JP4339640B2 - Method and apparatus for manufacturing lightweight cellular concrete board - Google Patents

Description

  The present invention relates to a method and an apparatus for manufacturing a lightweight cellular concrete board, and particularly to a technique for setting a reinforcing wire mesh embedded in a lightweight cellular concrete board with high accuracy.

  A mud-like raw material mortar slurry in which a foaming agent mainly composed of cement, limestone, silica stone, gypsum and the like and water are mixed with the light-weight cellular concrete raw material is used. And in the manufacture of lightweight lightweight concrete thin products, a reinforcing wire mesh is embedded inside the product to increase the strength of the product, and the reinforcing wire mesh is set in a mold for molding lightweight lightweight concrete before injection. . When injecting the raw material mortar, foaming, or semi-curing, the reinforcing wire mesh set in the mold moves, and it is not easy to ensure the positional accuracy of the reinforcing wire mesh in the lightweight cellular concrete.

In order to solve this, various methods have been proposed in the past. In particular, the method is roughly divided into a vertical support method in which the set bar is supported up and down and a cantilever method in which only the upper side is supported.
Among these, as a conventional example of the vertical support system, there is a technique shown in Patent Document 1 by the present applicants. That is, a pair of rod-shaped positioning support jigs (hereinafter referred to as set bars) are attached to a positioning support jig fixing jig (hereinafter referred to as a set frame) in a cantilever manner in which only the upper end is fixed, and the pair of sets What is spread between the rods by a slide mechanism is lowered with a crane or the like onto a reinforcing wire mesh aligning jig called a Ken mountain, in which a reinforcing wire mesh is previously set between the blades and vertically aligned. Thus, after inserting the reinforcing wire mesh between the set rods, the upper portion of the reinforcing wire mesh is held by the holding mechanism, and the space between the set rods is narrowed by the slide mechanism, and then the lower end of the set rod is attached to the lower end fixing plate. The set frame is transferred onto the formwork with a crane, the fixed plate at the lower end of the set bar is pressed against the formwork bottom plate, and concrete is poured into the formwork.
Japanese Patent Publication No. 3-48006

In addition, as a configuration that does not use a fixed plate, in the technique disclosed in Patent Document 2, a set rod as a rod-shaped reinforcing positioning support jig is inserted into a hole in the mold bottom plate so that the reinforcing wire mesh does not move into the mold in advance. After planting and setting, insert a reinforcing wire mesh between the set bars, then set the set frame as a jig to fix the upper part of the set bar on the mold, fix the upper part of the set bar, and then mold the mortar. There is a method to inject into the frame.
Japanese Utility Model Publication No. 49-3265

On the other hand, as an example of a cantilever method, Patent Document 3 discloses a set frame as a positioning support jig fixing jig in a cantilever type in which only a pair of rod-shaped reinforcing wire mesh positioning support jigs are fixed at the upper end. Attach and set a reinforcing wire mesh previously aligned by an alignment jig between the set bars. Thereafter, the reinforcing wire mesh is taken out together with the set frame from the alignment jig while the lower end of the set bar is in a free state, and a large number of reinforcing wire meshes are set on the mold frame. And after holding with a holding device so that a reinforcing wire mesh does not fall, it sets on a formwork which injects mortar with a crane etc., and injects mortar. A system is disclosed in which after a mortar foaming, the set frame is lifted by a crane or the like, taken out from the form frame for each set bar in the mortar, and the mortar attached to the set bar is removed and cleaned by a cleaning device.
JP-A-8-323733

Comparing such methods, in the vertical support method, as shown in the cited document 1, a fixing plate is attached to the lower end of the set bar, so that the fixing plate remains on the bottom plate after demolding. There is a problem that man-hours are required for assembly.
Moreover, since it is complicated and requires many members, there is a problem that the maintainability of the manufacturing apparatus is lowered and the manufacturing cost is increased.
In Citation 2, which does not use a fixed plate, an operation using an implanter is required to insert a set bar into the bottom plate. Not only is the work efficiency poor, but the holes in the bottom plate that are not used for product production are caused by mortar, etc. Cleaning work such as removal of mortar that has been buried and hardened during reuse is necessary. Moreover, since the hole of the bottom plate expands due to continuous use and the set rod may fall down, it is necessary to replace the bottom plate regularly.

  On the other hand, the cantilevered support method can simplify the structure compared to the vertical support method, but to compensate for the difference in strength from the vertical support, the set rod diameter must be increased, and after mortar curing In the configuration of extracting, there is a problem in the strength and appearance of the product obtained. Moreover, even if it is extracted before mortar curing, the same problem arises because it becomes uneven with the foamed portion.

  The present invention has been invented to eliminate the above-mentioned conventional drawbacks, and can be manufactured while suitably ensuring the positional accuracy of the reinforcing wire mesh, and contributes to improvement in work efficiency and product quality. It aims at providing the manufacturing method and manufacturing apparatus of a cellular concrete board.

In order to achieve the above object, the present invention provides the following method for producing a lightweight cellular concrete board.
That is, according to the first aspect of the present invention, the lightweight cellular concrete in which the reinforcing wire mesh is buried in the mold frame while the lightweight cellular concrete raw material mortar is injected, foamed and cured, and the reinforcing wire mesh is embedded. A method of manufacturing a plate, wherein at least one of the rod-like bodies is disposed on a set frame that is a positioning support jig fixing jig in the vicinity of an upper end portion of a set rod composed of a pair of rod-like bodies that are positioning support jigs of a reinforcing wire mesh. Manufactured after being mounted in a vertically movable state. The manufacturing method includes a step of inserting and supporting a reinforcing wire mesh between the rod-shaped bodies, and a raw material mortar in the mold frame while pressing the lower end of the rod-shaped body that can move up and down against the bottom plate of the mold frame. , A step of foaming and curing the raw material mortar, a step of extracting the set frame and the set bar, and a step of demolding the cured raw material mortar from the mold. In the manufacturing method of a lightweight cellular concrete board (ALC board), after demolding, it cut | disconnects to a predetermined | prescribed magnitude | size with a mortar cutter, and autoclave curing is performed subsequently. This completes the product plate.

  According to the invention of claim 2, the lower end of the rod-shaped body of the set bar is sharpened, the pressing pressure to the bottom plate of the mold is increased, and the set rod presses the bottom plate more strongly, This is intended to improve positioning accuracy.

  According to the invention described in claim 3, the bottom plate of the formwork is provided with a small recess where the lower end of the rod that can be moved up and down is abutted, and the set rod is moved by pouring or foaming raw material mortar. It is possible to prevent this more effectively.

The present invention also provides the following lightweight cellular concrete board manufacturing apparatus.
That is, the invention according to claim 4 is an apparatus for holding the reinforcing wire mesh at a predetermined position in the mold, and includes at least one of a set rod composed of a pair of rod-shaped bodies as positioning reinforcing jigs for the reinforcing wire mesh. In a state where the rod-shaped body of the set bar can move up and down, the set frame which is a positioning support jig fixing jig attached to the vicinity of the upper end of the set bar and the rod-shaped body acting on the bar-shaped body of the set bar which can move up and down It is characterized by comprising pressing means for pressing the lower end against the bottom plate of the mold and a mold consisting of a side plate and a bottom plate for injecting raw material mortar.

Moreover, the invention of Claim 5 provides the manufacturing apparatus of the lightweight cellular concrete board by which the rod-shaped body lower end of the said set stick | rod is a sharp shape.
Furthermore, the invention described in claim 6 is characterized in that a small concave portion is provided in the bottom plate of the formwork so that the lower end of the rod-shaped body capable of moving up and down of the set bar abuts.

That is, according to the first aspect of the invention, the position accuracy of the reinforcing wire mesh is obtained by injecting the raw material mortar into the mold frame while pressing the lower end of the set bar that can move up and down against the bottom plate of the mold frame. It is possible to manufacture a lightweight cellular concrete board while ensuring the above.
Since there is no need to fix the lower part of the set bar as in the conventional vertical support system, the workability is good and the productivity is improved.
Further, since the movement of the set bar can be effectively suppressed while adopting the cantilever method, the set bar diameter can be minimized, and the product quality and appearance can be improved.

  According to the invention described in claim 2, the set bar can press the bottom plate more strongly. Similarly, according to the invention described in claim 3, the lower end of the rod-shaped body abuts the small recess. The set bar becomes more difficult to move when the raw material mortar is injected or foamed, and the positioning accuracy can be improved.

In addition, according to the invention described in claim 4, in addition to providing a manufacturing apparatus that exhibits the effects of the above method, the apparatus can be simplified, contributing to the suppression of manufacturing equipment costs and the improvement of maintenance. .
Similarly, according to the invention described in claim 5, the set bar can press the bottom plate more strongly, and according to the invention described in claim 6, the lower end of the rod-shaped body abuts the small recess. Thus, the set bar becomes more difficult to move when the raw material mortar is injected or foamed, and the positioning accuracy can be improved.

  The present invention is a lightweight cellular concrete manufacturing method and apparatus for performing foam molding processing that can improve the work efficiency while ensuring the positional accuracy of the reinforcing wire mesh in the product plate. A set bar for setting the reinforcing wire mesh so as not to move is pressed against the mold.

As the best mode of the present invention, it is possible to use a manufacturing apparatus (1) as shown in FIG. 1 using a spring force. The manufacturing apparatus (1) includes a pair of main frames (20) and (20) above a container-shaped mold (12) composed of a side plate (10) and a bottom plate (11), and several pieces between the main frames. The set rod fixing frame (21) is installed to form the set frame (22).
The set rod fixing frame (21) is fixedly provided with a reinforcing pipe (30) at a predetermined interval related to the thickness of the product plate, and a reinforcing wire mesh (40) is sandwiched between the reinforcing pipe (30). The set bars (31) and (32) are fixed. The pair of set bars (31) and (32) are configured so that one of the lengths is slightly shortened, and when the reinforcing wire mesh (40) is set between the set bars, the set bars (31) and (32) are easily set.
The present invention is characterized in that an elevating / lowering set bar (33) having a shape similar to that of the set bar and configured to be partially movable up and down is provided.

That is, the lifting set bars (33), (33), and (33) are made by allowing a predetermined number of set bars on the side plate (10) side of the mold (12) to be lifted and lowered. Instead, it is provided. The slide guide tube (34) is fixed to the set rod fixing frame (21) instead of the reinforcing tube (30), and the lifting set rod (33) is slidable in the tube.
The short-side set bar (31) that is paired with the lifting set bar (33) is fitted in the reinforcing tube (30) in the same manner as described above.

Next, the lifting mechanism of the lifting set bar (33) will be described. The lifting / lowering set bar (33) extends to above the slide guide tube (34), and a moving plate (50) is connected to the upper end thereof. Below the moving plate (50), a fixed plate (51) having a hole portion through which an elevating set bar (33) is inserted so as to be movable up and down is disposed.
The fixing plate (51) is fixed by a connecting plate (52) from the upper surface of the set bar fixing frame (21), as shown in a partial sectional view A of FIG. The cylinder portion (53a) of the air cylinder (53) is attached to the lower surface.
On the other hand, the upper end of the rod portion (53b) of the air cylinder (53) is connected to the moving plate (50), and the moving plate (50) moves up and down as the air cylinder (53) expands and contracts.
Furthermore, a spring (35) is suspended between the fixing plate (51) and the middle locking portion (33a) of the lifting / lowering set rod (33), and the spring (35) is compressed and moved when the air cylinder (53) is operated. While the plate (50) is raised and is not in contact with the bottom plate (11) as shown in FIG. 2, for example, the height is substantially the same as that of the set rod (32) on the long side, while the air cylinder ( 53) returns, the lifting and lowering set bar (33) descends and presses the bottom plate (11) by the elastic force of the spring (35).
Since the movable plate (50) is connected to the three lifting / lowering set bars (33), (33) and (33), each lifting / lowering set bar (33) is lifted and lowered simultaneously by one air cylinder (53).

  In this way, for example, each of the three on the side plate (10) side of the formwork is set as an elevating set rod (33) and the bottom plate (11) is pressed, so that the elevating set rod (33) is an upper slide guide. Not only is it supported by the pipe (34), but also it does not move in the horizontal direction at the lower end due to friction with the bottom plate (11), so that the reinforcing wire mesh can be securely placed in place as in the conventional vertical support system. Can be held. Needless to say, the upward displacement of the reinforcing wire mesh (40) during foaming of the concrete can also be suppressed.

The lifting and lowering set bar (33) is preferably made of steel for economic efficiency and accuracy, and spring steel is preferred, and the cross-sectional shape may be rectangular other than circular, but circular for economic efficiency and straightness accuracy. preferable.
And a lower end makes it a sharp shape so that the bottom plate (11) may be pressed more effectively and the pressing pressure may increase. That is, as is apparent in the figure, the lower end is tapered to reduce the contact area with the bottom plate (11).
In the present invention, the shape of the lower end of the lifting / lowering set bar (33) does not necessarily need to be a sharp shape, but as described above, the tip cone or the shape cut obliquely like the lower end of the set bar (31). It is desirable.

The manufacturing apparatus (1) of the lightweight cellular concrete board by this invention can take the above structures. A manufacturing method using this will be described next.
A lath net, which is a reinforcing wire net, is loaded on the carriage and transported, and the lath net (40) is aligned upright (netted) on the sword mountain-shaped alignment jig (60) shown in FIG.
Then, a lath net (40) is set in the manufacturing apparatus (1). FIG. 5 shows the set work process. That is, in (A), a pair of set bars (31) (32) having a lower end formed in a conical shape or a side into which a reinforcing wire mesh is inserted in order to make it easier to enter the lath net (40), and ascending and descending The reinforcing frame (3) in which the lath net (40) is previously aligned between the blades of the alignment jig (50), as shown in (b), the set frame (22) to which the set bar (33) is attached. It is lowered with a crane or the like and set so that the lath net (40) is sandwiched between the set bars (31) and (32) or between the set bars (31) and the lift set bar (33).
Thereafter, the set frame (22) is lifted by a crane or the like, and the lath net (40) is taken out of the alignment jig (60) as shown in (c) and placed on the bottom plate (11) of the mold (12) into which concrete is poured ( Set (103) as in (d).

Then, after injecting and foaming lightweight concrete mortar, the set frame (22) is lifted with a crane or the like, and the set bars (31) (32) and the lifting set bar (33) in the mortar are taken out from the mold (12). .
Furthermore, after mortar hardening, it demolds and slices to the thickness of a product board with a mortar cutter. Subsequently, it is carried into an autoclave and subjected to autoclave curing. This completes the product plate.

By the way, in the operation process as described above, the lath net (40) falls from between the set bars (31) (32) and the lifting set bar (33) in the state shown in FIG. As shown in FIGS. 6 and 7, a rotary gripping tool (70) having a bifurcated tip is provided above the gripping tool insertion hole (22a) provided in the set frame (22). The set frame (22) is set on the mold after the lath net (40) is held by the holding tool (70).
And this method by the holding tool (70) using the rotation means which is not shown in figure which is disclosed by patent document 4, for example is carried out on the lath net | network (40) aligned between the blades of the alignment jig (60). The set frame (4) is lowered so that the lath net (40) is sandwiched between the set rods (31) (32) and the lifting set rod (33), and the set rods arranged in a horizontal row ( 31) (32)-The holding tool (70) suspended above is lowered from the rectangular holding tool insertion hole (22a) provided between the rows of the lifting and lowering set bars (33). .
As shown in FIG. 8, the lath net (40) is inserted into the slit of the forked portion formed at the front end of the gripping tool (70), and then the gripping tool (70) is moved about 90 by the rotating means. The lath net (40) is twisted and gripped by rotating it, and the metal net is flexibly utilized to make a firm grasp and transferred to a mold (12) for injecting mortar. When the grip is released, the lath net (40) is released by rotating in the reverse direction.
A plurality of gripping tools (70) are arranged in the longitudinal direction of the set frame (22) so as to grip at least two, preferably three or more, per lath net.
JP-A-9-234725

In this example, lightweight concrete having a product plate thickness of 50, 75, and 100 mm and a length of 1200 to 2400 mm was manufactured. The set rods (31), (32) and the lifting / lowering set rod (33) used have a diameter of 5.5 mm and do not impair the appearance with respect to the thickness of the product plate. With the conventional cantilever type, sufficient rigidity cannot be obtained with this diameter, and it has been difficult to ensure the positional accuracy of the lath net, but this method has made it possible to use it.
Each set bar is suspended in the form frame (12) of the side plate (10) at intervals of 50 mm and 75 mm according to the thickness of the product plate, and a long set bar (32) and a short set bar (31). Pours mortar from the bottom plate (11) with the lower end positioned upward. Further, when the elevating set bar (33) is set on the formwork (12), the lower end of the elevating set bar (33) is located above the bottom plate (11) with the air cylinder (53) protruding. However, when the mortar is injected, the air cylinder (53) returns and presses the bottom plate (11) by descending. In the embodiment of the present invention, any elastic member such as rubber or resin can be used without using a spring, or an actuator may be used for pressing. At this time, an actuator mechanism capable of moving up and down can be used without necessarily using an air cylinder.

In this embodiment, there are three lifting / lowering set bars (33) on the side plate (10) side. However, the number of lifting / lowering set bars (33) may be an appropriate number that can suppress the movement of the lath net. May be.
Moreover, although the length is changed by one set of rods (31) and (33), the length may be the same in the practice of the present invention. Further, in this case, the lifting / lowering set bar (33) is not limited to one, and one set of both set bars may be used as the lifting / lowering set bars (33) and (33).

In the present invention, as shown in FIG. 9, in addition to the first embodiment, a groove can be provided in the bottom plate (11).
That is, in this embodiment, the bottom plate (11) is provided with a small recess where the lower end of the lifting / lowering set rod (33) abuts, and an inscribed groove or a round groove is provided in parallel with the reinforcing wire mesh (40), Alternatively, a hole is provided at a corresponding position of the lifting set bar (33). The groove or hole is locked by the lower end of the lifting / lowering set bar (33) abutting in the groove or hole, and the set bar is more difficult to move than in the first embodiment, and the positional accuracy is improved. Is planned.
At this time, since the depth of the small concave portion of the present invention is very small as compared with the conventional vertical support system, the mortar is easily removed by normal cleaning of the bottom plate, and no separate work such as cleaning of the groove is required. There is a feature in the point.

It is front view sectional drawing of the manufacturing apparatus of the lightweight cellular concrete board concerning this invention. It is front view sectional drawing explaining the state at the time of the setting of the raising / lowering set stick | rod in the manufacturing apparatus of the lightweight cellular concrete board concerning this invention. It is front view sectional drawing explaining the state at the time of concrete injection | pouring of the raising / lowering set stick | rod in the manufacturing apparatus of the lightweight cellular concrete board concerning this invention. It is a perspective view which shows the state which inserts a set frame in an alignment jig. It is explanatory drawing which shows the operation | work process which sets a set frame to a formwork. It is explanatory drawing which shows the state which inserts a set stick | rod between the metal nets aligned with the alignment jig. It is explanatory drawing which shows the state which inserts a set stick | rod between the metal nets aligned with the alignment jig. It is explanatory drawing of a holding tool. It is sectional drawing of the baseplate vicinity in Example 2 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Light-weight cellular concrete board manufacturing apparatus 10 Side board 11 Bottom board 12 Formwork 20 Main frame 21 Set bar fixed frame 22 Set frame 30 Reinforcement pipe 31 Set bar (short)
32 set bars (long)
33 Lifting set bar 34 Slide guide tube 35 Spring 40 Reinforcing wire mesh 50 Moving plate 51 Fixed plate 52 Connecting plate 53 Air cylinder

Claims (6)

A method for producing a lightweight cellular concrete board in which a reinforcing wire mesh is embedded by holding a reinforcing wire mesh in a predetermined position in a formwork, injecting a lightweight cellular concrete raw material mortar, foaming and curing, and
The upper end of the set rod composed of a pair of rod-shaped bodies that are positioning support jigs for the reinforcing wire mesh is attached to a set frame that is a positioning support jig fixing jig so that at least one of the rod-shaped bodies can move up and down. so,
Inserting and supporting a reinforcing wire mesh between the rod-shaped bodies;
Injecting raw material mortar into the mold while pressing the lower end of the set bar that can move up and down against the bottom plate of the mold;
Foaming and curing the raw material mortar,
Extracting the set frame and set rod;
A method for producing a lightweight cellular concrete board, comprising a step of demolding a cured raw material mortar from a mold. The method for producing a lightweight cellular concrete board according to claim 1, wherein the lower end of the rod-like body of the set bar is sharpened to increase the pressure applied to the bottom plate of the formwork. The manufacturing method of the lightweight cellular concrete board of Claim 1 or 2 which provided the small recessed part which the lower end of the rod-shaped body which can move the said set bar up and down collided with the baseplate of the said formwork. An apparatus for holding a reinforcing wire mesh in a predetermined position in a mold,
A set bar composed of a pair of rod-shaped bodies, which is a positioning support jig for the reinforcing wire mesh,
In a state where at least one of the rod-like bodies can move up and down, a set frame which is a positioning support jig fixing jig to which the vicinity of the upper end portion of the set bar is attached;
A pressing means that acts on a vertically movable rod-shaped body of the set rod and presses the lower end of the rod-shaped body against the bottom plate of the mold;
An apparatus for producing a lightweight cellular concrete board, comprising: a mold comprising a side plate and a bottom plate for injecting a lightweight cellular concrete raw material mortar. The manufacturing apparatus of the lightweight cellular concrete board of Claim 4. The lower end of the rod-shaped body of the set bar has a sharp shape. The manufacturing apparatus of the lightweight cellular concrete board of Claim 4 or 5 which provided the small recessed part which the lower end of the rod-shaped body which can move the set bar up and down abutted in the baseplate of the said formwork.