Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Patent
1994-02-02
1997-07-15
McCamish, Marion E.
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
428218, 4283139, 4283179, 4283191, 264113, 264120, 264122, 264333, B32B 522, B32B 530, B32B 3120
Patent
active
056481543
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to an inorganic constructional board for use as wall backing material or the like, and a method of manufacturing the same.
BACKGROUND ART
Generally, an inorganic constructional board used as wall backing material or the like are required to have various performance characteristics including nail-holding strength, bending strength and impact strength of more than definite values, fire resistance, water and humidity resistance, severability and the like. Therefore, a plaster board has been conventionally used for the inorganic construction board. However, the plaster board has a specific gravity of more than 0.74 and is required to have a certain degree of thickness in order to provide a desired bending strength. This will necessitate the use of a large-size plaster board, which involves excessive weight that is inconvenient from the standpoints of transport and work execution.
Further, Both surfaces of the plaster board are made of paper, which result in the following disadvantages. Once the plaster board has absorbed water, the strength is noticeably reduced. Moreover, when the paper of both surfaces of the plaster board has been separated, the strength, water resistance and the like are extremely deteriorated.
Therefore, such plaster board cannot be used in a highly humid underground location, kitchen having a source of vapor generation or the like. For this reason, instead of the plaster board, a calcium silicate board which has superior water and humidity resistance is used in such locations.
However, the calcium silicate board has a large specific gravity (0.9 or more), which involves great weight per piece and inconvenience from the standpoints of transport and work execution.
Although the calcium silicate board is used as sheathing material, for example, eaves ceiling by virtue of their excellent resistance to water and humidity, there is a problem that such board cannot be used in a very cold region because the freezing and thawing endurance of the board is of the order of about 50 cycles (which corresponds to two to three years of use).
DISCLOSURE OF THE INVENTION
In view of the foregoing problems, it is a first object of the present invention to provide an inorganic constructional board which has performance characteristics equivalent to or better than any plaster board, which has lighter weight and greater resistance to water and humidity than the plaster board, and which has lighter weight and higher freezing and thawing endurance than any calcium silicate board.
Aforesaid first object is achieved by the provision of an inorganic constructional board in accordance with the invention which comprises a middle layer portion formed mainly of inorganic foamed material with an adequate quantity of fibrous material and binder added thereto, and outer layer portions placed on both surfaces of the middle layer portion, the outer layer portion being formed mainly of mineral fiber material and inorganic powder material with binder added thereto.
The inorganic foamed material which forms the middle layer portion is intended to reduce the weight, maintaining the compressive strength. Such material may be, for example, perlite, "Shirasu" foamed material, silica flour, or foamed glass material. These material may be used alone or in combination of two or more kinds.
The proportion of such inorganic foamed material in the middle layer portion is preferably 50 to 95 wt %. If the proportion is less than 50 wt %, no effective reduction in specific gravity is obtainable in spite of an improvement in the strength as a result of relative increase of the proportion of the fibrous material. If the proportion is more than 95 wt %, it is difficult to obtain a uniform layer formation incorporating the fibrous material.
The fibrous material used in forming the middle layer portion is to interconnect particles of the inorganic foamed material. For such fibrous material may be enumerated, for example, mineral fibers, such as rock wool, slag wool or the like; synthetic resi
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Fujiwara Hisashi
Koh Akio
Kurosaki Kiyoshi
Masamoto Shigezoh
Shutoh Keiji
Copenheaver Blaine R.
Daiken Trade & Industry Co. Ltd.
McCamish Marion E.
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