Inorganic board and method for producing the same

Patent metadata

Field	Value
Publication number	US-11331879-B2
Application number	US-202016824257-A
Country	US
Kind code	B2
Filing date	Mar 19, 2020
Priority date	Sep 28, 2017
Publication date	May 17, 2022
Grant date	May 17, 2022

Abstract

An object of the present invention is to provide an inorganic board suitable for achieving high specific strength and high freeze-thaw resistance as well as weight reduction and a method for producing the inorganic board. An inorganic board X1 according to the present invention includes a cured layer 11 that includes an inorganic cured matrix, an organic reinforcement material dispersed therein, and a hollow body that is attached to the organic reinforcement material and is smaller than the maximum length of the organic reinforcement material. A method for producing an inorganic board according to the present invention includes a first step of preparing a first mixture through mixing of an organic reinforcement material and a hollow body smaller than the maximum length of the organic reinforcement material, a second step of preparing a second mixture through mixing of the first mixture, a hydraulic material, and a siliceous material, and a third step of forming a second mixture mat by depositing the second mixture.

First claim

The invention claimed is:

1. A method for producing an inorganic board, comprising:
a first step of preparing a first mixture through mixing of an organic reinforcement material and a hollow body smaller than a maximum length of the organic reinforcement material so that the hollow body is attached to the organic reinforcement material;
a second step of preparing a second mixture through mixing of the first mixture, a hydraulic material, and a siliceous material; and
a third step of forming a second mixture mat by depositing the second mixture, wherein the hollow body has a median size (diameter D50) of 0.05 mm to 2 mm.

2. The method for producing an inorganic board according to claim 1 , wherein in the first step, the first mixture is prepared by mixing the organic reinforcement material mixed with a waterproofing agent with the hollow body.

3. The method for producing an inorganic board according to claim 2 , wherein the waterproofing agent contains a synthetic resin.

4. The method for producing an inorganic board according to claim 1 , wherein in the first step, the first mixture is prepared by mixing the organic reinforcement material with the hollow body, and then mixing the organic reinforcement material and the hollow body with a waterproofing agent.

5. The method for producing an inorganic board according to claim 4 , wherein the waterproofing agent contains a synthetic resin.

6. The method for producing an inorganic board according to claim 1 , further comprising:
a fourth step of preparing a third mixture through mixing of a hydraulic material, a siliceous material, and an organic reinforcement material; and
at least one fifth step of forming a third mixture mat by depositing the third mixture,
wherein the organic reinforcement material in the third mixture is smaller than the organic reinforcement material in the second mixture, and
the fifth step is performed after the third step to form the third mixture mat on the second mixture mat,
the third step is performed after the fifth step to form the second mixture mat on the third mixture mat, or
the third step is performed after the fifth step to form the second mixture mat on the third mixture mat, and the fifth step is further performed to form another third mixture mat on the second mixture mat.

7. The method for producing an inorganic board according to claim 6 , wherein in the fourth step, the third mixture is prepared by mixing the organic reinforcement material mixed with a waterproofing agent containing a fatty acid with the hydraulic material and the siliceous material.

Assignees

• Nichiha Kk
• Nichtha Corp

Inventors

• Takamura Yasuhiro
• Mizuno Hiroaki

Classifications

• C04B16/02

  Cellulosic materials (cellulosic waste materials, e.g. sawdust, rice husks, C04B18/24) · CPC title

• B32B21/02

  the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard · CPC title

• B32B2325/00

  Polymers of vinyl-aromatic compounds, e.g. polystyrene · CPC title

• E04F13/18 Primary

  of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)} · CPC title

• C04B28/08

  Slag cements · CPC title