Bulking agent for fiber-mixed board as building material board and use thereof

Abstract

To provide a technology capable of improving bulkiness of a fiber-mixed board as a building material board while suppressing a decrease in strength of the fiber-mixed board.SOLUTION: A bulking agent used for a fiber-mixed board as a building material board containing a cement and a pulp comprises at least one of a specific ether compound (1) or a specific ester compound (2). The fiber-mixed board as the building material board comprises a cement, a pulp, and at least one of the specific ether compound (1) or the specific ester compound (2). A method for manufacturing the fiber-mixed board as the building material board includes a step of mixing the pulp, the cement, and at least one of the specific ether compound (1) or the specific ester compound (2).SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a bulking agent for fiber-containing boards used as building boards. [Background technology]

[0002] In recent years, in the case of fiber-mixed boards used as building materials, due to factors such as rising material prices, the need for environmental protection, and the efficient use of resources, it has become desirable to maintain the thickness of fiber-mixed boards used in building materials while reducing the amount of pulp used, which is important for bulk.

[0003] Known pulp bulking agents used in the field of papermaking include those containing higher alcohols or their alkylene oxide adducts (Patent Document 1), those containing fats and oils or sugar alcohol-based nonionic surfactants (Patent Document 2), those containing alkylene oxide adducts of fatty acids (Patent Document 3), those containing cationic compounds, amines, acid salts of amines, and amphoteric compounds (Patent Document 4), as well as those containing polyhydric alcohol fatty acid esters (Patent Document 5), and those containing compounds obtained by reacting epihalohydrin with compounds obtained from aliphatic carboxylic acids and polyamines (Patent Document 6).

[0004] Patent Document 7 discloses a method for producing a bulky inorganic board, in which alkoxysilanes are added to a slurry, and foaming is promoted by mixing and stirring to incorporate fine bubbles. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 98 / 03730 Brochure [Patent Document 2] Japanese Patent Application Publication No. 11-200283 [Patent Document 3] Japanese Patent Application Publication No. 11-200284 [Patent Document 4] Japanese Patent Application Publication No. 11-269799 [Patent Document 5] Japanese Patent Application Publication No. 11-350380 [Patent Document 6] Japanese Patent Application Laid-Open No. 2000-273792 [Patent Document 7] Japanese Patent Application Laid-Open No. 2004-255618 Summary of the Invention [Problem to be solved by the invention]

[0006] The paper bulking agents described in Patent Documents 1 to 6 are added to acidic to neutral slurries. Therefore, the inventors have found that sufficient bulking effect cannot be obtained in fiber-mixed boards, which have strongly alkaline slurries. Furthermore, the slurry used in fiber-mixed boards has an extremely high calcium ion concentration. Therefore, the inventors have found that sufficient bulking effect cannot be obtained even when paper bulking agents that are used for objects with low calcium ion concentrations are used in fiber-mixed boards.

[0007] Furthermore, the inventors have found that the method described in Patent Document 7 requires the control of foaming during mixing and stirring, which may make it difficult to produce a fiber-containing board of stable quality, and as a result, a stable bulking effect cannot be obtained. In addition, the method described in Patent Document 7 may cause water runoff during pressure molding due to the inclusion of air bubbles, which may cause cuts in the molded material and may impair the quality of the fiber-containing board.

[0008] The paper bulking agents described in Patent Documents 1 to 6 are added to acidic to neutral slurries. Therefore, the inventors of the present application have found that they do not provide sufficient bulking effects in ceramic siding boards, which often have alkaline slurries. Therefore, a technology for improving the bulkiness of fiber-containing boards in building boards is desired. [Means for solving the problem]

[0009] The present invention has been made to solve the above problems, and can be realized in the following forms.

[0010] (1) According to one aspect of the present invention, there is provided a bulk-increasing agent for fiber-mixed boards used as building boards. This bulk-increasing agent for fiber-mixed boards is used in fiber-mixed boards used as building boards containing cement and pulp, and is characterized by containing at least one of an ether compound of the following general formula (1) or an ester compound of the following general formula (2). This form of bulk-increasing agent for fiber-mixed boards can improve the bulkiness of the fiber-mixed boards used as building boards. TIFF2025168677000001.tif54116 (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO represents an ethylene oxide chain, PO represents a propylene oxide chain, n and m represent the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n=m=0.)

[0011] (2) In the bulk-increasing agent for fiber-mixed boards as building boards of the above-mentioned form, R1 or R2 of the ether compound (1) or the ester compound (2) may have a chain length of 12 or more carbon atoms. This form of bulk-increasing agent for fiber-mixed boards can improve the bulkiness of the fiber-mixed boards as building boards.

[0012] (3) In the bulk-increasing agent for fiber-mixed boards of the above-mentioned form, R1 or R2 of the ether compound (1) or the ester compound (2) may have a chain length of 14 or more carbon atoms. This form of bulk-increasing agent for fiber-mixed boards can improve the bulkiness of the fiber-mixed boards used as building boards.

[0013] (4) In the bulk-increasing agent for fiber-mixed boards of the above-mentioned form, the total average number of moles of EO or PO added in the ether compound (1) or the ester compound (2) may be 7 moles or more. This bulk-increasing agent for fiber-mixed boards can improve the bulkiness of fiber-mixed boards used as building boards.

[0014] (5) In the bulk-increasing agent for fiber-mixed boards of the above-mentioned form, the total average number of moles of EO or PO added in the ether compound (1) or the ester compound (2) may be 20 moles or more. This bulk-increasing agent for fiber-mixed boards can improve the bulkiness of fiber-mixed boards used as building boards.

[0015] (6) In the bulk-increasing agent for fiber-mixed boards of the above-mentioned form, the carbon number of R1 of the ether compound (1) or the ester compound (2) may have a chain length of 14 or more, and the average total number of moles of EO and PO added may be 20 or more. This form of bulk-increasing agent for fiber-mixed boards can improve the bulkiness of fiber-mixed boards used as building boards.

[0016] (7) In the bulk-increasing agent for fiber-mixed boards of the above-mentioned form, the ether compound (1) may have a chain length of 14 or more carbon atoms in R1, and the average total number of moles of EO and PO added may be 30 or more. This form of bulk-increasing agent for fiber-mixed boards can improve the bulkiness of fiber-mixed boards used as building boards.

[0017] (8) According to another aspect of the present invention, there is provided a fiber-mixed board as a building material board. This fiber-mixed board as a building material board is characterized by containing cement, pulp, and at least one of the ether compound (1) and the ester compound (2). According to this aspect, the bulkiness of the fiber-mixed board as a building material board can be improved.

[0018] (9) According to another aspect of the present invention, there is provided a method for producing a fiber-mixed board as a building board. This method for producing a fiber-mixed board as a building board is characterized by including a mixing step of mixing pulp, cement, and at least one of the ether compound (1) and the ester compound (2). This method for producing a fiber-mixed board can improve the bulkiness of the fiber-mixed board.

[0019] (10) In the method for producing a fiber-mixed board of the above embodiment, the mixing step may include mixing at least one of the ether compound (1) and the ester compound (2) in an amount of 10 mg / kg to 1000 mg / kg based on the mass of a cement-mixed slurry containing pulp and cement. This method for producing a fiber-mixed board can improve the bulkiness of the fiber-mixed board.

[0020] (11) In the method for producing a fiber-mixed board of the above embodiment, in the mixing step, at least one of the ether compound (1) and the ester compound (2) may be mixed with a cement mixture slurry containing pulp and cement. This method for producing a fiber-mixed board of the above embodiment can improve the bulkiness of the fiber-mixed board.

[0021] The present invention can be realized in various forms, for example, a method for producing a bulking agent for fiber-mixed boards, a building using fiber-mixed boards, and the like. DETAILED DESCRIPTION OF THE INVENTION

[0022] A. Bulking agent for fiber-mixed boards as building materials A bulk-increasing agent according to one embodiment of the present invention is used in a fiber-mixed board, which is a building material board containing cement and pulp. The bulk-increasing agent of this embodiment is characterized by containing at least one of an ether compound represented by the following general formula (1) or an ester compound represented by the following general formula (2). TIFF2025168677000002.tif54116 (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n=m=0.)

[0023] This type of bulk-increasing agent, which contains at least one of the ether compound (1) and the ester compound (2), can improve the bulkiness of fiber-containing building boards. While the mechanism by which this effect is achieved is unclear, the following hypothetical mechanism is considered. Specifically, the addition of the compound having a specific alkyl group and an ethylene oxide chain and / or a propylene oxide chain inhibits hydrogen bonding between pulp fibers, thereby increasing the space between the pulp fibers and improving bulkiness. Furthermore, by incorporating at least one of the ether compound (1) and the ester compound (2) into a cement-mixed slurry, the compound coordinates with the cement or aggregate surface, preventing excessive aggregation and further improving bulkiness.

[0024] The ether compound in the present invention has at least one ether bond in the molecule and is represented by the following general formula (1). TIFF2025168677000003.tif25116 (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n=m=0.)

[0025] R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms. From the viewpoint of effectively improving bulkiness, the chain length preferably has 1 or more carbon atoms, more preferably 10 or more carbon atoms, even more preferably 12 or more carbon atoms, particularly preferably 14 or more carbon atoms, and most preferably 18 or more carbon atoms.

[0026] EO represents an ethylene oxide chain, and PO represents a propylene oxide chain. n and m represent the average number of moles added and represent positive integers. n and m may be the same or different and each represent 0 to 50, but n = m = 0 is not the case. From the viewpoint of effectively improving bulkiness, n is 4 or more, more preferably n is 10 or more, and even more preferably n is 20 or more. Furthermore, m is 4 or more, more preferably m is 10 or more, and even more preferably m is 20 or more. From the viewpoint of effectively improving bulkiness, the sum of n and m is 4 or more, more preferably the sum of n and m is 7 or more, even more preferably the sum of n and m is 20 or more, and particularly preferably the sum of n and m is 30 or more.

[0027] The ester compound in the present invention has at least one ester group in the molecule and is represented by the following general formula (2). TIFF2025168677000004.tif25116 (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n=m=0.)

[0028] R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms. From the viewpoint of effectively improving bulkiness, the chain length preferably has 1 or more carbon atoms, more preferably 10 or more carbon atoms, even more preferably 12 or more carbon atoms, particularly preferably 14 or more carbon atoms, and most preferably 18 or more carbon atoms.

[0029] EO represents an ethylene oxide chain, and PO represents a propylene oxide chain. n and m represent the average number of moles added and represent positive integers. n and m may be the same or different and each represent 0 to 50, but n = m = 0 is not the case. From the viewpoint of effectively improving bulkiness, n is 4 or more, more preferably n is 10 or more, and even more preferably n is 20 or more. Furthermore, m is 4 or more, more preferably m is 10 or more, and even more preferably m is 20 or more. From the viewpoint of effectively improving bulkiness, the sum of n and m is 4 or more, more preferably the sum of n and m is 7 or more, even more preferably the sum of n and m is 20 or more, and particularly preferably the sum of n and m is 30 or more.

[0030] The bulk-increasing agent for fiber-containing boards as building boards can be used as is if the ether compound (1) or the ester compound (2) is liquid, or may be prepared by appropriately diluting it with water or the like from the viewpoint of ease of handling.

[0031] The bulk-increasing agent for fiber-reinforced boards as building materials may be the ether compound (1) or the ester compound (2) dissolved in a solvent or dispersed (e.g., suspended or emulsified) in a dispersion medium. Examples of such solvents or dispersion mediums include, but are not limited to, water; ketones such as acetone, methyl ethyl ketone, diethyl ketone, methyl isobutyl ketone, cyclohexanone, and benzophenone; esters such as methyl acetate, ethyl acetate, propyl acetate, butyl acetate, and glycerin fatty acid esters; alcohols such as methanol, ethanol, isopropyl alcohol, 2-butanol, lauryl alcohol, and myristyl alcohol; aqueous alkali solutions such as aqueous sodium hydroxide, aqueous potassium hydroxide, and aqueous barium hydroxide; and amines such as monoethanolamine, triethanolamine, dicyclohexylamine, and polyetheramines.

[0032] The bulk-increasing agent for fiber-reinforced boards as building boards of this embodiment may contain optional components as needed, as long as the effects of the present invention are not impaired. Examples of such optional components include, but are not limited to, preservatives, mildew inhibitors, bactericides, dispersants, etc. These optional components may be used alone or in combination of two or more.

[0033] The concentration of the ether compound (1) or the ester compound (2) in the bulk-increasing agent for fiber-mixed boards as building boards is preferably 1% by mass or more, more preferably 10% by mass or more, and even more preferably 50% by mass or more, from the viewpoint of improving the bulk-increasing effect. Also, the concentration of the ether compound (1) or the ester compound (2) in the bulk-increasing agent for fiber-mixed boards as building boards is preferably 90% by mass or less, more preferably 75% by mass or less, from the viewpoint of handleability.

[0034] The bulk-increasing agent for fiber-mixed boards as building boards of this embodiment can provide fiber-mixed boards with excellent bulkiness. This bulk-increasing effect can contribute to reducing raw material costs and reducing the weight of fiber-mixed boards. Furthermore, the bulk-increasing agent for fiber-mixed boards as building boards of this embodiment can be mixed with other raw materials when manufacturing fiber-mixed boards. This prevents the manufacturing process for fiber-mixed boards from becoming too complicated, eliminating the need for major equipment modifications and reducing the complexity of process management. This makes it easy to improve the bulkiness of fiber-mixed boards.

[0035] B. Fiber-reinforced board as a building material Another embodiment of the present invention is a fiber-mixed board as a building material board, characterized by containing cement, pulp, and at least one of the ether compound (1) and the ester compound (2). The fiber-mixed board as a building material board of this embodiment is not particularly limited, but examples thereof include ceramic siding boards, artificial slate, slag lime boards, calcium silicate boards, etc. In this specification, ceramic siding boards are used, for example, as exterior or interior wall materials for houses and stores. The bulk-increasing agent described above can be suitably used in ceramic siding boards.

[0036] [Raw material for fiber-mixed boards used as building materials] The cement used in this embodiment is not particularly limited, but examples include various types of Portland cement, such as ordinary, early-strength, extra-early-strength, low-heat, and medium-heat cements; filler cements containing limestone powder or ground granulated cooled blast furnace slag; and environmentally friendly cements produced primarily from various industrial waste materials. One type of cement may be used alone, or two or more types may be used in combination. Furthermore, the cement may be mixed with inorganic powders such as fly ash, calcium silicate, gypsum, calcium carbonate, blast furnace slag, and silica.

[0037] The pulp of this embodiment contains natural fibers and serves as reinforcing fibers in the fiber-mixed board. The raw material pulp may be wood pulp or non-wood pulp. Examples of wood pulp include, but are not limited to, softwood kraft pulp (NKP) and hardwood kraft pulp (LKP). Examples of non-wood pulp include, but are not limited to, kenaf, bagasse, bamboo, hemp, and straw. The pulp may be bleached pulp or unbleached pulp. The pulp may be virgin pulp made directly from wood or non-wood, or recycled pulp made by recovering previously manufactured paper or other materials. One type of pulp may be used alone, or two or more types may be used in combination.

[0038] The fiber-mixed board serving as a building material board of this embodiment may contain optional components as needed, provided that the effects of the present invention are not impaired. Examples of such optional components include, but are not limited to, antifoaming agents, hydrocarbons, preservatives, mildew inhibitors, bactericides, rust inhibitors, and antiskinning agents. These optional components may be used alone or in combination of two or more.

[0039] [Method for manufacturing fiber-mixed boards as building boards] The method for producing the fiber-mixed board serving as a building board of this embodiment is not particularly limited, and various production methods such as casting, extrusion, and papermaking can be applied. The method for producing the fiber-mixed board serving as a building board of this embodiment includes a mixing step of mixing pulp, cement, and at least one of the ether compound (1) and the ester compound (2). In the mixing step, a slurry containing the above raw materials added to water is mixed and stirred.

[0040] The mixing step of this embodiment may include (i) a first step of mixing at least one of the ether compound (1) and the ester compound (2) with a pulp slurry containing pulp, and (ii) a second step of mixing cement after the first step. In the first step, a pulp slurry containing raw pulp in water is mixed with at least one of the ether compound (1) and the ester compound (2) and stirred. In the first step, the pulp is disintegrated. The pH of the pulp slurry is strongly alkaline (e.g., pH 10 to pH 13.5, preferably pH 11.5 to pH 13.2). In the second step, the mixed pulp slurry and cement are mixed and stirred. A cement-mixed slurry is obtained in the second step. By including the first and second steps in the mixing step, the bulkiness of the fiber-mixed board can be further improved. In the second step, an inorganic powder may be mixed with the cement.

[0041] The mixing step may be a step of mixing at least one of the ether compound (1) and the ester compound (2) with a cement-mixed slurry obtained by mixing cement with a pulp slurry, instead of the first step and the second step. From the viewpoint of bulking effect, it is preferable to add at least one of the ether compound (1) and the ester compound (2) to the cement-mixed slurry.

[0042] The method for mixing the ether compound (1) or the ester compound (2) with the pulp slurry or the cement mixture slurry is not particularly limited as long as the ether compound (1) or the ester compound (2) is dispersed in the slurry. Examples of the method include a continuous mixing method using a liquid pump and a method for mixing a specified batch amount at regular intervals. The compound may be mixed, for example, in a pulper, a return line for filtrate discharged during the production of a fiber-mixed board, or raw material dilution water. If necessary, the ether compound (1) or the ester compound (2) may be added at multiple locations.

[0043] From the viewpoint of improving the bulking effect, the ether compound (1) or the ester compound (2) is mixed in a proportion of preferably 10 mg / kg or more, more preferably 200 mg / kg or more, and even more preferably 500 mg / kg or more, based on the mass of the cement mixed slurry. From the viewpoint of economy, it is preferably mixed in a proportion of 1000 mg / kg or less, based on the mass of the cement mixed slurry.

[0044] The preferred mass ratio of the ether compound (1) or the ester compound (2) relative to the mass of the cement mixed slurry is also applicable when the compound is mixed with a pulp slurry. The pulp concentration in the pulp slurry is not particularly limited, but may be, for example, 0.1 to 10 mass%, and the cement concentration in the cement mixed slurry is not particularly limited, but may be, for example, 2 to 70 mass%.

[0045] When fiber-mixed boards are manufactured by papermaking, the manufacturing process further includes a papermaking step in which the cement mixed slurry obtained in the mixing step is paper-made. In the papermaking step, the cement mixed slurry is paper-made like paper to produce a plate-shaped molded board. More specifically, for example, the cement mixed slurry is poured onto a mesh, and then filtered and dehydrated to produce a cement cake. The produced cement cake is pressed to form a mold, and then dried and hardened to produce the fiber-mixed board.

[0046] In this embodiment, there is no limitation on the time elapsed from dispersing the ether compound (1) or the ester compound (2) in the slurry until the papermaking process. Generally, the prepared cement mixed slurry and pulp slurry are sent to the papermaking process within about 1 to 30 minutes, and a fiber-mixed board having excellent bulkiness and suppressed strength loss can be produced regardless of the length of time elapsed from mixing the ether compound (1) or the ester compound (2). [Example]

[0047] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples. In the examples, "%" means % by mass unless otherwise specified.

[0048] [Synthesis Example 1] A stainless steel high-pressure reactor equipped with a thermometer, stirrer, pressure gauge, and nitrogen inlet tube was charged with 270.5 g of stearyl alcohol and 1 g of 96% KOH. The reactor was then purged with nitrogen and heated to 120 °C under a nitrogen atmosphere. Then, 1860 g of propylene oxide was introduced into the reactor over 12 hours while maintaining the temperature at 120 °C under a safe pressure, and the temperature was maintained for two hours. The reactor was then heated to 150 °C, and 176.2 g of ethylene oxide was introduced into the reactor over 5 hours while maintaining the temperature at 150 °C under a safe pressure. The temperature was then maintained for one hour to complete the alkylene oxide addition reaction, yielding Compound 1.

[0049] [Synthesis Example 2] Compound 2 was obtained in the same manner as in Synthesis Example 1, except that 270.5 g of stearyl alcohol was changed to 186.3 g of lauryl alcohol.

[0050] [Synthesis Example 3] Compound 3 was obtained in the same manner as in Synthesis Example 1, except that 270.5 g of stearyl alcohol was changed to 214.4 g of myristyl alcohol.

[0051] [Synthesis Example 4] Compound 4 was obtained in the same manner as in Synthesis Example 1, except that 270.5 g of stearyl alcohol was changed to 354.6 g of lignoceryl alcohol.

[0052] [Synthesis Example 5] Compound 5 was obtained in the same manner as in Synthesis Example 1, except that the amount of propylene oxide introduced was 697.2 g and the amount of ethylene oxide introduced was 352.4 g.

[0053] [Synthesis Example 6] Compound 6 was obtained in the same manner as in Synthesis Example 1, except that the amount of propylene oxide introduced was changed to 232.4 g.

[0054] [Synthesis Example 7] A stainless steel high-pressure reactor equipped with a thermometer, stirrer, pressure gauge, and nitrogen inlet tube was charged with 186.3 g of lauryl alcohol and 1 g of 96% KOH. The reactor was then purged with nitrogen and heated to 120 °C under a nitrogen atmosphere. Then, 174.3 g of propylene oxide was introduced into the reactor over 12 hours while maintaining the temperature at 120 °C under a safe pressure, and the temperature was maintained for two hours. The reactor was then heated to 150 °C, and 176.2 g of ethylene oxide was introduced into the reactor over 5 hours while maintaining the temperature at 150 °C under a safe pressure. The temperature was then maintained for one hour to complete the alkylene oxide addition reaction, yielding Compound 7.

[0055] [Synthesis Example 8] A stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube was charged with 186.3 g of lauryl alcohol and 1 g of 96% KOH, the atmosphere inside the reactor was replaced with nitrogen, and the reactor was heated to 150°C in a nitrogen atmosphere. While maintaining the temperature at 150°C under a safe pressure, 528.6 g of ethylene oxide was introduced into the reactor over 5 hours, and the temperature was then maintained for 1 hour to complete the alkylene oxide addition reaction, thereby obtaining compound 8.

[0056] [Synthesis Example 9] A stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube was charged with 186.3 g of lauryl alcohol and 1 g of 96% KOH, and the atmosphere inside the reactor was replaced with nitrogen and heated to 120°C in a nitrogen atmosphere. Then, while maintaining the temperature at 120°C under a safe pressure, 697.2 g of propylene oxide was introduced into the reactor over 12 hours, and the temperature was maintained for two hours to complete the alkylene oxide addition reaction, yielding compound 9.

[0057] [Synthesis Example 10] 2305 g of compound 1 and 40 g of 96% KOH were charged into a stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube, and the atmosphere inside the reactor was replaced with nitrogen and heated to 150°C in a nitrogen atmosphere. Then, while maintaining the temperature at 150°C under a safe pressure, 94.9 g of methyl bromide was introduced into the reactor over 3 hours to obtain compound 10.

[0058] [Synthesis Example 11] Into a glass reaction vessel were placed 2305 g of compound 1, 40 g of 96% KOH, and 305.0 g of 1-bromotetradecane. After the reaction vessel was purged with nitrogen, the vessel was heated at 150° C. for 3 hours to obtain compound 11.

[0059] [Synthesis Example 12] A stainless steel high-pressure reactor equipped with a thermometer, stirrer, pressure gauge, and nitrogen inlet tube was charged with 284.5 g of stearic acid and 1 g of 96% KOH. The reactor was then purged with nitrogen and heated to 120 °C under a nitrogen atmosphere. Then, 1860 g of propylene oxide was introduced into the reactor over 12 hours while maintaining the temperature at 120 °C under a safe pressure, and the temperature was maintained for two hours. The reactor was then heated to 150 °C, and 176.2 g of ethylene oxide was introduced into the reactor over 5 hours while maintaining the temperature at 150 °C under a safe pressure. The temperature was then maintained for one hour to complete the alkylene oxide addition reaction, yielding compound 12.

[0060] [Synthesis Example 13] Compound 13 was obtained in the same manner as in Synthesis Example 12, except that 284.5 g of stearic acid was changed to 200.3 g of lauric acid.

[0061] [Synthesis Example 14] Compound 14 was obtained in the same manner as in Synthesis Example 12, except that 284.5 g of stearic acid was changed to 368.6 g of lignoceric acid.

[0062] [Synthesis Example 15] Compound 15 was obtained in the same manner as in Synthesis Example 12, except that the amount of propylene oxide introduced was 697.2 g and the amount of ethylene oxide introduced was 352.4 g.

[0063] [Synthesis Example 16] Compound 16 was obtained in the same manner as in Synthesis Example 12, except that the amount of propylene oxide introduced was changed to 232.4 g.

[0064] [Synthesis Example 17] A stainless steel high-pressure reactor equipped with a thermometer, stirrer, pressure gauge, and nitrogen inlet tube was charged with 200.3 g of lauric acid and 1 g of 96% KOH. The reactor was then purged with nitrogen and heated to 120°C under a nitrogen atmosphere. Then, 174.3 g of propylene oxide was introduced into the reactor over 12 hours while maintaining the temperature at 120°C under a safe pressure, and the temperature was maintained for two hours. The reactor was then heated to 150°C, and 176.2 g of ethylene oxide was introduced into the reactor over 5 hours while maintaining the temperature at 150°C under a safe pressure. The temperature was then maintained for one hour to complete the alkylene oxide addition reaction, yielding compound 17.

[0065] [Synthesis Example 18] A stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube was charged with 200.3 g of lauric acid and 1 g of 96% KOH, and the reactor was purged with nitrogen and heated to 150°C in a nitrogen atmosphere. Then, while maintaining the temperature at 150°C under a safe pressure, 528.6 g of ethylene oxide was introduced into the reactor over 5 hours, and the temperature was maintained for 1 hour to complete the alkylene oxide addition reaction, yielding compound 18.

[0066] [Synthesis Example 19] A stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube was charged with 200.3 g of lauric acid and 1 g of 96% KOH, and the reactor was purged with nitrogen and heated to 120°C in a nitrogen atmosphere. Then, while maintaining the temperature at 120°C under a safe pressure, 697.2 g of propylene oxide was introduced into the reactor over 12 hours, and the temperature was maintained for two hours to complete the alkylene oxide addition reaction, yielding compound 19.

[0067] [Synthesis Example 20] A stainless steel high-pressure reactor equipped with a thermometer, a stirrer, a pressure gauge, and a nitrogen inlet tube was charged with 2333 g of compound 12 and 40 g of 96% KOH, and the atmosphere inside the reactor was replaced with nitrogen. The reactor was heated to 150°C in a nitrogen atmosphere. Then, while maintaining the temperature at 150°C under a safe pressure, 94.9 g of methyl bromide was introduced into the reactor over 3 hours to obtain compound 20.

[0068] [Synthesis Example 21] Into a glass reaction vessel were placed 2333 g of compound 10, 40 g of 96% KOH, and 305.0 g of 1-bromotetradecane. After the reaction vessel was purged with nitrogen, the vessel was heated at 150° C. for 3 hours to obtain compound 21.

[0069] Using compounds 1 to 21 for the examples and compounds 22 to 26 for the comparative examples shown in the table below, ceramic siding boards as fiber-mixed boards of Examples 1 to 30 and Comparative Examples 1 to 18 were produced as follows: The pH of the pulp slurries in the examples and comparative examples was as shown in the table below.

[0070] Example 1 250 g of pulp slurry containing 3.7% recycled paper pulp in water was mixed with 1250 g of water, 75 g of fly ash (equivalent to JIS A6201-II type), and 45 g of Portland cement and stirred vigorously for 1 minute to obtain a cement-mixed slurry. Compound 1 was added to the resulting cement-mixed slurry at a compound mass of 1000 mg / kg and stirred for 5 minutes. The cement-mixed slurry was then suction-filtered using No. 1 filter paper through a 100 mm diameter filter. Suction filtration was continued until the moisture content was approximately 40%, and the filtration residue, a cement cake, was recovered. The recovered cement cake was placed in a 100 mm diameter mold and pressed at a pressure of 18 kgf / cm2 to form a mold. The molded product was left to stand at 50°C under saturated steam pressure for approximately 12 hours, and then treated at 160°C under saturated steam pressure for 5 hours to harden through a hydration reaction and undergo curing. Thereafter, the board was left to stand and dried at 120° C. for 24 hours, thereby obtaining the ceramic siding board of Example 1.

[0071] Examples 2 to 6 Ceramic siding boards of Examples 2 to 6 were obtained in the same production method as in Example 1, except that Compound 1 was added in the amount shown in Table 1 below.

[0072] Examples 7 to 16 Ceramic siding boards of Examples 2 to 16 were obtained in the same production method as in Example 1, except that instead of Compound 1, Compounds 2 to 11 were added in the amounts shown in Table 1 below.

[0073] Example 17 Compound 1 was added to 250 g of a pulp slurry containing 3.7% recycled paper pulp in water at a compound mass of 200 mg / kg relative to the mass of the cement mixture slurry described below, and the mixture was stirred for 5 minutes. Subsequently, 1250 g of water, 75 g of fly ash (equivalent to JIS A6201-II type), and 45 g of Portland cement were added and stirred vigorously for 1 minute to obtain a cement mixture slurry. The resulting cement mixture slurry was suction filtered through a 100 mm diameter filter using No. 1 filter paper. Suction filtration was continued until the moisture content was approximately 40%, and the filtration residue, a cement cake, was recovered. The recovered cement cake was placed in a 100 mm diameter mold and pressed at a pressure of 18 kgf / cm2 to form a mold. The molded product was left to stand at 50 °C under saturated steam pressure for approximately 12 hours, and then treated at 160 °C under saturated steam pressure for 5 hours to harden through a hydration reaction and undergo curing. Thereafter, the board was left to stand and dried at 120°C for 24 hours to obtain a ceramic siding board of Example 17.

[0074] Example 18 A ceramic siding board of Example 18 was obtained in the same manufacturing method as in Example 3, except that virgin pulp was used instead of recycled paper pulp.

[0075] Examples 19 to 28 Ceramic siding boards of Examples 19 to 28 were obtained in the same production method as in Example 1, except that instead of Compound 1, Compounds 12 to 21 were added in the amounts shown in Table 1 below.

[0076] Example 29 Compound 12 was added to 250 g of a pulp slurry containing 3.7% recycled paper pulp in water at a compound mass of 200 mg / kg relative to the mass of the cement mixture slurry described below, and the mixture was stirred for 5 minutes. Subsequently, 1250 g of water, 75 g of fly ash (equivalent to JIS A6201-II type), and 45 g of Portland cement were added and stirred vigorously for 1 minute to obtain a cement mixture slurry. The resulting cement mixture slurry was suction filtered through a 100 mm diameter filter using No. 1 filter paper. Suction filtration was continued until the moisture content was approximately 40%, and the filtration residue, a cement cake, was recovered. The recovered cement cake was placed in a 100 mm diameter mold and pressed at a pressure of 18 kgf / cm2 to form a mold. The molded product was left to stand at 50 °C under saturated steam pressure for approximately 12 hours, and then treated at 160 °C under saturated steam pressure for 5 hours to harden through a hydration reaction and undergo curing. Thereafter, the board was left to stand and dried at 120°C for 24 hours to obtain a ceramic siding board of Example 29.

[0077] Example 30 A ceramic siding board of Example 30 was obtained in the same manner as in Example 19, except that virgin pulp was used instead of recycled paper pulp.

[0078] Comparative Example 1 A ceramic siding board of Comparative Example 1 was obtained in the same production method as in Example 1, except that Compound 1 was not added.

[0079] Comparative Examples 2 to 11 Ceramic siding boards of Comparative Examples 2 to 11 were obtained in the same production method as in Comparative Example 1, except that Compounds 22 to 26 were added in the amounts shown in Table 2 below.

[0080] Comparative Example 12 A ceramic siding board of Comparative Example 12 was obtained in the same production method as in Example 17, except that Compound 23 was used instead of Compound 1.

[0081] Comparative Example 13 A ceramic siding board of Comparative Example 13 was obtained in the same manufacturing method as in Comparative Example 1, except that virgin pulp was used instead of recycled paper pulp.

[0082] Comparative Examples 14 to 18 Ceramic siding boards of Comparative Examples 14 to 18 were obtained in the same production method as in Comparative Example 13, except that Compounds 22 to 26 were added in the amounts shown in Table 2 below.

[0083] Using the ceramic siding boards as fiber-mixed boards of Examples 1 to 30 and Comparative Examples 1 to 18, various properties were determined according to the following methods.

[0084] <Thickness of ceramic siding board> The ceramic siding board was dried at 120°C for 24 hours, and the thickness of the dried ceramic siding board (board thickness) was measured using a vernier caliper.

[0085] <Bulking rate of ceramic siding board> The bulkiness of Examples 1 to 17, Examples 19 to 29, and Comparative Examples 2 to 12, based on Comparative Example 1, and the bulkiness of Examples 18 and 30, and Comparative Examples 14 to 18, based on Comparative Example 13, were calculated using the board thickness measured by the above method. More specifically, the bulkiness was calculated from the thickness of the ceramic siding boards of Examples 1 to 17, Examples 19 to 29, and Comparative Examples 2 to 12, when the thickness of the ceramic siding board of Comparative Example 1 was taken as 100%. Similarly, the bulkiness of Examples 18 and 30, and Comparative Examples 14 to 18, based on Comparative Example 13, were calculated.

[0086] The results obtained are shown below.

[0087] [Table 1]

[0088] [Table 2]

[0089] The above results reveal the following: Comparison of Examples 1 to 17 and Examples 19 to 29 with Comparative Example 1, and comparison of Examples 18 and 30 with Comparative Example 13 reveals that the bulkiness of the ceramic siding board as a fiber-containing board is improved by including the ether compound (1) or the ester compound (2).

[0090] Furthermore, comparison of Example 3 with Example 17, and Example 19 with Example 29 revealed that bulkiness was improved more when the ether compound (1) or the ester compound (2) was added to a cement mixed slurry than when it was added to a pulp slurry.

[0091] Furthermore, a comparison between Example 3 and Example 18, and Example 19 and Example 30 revealed that the bulkiness of the ceramic siding board can be improved regardless of whether recycled paper pulp or virgin pulp is used as the raw material pulp.

[0092] On the other hand, sodium lignosulfonate (compound 22) added in Comparative Examples 2, 3, and 14 is a substance generally added to cement boards as an air-entraining water-reducing agent. Substances used as air-entraining water-reducing agents, such as sodium lignosulfonate, were not found to have the effect of improving the bulkiness of ceramic siding boards.

[0093] Lauryl alcohol (compound 23), which was added in Comparative Examples 4, 5, 12, and 15, is a typical substance generally added as a bulking agent for paper in the papermaking process. Substances used as bulking agents for papermaking, such as lauryl alcohol, were not found to have the effect of improving the bulkiness of ceramic siding boards.

[0094] Tetrabutoxysilane (compound 24), which was added in Comparative Examples 6, 7, and 16, is a known substance that provides bulk by incorporating bubbles during the manufacturing process of building boards. However, since there was no process for incorporating bubbles in the manufacturing process of the ceramic siding boards, the bulk-increasing effect was not observed.

[0095] Sodium stearate (compound 25) added in Comparative Examples 8, 9, and 17 is a substance generally added as a paper bulking agent in the papermaking process. However, sodium stearate was not found to have the effect of improving the bulkiness of ceramic siding boards.

[0096] Methyl laurate (compound 26) added in Comparative Examples 10, 11, and 18 is a substance added as a paper bulking agent in the papermaking process. However, methyl laurate was not found to have the effect of improving the bulkiness of ceramic siding boards.

[0097] The present invention is not limited to the above-described embodiments and can be realized in various configurations without departing from the spirit of the present invention. For example, the technical features in the embodiments and examples corresponding to the technical features in each aspect described in the Summary of the Invention section can be appropriately replaced or combined to solve some or all of the above-described problems or achieve some or all of the above-described effects. Furthermore, if a technical feature is not described as essential in this specification, it can be deleted as appropriate. [Industrial Applicability]

[0098] The bulk-increasing agent for fiber-mixed boards as building boards, the fiber-mixed boards as building boards, and the method for producing fiber-mixed boards as building boards of the present invention can provide fiber-mixed boards as building boards with excellent bulkiness, which can contribute to reducing raw material costs by increasing the bulk.

Claims

1. A bulking agent used in a fiber-mixed board as a building material board containing cement and pulp, The composition is characterized by containing at least one of an ether compound represented by the following general formula (1) and an ester compound represented by the following general formula (2): Bulking agent for fiber-mixed boards used as building materials. (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n = m = 0.)

2. The bulking agent for fiber-containing boards as building material boards according to claim 1, R1 or R2 of the ether compound (1) or the ester compound (2) has a chain length of 12 or more carbon atoms. Bulking agent for fiber-mixed boards used as building materials.

3. In the bulking agent for fiber-mixed boards as building material boards according to claim 2, R1 or R2 of the ether compound (1) or the ester compound (2) has a chain length of 14 or more carbon atoms. Bulking agent for fiber-mixed boards used as building materials.

4. The bulking agent for fiber-mixed boards as building material boards according to claim 2 or 3, the total average number of moles of EO or PO added to the ether compound (1) or the ester compound (2) is 7 moles or more; Bulking agent for fiber-mixed boards used as building materials.

5. The bulking agent for fiber-containing boards as building materials according to claim 4, the total average number of moles of EO or PO added to the ether compound (1) or the ester compound (2) is 20 moles or more; Bulking agent for fiber-mixed boards used as building materials.

6. The bulking agent for fiber-containing boards as building materials according to claim 5, the ether compound (1) or the ester compound (2) has a chain length of 14 or more carbon atoms in R1, and the total average number of moles of EO and PO added is 20 or more moles. Bulking agent for fiber-mixed boards used as building materials.

7. The bulking agent for fiber-containing boards as building boards according to claim 6, The ether compound (1) is characterized in that R1 has a chain length of 14 or more carbon atoms, and the total average number of moles of EO and PO added is 30 or more. Bulking agent for fiber-mixed boards used as building materials.

8. A fiber-mixed board as a building material board, Cement and Pulp and The composition is characterized by containing at least one of an ether compound represented by the following general formula (1) and an ester compound represented by the following general formula (2): Fiber-mixed board as a building material board. (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n = m = 0.)

9. A method for manufacturing a fiber-mixed board as a building material board, The method includes a mixing step of mixing pulp, cement, and at least one of an ether compound represented by the following general formula (1) and an ester compound represented by the following general formula (2), A method for manufacturing fiber-mixed boards as building materials. (In the formula, R1 and R2 are the same or different and each represents a hydrogen atom or an alkyl group having 1 to 50 carbon atoms, EO is an ethylene oxide chain, PO is a propylene oxide chain, n and m are the average number of moles added, and n and m are the same or different and each represents 0 to 50, but there is no case where n = m = 0.)

10. In the method for manufacturing a fiber-mixed board as a building material board according to claim 9, In the mixing step, at least one of the ether compound (1) and the ester compound (2) is mixed in an amount of 10 mg / kg or more and 1000 mg / kg or less relative to the mass of a cement-mixed slurry containing pulp and cement. A method for manufacturing fiber-mixed boards as building materials.

11. In the method for manufacturing a fiber-mixed board as a building material board according to claim 9 or 10, The mixing step a cement mixed slurry containing pulp and cement, and mixing at least one of the ether compound (1) and the ester compound (2). A method for manufacturing fiber-mixed boards as building materials.

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