Surface-waterproofing sheet for mineral board using a mixed-use nonwoven fabric and a waterproofing coating layer, and a production method therefor

Abstract

The present invention relates to a surface-waterproof sheet for inorganic boards including multi-use non-woven fabrics and a waterproof coating layer, and a method of manufacturing the same. The method includes preparing a multi-use non-woven fabric composed of cellulose fibers, glass fibers and organic fibers; preparing a waterproof coating solution containing a powdery acrylic binder, water, an inorganic filler, a water repellent, a pigment and an antimicrobial agent; and coating the waterproof coating solution on the multi-use non-woven fabric, followed by drying the waterproof coating solution, thereby providing surface-waterproof sheet for inorganic boards for buildings, which has improved adhesion to the inorganic board and economic feasibility.

1 . A surface-waterproof sheet for inorganic boards, comprising a multi-use non-woven fabric comprising cellulose fibers, glass fibers and organic fibers; and
 a waterproof coating layer coated on the multi-use non-woven fabric.   
     
     
         2 . The surface-waterproof sheet according to  claim 1 , wherein the non-woven fabric comprises 30˜70 wt % of the cellulose fibers, 28˜60 wt % of the glass fibers, and 2˜20 wt % of the organic fibers. 
     
     
         3 . The surface-waterproof sheet according to  claim 1 , wherein the cellulose fibers have an average diameter of 5 μm to 100 μm and an average length of 1 mm to 30 mm 
     
     
         4 . The surface-waterproof sheet according to  claim 1 , wherein each of the glass fibers and the organic fibers has an average diameter of 5 μm to 20 μm and an average length of 1 mm to 30 mm 
     
     
         5 . The surface-waterproof sheet according to  claim 1 , wherein the multi-use non-woven fabric is formed as a single layer of the nonwoven fabric having a basis weight of 30 g/m 2  to 100 g/m 2 . 
     
     
         6 . The surface-waterproof sheet according to  claim 1 , wherein the multi-use non-woven fabric has a thickness of 0.25 mm to 0.55 mm 
     
     
         7 . The surface-waterproof sheet according to  claim 1 , wherein the multi-use non-woven fabric further comprises 0.1˜3 wt % of a dry paper strengthener or wet paper strengthener. 
     
     
         8 . The surface-waterproof sheet according to  claim 7 , wherein the dry paper strengthener contains starch or polyacrylamide, and the wet paper strengthener contains at least one selected from among urea formaldehyde resins, melamine formaldehyde resins, polyamide resins, glyoxylated polyacrylamide resins, and polyethylene imine resins. 
     
     
         9 . The surface-waterproof sheet according to  claim 1 , wherein the waterproof coating layer is formed using a waterproof coating solution that comprises 3˜30 wt % of a powdery acrylic binder, 10˜50 wt % of water, 20˜70 wt % of an inorganic filler, 0.5˜10 wt % of a water repellent, 0.5˜5 wt % of a pigment, and 0.2˜5 wt % of an antimicrobial agent. 
     
     
         10 . The surface-waterproof sheet according to  claim 9 , wherein the waterproof coating solution has a viscosity of 50˜500 cps. 
     
     
         11 . The surface-waterproof sheet according to  claim 9 , wherein the waterproof coating solution is coated in an amount of 30˜200 g/m 2  on the multi-use non-woven fabric. 
     
     
         12 . The surface-waterproof sheet according to  claim 9 , wherein the inorganic filler comprises calcium carbonate (CaCO 3 ) having an average particle size of 5 μm to 50 μm. 
     
     
         13 . The surface-waterproof sheet according to  claim 9 , wherein the water repellent comprises a fluorocarbon or wax type water repellent. 
     
     
         14 . The surface-waterproof sheet according to  claim 1 , wherein the waterproof coating layer is permeated up to 5% to 80% of a thickness of the non-woven fabric from an upper surface of the non-woven fabric to a bottom thereof. 
     
     
         15 . The surface-waterproof sheet according to  claim 14 , wherein the non-woven fabric has an average pore size of 10 μm to 100 μm in a region into which the waterproof coating layer is not permeated, and an average pore size of 5 μm to 50 μm in a region into which the waterproof coating layer is permeated. 
     
     
         16 . The surface-waterproof sheet according to  claim 1 , wherein the surface-waterproof sheet has a total thickness of 0.27 mm to 0.57 mm 
     
     
         17 . The surface-waterproof sheet according to  claim 1 , wherein the inorganic board comprises at least one selected from among medium density fiberboard (MDF), plywood, cellulose fibers-reinforced cement board, magnesium board, glued laminated timber, high-density fiberboard, ceramic tile, porcelain tile, ceramic board, gypsum board, cement board, and MgO board. 
     
     
         18 . A method of manufacturing a surface-waterproof sheet for inorganic boards, the method comprising the steps of:
 (a) preparing a multi-use non-woven fabric by mixing cellulose fibers, glass fibers and organic fibers;   (b) preparing a waterproof coating solution containing a powdery acrylic binder, water, an inorganic filler, a water repellent, a pigment, and an antimicrobial agent; and   (c) coating the waterproof coating solution on the multi-use non-woven fabric, followed by drying the waterproof coating solution.   
     
     
         19 . The method according to  claim 18 , wherein the waterproof coating solution is coated by one method selected from among drum coating, roll coating, knife coating, spray coating, and comma coating. 
     
     
         20 . The method according to  claim 18 , wherein the waterproof coating solution is dried at a temperature of 100° C. to 200° C. for 1 to 10 minutes.