JP3606971B2 - Manufacturing method of non-combustible plate - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to an incombustible plate with a concavo-convex pattern, which is mainly used for an outer wall, an inner wall, a ceiling and the like of a house.
[0002]
[Prior art]
Examples of the incombustible plate include a cement plate and a silicate calcium plate, and the cement plate is obtained by solidifying a raw material obtained by mixing cement, an extender, a short reinforcing fiber, etc. with water in a slurry state. The silicate calcium plate is also obtained by making a raw material in which a filler, a short fiber for reinforcement, and the like are mixed in a slurry form with water into a plate shape and solidified.
[0003]
And, the surface of these plates is provided with uneven patterns of various shapes, and is colored with a paint for sale. The concavo-convex pattern was made by a press when in a semi-solid state, and the depth was 2 to 3 mm. However, when the depth is increased and the corners are sharpened, a luxurious feeling can be obtained. Recently, there is a tendency to increase the depth by increasing the depth of the concavo-convex portion to 4 to 6 mm because the number of types of patterns increases if the height is varied in various ways.
[0004]
However, it is difficult to press semi-solidified products to form deep irregularities, and the sharpness of the corners of the pattern disappears, and when the concave portions are deepened, the minimum thickness of the plate decreases accordingly. When the plate is lifted at both ends in the longitudinal direction during construction, etc., the center part may be bent due to its own weight and bend, and if the thickness is increased to increase the strength, the weight will increase and handling will be difficult. It becomes inconvenient.
[0005]
Also known is a laminated board in which the above-mentioned raw materials are used to make a semi-solid thin sheet by making the reinforcing fibers thinly aligned in the longitudinal direction, wound around a roll several times, incised, pressed and solidified. ing. The laminate has a large bending strength because the reinforcing fibers are aligned in the longitudinal direction, but gaps are likely to remain between the layers. The length may be increased, and the plate may be lost due to delamination.
[0006]
[Problems to be solved by the invention]
It is an object of the present invention to increase the depth of unevenness without increasing the thickness or weight of the plate and improve the quality, and to prevent a decrease in strength.
[000 7 ]
[Means for Solving the Problems]
The structure of the plate that solves the above problems is to make a slurry-like raw material made by mixing a curable non-combustible material, water, reinforcing fibers, etc. into a plate shape, and to form an uneven pattern on the surface. In a long non-combustible board solidified by the above process, the fiber is made by increasing the number of fibers facing the longitudinal direction of the board, and the base material formed with a strength in the longitudinal direction larger than the strength in the width direction by 10% or more, A surface material in which an uneven pattern is formed by embedding almost the same raw material as the raw material is integrally polymerized.
[000 8 ]
Then, one of the manufacturing method of the plate, according to claim 1 as described in, along with moving the breathable belt up-ramp portion through by endless, by the action of negative pressure to the lower surface of said uplink inclined portion, A slurry-like raw material mixed with a curable non-combustible material, water, reinforcing fibers, etc. is supplied to the upward inclined portion, and the raw material is transported upward while flowing down on the belt, so that the fiber is brought to the surface side. On the other hand, a semi-dehydrated base material having a substantially equal thickness is made in a state where it is aligned more than 10% more in the longitudinal direction on the back side, and apart from the base material, a mold surface for forming the surface of the plate is formed at the bottom. After the surface material mold is placed in a mold of the surface material provided, the surface side of the substrate is polymerized on the upper surface of the unsolidified surface material in the mold , and then the back surface of the substrate this that by applying a water-absorbing dewatering member and perforated plate, and the base material and the surface material by pressure each of the formwork and solidified integrally with the The features.
[000 9 ]
As described in claim 2 , another manufacturing method is as described in claim 1 , wherein the polymerized base material and the surface material are turned upside down together with a mold , and the base material is positioned on the lower side. A pressurizing step is performed .
[00 10 ]
Another manufacturing method also, as described in claim 3, in claim 2, characterized in that dehydration by vacuum from the back side while the said substrate and the surface material pressed each of the formwork .
[00 11 ]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments will be described with reference to the drawings. 1 is a front view of a nonflammable wallboard 1 having a masonry pattern according to the present invention, FIG. 2 is an end view, FIG. 3 is an enlarged view of section 3-3 in FIG. On the back surface, for example, the width W is 45 cm, the thickness T is 14 mm, the length L is 3 m, and the depth of the groove 4 as the joint pattern provided on the front surface 2 is 5 mm, for example. This wall plate 1 is made of a slurry-like material in which 5 to 20% by weight of fibers 5 having a length of 10 mm and a length of 10 mm are mainly mixed with cement as a reinforcing material, and pulp is mainly used as a reinforcing material. A solidified cement board having a width several times larger than the width W by a device to be described later is continuously made in the length direction, cut into a predetermined length L, and then the ears on both sides are excised. It is made by dividing the width W vertically.
[00 12 ]
As for the said fiber 5, the ratio of what was arranged facing the longitudinal direction of the wall board 1 as shown to 5a in FIG. Many are suitable. By making 10% or more of the entire reinforcing fibers 5 so as to face the longitudinal direction, the strength in the longitudinal direction can be increased by 10% or more compared to the width direction. With this configuration, as shown in FIG. 4, even when the wall plate 1 is bent with the load F as shown by the imaginary line 1a with the back surface 3 down, the fiber 5a on the back surface 3 side acts as a tension member to generate tensile strength. It is hard to break.
[00 13 ]
Next, FIG. 5 shows the manufacturing apparatus 10 of the base material which becomes the back side of the wallboard, and here, for example, cement, a filler, a short fiber mainly composed of pulp as a reinforcing material, a slurry in which water is mixed. When the raw material M ₁ is supplied, the arrangement of the fibers 5 can be obtained by the papermaking operation of the apparatus 10 to be described later. A similar substrate can be obtained when silicate calcium is used as the main raw material. In the figure, reference numeral 11 denotes a belt having air permeability, which is moved in the direction of the arrow A by the rollers 12, 13, 14 and an appropriate guide member through the upward inclined portion 15 and the horizontal portion 16, and the unloaded side 17 is guided to the guide roller 18. To return.
[00 14 ]
The upper surface of the upward inclined portion 15 is covered with a cover 19, a feed port 20 for the raw material M ₁ is connected to the upper side thereof, and a reflux device 21 is connected to the lower end thereof. Via the supply port 20. Further, a leveling device 24 is provided on the upper surface of the horizontal portion 16 so that the belt 26 is stretched over three rollers 25 and is driven at substantially the same speed as the belt 11. Negative pressure chambers 27 and 28 are provided on the lower surface of the upward inclined portion 15 and the lower surface of the horizontal portion 16 and are evacuated by a vacuum pump. Of these, the negative pressure chamber 27 is particularly important.
[00 15 ]
When the belt 11 is run in the direction of arrow A and the raw material M ₁ is supplied from the supply port 20,
The raw material M ₁ is transported in the direction of arrow A by friction force while receiving a downward suction force from the negative pressure chamber 27 and flows down in the direction of arrow B by gravity, and the lower layer portion is moved upward by the speed difference in both directions. The upper layer portion flows down, returns from the annular flow path 23 to the supply port 20, and is mixed with new raw materials.
[00 16 ]
At this time, since the lower layer portion of the raw material M ₁ is strongly subjected to the negative pressure of the negative pressure chamber 27, if one of the fibers 5 in the lower layer portion is viewed, the portion close to the belt 11 is sucked together with water to the belt 11 side. The belt 5 and the raw material M _{1 in} the vicinity thereof move together, and the portion far from the belt 11 moves according to the movement of the raw material M _{1 in} the direction of arrow B.
3 indicates the movement direction of the belt 11 as indicated by 5a in FIG. 3, and the fibers in the vicinity of the belt 11 are subjected to a strong papermaking action, and are aligned and increased in strength as shown in FIG. The upper surface of the fiber 5 also papermaking is acted the ratio facing the falling direction as the belt 11 side not large, because the ones facing the multidirectional many, not aligned fibers, polymerized surface material M ₂ below There are easy advantages.
[00 17 ]
Next, the raw material M ₁ is squeezed by the horizontal portion 16 and the roll 25 of the leveling device 24 and the upper surface is rubbed by the belt 26, but small irregularities remain on the surface. Then, the paper making action under the negative pressure and the squeezing action of the roll 25 result in a semi-dehydrated state that does not flow, and is carried out with a substantially constant thickness, cut into a constant length, and cut into a constant length. It becomes.
[00 18 ]
On the other hand, a mold frame 30 shown in FIG. 6 is prepared for the raw material M _{2 of the} surface material that becomes the surface portion of the wall plate 1, and the bottom surface 31 of the mold frame 30 has a ridge 32 for forming the groove 4. And other uneven patterns are appropriately provided, and slurry-like raw material M ₂ made of substantially the same material as the base material 34 is flowed down and sprayed into the mold 30. This allows the fibers of the raw material M ₂ is not aligned but uneven pattern is deeply Moreover corner can sharp surface material M _2.
[00 19 ]
The raw material M ₁ carried out from the base material manufacturing apparatus 10 is cut into a predetermined length while being conveyed by the conveyor 33 in FIG. In the lifting device 35, a lattice body 37 for preventing air flow is fixed to an opening portion of a downward shallow box-shaped lifting adsorber 36, and a wire net and a felt that act as a perforated plate on the lattice body 37. A dewatering body 38 is stretched, and a lifting adsorber 36 is connected to a vacuum source by a hose 39 and fixed to a robot arm 40. When the lifting device 35 is brought into contact with the surface of the base material 34 and evacuated, the base material 34 is adsorbed while being absorbed, so that the base material 34 is separated from the conveyor 33 by moving the device 35 with the robot arm 40. Can move to a position.
[00 20 ]
FIG. 8 shows a reversing device 41. The reversing device 41 receives the base material 34 lifted by the lifting device 35, adsorbs the back surface 34a thereof, and then reverses it so that the front side is turned down. Is pressed onto the raw material M ₂ of the surface material in the mold 30 of FIG. In FIG. 8, a dewatering body 38 composed of a wire net 43 and a felt 44 is supported by a lattice body 45 that does not impede air flow at the opening of a shallow box-shaped inverted adsorber 42 facing upward. Connected to the source. The bottom of the adsorber 42 is connected to the robot arm 48 via a plurality of reinforcing ribs 47.
[00 21 ]
As shown in FIG. 8, the reversing device 41 is moved below the lifting device 35, one of the devices 35, 41 is moved up and down to bring the adsorber 42 of the reversing device 41 into close contact with the back surface of the base material 34, After the upper lifting adsorber 36 is returned to atmospheric pressure and the inside of the lower reverse adsorber 42 is depressurized to adsorb the base material 34 to the reverse adsorber 42, the reversing device 41 is rotated in the direction of arrow A. As shown in FIG. 9, the base material 34 is polymerized on the uncured surface material M ₂ filled in the mold 30 to release the negative pressure, and the base material 34 is placed on the surface material M ₂ . Placed on.
[00 22 ]
In FIG. 9, the mold 30 is stopped when it is conveyed by the conveyor 50 and comes on the abutment 51, and the reversing device 41 is moved away by superposing the base material 34 on the surface material M ₂ by the above operation. After that, it is conveyed, and after being cured, the mold is formed to become the wall plate 1.
[00 23 ]
Incidentally, wherein at the substrate 34 to the surface material M ₂ it was polymerized by adsorption reversed in operation, may of course also be polymerized by other methods. Further, when the polymerized wallboards are stacked and pressed, and the molds are separated after curing, a sharply patterned wallboard may be formed.
[00 24 ]
After placing the base material 34 on the surface material M _{2 in} the step of FIG.
To increase the adhesion between the surface material M ₂ and the base material 34,
The surface material M ₂ in the mold 30. In forming a pressurized precise uneven pattern, it is possible to solidify the water extruded.
[00 25 ]
Next the embodiment shown in FIG. 10 to 13, after repeated substrate 34 in the raw material M ₂ of the surface material, in order to further promote the solidification of the surface material M ₂ and the base material 34 actively perform dehydration It is something to make. In addition, the thickness of the surface material M ₂ and the base material 34 is shown enlarged compared with that of FIG.
[00 26 ]
The reverse adsorber 42 is pulled up from the state of FIG. 9, and the surface material M ₂ and the base material 3 are placed on the mold 30.
4 is placed on the conveyor 52 in FIG. 10 and sent to the reversing mechanism 53. In the reversing mechanism 53, a rotating ring 54 is rotatably supported by a support roller 53a, and conveyors 55 and 56 are installed on the upper and lower sides. The mold 30 and the surface material 34 are moved from the conveyor 52 to the inside of the rotating ring 54. Then, it is fed between the conveyors 55 and 56, is rotated halfway in the direction of arrow B, the base material 34 is lowered, sent out onto the conveyor 57, and further sent to the dehydrator 58 of FIG.
[00 27 ]
The dehydrator 58 has a porous conveyor 59, a vacuum chamber 60, a vacuum duct 61, a support grid 62 that supports the conveyor 59 in the lower part, and a pressure plate 63 in the upper part. When the pressing plate 63 is pressed in the direction of arrow C, the base material 34 and the surface material M ₂ are pressed through the mold 30 to squeeze out moisture, and the dehydration is further promoted by the suction action of the vacuum chamber 60. And cure faster.
[00 28 ]
Then, as shown in FIG. 13, the wall plate 1 in which the surface material M ₂ is in close contact with the base material 34 is obtained by removing the mold 30 from the conveyor 64.
[00 29 ]
In the dehydrator 58, dehydration may be performed only by evacuation, or water may be squeezed only by pressurization of the pressure plate 63. In either case, the water flows downward and is discharged so that it can be easily dehydrated.
[00 30 ]
The wall plate 1 made by the above operation has a high ratio of the reinforcing fibers 5 facing the longitudinal direction of the base material 34, so that the tensile strength in the longitudinal direction is larger than that in the width direction and the bending is curved in the longitudinal direction. The strength is high, and the reinforcing fibers 5 are arranged in the longitudinal direction in a large amount on the back side, particularly as indicated by 5a. Therefore, the strength against bending causing the longitudinal tension on the back side is large. The front side of the material 34 and the surface material M ₂ are easy to polymerize because the fibers are not aligned with each other, and are molded in the mold 30 in an uncured state, and therefore have a surface shape that accurately transfers the mold surface As a result, a wall plate having high strength and a desired deep uneven shape on the surface can be obtained.
[00 31 ]
【The invention's effect】
As described above, the nonflammable plate according to the present invention has a plate surface with a large depth of unevenness because the surface material is formed with an uneven pattern by embedding a slurry-like raw material in a mold. In addition, by increasing the ratio of the reinforcing fibers facing the longitudinal direction in the base material, the strength in the longitudinal direction of the seat plate is increased by 10% or more from the width direction, so even if the same amount of reinforcing fibers are used, The ratio of strength in the longitudinal direction can be improved compared to the case where the direction of the reinforcing fiber is not, and the bending in the longitudinal direction is most caused by the pressure or impact applied to the surface when handling the board or attaching to the building. Since the bending is easy to receive, there is an advantage that the substantial strength can be increased.
[00 32 ]
According to the present invention , the reinforcing fibers for the base material can be directed in the longitudinal direction only by using a conveyor belt having an upwardly inclined portion and a negative pressure chamber. In addition, it is easy to manufacture a base material having a large strength aligned in the longitudinal direction, and on the other hand, since the surface portion is made of a separate mold, there is an advantage that an accurate pattern can be easily made. Since it is used for lifting, reversing and mounting on a surface material, there is an advantage that a large-sized plate can be easily made.
[00 33 ]
Further , according to the present invention , since the unsolidified surface material is pressed through the base material in the mold, there is an advantage that accurate unevenness is formed and the base material can be closely adhered to the base material. And the water | moisture content in a surface material is spin-dry | dehydrated through a dehydration body, and solidification and drying of a board are accelerated | stimulated.
[00 34 ]
Alternatively, the base material is brought into close contact with the upper surface of the uncured surface material, and these are inverted to pressurize the surface material, and the back side of the base material is evacuated. In addition to the action, a water-absorbing action is produced, solidification is promoted, and work efficiency is improved.
[00 35 ]
Further , since the uncured surface material is stacked on the base material and vacuumed from below, moisture flows downward and is easily separated from the raw material, and there is an advantage that the dehydration efficiency is improved.
[Brief description of the drawings]
FIG. 1 is a plan view of a plate embodying the present invention. FIG. 2 is a side view of the same. FIG. 3 is an enlarged cross-sectional view of the same. FIG. 6] Cross-sectional view of the form of the surface material [Fig. 7] Front view of the substrate lifting device [Fig. 8] Front view when receiving the reversing device [Fig. 9] Front view when the device is mounted [Fig. 10] Front view of the reversing mechanism used in another manufacturing method [FIG. 11] Front view in the reversed state [FIG. 12] Front view of the dehydrator [FIG. 13] Front view when the product is taken out [Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Board 2 Front surface 3 Back surface 4 Groove 5 Fiber 10 Base material manufacturing apparatus 11 Belt 24 Leveling device 27, 28 Negative pressure chamber 30 Mold 34 Base material 35 Lifting device 36 Moving adsorption device 41 Reverse device 42 Reverse adsorption device 53 Reverse mechanism 58 Dehydrator

Claims (3)

While running the breathable belt endlessly through the ascending slope, negative pressure is applied to the lower surface of the ascending slope,
A slurry-like raw material mixed with a curable non-combustible material, water, reinforcing fibers, etc. is supplied to the ascending slope, and the raw material is transported upward while flowing down on the belt, and the fiber is brought to the surface side. On the other hand, a semi-dehydrated base material having a substantially equal thickness is made in a state where the length is aligned more than 10% on the back side,
Separately from the base material, the raw material substantially the same as the base material is molded into the mold of the surface material provided with a mold surface for forming the surface of the plate at the bottom,
After polymerizing the surface of the substrate to the unsolidified top surface of the surface material of the said mold, by applying a water-absorbing dewatering member and perforated plate on the back surface of the base material, and the substrate and the surface material by pressure each of the mold, the production method of incombustible plate, characterized in that solidified together. The incombustible plate according to claim 1 , wherein the polymerizing base material and the surface material are turned upside down together with a formwork, and the pressing step is performed in a state where the base material is positioned on the lower side . Production method. In claim 2, the manufacturing method of incombustible plate, which comprises dehydrating the said substrate and the surface material was evacuated from the back side while pressurizing each of the formwork.

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