JPS6111169B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a plate-shaped cement product reinforced by, for example, incorporating glass fiber, steel fiber, mineral fiber, or organic fiber, which has excellent alkali resistance, is lightweight, and has high strength. Within the wall thickness, amorphous fluid core materials such as barlite mortar and Styropol concrete, foamed resin boards such as foamed urethane and foamed polystyrene, foamed concrete boards, barlite boards, wood wool cement boards, and calcium silicate. A method for manufacturing fiber-reinforced cement composite boards that have excellent mechanical strength and heat insulation performance while being lightweight overall by embedding a shaped core material such as a board.
In detail, the process involves forming a first layer of reinforcing fiber-containing cement mortar in the lower formwork by spraying or premix scotting, and applying a fluid or solid core onto this first layer by pouring or placing means. A second layer of reinforcing fiber-containing cement mortar is applied onto this core material by spraying.
The present invention relates to a method of manufacturing a fiber-reinforced cement composite board, which comprises a step of forming a coating layer.

As mentioned above, conventional methods of this type generally involve only the first step of forming the first layer, the second step of positioning the core material for polymerization, and the third step of forming the second layer. However, in this case, when using a solid core material, in order to ensure good adhesion between the first layer and this solid core material without creating a gap, it is necessary to It is necessary to precisely shape it to match the shape of the core material, and depending on the thickness of the rising part that covers the peripheral side of the core material, the core material may not fit in, requiring the effort of scraping off the first layer part. Furthermore, when using a flowable core material, it is difficult to finish the top surface of the core material flat, and when using either a solid or a flowable core material, it is difficult to finish the top surface of the core material flat.
When the layer is formed, the core material sinks unevenly or tilts and the second layer is formed.
It becomes difficult to finish the top surface of the layer flat, requiring a great deal of manual labor for forming, resulting in poor production efficiency, large thickness errors in the composite board as a whole, and poor surface finish. There were some flaws that could easily result in a poor product.

Therefore, the present inventors developed a manufacturing method that added a step, after the above-mentioned second layer coating formation step, to pressure-form the entire surface while applying vibration by bringing a press frame into contact with the upper surface of the second layer. , this improves the fluidity of cement mortar due to vibration, and the first
The gaps between the layer and the core material and between the core material and the second layer can be sufficiently filled with cement mortar to ensure that they are in close contact with each other and bonded. In both cases, manual defoaming is no longer necessary, and the shaping work of the top and side surfaces of the first layer, which was previously required when using a solid core material, is no longer required. Furthermore, since the top surface of the second layer is pressed while in contact with the pressing frame, both the top and bottom surfaces of the entire composite board can be finished flat, and the board can be finished flat. Thickness errors can be reduced to almost zero, which not only improves production efficiency by shortening overall manufacturing time, but also makes it possible to obtain products with good dimensional accuracy and surface finish.

The present invention adds an extremely simple process to the method that is superior in terms of production efficiency and finish as described above, and thereby not only improves workability but also achieves further superiority in terms of appearance, dimensional accuracy, and performance. The purpose is to make it possible to obtain quality products.

The method for manufacturing a fiber-reinforced cement composite board according to the present invention includes the steps of placing the core material in a polymerized position and coating the core material with a second layer of reinforcing fiber-containing cement mortar by a spraying method. It is characterized by the addition of a step of forming a waterproof membrane on or near the surface layer of the core material.

In other words, this type of composite board is generally required to have fire resistance and heat insulation performance in addition to strength performance, and for this reason, a material with high water absorption such as barlite mortar or foamed resin board is used as the core material. material is used. Therefore, when the second layer of cement mortar is directly coated on the core material by spraying, the core material absorbs moisture from the second layer of cement mortar and its moisture is absorbed by the core material. The moisture content of the second cement mortar layer has decreased significantly and this layer has become quite loose, and even when vibrations are applied, the mortar does not flow sufficiently, and the fibers and mortar are pressurized without getting acquainted with each other. Defective products are likely to occur due to dimensional accuracy such as appearance and thickness, as well as the fire resistance and insulation performance mentioned above, and in order to suppress the occurrence of such defective products as much as possible, it is necessary to take measures such as defoaming and degassing especially for the second layer. It required surface finishing, etc., and was unsatisfactory in terms of production efficiency.

However, according to the method of the present invention, after forming a waterproof membrane on or near the surface layer of the water-absorbing core material,
Since it forms the second layer, water absorption from the second layer by the core material is suppressed or sufficiently reduced, and the fluidity of cement mortar due to vibration and the fibers caused by it are suppressed. This allows for extremely good compatibility with the mortar, making it possible to obtain products that are even better in terms of performance such as fire resistance and heat resistance, as well as dimensional accuracy such as appearance and thickness. By eliminating or simplifying the manual finishing work for the two layers, it has become possible to achieve sufficiently high production efficiency.

Examples of the method of the present invention will be listed below in order of steps based on the drawings.

Lower formwork 1 with U-shaped vertical cross-section and upward opening
Preferably 1 part cement and 0.1 to 1.0 sand.
A cement mortar with a mixing ratio of 0.8, water 0.2 to 0.5, preferably 0.3, and alkali-resistant glass fiber in a weight ratio of 1 to 8%, preferably 3% to this cement mortar, are sprayed directly using a spray gun 4. Spray to a thickness of about 2 cm
A first layer of reinforcing fiber-containing cement mortar, that is, a first shell material _A1 is formed. (See Figure 1) On the first outer shell material _A1 , a fluid core material B such as pearlite mortar with a mixing ratio of pearlite:cement mortar:water of 1:1:0.65, or Styropol concrete, etc. Pour the material to a thickness of 8 cm (see Figure 2 A), or use foamed resin boards, foamed concrete boards, perlite boards, wood wool cement boards, mineral fiber boards, calcium silicate boards, etc. to be pre-formed to the specified dimensions. Place the solid core material B (see Figure 2B). Incidentally, after the core material B is placed in the superposition position, the first outer shell material A ₁
By folding back the selvedge part a so as to wrap around the core material B, the fibers can be connected to the corner part.

If it is a solid core material on the core material B,
As an example of a waterproof membrane, the core material B surface layer 5~
1 with a thickness of about 0.01 mm, with a large number of holes formed on the average over the entire surface to cover 60%, preferably 50% of the area.
A sheet of water-impermeable sheet, specifically polyethylene sheet C, is placed and covered (see FIG. 3A).
In the case of a fluid core material, the perforated polyethylene sheet C is further coated with pearlite mortar or Styropol concrete C' to a thickness of 0 to 20 mm by pouring. The total thickness of the first layer of core material and the second layer of core material should be 8 cm. [See Figure 3B) Cement mortar and alkali-resistant glass fibers are sprayed onto the waterproof membrane C or C+C' using the same direct spray method as described above to form reinforced fiber-containing cement with a thickness of about 2 cm. A second layer of mortar, ie, a second shell material _A2 , is applied. (See Figure 4 A and B) Next, the upper surface of the second outer shell material A ₂ is brought into contact with the push frame 2, and a vibrator is applied to the lower formwork 1 at a vibration rate of 2000 to 30000 rpm, preferably
It has a vibration frequency of 3000rpm, and a swing width of
A vibration motor 3 of 0.01 to 3.5 mm, preferably 0.2 to 2.0 mm, is detachably attached via, for example, a magnet, and then the first and second While applying vertical vibration to the outer shell materials A ₁ , A ₂ and the core material B for about 1.5 minutes,
The pressure of the pressing frame 2 is 0.01 to 1.0 Kg/cm ² , preferably
By pressing and moving with a force of 0.1Kg/ ^cm2 ,
Press and form the entire piece to a thickness of 9.5cm. (See Figure 5A) After the molding, it is cured in the mold 1 for 24 hours, then removed from the mold, and then cured for about one week.

In carrying out the method of the present invention, the above-mentioned vibration applying means may be a means in which a vibration motor 3 is attached to the push frame 2 side, as shown in FIG. As shown in FIG.
Alternatively, the formwork may be placed on a separately constructed vibration table (not shown).

Further, in the present invention, even if the waterproof membrane C is formed by dispersing a large number of small pieces of polyethylene sheets evenly on the core material B, paint, adhesive, etc. are applied to the upper surface of the core material B. It may be formed by spraying.

[Brief explanation of the drawing]

The drawings illustrate embodiments of the method for manufacturing a fiber-reinforced cement composite board according to the present invention, and show FIGS. 1 to 5.
Figures A, B, and C are schematic vertical cross-sectional views of each manufacturing process. 1... Lower formwork, 3... Push frame, A ₁ ... 1st
Layer, A ₂ ... second layer, B ... core material, C ... waterproof membrane.

Claims (1)

[Claims] 1. A first step of forming a first layer A ₁ of reinforcing fiber-containing cement mortar in the lower formwork 1 by a spray method or premix scotting method, and pouring or placing on this first layer A ₁ A second step of polymerizing and positioning the fluid or solid core material B by means of polymerization, on or in the surface layer of the core material B in the case of a fluid core material, and on the surface surface of the core material in the case of a solid core material. The third step is to form a waterproof membrane C on the surface of the waterproof membrane C or the surface layer of the core material.
The fourth step of coating layer A ₂ and the second step
A method for manufacturing a fiber-reinforced cement composite board, comprising: a fifth step of press-forming the entire body while applying vibration by bringing a press frame 2 into contact with the upper surface of the layer A ₂ . 2. The waterproof membrane C covers 5 to 60 mm of the surface layer portion of the core material B.
%, preferably 50% of the area of the fiber-reinforced cement composite board. 3. The method for manufacturing a fiber-reinforced cement composite board according to claim 1, wherein the waterproof membrane C is formed on the surface layer of the core material B by spraying paint or adhesive. 4. The method for manufacturing a fiber-reinforced cement composite board according to claim 2, wherein the water-impermeable sheet C is a single perforated sheet. 5. The method for manufacturing a fiber-reinforced cement composite board according to claim 2, wherein the water-impermeable sheet C is a large number of small piece sheets. 6. The fiber-reinforced cement composite according to claims 1 to 5, wherein the core material B is a fluid core material and the waterproof membrane C is embedded within the core material by at most 20 mm from the upper surface of the core material B. Method of manufacturing the board.