Porous glass particle-containing building material, and manufacturing method of the same

Abstract

To provide a porous glass particle-containing building material having excellent machinability.SOLUTION: A porous glass particle-containing building material comprises a support material and a function layer formed on a surface of the support material. The function layer contains porous glass particles and a binder resin. In the function layer, the porous glass particles are bonded together via the binder resin and a part of a surface of the porous glass particles is exposed without being covered with the binder resin.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a building material containing porous glass particles and a method for manufacturing the same.

Background Art

[0002] Conventionally, it has been studied to impart various functions to interior materials constituting living spaces or exterior materials of buildings. For example, the interior paint composition described in Patent Document 1 is used for interior materials or ceiling materials of buildings, and has a basic composition of (A) a synthetic resin emulsion, (B) moisture-absorbing and -releasing polymer particles, and (C) an inorganic lightweight aggregate. According to the invention described in Patent Document 1, since it has high water vapor absorption and release properties, is excellent in humidity control in a room, and exhibits excellent sound absorption performance in the low-frequency range, it is said to have a great effect on improving the indoor environment such as preventing condensation and suppressing the intrusion of noise.

[0003] In paragraph

[0030] of Patent Document 1, it is described that “the component (C) is not particularly limited as long as it is an inorganic lightweight aggregate having an average particle diameter of 30 μm or more. For example, foams of natural stones such as obsidian, pearlite, vermiculite, pumice, and shirasu, and foamed granular materials of various ceramics such as glass and fly ash” can be used. Paragraph

[0036] describes that the above interior paint composition may contain a porous powder in addition to the above components (A) to (C). Specific examples of the porous powder include charcoal, bamboo charcoal, sawdust, pulp waste liquid, coconut shells, coal, coke, etc.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] As described above, the coating composition described in Patent Document 1 contains "(B) moisture-absorbing and -releasing polymer particles" and "(C) inorganic lightweight aggregate" as essential components. The inventors have found that by replacing at least a part of the aggregate with porous glass particles, it is possible to aim for weight reduction of building materials and improve the workability of cutting building materials.

[0006] The present disclosure provides a building material containing porous glass particles having excellent workability of cutting and a method for manufacturing the same.

Means for Solving the Problems

[0007] One aspect of the present disclosure relates to a method for manufacturing a building material containing porous glass particles. This manufacturing method includes: (a) a step of preparing a coating liquid containing porous glass particles in a water-absorbed state, a binder resin, and water; (b) a step of forming a coating film of the coating liquid on the surface of a first base material; and (c) a step of drying the coating film by heating to obtain a functional layer from the coating film. In the step (c), the porous glass particles are bonded to each other via the binder resin, and at least a part of the water in the porous glass particles is released to the outside with heating, so that a part of the surface of the porous glass particles is exposed without being covered with the binder resin.

[0008] In the step (a), by using porous glass particles in a water-absorbed state in advance, it is possible to suppress the binder resin from entering the voids of the porous glass particles and closing the voids even when the porous glass particles are in contact with the binder resin in the process of preparing the coating liquid. Further, in the step (c), by releasing at least a part of the water in the porous glass particles to the outside with heating, it is also possible to suppress the binder resin from entering the voids of the porous glass particles and closing the voids in this step. Thereby, for example, a liquid medicine containing components such as a fragrance and a deodorant can be held in the functional layer for a long time, and the effect of the medicine can be exhibited over a long period.

[0009] The coating liquid may further contain an aggregate. The functional layer formed through step (c) is composed of porous glass particles, a binder resin, and an aggregate that is blended as needed. By using porous glass particles with a lower density than the aggregate, the weight of the functional layer can be reduced compared to the case where the functional layer is composed of the aggregate and the binder resin. In addition, by using porous glass particles and the binder resin in combination, the machinability is improved.

[0010] The manufacturing method may further include, in this order, a step of obtaining a laminate in which a second base material is bonded onto the surface of the coating film formed through step (b), and the first base material, the coating film, and the second base material are arranged in this order from bottom to top; a step of inverting the laminate; and a step of peeling the second base material from the functional layer after forming the functional layer by performing step (c) on the laminate. In the process of forming the functional layer from the coating film, the binder resin is likely to settle due to gravity. Therefore, by inverting the laminate as described above, the vicinity of the second base material in the functional layer is likely to become a region rich in the binder resin compared to the vicinity of the first base material. By peeling the second base material, a surface relatively rich in the binder resin can be made the outermost surface of the building material.

[0011] One aspect of the present disclosure relates to a building material containing porous glass particles. This building material includes a support material and a functional layer formed on the surface of the support material. The functional layer contains porous glass particles and a binder resin. In the functional layer, the porous glass particles are bonded to each other via the binder resin, and a part of the surface of the porous glass particles is exposed without being covered by the binder resin.

[0012] The functional layer includes porous glass particles and a binder resin that binds adjacent porous glass particles to each other, and a part of the surface of the porous glass particles is exposed without being covered by the binder resin. The voids of the porous glass particles are suppressed from being blocked by the binder resin. Therefore, as described above, the liquid medicine can be retained in the functional layer for a long time, and the effect of the medicine can be exhibited over a long period. Further, the functional layer may further include an aggregate. By including the porous glass particles, the binder resin, and the aggregate that is blended as necessary, the weight of the functional layer is reduced compared to the case where the functional layer is composed of the aggregate and the binder resin. Further, by including both the porous glass particles and the binder resin, sufficient machinability is exhibited.

Effects of the Invention

[0013] According to the present disclosure, there are provided a porous glass particle-containing building material having excellent machinability and a method for manufacturing the same.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0015] Hereinafter, embodiments of the present disclosure will be described. The following embodiments are examples for explaining the present disclosure and are not intended to limit the present disclosure to the following content. The upper limit value or the lower limit value of the numerical range explicitly stated in this specification may be replaced with any value shown in the examples. Further, the individually described upper limit value and the lower limit value may be arbitrarily combined. The materials or components exemplified in this specification can be used alone or in combination of two or more unless otherwise specified. In the description, the same reference numerals are given to the same elements or elements having the same function, and duplicate descriptions are omitted. Also, the positional relationships such as up, down, left, and right used in the description are based on the positional relationships shown in the drawings unless otherwise specified.

[0016] [Building material containing porous glass particles] FIG. 1 is a cross-sectional view schematically showing a building material containing porous glass particles (hereinafter simply referred to as "building material") according to the present embodiment. The building material 10 shown in FIG. 1 is a sheet-shaped building material, and the overall thickness is, for example, 0.5 to 15 mm. The building material 10 includes a support material 1A and a functional layer 5A formed on the surface of the support material 1A. The support material 1A may be a sufficiently thin film or sheet, and specific examples include non-woven fabric, woven fabric, resin film, and metal mesh. Examples of the material of the non-woven fabric or the woven fabric include glass and synthetic resin. A non-woven fabric is particularly suitable as the support material 1A. By using a non-woven fabric as the support material 1A, the building material 10 can be imparted flexibility, and there are advantages that the functional layer is easily dried and the adhesion between the functional layer and the support material is improved.

[0017] As shown in the enlarged view in FIG. 1, the functional layer 5A is composed of porous glass particles 6, aggregates 7, and a binder resin 8. The binder resin 8 binds adjacent aggregates 7 together. In the present embodiment, a plurality of cells C are defined by the aggregates 7 and the binder resin 8, and the porous glass particles 6 are respectively accommodated in these cells C. As shown in FIG. 1, voids are formed between the porous glass particles 6 and the aggregates 7, and also between the aggregates 7. That is, the binder resin 8 covers the aggregates 7, and at least a part of the binder resin 8 on the aggregates 7 is in contact with a part of the surface of the porous glass particles 6. Thereby, the porous glass particles 6 are held between the aggregates 7 and voids are formed in the cells C.

[0018] A part of the surface of the porous glass particles 6 is exposed without being covered by the binder resin 8. As will be described later, in the process of forming the functional layer 5A, the voids of the porous glass particles 6 are suppressed from being blocked by the binder resin 8. Thereby, for example, a liquid medicine containing components such as a fragrance and a deodorant can be held in the functional layer 5A for a long time, and the effect of the medicine can be expressed over a long period.

[0019] The porous glass particles 6 are obtained, for example, by pulverizing a glass foam. From the viewpoint of effective utilization of waste, at least a part of the many porous glass particles 6 contained in the functional layer 5A may be composed of waste glass. The particle size of the porous glass particles 6 may be appropriately set according to the thickness of the functional layer 5A. The particle size of the porous glass particles 6 is, for example, 0.0001 to 25 mm, preferably 0.0001 to 4 mm. The pulverized product of the glass foam may be classified by a sieve, and for example, the pulverized product that has passed through a mesh with an opening of 4 mm may be used as the porous glass particles 6. Commercially available products may be used as the porous glass particles 6. Specific examples of commercially available products include porous glass foam material (trade name: Porous α (registered trademark), manufactured by Tiger Chiyoda Material Co., Ltd.), and glass foam lightweight material (trade name: Super Sol, manufactured by the Glass Foam Material Business Cooperative).

[0020] The content ratio of the porous glass particles 6 in the functional layer 5A is preferably 10 to 50% by mass, more preferably 20 to 40% by mass, based on the mass of the functional layer 5A. When this value is 10% by mass or more, the weight reduction of the functional layer 5A can be sufficiently achieved, and the water retention property of the porous glass particles 6 tends to be sufficiently exhibited. On the other hand, when this value is 50% by mass or less, the tendency is that the porous glass particles 6 can be sufficiently suppressed from falling off the functional layer 5A.

[0021] As the aggregate 7, for example, silica sand such as river sand and sea sand; natural stone, crushed natural stone, colored aggregate, cold water sand, and ceramic crushed particles can be used. The particle size of the aggregate 7 may be appropriately set according to the thickness of the functional layer 5A. The particle size of the aggregate 7 may be, for example, 150 to 800 μm.

[0022] The content ratio of the aggregate 7 in the functional layer 5A is preferably 50 to 90% by mass, more preferably 60 to 80% by mass, based on the mass of the functional layer 5A. When this value is 50% by mass or more, the cells C tend to be sufficiently formed in the functional layer 5A. On the other hand, when this value is 90% by mass or less, the weight reduction of the functional layer 5A tends to be achieved.

[0023] The binder resin 8 may be a thermosetting resin or a thermoplastic resin. When the binder resin is a thermosetting resin, the binder resin 8 in the functional layer 5A is exactly "the cured product of the thermosetting resin", but here, for the sake of convenience, the "cured product of the thermosetting resin" is also referred to as the "binder resin".

[0024] The content ratio of the binder resin 8 in the functional layer 5A is preferably 6 to 12% by mass, based on the mass of the functional layer 5A. When this value is 6% by mass or more, the binder resin 8 tends to firmly fix the aggregates 7 to each other. On the other hand, when this value is 12% by mass or less, the amount of heat generated even when the functional layer 5A burns can tend to be sufficiently small.

[0025] The total content rate of the porous glass particles 6, the aggregate 7, and the binder resin 8 in the functional layer 5A is, for example, 90% by mass or more, and may be 95% by mass or more, or 98% by mass or more, based on the mass of the functional layer 5A. The upper limit value of this value is, for example, 99% by mass, and may be 99.5% by mass or 100% by mass. As components other than the above components in the functional layer 5A, various additives can be mentioned. Specific examples of the additives include pigments, thickeners, plasticizers, dispersants, and preservatives.

[0026] In the present embodiment, the thickness of the functional layer 5A is preferably 10 mm or less. By using a resin having flexibility as the binder resin, flexibility can be imparted to the building material 10. Examples of the resin having flexibility include acrylic resins and urethane resins. In addition, when it is not necessary to impart flexibility to the building material 10, as the binder resin, in addition to the above resins, for example, epoxy resins and polyester resins may be used. The thickness of the functional layer 5A may be, for example, 0.5 to 7 mm, or may be 1 to 5 mm.

[0027] [Method for manufacturing a building material containing porous glass particles] Next, the manufacturing method of the building material 10 will be described. The building material 10 can be manufactured through the following steps. (a) A step of preparing a coating liquid containing water-absorbed porous glass particles, an aggregate, a binder resin, and water. (b) A step of forming a coating film 3A of the coating liquid on the surface 1f of the support 1A (the first base material) (see Figure 2). (c) A step of forming a functional layer 5A on the surface 1f of the support 1A by heating the coating film 3A.

[0028] Hereinafter, each step will be described. <Step (a)> (a) The process is the process of preparing the coating liquid as described above. In the process (a), by using the porous glass particles in a pre-absorbed state, in the process of preparing the coating liquid, it is possible to suppress the binder resin from invading the voids of the porous glass particles and closing the voids even when the porous glass particles are in contact with the binder resin.

[0029] From the viewpoint of efficiently preparing the coating liquid, the process (a) may include the steps of: (a1) preparing a first slurry containing water and porous glass particles; (a2) preparing a second slurry containing a resin emulsion containing a binder resin and an aggregate; and (a3) mixing the first slurry and the second slurry. When the slurries are mixed, there is an advantage that a sufficiently uniform coating liquid can be prepared in a short time. As the resin emulsion, a commercially available product may be used. Specific examples of commercially available products include acrylic resins (trade name: Talkril BCX-8111, manufactured by Toyochem Co., Ltd., "Talkril" is a registered trademark).

[0030] The content of the porous glass particles (in the water-absorbed state) in the coating liquid according to the present embodiment is, for example, 10 to 50% by mass, preferably 20 to 40% by mass based on the mass of the coating liquid. When this value is 10% by mass or more, it tends to be easy to process into a sheet shape or a panel shape. On the other hand, when it is 50% by mass or less, it also tends to be easy to process into a sheet shape or a panel shape.

[0031] The content of the aggregate in the coating liquid is, for example, 40 to 80% by mass, preferably 50 to 70% by mass based on the mass of the coating liquid. When this value is 40% by mass or more, it tends to be easy to form into a sheet shape or a panel shape. On the other hand, when it is 80% by mass or less, it also tends to be easy to process into a sheet shape or a panel shape.

[0032] The content rate of the binder resin in the coating liquid is, based on the mass of the coating liquid, for example, 6 to 12 mass%. When this value is 6 mass% or more, the binder resin tends to firmly adhere the aggregates to each other. On the other hand, when it is 12 mass% or less, a functional layer 5A with a sufficiently small amount of heat generated even when burned can be formed.

[0033] <(b) step> (b) step is a step of forming a coating film 3A of the coating liquid on the surface 1f of the support 1A as described above. FIG. 2 is a cross-sectional view schematically showing a state where the coating film 3A is formed on the surface of the support 1A. The method for forming the coating film 3A is not particularly limited. For example, the coating film 3A may be formed by a dip coating method, a curtain coating method, a sponge roll method, or coating with a brush. The thickness of the coating film 3A may be adjusted so that a functional layer 5A with a desired thickness is formed after drying.

[0034] <(c) step)> (c) step is a step of forming a functional layer 5A on the surface 1f of the support 1A by heating the coating film 3A as described above. For example, the functional layer 5A is formed by heating the coating film 3A at a temperature of 70 to 100°C for 60 to 180 minutes. By heating the coating film 3A under such conditions, the water contained in the coating film 3A can be sufficiently removed by vaporization. Also, if the binder resin is a thermosetting resin, the binder resin can be sufficiently cured.

[0035] In the (c) step, the aggregates 7 are bonded to each other via the binder resin 8, and at least a part of the water in the porous glass particles 6 is released to the outside as the heating progresses. It is presumed that as the water contained in the coating film 3A decreases, the surface of the porous glass particles 6 is covered with the binder resin 8. In this process, by releasing the water in the porous glass particles 6 to the outside, it is possible to suppress the binder resin 8 from entering the voids of the porous glass particles 6 and closing the voids, and to suppress the entire surface of the porous glass particles 6 from being covered with the binder resin 8.

[0036] As described above, the embodiments of the present disclosure have been described in detail. However, the present invention is not limited to the above embodiments. For example, in the above embodiments, the sheet-like building material 10 has been exemplified. However, the building material according to the present disclosure is not limited to a sheet shape and may be in a panel shape. FIG. 3 is a cross-sectional view schematically showing a building material according to another embodiment. The building material 20 shown in FIG. 3 is a panel-shaped building material, and the overall thickness is, for example, 5 to 20 mm. The building material 20 has the same configuration as the above-described building material 10 except that it is in a panel shape. Hereinafter, the differences between the building material 20 and the building material 10 will be mainly described.

[0037] The building material 20 includes a support material 1B and a functional layer 5B formed on the surface of the support material 1B. When flexibility is not required for the building material 20, the support material 1B may be, for example, a plate material having a thickness of about 5 to 15 mm. Specific examples of the material of the plate material include wood, synthetic resin, metal, gypsum board, and stone. The thickness of the functional layer 5B is preferably 10 mm or less. The binder resin 8 may or may not have flexibility, and as the binder resin, for example, an acrylic resin, a urethane resin, an epoxy resin, or a polyester resin can be used. The thickness of the functional layer 5B may be, for example, 1 to 10 mm or 2 to 7 mm. In the case of a panel shape, the aggregate may not be provided.

[0038] Further, in the above embodiment, an aspect in which after forming the coating film 3A on the support material 1A in the step (b), the step (c) is carried out as it is has been exemplified. However, after inverting the coating film upside down after the step (b), the step (c) may be carried out. FIG. 4(a) is a cross-sectional view schematically showing a laminate after the step (b) is carried out. The laminate 25 shown in FIG. 4(a) includes a first base material 1 and a coating film 3 formed on the surface of the first base material 1. FIG. 4(b) is a cross-sectional view schematically showing a state in which a second base material 2 is attached to the first surface 3a of the coating film 3. In the laminate 26 shown in the figure, the first base material 1, the coating film 3, and the second base material 2 are arranged in this order from bottom to top. Note that the first surface 3a is the surface that was positioned upward in the process of forming the coating film 3.

[0039] FIG. 4(c) is a cross-sectional view schematically showing a state in which the laminate 26 is turned upside down. The step (c) is performed on the laminate 26 in this state. By performing the step (c), the coating film 3 becomes the functional layer 5. In the process of forming the functional layer 5 from the coating film 3, the binder resin is likely to settle due to gravity. Therefore, the vicinity of the first surface 5a of the functional layer 5 is likely to be a region rich in the binder resin as compared with the vicinity of the second surface 5b. Note that the first surface 5a is the surface that was located downward and in contact with the second base material 2 in the process of forming the functional layer 5 from the coating film 3.

[0040] Thereafter, by peeling the second base material 2, the first surface 5a that is relatively rich in the binder resin can be made the outermost surface of the building material 30 (see FIG. 4(d)). Since the porous glass particles 6 near the first surface 5a tend to be covered with the binder resin as compared with the porous glass particles 6 near the second surface 5b, it is presumed that the water retention property of the building material 30 is lower than that of the building materials 10 and 20. On the other hand, since the vicinity of the outermost surface (the first surface 5a) of the building material 30 is resin-rich, there is an advantage that the porous glass particles 6 and the aggregate 7 can be more highly suppressed from falling off the building material 30.

[0041] In the above embodiment, an aspect in which the coating liquid contains the aggregate and forms a functional layer containing the aggregate is exemplified, but the coating liquid may not contain the aggregate and may form a functional layer not containing the aggregate. In this case, the porous glass particles are bonded to each other via the binder resin, and a part of the surface of the porous glass particles is exposed without being covered with the binder resin.

[0042] In the above embodiment, an aspect of using the first slurry and the second slurry is exemplified, but instead of the first slurry and the second slurry, a third slurry may be used. The third slurry may contain, for example, a resin emulsion containing a binder resin, porous glass particles, and an aggregate. When using the third slurry, water and a resin curing agent may be mixed into the third slurry to form a functional layer.

[0043] The present disclosure relates to the following matters. [1] A step of preparing a coating liquid containing porous glass particles in a water-absorbed state, a binder resin, and water; (b) A step of forming a coating film of the coating liquid on the surface of a first substrate; (c) A step of drying the coating film by heating to obtain a functional layer from the coating film; comprising (c) In the step, the porous glass particles are bonded to each other via the binder resin, and at least a part of the water in the porous glass particles is discharged to the outside with heating, so that a part of the surface of the porous glass particles is exposed without being covered by the binder resin. A method for manufacturing a building material containing porous glass particles. [2] The method for manufacturing a building material containing porous glass particles according to [1], wherein the coating liquid further contains an aggregate. [3] The step (a) includes a step of preparing a first slurry containing water and the porous glass particles, a step of preparing a second slurry containing a resin emulsion containing the binder resin and the aggregate, and a step of mixing the first slurry and the second slurry. The method for manufacturing a building material containing porous glass particles according to [2]. [4] The step (a) includes a step of preparing a third slurry containing a resin emulsion containing the binder resin, the porous glass particles, and the aggregate, and a step of mixing the third slurry, a resin curing agent, and water. The method for manufacturing a building material containing porous glass particles according to [2]. [5] In the step (c), the functional layer is formed by heating the coating film at a temperature of 70 to 100 °C for 60 to 180 minutes. The method for manufacturing a building material containing porous glass particles according to any one of [1] to [4]. [6] A step of bonding a second substrate on the surface of the coating film formed through the step (b) to obtain a laminate in which the first substrate, the coating film, and the second substrate are arranged in this order from bottom to top; A step of inverting the top and bottom of the laminate; After performing the step (c) on the laminate to form the functional layer, a step of peeling the second substrate from the functional layer; The method for manufacturing a porous glass particle-containing building material according to any one of [1] to [5], further including in this order. [7] A support material, A functional layer formed on the surface of the support material, Comprising, The functional layer contains porous glass particles and a binder resin, In the functional layer, the porous glass particles are bonded to each other via the binder resin, and a part of the surface of the porous glass particles is exposed without being covered by the binder resin. A porous glass particle-containing building material. [8] The porous glass particle-containing building material according to [7], wherein the functional layer further contains an aggregate. [9] The porous glass particle-containing building material according to [7] or [8], wherein the content of the porous glass particles in the functional layer is 10 to 50% by mass based on the mass of the functional layer.

[10] The porous glass particle-containing building material according to any one of [7] to [9], wherein the content of the binder resin in the functional layer is 6 to 12% by mass based on the mass of the functional layer.

[11] The porous glass particle-containing building material according to any one of [7] to

[10] , wherein the support material is a non-woven fabric.

[12] The porous glass particle-containing building material according to any one of [7] to

[11] , wherein the thickness of the functional layer is 5 mm or less.

[13] The porous glass particle-containing building material according to any one of [7] to

[10] , wherein the support material is a plate material.

[14] The porous glass particle-containing building material according to any one of [7] to

[10] and

[13] , wherein the thickness of the functional layer is 10 mm or less.

[15] The porous glass particle-containing building material according to any one of [7] to

[14] , wherein at least a part of the large number of porous glass particles contained in the functional layer is composed of waste glass.

Example

[0044] Hereinafter, the present disclosure will be described in more detail based on examples and comparative examples. Note that the present invention is not limited to the following examples.

[0045] (Example 1) By the "Aggregate Sieving Test Method" specified in JIS A 1102:2014, porous glass particles with a minimum diameter of 1 mm or less (density: 1.0 to 1.6 g / cm 3 ) and water were mixed to obtain a first slurry. On the other hand, an aggregate with a particle size of 1 mm or less (material: calcium carbonate), an acrylic resin emulsion, and a resin curing agent (isocyanate curing agent) were mixed to obtain a second slurry. A coating liquid was obtained by mixing the first slurry and the second slurry. The content of each component in the coating liquid (based on the mass of the coating liquid) was as follows. Content of porous glass particles (in the water-absorbed state): 20% by mass Content of aggregate: 60% by mass Content of binder resin: 7% by mass Content of water: 13% by mass

[0046] The coating liquid was applied onto a glass nonwoven fabric, a polyethylene terephthalate film was placed thereon, and a roller pressure was applied to form a coating film with a thickness of 1 mm. It was inverted and placed in an oven and heated at a temperature of 80°C for 150 minutes. Thereby, the moisture in the coating film was removed and the acrylic resin was thermally cured to form a functional layer. The content of each component in the functional layer (based on the mass of the functional layer) was as follows. Content of porous glass particles (in the dried state): 21% by mass Content of aggregate: 71% by mass Content of binder resin: 8% by mass

[0047] The polyethylene terephthalate film was peeled off from the functional layer to obtain a building material according to this example. This building material was 300 mm in length, 300 mm in width, and 1 mm in thickness.

[0048] (Example 2) Using the "Aggregate Sieving Test Method" specified in JIS A 1102:2014, porous glass particles with a minimum diameter of 1 mm or less (density: 1.0 to 1.6 g / cm 3 ) were mixed with aggregates with a particle diameter of 1 mm or less (material: calcium carbonate) and an acrylic resin emulsion to obtain a third slurry. The third slurry was mixed with a resin curing agent (isocyanate curing agent) and water. Fine bubbles were generated from the water-absorbed glass foam, and a coating liquid containing fine bubbles was obtained. The content rate (based on the mass of the coating liquid) of each component in the coating liquid was as follows. Content rate of porous glass particles (in the water-absorbed state): 20% by mass Content rate of aggregates: 60% by mass Content rate of binder resin: 7% by mass Content rate of water: 13% by mass

[0049] The coating liquid was placed on the gypsum board, and the excess portion was scraped off with a squeegee to form a 5-mm coating film. It was then directly placed in an oven and heated at a temperature of 80°C for 150 minutes. This removed the moisture in the coating film and thermally cured the acrylic resin to form a functional layer. The content rate (based on the mass of the functional layer) of each component in the functional layer was as follows. Content rate of porous glass particles (in the dried state): 21% by mass Content rate of aggregates: 71% by mass Content rate of binder resin: 8% by mass

[0050] (Example 3) Building materials were produced in the same manner as in Example 1, except that the aggregates were replaced with porous glass particles.

[0051] (Example 4) Building materials were produced in the same manner as in Example 2, except that the aggregates were replaced with porous glass particles.

[0052] (Comparative Example 1) Building materials were produced in the same manner as in Example 1, except that the second slurry was not used and the first slurry was used as the coating liquid.

[0053] The cutting processability and bending processability of the building materials according to the examples and comparative examples were evaluated by the following methods.

[0054] <Evaluation of cutting processability> The produced building materials were cut with a cutter, and those that could be cut were marked as "○", while those that could not be cut were marked as "×".

[0055] <Evaluation of bending processability> The produced building materials were bent to R40, and those that did not crack were marked as "○", while those that cracked were marked as "×".

[0056]

Table 1

[0057] In Examples 1 to 4, since the volume can be increased by the glass foam, the amount of acrylic resin used can also be reduced. Therefore, the calorific value can be lowered and the non-combustibility can be improved. In Examples 2 and 4, when an acrylic resin emulsion is added to the powder of the glass foam, water enters the pores and air is discharged, but the minute bubbles generated in the resin remain without disappearing. By curing the coating liquid containing the minute bubbles, a functional layer having a large number of minute gaps can be formed between the glass foam and the aggregate. As a result, the sound absorption effect is enhanced, and it can be used as a soundproof panel. In addition, since the heat insulation property is also improved, it can also be used as a heat insulating material.

Explanation of reference numerals

[0058] 10, 20, 30... Building materials (building materials containing porous glass particles), 1... First base material, 2... Second base material, 1A, 1B... Support materials, 1f... Surface, 3, 3A... Coating films, 5, 5A, 5B... Functional layers, 5a... First surface, 5b... Second surface, 6... Porous glass particles, 7... Aggregate, 8... Binder resin, 25, 26... Laminates, C... Cells.

Claims

1. (a) preparing a coating liquid containing porous glass particles in a water-absorbed state, a binder resin, and water; (b) forming a coating film of the coating liquid on the surface of a first substrate; (c) drying the coating film by heating to obtain a functional layer from the coating film; comprising In step (c), the porous glass particles are bonded to each other via the binder resin, and at least a part of the water in the porous glass particles is released to the outside with heating, so that a part of the surface of the porous glass particles is exposed without being covered by the binder resin. A method for manufacturing a building material containing porous glass particles.

2. The method for manufacturing a building material containing porous glass particles according to claim 1, wherein the coating liquid further contains an aggregate.

3. Step (a) includes preparing a first slurry containing water and the porous glass particles, preparing a second slurry containing a resin emulsion containing the binder resin and the aggregate, and mixing the first slurry and the second slurry. The method for manufacturing a building material containing porous glass particles according to claim 2.

4. Step (a) includes preparing a third slurry containing a resin emulsion containing the binder resin, the porous glass particles, and the aggregate, and mixing the third slurry, a resin curing agent, and water. The method for manufacturing a building material containing porous glass particles according to claim 2.

5. In step (c), the functional layer is formed by heating the coating film at a temperature of 70 to 100 ° C. for 60 to 180 minutes. The method for manufacturing a building material containing porous glass particles according to any one of claims 1 to 4.

6. A step of laminating a second base material onto the surface of the coating film formed through the step (b) to obtain a laminate in which the first base material, the coating film, and the second base material are arranged in this order from bottom to top; A step of inverting the top and bottom of the laminate; After performing the step (c) on the laminate to form the functional layer, a step of peeling the second base material from the functional layer; The method for manufacturing a porous glass particle-containing building material according to any one of claims 1 to 4, further including these steps in this order.

7. A support material; A functional layer formed on the surface of the support material; Comprising: The functional layer contains porous glass particles and a binder resin; In the functional layer, the porous glass particles are bonded to each other via the binder resin, and a part of the surface of the porous glass particles is exposed without being covered by the binder resin. A porous glass particle-containing building material.

8. The porous glass particle-containing building material according to claim 7, wherein the functional layer further contains an aggregate.

9. The porous glass particle-containing building material according to claim 7 or 8, wherein the content rate of the porous glass particles in the functional layer is 10 to 50% by mass based on the mass of the functional layer.

10. The porous glass particle-containing building material according to claim 7 or 8, wherein the content rate of the binder resin in the functional layer is 6 to 12% by mass based on the mass of the functional layer.

11. The porous glass particle-containing building material according to claim 7 or 8, wherein the support material is a non-woven fabric.

12. The porous glass particle-containing building material according to claim 11, wherein the thickness of the functional layer is 5 mm or less.

13. The porous glass particle-containing building material according to claim 7 or 8, wherein the support material is a plate material.

14. The porous glass particle-containing building material according to claim 13, wherein the thickness of the functional layer is 10 mm or less.

15. The porous glass particle-containing building material according to claim 7 or 8, wherein at least a part of the large number of the porous glass particles contained in the functional layer is composed of waste glass.

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