JPH0338305A - Decorative sheet for alc, manufacture of alc, and alc with decorative sheet - Google Patents

Abstract

PURPOSE:To manufacture ALC with a decorative sheet not to be release by disposing a decorative sheet constituted of a laminate formed with a printed plastic sheet and a fiber sheet and a fiber sheet on the inner surface of a frame, casting aqueous slurry mainly composed of lime, siliceous subtance and aluminum powder, foaming, curing and integrating thereon. CONSTITUTION:A decorative sheet 1 is manufactured by integrally laminating a fabric sheet 12 and a printed plastic sheet 11. The decorative sheet 1 is disposed in a frame 2 in a manner that the fiber sheet 12 may be placed on the inner surface side. Aqueous slurry is mainly composed of lime, siliceous material and aluminum powder. Aqueous slurry 3 is cast into the decorative sheet 1 disposed in the frame 2, and the aqueous slurry 3 is foamed and cured to the given hardness, and then the slurry 3 is taken out together with the decoative sheet 1, cured in the high temperature water vapor and cured completely. ALC is penetrated into the fiber sheet 12 on the rear surface of the decorative sheet 1, entangled with the fiber and integrated therein firmly.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a sheet for decorating ALC, a method for manufacturing a decorated ALC using this sheet, and the obtained ALC.

<Prior art> ALC is made by reacting an aqueous slurry containing calcareous, silica, and aluminum powders and various additives in a mold, and after reaching a certain hardness, it is removed from the mold and placed in an autoclave. It is cured and hardened. During the reaction in the mold, hydrogen gas is generated to form uniform bubbles. The obtained ALC is lightweight with an apparent specific gravity of 0.3 to 0.9, and is also heat insulating.

Due to its excellent fire resistance and strength, it is suitably used for the exterior walls of houses.

However, on the other hand, ALC has a drawback in that the surface is flat and lacks design. Japanese Patent Publication 1986-100
40, JP-A-60-141509, and JP-A-63-25284 describe methods for imparting design properties to such ALC, but all of them provide unevenness on the surface and remove the unevenness. It is limited to expressing the pattern.

There is a limit to the patterns that can be expressed using this method; for example, it is not possible to express multicolored patterns or detailed patterns.

It is clear that in order to express a multicolor pattern or a detailed pattern on ALC, it is sufficient to attach a film printed with such a pattern to AI and C. However, in this case, there are problems such as the following.

That is, ■ALC has a brittle and porous appearance, making it difficult to bond firmly with an adhesive. If a large amount of adhesive were to be infiltrated into the ALC surface to supplement the surface strength and smooth the surface for bonding, the cost would be extremely high and it would be impractical.

■The dimensional change of printed plastic film due to heat is much larger than that of ALC. For this reason, when bonded ALC is used for an outer wall, large shear stress is generated at the adhesive interface due to repeated heating and cooling over time, resulting in peeling.

■A bottom-shaped ALC generally has a length of several meters. In order to adhere a film to such a large object with a porous surface, fairly large equipment is required that cannot be used for other purposes.

<Problems to be Solved by the Invention> Therefore, the present invention integrates a printing sheet into an ALC without using an adhesive or requiring new equipment, and also absorbs shear stress caused by repeated heating and cooling. AL with decorative sheet that prevents film peeling
Manufacturing method of C, decorative sheet used therein and obtained A
The purpose is to provide LC.

Means for Solving the Problem> To achieve this object, the invention of claim (1) provides a decorative decorative sheet for ALC, which is made by laminating a printed plastic sheet and a fibrous sheet.

In addition, the invention of claim (2) provides that after this decorative sheet is placed on the inner surface of the mold, an aqueous slurry containing limestone, silica, and aluminum powder as main components is poured into the mold, and the sheet is foamed and hardened to be integrated. Provided is a method for manufacturing ALC characterized by the following.

Furthermore, the invention of claim (3) provides a foamed cured product (AL, C) mainly composed of calcareous, silicic acid, and aluminum powder.
An ALC with a decorative sheet formed by laminating a printed plastic sheet with a fibrous sheet interposed on the surface of the ALC, characterized in that the foamed cured product has penetrated into the interior of the fibrous sheet. Provide ALC.

<Specific Description of the Invention> The plastic sheet according to the present invention not only protects the surface of the ALC, but also imparts design to the ALC through the printed pattern applied to the plastic sheet. As the plastic sheet, polyolefins such as polyethylene, polypropylene, or polystyrene, polycarbonate, polyvinyl chloride, polyamide, polyester, polyacrylonitrile, acrylonitrile-butadiene-styrene copolymer, etc. can be used.

Printing can be done by gravure printing in a conventional manner. Any pattern may be used, but a stone pattern, for example, is suitable.

The fibrous sheet has a swallow's number of voids, and the ALC enters into these voids and becomes entangled with the fibers, fixing them firmly.The remaining voids also absorb and absorb shear stress during repeated cold and hot cycles to prevent peeling. To prevent. Examples of such fibrous sheets include paper-woven fabrics and non-woven fabrics.

As the paper, titanium paper, coated paper, thin paper, synthetic paper made of base pulp, mixed paper of natural valve and base pulp, etc. can be used.

Woven fabrics and non-woven fabrics include polyester, polyamide,
polyacrylonitrile, polyethylene polypropylene,
In addition to knitted or nonwoven fabrics made from thermoplastic fibers such as aromatic polyamide, knitted or nonwoven fabrics made from inorganic fibers such as glass fibers, carbon fibers, and ceramic fibers, or natural fibers such as cellulose fibers and protein fibers can be used. .

A fibrous sheet (+21 is laminated and integrated with a printed plastic sheet (I+) to form a decorative sheet (1) (Figure 1), a fibrous sheet 0 is a plastic sheet (1)
It may be laminated on either the printed side or the non-printed side of 1).

The surface of the ALC with decorative sheet, which is the final product, will be the opposite side to the laminated surface of the fibrous sheet 021, so if the fibrous sheet 021 is laminated on the printed surface, the ALC surface will be the non-printed surface. , a pattern with excellent gloss can be obtained. When the fibrous sheet θ force is laminated on the non-printing surface, the ALC surface becomes the printing surface and a matte pattern is obtained.

The fibrous sheet 02) and the plastic sheet 01) can be laminated using an adhesive. If necessary, the surfaces of either sheet may be subjected to a treatment such as corona treatment or anchor coating treatment, and then bonded together with an adhesive. Urethane adhesive can be used as the adhesive.

In addition, fibrous sheet 0 and plastic sheet (11)
The two may be thermally fused by overlapping and hot pressing, but care should be taken to maintain sufficient voids in the fibrous sheet 0211.

Note that another thermoplastic sheet may be laminated on the surface of the plastic sheet 00 to form a decorative sheet (1).

Examples include weather-resistant sheets such as fluororesin sheets, silicone acrylic resin sheets, urethane resin sheets, and weather-resistant polyester sheets. By using such a weather-resistant sheet, when the final product ALC is used outdoors, it can be protected from the effects of ultraviolet rays, wind and rain, etc.

The resulting decorative sheet (1) is placed in a mold (2).

The formwork (2) may be made of a known iron plate. For example, the length is 6m.

The formwork is 1.5 m wide and 0.6 m deep. Formwork (2
) is preferably provided with holes for air venting.

The decorative sheet (1) is arranged so that the fibrous sheet 0 force is on the inner surface side. This is to pour slurry, which will be described later, into the voids of the fibrous sheet.

As shown in FIG. 2, it is desirable that the decorative sheet (1) be placed along the inner surface of the formwork (2) so as to be in close contact therewith.

The aqueous slurry according to the present invention has limestone, silica, and aluminum powder as main components.

Calcareous material is a hardening agent for ALC, and quicklime, slaked lime, or cement such as Portland cement can be used.

The silica material is pozzolan or fine aggregate, and powders such as silica sand and silica stone, clay, finely ground tiles, slag powder, volcanic ash, etc. can be used.

The aluminum powder reacts with limestone in the presence of water to generate hydrogen gas and foam the slurry. A particle size of 10 to 3000 μm is desirable.

In addition, additives can be added to the aqueous slurry, such as foaming promoters such as sodium hydroxide, dispersants such as surfactants, foam stabilizers such as saponin, zinc oxide and zinc sulfate, etc. antifreeze agents, etc.

Calcareous material and silicic acid material are mixed at a weight ratio of 1:1 to 1:5. The ratio is preferably 1:1 to 1:3.

The aluminum powder may be added in an amount of 0.001 to 0.5 parts by weight per 100 parts by weight of the total amount of calcareous and silicic substances.

For calcareous and silicic acid, first add water and stir and mix well, then add aluminum powder and mix.Additives are added at the same time as silicic acid.

The aqueous slurry (3) thus obtained was poured into the formwork (2).
) into the decorative sheet (1) (Fig. 3) 0 Next, add reinforcing bars as reinforcing material, and pour it into the decorative sheet (1) placed in the container (Fig. 3).
The aqueous slurry (3) is left to stand for 0 hours, and at the same time as the aqueous slurry (3) is foamed and cured to a certain level of hardness at zero foaming pressure, the slurry (3) penetrates into the interior of the fibrous sheet 02).
Gets entangled in fibers.

After curing to a certain level of hardness, the slurry (3) is taken out together with the decorative sheet (1) and cured in an autoclave with high temperature steam to be completely cured. 15 as high temperature water vapor
Use steam at 0-200°C. The pressure is between 5 and 20 atmospheres. The curing time is approximately 5 to 15 hours.

Finally, finish by trimming the decorative sheet (1) that protrudes around the ALC.

The obtained ALC has the decorative sheet (1) integrated on its surface, and the ALC penetrates into the inside of the decorative sheet (1) (the fibrous sheet on the back side) Q21 and is entangled with the fibers to become firmly integrated. It is.

<Example> After a stone grain pattern was applied to a polyester film by gravure printing, a polyethylene nonwoven fabric was laminated to the printed surface. Urethane adhesive was used for adhesion.

The obtained decorative sheet was cut into a sheet with a length of 6 m, a width of 1.5 m, and a depth of 0.5 m.
It was placed in a 6 m steel plate formwork. The decorative sheet was placed so that the polyester film surface faced the formwork, and was bent so as to be in substantially close contact with the formwork.

Next, an aqueous slurry of 11 below was poured.

Water-based slurry Portland cement 2 parts quicklime
I Finely ground silica stone 7 Aluminum powder 0.008 Water 6
Note that the aqueous slurry was prepared by mixing water with Portland cement, quicklime, and crushed silica stone and thoroughly stirring the slurry, followed by mixing and stirring the alfresium powder and immediately pouring the mixture into the slurry.

When the slurry was left in this state for about 8 hours, the aqueous slurry foamed and hardened to have shape retention properties.

Then, we took out the hardened slurry along with the decorative sheet.
8 with saturated steam at 180'c in an autoclave.
It was cured for some time to completely harden.

Finally, it was trimmed to obtain an ALC with a decorative sheet.

In this ALC, the cured product of the aqueous slurry entered the inside of the polyethylene nonwoven fabric and became entangled with the fibers, resulting in extremely strong adhesion.

It also withstood repeated cold and heat cycles without peeling.

<Effects of the Invention> According to the invention of claim (3), it is possible to provide an ALC with a decorative sheet in which the decorative sheet having a multicolored pattern or a fine pattern is firmly integrated with the ALC, and does not peel off over time.

According to the invention of claim (2), the ALC with decorative sheet can be manufactured without making any changes to the existing ALC manufacturing equipment.

Moreover, according to the invention of claim (1), a decorative sheet used for manufacturing such an ALC with a decorative sheet can be obtained.

[Brief explanation of drawings]

The drawings show embodiments of the present invention, and FIGS. 1 to 3 are sectional views showing the manufacturing process, and FIG. 4 is a perspective view of the ALC. (1) Decorative sheet 01) Plastic sheet (+2) Fibrous sheet (2) Formwork (3
)...Aqueous slurry (3゛)...ALC special
Applicant: Toppan Printing Co., Ltd. Representative: Kazuo Suzuki Figure 1 Figure 2 Figure 3

Claims (3)

[Claims] (1) A decorative sheet for ALC made by laminating a printed plastic sheet and a fibrous sheet. (2) After the decorative sheet according to claim (1) is placed on the inner surface of the mold, an aqueous slurry mainly composed of calcareous, silicic acid, and aluminum powder is poured into the mold, and the sheet is foamed and hardened to be integrated. Features ALC manufacturing method. (3) ALC with a decorative sheet formed by laminating a printed plastic sheet via a fibrous sheet on the surface of a foamed cured product (ALC) mainly composed of calcareous, silicic acid, and aluminum powder, An ALC with a decorative sheet, characterized in that the foamed cured product is embedded inside a fibrous sheet.