JPS5818352B2 - Fully automatic batch continuous polymer impregnated reinforcement manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a polymer-impregnated reinforcement material for civil engineering and construction, namely, polymer-impregnated concrete (PIC: Polymer I).
The present invention relates to a method for producing polymer-impregnated reinforcing materials developed for the purpose of producing pregnate concrete in a continuous batch manner in the shortest possible time.

As is well known, the materials of PIC for civil engineering and construction, namely concrete (solidified material), include cement-based concrete that uses cement as a caking hardening agent as its main material, and gypsum-based concrete that uses gypsum as its main material. There is clay-based concrete (for example, plastered walls) that uses clay as the main material, and if such concrete is impregnated with monomer and hardened to become PrC, its properties can be greatly improved.

However, there are various conditions and problems depending on the material during monomer impregnation treatment.

For example, materials that require curing before being impregnated with a monomer solution are cured, hardened, and dried; plaster-based and clay-based materials are dried and hardened to prevent deformation, and then all are heated to 30°C.
Thereafter, it is necessary to cool down.

In general, the standard curing period for cement-based materials takes a long time, from 3 to 28 days, and in order to shorten this curing time, special curing methods such as autoclave curing and steam curing require considerable capital investment and running time. Requires cost.

Furthermore, drying of cement-based materials using the hot air circulation method requires drying at a temperature of at least 120° C. for about two days.

In other words, the usual method requires at least 5 days to obtain a dry material that can be impregnated.

Moreover, in polymerization using heated air, for example, 4×4×16
(Even a small mortar molded product called l177i has a temperature of 80°C.
It takes 3 hours to sum.

Therefore, for large molded products, the time required to complete the entire manufacturing cycle is considerable.

In addition, in the case of cured wet cement-based concrete materials or wet gypsum-based or clay-based concrete materials immediately after forming,
When drying with high-temperature hot air, there is a risk that the surface layer dries too much first and becomes weathered.Also, even if hot air below 120°C is used, the surface layer dries first, so a heat insulating layer is formed on the surface. This results in deformation and cracking due to internal heating delays and uneven drying shrinkage.

Therefore, under normal pressure, it is necessary to gradually raise the temperature and wait for the internal moisture to diffuse before evaporating on the surface, so it is difficult to uniformly dry the inside of a large material even if it takes about 48 hours.

On the other hand, due to the heat insulating effect of the surface layer of the high temperature drying material, a long time is required for air cooling.

Therefore, this invention uses a new drying method to finish curing items that require curing in a short time, and uses a new drying and cooling method to finish drying and cooling items that do not require curing but requires a certain amount of drying. In addition to adopting a new method for monomer impregnation and polymerization, we aim to shorten the time required to complete the entire manufacturing cycle. By conducting the process continuously, we have developed a short-time continuous manufacturing method for PIC, which has been considered difficult in the past.

That is, the present invention provides a conveyance path that automatically conveys a certain number of slatted pallets loaded with materials to be processed in one batch on a roller conveyor in a continuous batch manner according to a set program. The first tunnel-type multistage pressure-resistant treatment chamber consists of a blowing countercurrent circulation heating chamber, a pressure vacuum self-evaporation drying chamber, and a low-temperature dehumidification air circulation cooling chamber, an automatic weighing device, a vacuum pressure impregnation chamber, and a pressurized moist heat polymerization chamber. A second tunnel-type multi-stage pressure-resistant treatment chamber and an automatic weighing device are arranged in series, and the doors of each chamber are connected by two parallel doors with multiple sets of booster joints, and the central axis of the booster joints is connected to the It is an automatic door with one-operation opening/closing double pressure-resistant seal that can be insulated and operated by the piston rond of the cylinder, and is carried one batch at a time through the steam displacement pressure equilibrium chamber at the inlet to the high-pressure, high-temperature, superheated steam blowing countercurrent circulation heating chamber, and set. While the number of batches is being carried in, the first batch that has undergone the prescribed heat treatment is carried into the pressure relief vacuum self-evaporation drying chamber, where it is rapidly dried. After that, low-temperature dehumidified air is blown into it, and then it is transferred to the low-temperature dehumidified air circulation cooling chamber. After being carried in and cooled, the dry weight is automatically weighed and recorded, and then the specified monomer solution is impregnated with vacuum pressure and pressure, and then carried into a pressurized wet heat polymerization chamber under air pressure, and the impregnated monomer solution flows out, foams, and blows out. After performing high-pressure wet heat polymerization while suppressing the pressure, the product is depressurized and transported, air-dried, and the impregnated weight is automatically weighed and recorded, and all these operations are centrally controlled according to a set program. be.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The features of this invention and its specific configuration will be described below based on embodiments shown in the drawings.

Figure 1 is a schematic diagram of the layout of the main parts of the embodiment, and ■ and ■ are the first and second tunnel-type multi-stage pressure-resistant processing chambers (hereinafter referred to as the first and second processing chambers) provided in the automatic conveyance path of the material to be processed. ), 13 and 16 are automatic weighing devices provided on the exit sides of the first and second processing chambers, respectively.

The first processing chamber (2) is composed of a steam displacement pressure equilibrium chamber 9, a high pressure high temperature superheated steam blowing countercurrent circulation heating chamber 10, a pressure relief vacuum self-evaporation drying chamber 11, and a low temperature dehumidification air circulation cooling chamber 12.
The second processing chamber U includes a vacuum pressurized impregnation chamber 14 and a pressurized moist heat polymerization chamber 1.
The crotch pressure-resistant automatic doors 1 to 8 of each processing chamber have a single-operation opening/closing double pressure-resistant seal type structure as schematically shown in FIG.

That is, in the example shown in Fig. 2, two parallel doors a and b are connected by two sets of booster joints c and d, and the central axis e of each booster joint is directly connected to the piston rod f of the hydraulic cylinder. rod f
When the piston rod f is lowered, the parallel doors a and b on both sides are released from the door backing surface and then raised, and when the piston rod f is lowered, the parallel doors a and b are opened by the booster joint and the The structure is such that it can be crimped with an arbitrary boost depending on the joint angle while providing an allowable amount of compression.

Also, as is clear from the drawing, parallel door a.

Needless to say, if the room temperature on both sides of b is different, the heat insulation effect can be easily increased by keeping the door on the high temperature side or both doors warm.

Note that when opening and closing these doors, the pressure on both sides must be balanced before operation, so it is unnecessary to explain that the differential pressure detector and hydraulic system must be interlocked to ensure safe and secure opening and closing. Nor.

First, the case of processing uncured cement concrete material immediately after forming will be specifically explained.

As a preparatory work before the start of operation, the jackets of the steam displacement pressure equilibrium chamber (hereinafter simply referred to as the equilibrium chamber) 9 and the high pressure and high temperature superheated steam blowing countercurrent circulation heating chamber (hereinafter simply referred to as the heating chamber) 10 are heated to a set temperature, Steam is sent from 2 to the heating chamber 10 and heated to the set pressure and temperature, and the superheated steam generator (hereinafter simply referred to as the heater) 17 and circulation blower 23 are started. When a steady state is reached, the After confirming that a set number of batches of pallets loaded with materials are stored in front of door 1, operation is started.

First, the valve V13 opens, and the drain and air in the equilibrium chamber 9 are discharged, and the differential pressure detector (
(not shown) becomes close to 0, No. 1 #1 opens,
After the first batch is carried into the equilibrium chamber 9, the first door is closed,
Steam is sent from valve v1, and air that is heavier than water vapor is sent to valve V1.
3 and the inside of the equilibrium chamber 9 is replaced with steam.

Then, the set time release valve V13 closes.

When the vapor pressure in the equilibrium chamber 9 rises and the pressure on both sides of the second door 2 is balanced, the valve 1 closes, and the valve v2 opens to maintain the differential pressure close to 0, while the second door 2 opens. , the first batch is carried into the heating chamber 10, and at the same time the second door 2 is closed.
is closed, valve V13 is opened, and the drain and high pressure steam in the equilibrium chamber 9 are discharged.

Meanwhile, the first door 1 is opened in the manner described above, the second batch is carried into the equilibrium chamber 9, and the above operation is repeated to carry the second batch into the heating chamber 10.

In this way, while the set number of batches are brought in, the first batch is constantly gradually dried with superheated steam while high-pressure and high-temperature curing progresses rapidly, causing most of the contained moisture to undergo a water-use reaction and harden and fix in the form of crystallized water. The free moisture is then dried at high pressure and high temperature until it approaches the equilibrium water retention rate of the relative humidity of the atmosphere.

This fact shows that when manufacturing concrete blocks, if a certain ratio of cement and sand is mixed, the water content is reduced to close to the amount of crystallized water required for the water-recycling reaction, and the mixture is kneaded while heating and compacted under pressure. It was easily confirmed through experiments that curing progresses rapidly even after curing in humid air.

From this point on, when the pressure in the equilibrium chamber 9 is released, the valve;
11 to release the water vapor in the equilibrium chamber 9, and release the valve for a set time ■
3 is closed, valve V13 is opened, and the equilibrium chamber 9 is brought into equilibrium with the atmospheric pressure. At the final stage when the succeeding batch is carried into the equilibrium chamber 9 and steam exchanged and pressurized, valve 3 opens again, and then valve V13 is opened. When the pressures in the equilibrium chamber 9, the heating chamber 10 and the drying chamber 11 are opened, the second door 2 and the third door 3 are simultaneously opened and one batch is transported through each door.

When the third door 3 and the valve 3 are closed, the valve v4 is opened and the steam in the drying chamber 11 is released.

When the discharge is finished, valve v4 is closed, valve V6 is opened, and vacuum pump 18 is started to evacuate the inside of drying chamber 11 through a condenser (not shown).

As a result, the free moisture in the material self-evaporates under reduced pressure vacuum due to the heat capacity of the material, similar to when the material is released, and vacuum drying progresses in the shortest possible time, and the high-temperature moisture contained inside the material also spontaneously evaporates. The surface evaporates, drying progresses, and the self-evaporation has the effect of rapidly vacuum cooling the inside.

Next, the set time vent valve v6 closes, the valve 5 opens, and the compressed air pressurized by a compressor (not shown) is cooled and dehumidified in the cold trap 19, becoming low-temperature dehumidified air and entering the drying chamber 11. Infused.

When the pressures of the drying chamber 11 and the low-temperature dehumidifying air circulation cooling chamber (hereinafter simply referred to as the cooling chamber) 11 are balanced, the fourth door 4 opens and one batch is transported, and the fourth door 4 and the valve 5 closes,
While the batch conveyed to the cooling chamber 12 is cooled for a set time, the conveyance process of subsequent batches proceeds as described above.

However, if it is necessary to control the partial pressure of the air in the drying chamber 11 when the third door 3 is opened, the inside of the drying chamber 11 must be evacuated each time, or the remaining air can be replaced with steam using a steam displacement valve (not shown). Replace with

Next, the batch that has been cooled for a certain period of time opens the pressure relief valve (not shown) to bring the inside of the cooling chamber 12 to atmospheric pressure, and then opens the fifth door 5.
The container is opened and carried out, and the dry weight is recorded using the automatic weighing device 13.

The above is a method for rapid curing, drying, and cooling of cement-based concrete molded products, but for plaster-based or clay-based molded products that do not require curing, drying, hardening, and rapid cooling is sufficient to prevent deformation or cracking. Therefore, equilibrium chamber 9, heating chamber 1
0. Compressed air is blown into the drying chamber 11, and water vapor that evaporates from the material makes the atmosphere inside the room humid.The atmosphere inside the heating chamber 10, where there is a risk of excessive humidity, is controlled by a circulation blower 23.
Low-temperature compressed air is introduced from (2) while being released from a relief valve (not shown) provided on the suction side of the air, so that the humidity level is adjusted to 8 cycles.

The material thus cured, dried and cooled is then transported into the vacuum pressurized impregnation chamber (hereinafter simply referred to as the impregnation chamber) 14 by opening the sixth door 6, and after the sixth door 6 is closed, the valve ■8 is opened. , At the same time, the vacuum pump 18 is activated to evacuate the room to a high vacuum, and then the valve v
8, then open the valve VIO to open the cooling cold storage tank 20.
The monomer solution inside is passed through the float valve 21 to the impregnation chamber 14.
inhale.

When the set liquid level is reached, valve VIO closes and valve v7 opens to introduce compressed air.

The liquid level is pressurized by this compressed air, the monomer solution is vacuum-impregnated into the voids of the material, and the liquid level gradually falls.

Therefore, the liquid level must be set to such an extent that the liquid level that falls after the vacuum pressurized metal sinks is slightly higher than the highest surface of the impregnated material.

When the set time has elapsed, when the valve V10 is opened under air pressure, the remaining monomer liquid is pushed back into the cooling tank 20, and the liquid adhering to the liquid contact surface such as the material surface also flows down, causing the liquid level to fall. When the float of the float valve 21 loses its buoyancy, the float valve 21 automatically closes.

By then, compressed air and high-pressure steam are mixed and introduced at a set ratio from valve ■1□ and Vll to bring the pressure in the pressurized moist heat polymerization chamber (hereinafter simply referred to as the polymerization chamber) 15 into equilibrium with the pressure in the impregnation chamber 14. At that time, the seventh door 7 is opened to transport the impregnated batch to the polymerization chamber 15, the seventh door 7 is closed, the propeller 22 is started, and the pressurized wet heat polymerization proceeds.

Meanwhile, the pressurized air in the impregnation chamber 14 is released by opening the valve 9, and after returning to atmospheric pressure, the sixth door 6 is opened and the vacuum pressurization impregnation operation described above is repeated from the introduction of the subsequent batch.

When the pressurized wet heat polymerization in the polymerization chamber 15 is completed, the valve v1
□ opens and pressurized moist hot air is released, and after both sides of the 8th door 8 reach atmospheric pressure, the 8th door 8 is opened and the polymerized product is taken out. After being air-dried, it is impregnated with an automatic weighing device 16. The weight is recorded.

In all conventional vacuum pressure impregnation methods, the remaining impregnating liquid is returned after vacuum pressure impregnation, the pressure is released to atmospheric pressure to take out the impregnated material, and then the impregnating liquid is hardened, so it is necessary to apply pressure. Not only does a portion of the impregnated liquid flow out due to internal pressure or gravity, reducing the impregnation rate, but the viscosity of the liquid increases as it flows down the surface, causing the surface to become rough. However, in the present invention, the surface layer is transferred to a polymerization chamber under pressure, and the surface layer is then transferred to a polymerization chamber under pressure. The pressure-moist heat polymerization proceeds rapidly from the initial stage, and the polymerization is completed while suppressing the swelling caused by the temperature rise of the internal impregnating liquid, which substantially improves the impregnation rate and eliminates the need for finishing the surface of the final product. It has a smoothing effect to some extent.

i It should be noted that because we expected an energy-saving effect by using part of the medium-pressure steam and air to pressurize other processing chambers, the setting program appears to be complicated and the waiting time to be long. Since the main process to accomplish the purpose of the present invention takes a considerable amount of time, it is easy to set the program so that even if a long waiting time is provided in the -; part, it will hardly affect the entire process. there is a possibility.

Therefore, in the method of the present invention, the setting program 10g can be partially changed by increasing or decreasing the piping system, especially automatic valves, etc., within the scope of the claims.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram of a layout of an embodiment of the present invention, and FIG. 2 is a schematic diagram of an example of a sectional view of a main part of an interstage heat-resistant automatic door. ; ■ and T...First and second tunnel-type multi-stage pressure-resistant treatment chambers, 1 to 8...Inter-stage pressure-resistant automatic doors, 9...
. . . Steam displacement pressure balance chamber, 10 . . . High pressure high temperature superheated steam blowing countercurrent circulation heating chamber, 11 . . . Pressure release vacuum self-evaporation drying chamber, 12 . . . Low-temperature dehumidification air circulation cooling room, 13 and 16... Automatic weighing device, 1
4... Vacuum pressurized impregnation chamber, 15... Pressurized moist heat polymerization chamber, 17... Superheated steam generator, 18...
... Vacuum pump, 19 ... Cold trap, 20 ... Monomer solution storage tank, 21
... Automatic float valve, 22 ... Stirring propeller, 23 ... Circulation blower, ■1 ~ V1
4... Valve.

Claims (1)

[Claims] 1 A certain number of slatted pallets loaded with materials to be processed are automatically conveyed in batches on a roller conveyor according to a set program. Steam displacement pressure equilibrium chamber 9, high pressure high temperature superheated steam blowing countercurrent circulation heating room 10
, a first tunnel type multi-stage pressure treatment chamber I consisting of a pressure relief vacuum self-evaporation drying chamber 11 and a low temperature dehumidification air circulation cooling chamber 12, an automatic weighing device 13, a vacuum pressure impregnation chamber 14 and a pressurized wet heat polymerization chamber 15. The second tunnel-type multi-stage pressure-resistant treatment chamber (■) and the automatic weighing device 16 are arranged in series in this order, and the doors of each of the chambers are
Two parallel doors are connected by multiple sets of booster joints, and the central axis of the booster joints is operated by the piston rod of a hydraulic cylinder, making it an easy-to-insulate, one-operation opening/closing double pressure-resistant seal type automatic door. Batch by batch is carried into the high pressure high temperature superheated steam blowing countercurrent circulation heating chamber 10 via the steam displacement pressure equilibrium chamber 9, and while the set number of batches are being carried in, the first batch that has undergone the prescribed heat treatment is transferred to the pressure relief vacuum self-evaporation drying chamber. After being carried into a chamber 11 for rapid drying, low-temperature dehumidified air is blown into the chamber 11, and then carried to a low-temperature dehumidified air circulation cooling chamber 12 for cooling, the dry weight is recorded by an automatic weighing device 13, and then vacuum pressurized. In the impregnation chamber 14, a predetermined monomer solution is impregnated under vacuum and pressure, and then carried into the pressurized moist heat polymerization chamber 15 under vacuum pressure, and is subjected to high pressure moist heat while suppressing outflow, foaming, and blowing out of the impregnated monomer solution. Fully automatic batch continuous polymer impregnation reinforcement characterized by centrally controlling the entire operation of polymerizing, releasing the pressure, transporting it out, air-drying it, and recording the impregnated weight with an automatic weighing device 16 according to a set program. Method of manufacturing wood.