by weight of powdered phenol as a binder, water While spraying, the mixture was stirred and mixed for 1 minute to obtain a mixture having a water content of 7%. This was formed on the above back surface layer mat to form a surface layer mat, and these two layer mats were hot-pressed for 3 minutes at 210 ° C, with a thickness of 6 g and a density of 0.8 g / cm ³ . An inorganic board was obtained.

 [0125] (Example 4)

 7% by weight of glass fiber, 16% by weight of shirasu foam, 70% by weight of calcium carbonate, and 7% by weight of powdered phenol are stirred with a mixer for 2 minutes while spraying water, and a mixture with a moisture content of 7% Got. This was uniformly formed to form a back surface layer mat.

[0126] Separately, 70% by weight of rock wool pulverized to a length of 850 m or less, 10% by weight of shirasu foam having a size of 500 m or less, 10% by weight of aluminum hydroxide, and 10% by weight of powdered phenol Were mixed with stirring for 1 minute while spraying water to obtain a mixture having a water content of 7%. This is formed on the back surface layer mat to form the surface layer mat, and the two layer mat is hot-pressed at 210 ° C for 3 minutes, and is 3 mm thick and 1.5 g / cm ³ density inorganic plate Got

[Example 5]

 7% by weight of glass fiber, 70% by weight of shirasu foam, 16% by weight of calcium carbonate, and 7% by weight of powdered phenol are stirred with a mixer for 2 minutes while spraying water, and a mixture with a moisture content of 10% Got. This was uniformly formed to form a back surface layer mat.

 [0128] Separately, 30% by weight of rock wool pulverized to a length of 850 m or less, 50% by weight of shirasu foam having a size of 500 m or less, 10% by weight of aluminum hydroxide, and 10% by weight of powdered phenol Were mixed with stirring for 1 minute while spraying water to obtain a mixture having a water content of 10%. This is formed on the back surface layer mat to form a surface layer mat, and the two layer mats are hot-pressed at 210 ° C for 4 minutes to form an inorganic plate with a thickness of 9 g and a density of 0.3 g / cm3. Obtained.

[0129] As shown in Fig. 5, when coated paper, veneer and DAP impregnated paper as a decorative sheet were pasted on the inorganic board obtained in the above examples;! Adhesion was also good. A decorative board with a very good surface property was obtained. In addition, for inorganic plates Coating and mirror coating were also good.

[0130] (Example 6)

 Mix 7% by weight of glass fiber with a fiber length of 6mm and fiber diameter lO ^ m as inorganic fiber, 63% by weight of calcium carbonate as inorganic powder, and 2% by weight of polyester fiber as an auxiliary agent in a mixer 1 Stir for minutes and defiltrate, add 20% by weight of glass foam with a size of lmm or less as a lightweight aggregate, 8% by weight of powdered phenol as a binder, and water and stir for 30 seconds to contain water A mixture with a rate of 7% was obtained. This was uniformly formed to form a back layer mat.

[0131] Separately, 50% by weight of rock wool pulverized to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam of size 500 111 as lightweight aggregate, and water as inorganic powder Water is added to and mixed with 10% by weight of aluminum oxide and 10% by weight of powdered phenol as a binder to obtain a mixture with a moisture content of 7%, which is formed on the back layer mat to form a surface layer mat. Then, the two-layer mat was hot-pressed at 220 ° C. for 120 seconds. After cooling, a glass nonwoven fabric (sheet-like material) with a basis weight of 50 g / m ² coated with acrylic resin 30 g / m ² (solid component) is pasted, and an inorganic plate with a thickness of 3 mm and a density of 1.2 g / cm ³ is attached. Obtained.

 [0132] (Comparative Example 1)

 Water is sprayed on 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10 μm, 70% by weight of Shirasu foam with a size of lmm or less, 16% by weight of calcium carbonate, and 7% by weight of powdered phenol. While stirring with a mixer for 2 minutes, a mixture having a water content of 10% was obtained. This was uniformly formed to form a back surface layer mat.

[0133] Separately, 10% by weight of rock wool pulverized to a length of 850 m or less, 80% by weight of shirasu foam having a size of 500 m or less, and 10% by weight of powder phenol are sprayed with water. In addition, the mixture was stirred and mixed for 1 minute to obtain a mixture having a water content of 7%. This is formed on the back surface layer mat to form a surface layer mat, and the two layer mats are hot-pressed at 210 ° C for 3 minutes, and are 6 mm thick and 0.8 g / cm ³ in density. I got a plate. As shown in FIG. 5, Comparative Example 1 had low surface hardness and poor smoothness.

 [0134] (Comparative Example 2)

7% by weight glass fiber with a fiber length of 6mm and fiber diameter of 10m as inorganic fiber, lightweight aggregate Then, 70% by weight of shirasu foam with a size of lmm or less, 16% by weight of calcium carbonate as an inorganic powder, 7% by weight of powdered phenol as a binder, and water for 2 minutes with a mixer. Bonded to obtain a mixture with a moisture content of 10%. This was uniformly formed to form a back surface layer mat.

[0135] Separately, 50% by weight of rock wool crushed to a length of 1500 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam with a size of δΟΟ ^ ιη or less as a lightweight aggregate, and an inorganic powder As a binder, 10% by weight of aluminum hydroxide and 10% by weight of powdered phenol as a binder were mixed with stirring for 1 minute while spraying water to obtain a mixture having a water content of 7%. This is formed on the back surface layer mat to form a surface layer mat, and the two layer mats are hot-pressed for 3 minutes at 210 ° C, and are 6 mm thick and 0.8 g / cm ³ in density. I got a plate. As shown in FIG. 5, in Comparative Example 2, fiber lumps (fiber clumps) were generated on the surface, and smoothness was lost.

 [0136] (Comparative Example 3)

 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10m as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and 16% by weight of calcium carbonate as inorganic powder. The mixture was stirred for 2 minutes with a mixer while spraying 7% by weight of powder phenol as a binder and water to obtain a mixture having a water content of 10%. This was uniformly formed to form a back surface layer mat.

[0137] Separately, 50% by weight of rock wool pulverized to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam with a size of lmm or less as a lightweight aggregate, and an inorganic powder 10% by weight of aluminum hydroxide and 10% by weight of powdered phenol as a binder were mixed with stirring for 1 minute while spraying water to obtain a mixture having a water content of 7%. This is formed on the back surface layer mat to form a surface layer mat, and the two layer mats are hot-pressed at 210 ° C for 3 minutes, and are 6 mm thick and an inorganic plate with a density of 0.8 g / cm ³ . Got. As shown in FIG. 5, this Comparative Example 3 had irregularities on the surface and lost smoothness.

 [0138] (Comparative Example 4)

7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10m as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and calcium carbonate as inorganic powder. The mixture was stirred for 2 minutes with a mixer while spraying 16% by weight of the powder, 7% by weight of powder phenol as a binder, and water to obtain a mixture having a water content of 30%. This was uniformly formed to form a back surface layer mat.

 [0139] Separately, 50% by weight of rock wool crushed to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of Shirasu foam having a size of 500 ^ 111 or less as a lightweight aggregate, and an inorganic powder As a binder, 10% by weight of aluminum hydroxide and 10% by weight of powdered phenol as a binder were mixed with stirring for 1 minute while spraying water to obtain a mixture having a water content of 30%. This was formed on the back surface layer mat to form a surface layer mat. An attempt was made to hot-press two layers of mats, but the mat material, which was apt to evaporate water, explode and was unable to produce a sheet.

 [0140] (Example 7)

 50% by weight of rock wool crushed to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam with a size (particle size) of 500 μm or less as a light aggregate, and inorganic powder As a binder, water was added to 10% by weight of aluminum hydroxide and 10% by weight of powdered phenolic resin as a binder, and mixed with a mixer to obtain a first mixture having a water content of 7%. Then, the first mixture was formed to form a back layer mat.

 [0141] Next, separately, 7% by weight of glass fiber having a fiber length of 6 mm and a fiber diameter of 10 m as inorganic fibers, 70% by weight of shirasu foam having a size of 1 mm or less as a lightweight aggregate, and charcoal as an inorganic powder. Water was added to 15% by weight of calcium acid and 8% by weight of powdered phenol resin as a binder, and the mixture was stirred and mixed with a mixer to obtain a water content of 10% to obtain a second mixture. The obtained second mixture was formed on the backing mat to form a core layer mat.

 [0142] Furthermore, the first mixture obtained by mixing in the same manner as described above was formed on the core layer mat to form a surface layer mat.

[0143] Then, the three-layer mat performs hot press of 210 ° C5 minutes to obtain 9mm thickness, the inorganic board of density 0. 8 g / cm ^3.

 [Example 8]

50% by weight of rock wool pulverized to a length of 850 Hm or less as fine inorganic fibers, 30% by weight of shirasu foam having a size of 500 m or less as light aggregate, and aluminum hydroxide as inorganic powder 10 Water and 10% by weight of powdered phenolic resin as binder. Was added and mixed with a mixer to obtain a first mixture having a water content of 7%. The first mixture was formed to form a back layer mat.

 [0145] Next, 7% by weight of glass fiber having a fiber length of 6 mm and a fiber diameter of 10 m as inorganic fibers, 30% by weight of shirasu foam having a size of 1 mm or less as a lightweight aggregate, and charcoal as an inorganic powder. Add water to 16% by weight of calcium oxide, 7% by weight of powdered phenolic resin as a binder, and 40% by weight of diatomaceous earth as a material to add functionality, and stir and mix with a mixer to a moisture content of 10%. To obtain a second mixture. The second mixture thus obtained was formed on the back layer mat to form a core layer mat.

 [0146] Further, the first mixture obtained by mixing in the same manner as described above was formed on the core layer mat to form a surface layer mat.

[0147] Then, the three-layer mat performs hot press of 210 ° C5 minutes to obtain 9mm thickness, the inorganic board of density 0. 8 g / cm ^3.

 [0148] When coated paper, veneer and DAP-impregnated paper were pasted as decorative sheets to the inorganic boards of Examples 7 and 8 obtained in this manner, the adhesion to the inorganic boards was also good. . And, a decorative board having a very good surface property could be obtained.

[0149] The moisture absorption / release performance was measured in accordance with JIS A 1470-1, and it was 18 g / m ² in Example 7, but 72 g / m ² was measured in Example 8. I was able to.

 [0150] (Comparative Example 5)

 10% by weight of rock wool ground to a length of 850 m or less as fine inorganic fibers, 80% by weight of shirasu foam with a size of 500 m or less as lightweight aggregate, and 10% by weight of powdered phenol as a binder Water was sprayed onto the mixture and stirred and mixed for 1 minute to obtain a first mixture having a water content of 7%. This first mixture was formed to form a back layer mat.

 [0151] Next, 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10μm as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and carbonic acid as inorganic powder The mixture was stirred for 2 minutes with a mixer while spraying water on 16% by weight of Lucium and 7% by weight of powdered phenol as a binder to obtain a second mixture having a water content of 10%. This was uniformly formed on the back layer mat to form a core layer mat.

[0152] Further, the first mixture obtained in the same manner as described above was formed on the core layer mat and displayed. A layer mat was formed.

[0153] Then, the three-layer mat was hot-pressed at 210 ° C for 3 minutes to obtain an inorganic plate having a thickness of 9 mm and a density of 0.8 g / cm ³ . As shown in FIG. 6, this comparative example 5 had a low surface hardness and a poor smoothness.

 [0154] (Comparative Example 6)

 50% by weight of rock wool crushed to a length of 1500 m or less as fine inorganic fibers, 30% by weight of shirasu foam with a size of 500 m or less as light aggregate, and 10% by weight of aluminum hydroxide as an inorganic powder Then, water was added to 10% by weight of powder phenol as a binder while spraying water, and the mixture was stirred and mixed for 1 minute to obtain a first mixture having a moisture content of 7%. The first mixture was formed to form a back layer mat.

 [0155] Next, 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10μm as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and carbonic acid as inorganic powder Water was sprayed onto 16% by weight of Lucium and 7% by weight of powdered phenol as a binder, and the mixture was stirred for 2 minutes with a mixer to obtain a second mixture having a water content of 10%. This was uniformly formed on the above-mentioned back layer mat to form a core layer mat.

 [0156] Further, the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface mat.

[0157] The three-layer mat was hot-pressed at 210 ° C for 3 minutes to obtain an inorganic plate having a thickness of 9 mm and a density of 0.8 g / cm ³ . As shown in FIG. 6, in Comparative Example 6, fiber lumps (fiber clumps) were generated on the surface, and smoothness was lost.

 [0158] (Comparative Example 7)

 50% by weight of rock wool pulverized to a length of 850 m or less as fine inorganic fibers, 30% by weight of shirasu foam with a size of 1000 m or less as lightweight aggregate, and 10% by weight of aluminum hydroxide as an inorganic powder Then, 10% by weight of powdered phenol as a binder was added while spraying water and mixed with stirring for 1 minute to obtain a first mixture having a moisture content of 7%. This first mixture was formed to form a back layer mat.

[0159] Next, 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10μm as inorganic fiber, 70% by weight of shirasu foam with a size of lmm or less as a lightweight aggregate, and carbonic acid as an inorganic powder 16% by weight of Lucium and 7% by weight of powdered phenol as a binder were added while spraying water and stirred for 2 minutes with a mixer to obtain a second mixture having a water content of 10%. A core layer mat was formed by uniformly forming this on the back layer mat.

[0160] Further, the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface layer mat.

[0161] The three-layer mat was hot-pressed at 210 ° C for 3 minutes to obtain an inorganic plate having a thickness of 9 mm and a density of 0.8 g / cm ³ . In Comparative Example 7 as shown in FIG. 6, the surface was uneven and the smoothness was lost.

 [0162] (Comparative Example 8)

 50% by weight of rock wool crushed to a length of 850 m or less as fine inorganic fibers, 30% by weight of shirasu foam with a size of 500 m or less as lightweight aggregate, and 10% by weight of aluminum hydroxide as an inorganic powder Then, 10% by weight of powdered phenol as a binder was added while spraying water and mixed with stirring for 1 minute to obtain a first mixture having a water content of 30%. This first mixture was formed to form a back layer mat.

 [0163] Next, 7% by weight of glass fiber with a fiber length of 6mm and a fiber diameter of 10μm as inorganic fiber, 70% by weight of shirasu foam with a size of 1mm or less as lightweight aggregate, and carbonic acid as inorganic powder 16% by weight of Lucium and 7% by weight of powdered phenol as a binder were added while spraying water and stirred for 2 minutes with a mixer to obtain a second mixture having a water content of 30%. This was uniformly formed on the above-mentioned back layer mat to form a core layer mat.

 [0164] Further, the first mixture obtained in the same manner as described above was formed on the core layer mat to form a surface layer mat.

 [0165] And the power to try to hot-clamp the three-layered mat. The mat material, whose water evaporation is intense, explodes and has the power to make a sheet.

 Industrial applicability

[0166] The present invention provides a high-strength inorganic plate excellent in surface smoothness, nonflammability, handleability, workability, and workability, and thus is extremely useful and highly industrially applicable.

Claims

The scope of the claims  [1] Length 3 ~; 15mm inorganic fiber;! ~ 10wt%, lightweight aggregate 10 ~ 70wt%, inorganic powder 10 ~ 70wt%, binder 5 ~; 15wt% A back layer having  10 to 70% by weight of inorganic fibers with a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate with a particle size of 500 m or less, 10 to 70% by weight of inorganic powder, 3 to 10% of binder, An inorganic plate characterized by being formed by being integrated with a surface layer having a surface.  [2] The inorganic plate according to [1], wherein a sheet-like material is integrated on the back surface.  [3] Length 3 to; 15 mm inorganic fiber;! To 10 wt%, lightweight aggregate 10 to 70 wt%, inorganic powder 10 to 70 wt%, binder 5 to 15 wt% Forming a back layer mat by forming a mixture adjusted to have a water content of 5 to 15% by adding water, and further forming an inorganic fiber having a length of 1 mm or less on the back layer mat 10 ~ 70 wt%, lightweight aggregate with particle size of 500 ^ 111 or less, 10-50 wt%, inorganic powder 10-70 wt%, binder 3 ~; 10 wt%, water added Forming a surface layer mat by forming a mixture adjusted to a moisture content of 5 to 15%;  A method for producing an inorganic plate, comprising: a step of hot pressing the two mats of the back surface layer and the front surface layer and forming them integrally.  [4] length 3 to 15 mm inorganic fiber;! To 10 wt%, lightweight aggregate 10 to 70 wt%, inorganic powder 10 to 70 wt%, binder 5 to 15 wt% And forming a back surface layer mat by forming a mixture adjusted to have a water content of 5 to 15% by adding water to a sheet-like material,  On the back layer mat, 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 ^ 111 or less, and 10 to 70% by weight of inorganic powder Forming a surface layer mat by forming a mixture having a binder of 3 to 10% by weight and water added to adjust the water content to 5 to 15%;  A method for producing an inorganic plate, comprising: a step of hot-pressing the two-layer mat and the sheet-like material of the back surface layer and the surface layer and forming them integrally. [5] A core layer, a surface layer integrated on the surface of the core layer, and a back layer integrated on the back surface of the core layer, The above surface layer and back layer are bonded to 10 to 70% by weight of inorganic fibers having a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate having a particle size of 500 μm or less, and 10 to 70% by weight of inorganic powder. 3 to 10% by weight of agent,  The core layer has a length of 3 to 15 mm inorganic fiber;! To 10 wt%, lightweight aggregate 10 to 70 wt%, inorganic powder 10 to 70 wt%, binder 5 to 15 wt %. An inorganic board characterized by comprising:  [6] The inorganic board according to claim 5, wherein a sheet-like material is stuck and integrated on at least one of the front and back surfaces. [7] 10 to 70% by weight of inorganic fibers with a length of lmm or less and lightweight aggregate with a particle size of 500 m or less 10 to  50% by weight, 10 to 70% by weight of an inorganic powder, 3 to 10% by weight of binder, water added to form a mixture adjusted to a water content of 5 to 15% Forming a back layer mat,  On the back layer mat, an inorganic fiber having a length of 3 to 15 mm;! To 10 wt%, a light aggregate 10 to 70 wt%, an inorganic powder 10 to 70 wt%, and a binder 5 to Forming a second core layer mat by forming a mixture having a water content of from 5 to 15% and a water content of 5 to 15%;  On the two-layer mat, 10 to 70% by weight of inorganic fibers with a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate with a particle size of 500 ^ 111 or less, and 10 to 70% by weight of inorganic powder And forming a third surface mat by forming a mixture having a binder of 3 to 10% by weight and water added to adjust the water content to 5 to 15%.  And a step of integrally forming the three-layer mat with a hot-pressing method.  [8] 10 to 70% by weight of inorganic fibers with a length of lmm or less and lightweight aggregate with a particle size of 500 m or less 10 to  50% by weight, inorganic powder 10 to 70% by weight, binder 3 to 10% by weight, water added to adjust the water content to 5 to 15%, sheet-like mixture Forming the back layer mat by forming above, On the back layer mat, an inorganic fiber having a length of 3 to 15 mm;! To 10 wt%, a light aggregate 10 to 70 wt%, an inorganic powder 10 to 70 wt%, and a binder 5 to Having 15% by weight and water And forming a second core layer mat by forming a mixture adjusted to a moisture content of 5 to 15%,  On the two-layer mat, 10 to 70% by weight of inorganic fibers with a length of 1 mm or less, 10 to 50% by weight of lightweight aggregate with a particle size of 500 ^ 111 or less, and 10 to 70% by weight of inorganic powder And forming a third surface mat by forming a mixture having a binder of 3 to 10% by weight and water added to adjust the water content to 5 to 15%.  A method for producing an inorganic plate, comprising: a step of integrally forming the three-layer mat and the sheet-like material by a hot press.