JPH0149084B2

JPH0149084B2 -

Info

Publication number: JPH0149084B2
Application number: JP6217285A
Authority: JP
Inventors: Masatoshi Matsuzaki
Original assignee: Kyuken Corp
Current assignee: Kyuken Corp
Priority date: 1985-03-28
Filing date: 1985-03-28
Publication date: 1989-10-23
Also published as: JPS61220804A

Description

[Detailed description of the invention]

（産業上の利用分野）本発明は、軽量で断熱性及び吸音性を有しかつ
普通のコンクリート板より強度の大きい軽量パネ
ルとその製造方法に関するものである。（従来の技術）断熱性を有するパネルとして、例えば石膏ボー
ドや気泡コンクリート板が知られている。石膏ボ
ードを間仕切壁として使用する場合には、吸音性
をもたせるためにある程度板厚を厚くする必要が
あるが、重要が重くなり施工性等の点で問題が生
ずる。これに対し、気泡コンクリート板では、内
部に多数の気泡があることから、断熱性の他に吸
音性があり、しかも軽量で、上述のような問題は
ない。しかし、気泡コンクリート板は、湿気を吸収し
やすく、一旦気泡内に湿気を取り込むと湿気が逃
げにくくなり、カビ等が発生しやすい問題があつ
た。また、曲げ強度が10〜13Kgｆ／cm²、普通のコ
ンクリート板（曲げ強度30〜35Kgｆ／cm²）の３分
の１程度であり、強度的に充分でない問題もあつ
た。そこで、気泡コンクリート板の表面を繊維強化
コンクリートで覆うことが考えられる。このよう
にすれば、湿気を取り込むおそれもなく、強度的
にも充分なパネルが得られる。しかし、内板とな
る気泡コンクリート板と外板となる繊維強化コン
クリート板はその機械的強度等が大きく相違する
ため、剥離のおそれがある。また、重量の点にお
いて気泡コンクリート板に比して重くなる問題が
ある。（発明が解決しようとする問題点）本発明は上記事情に鑑みてなされたもので、そ
の目的とするところは、軽量で、断熱性及び吸音
性を有しかつ普通のコンクリート板よりも強度が
大きく、内板となる気泡コンクリート板と外板と
なる繊維強化コンクリート板との付着強度の大き
い軽量パネルおよびその製造方法を提供すること
である。（問題点を解決するための手段）本発明は上記目的を達成するため、型枠を展開
状態にして該型枠上に可撓性シートを敷き、該可
撓性シートの上から砂等の代わりにシラスからな
る微小空体を混入したモルタルと強化繊維とを使
用してスプレー法により繊維強化コンクリート層
を形成し、該繊維強化コンクリート層が硬化する
前に型枠を展開状態から起立させて組み立て、次
いで微細な気泡が生じている状態のセメントスラ
リー中に合成樹脂発泡粒を混入して均一に分散さ
せたセメントスラリーと合成樹脂発泡粒との混合
物を投入し、次いで型枠内の該混合物の上面に砂
等の代わりにシラスからなる微小中空体を混入し
たモルタルに強化繊維を混合してなる繊維モルタ
ルを投入して型枠に蓋をし、この後、蒸気養生す
ることを特徴としている。（実施例）以下本発明の一実施例を図面に参照して説明す
る。第１図〜第４図は本発明の軽量パネルの製造方
法の一例を示している。まず、第１図に示すよう
に、型枠１の左右側板１ａ，１ｂを水平に倒して
型枠１を展開状態にし、該型枠１の内面にビニー
ルシート２を敷き、スプレー法により該ビニール
シート２の上からモルタルと耐アルカリガラス繊
維を吹き付けてローラで軽くならし外板となる繊
維強化コンクリート層３を形成する。このとき、
繊維強化コンクリート層３の表面に耐アルカリガ
ラス繊維が毛羽立つようにする。上記モルタルには、砂等の代わりにシラスかな
る微小中空体（平均径36〜189μｍ、比重0.11〜
0.3、(株)伊地知種鶏場製、商品名ウインライト）
が混入されている。このモルタル（セメント、
水、微小中空体、減水剤からなる）と上記耐アル
カリガラス繊維の配合比は、例えば表１に示すよ
うに設定される。この配合比の場合には、繊維強
化コンクリート層３の比重は1.45で従来のスプレ
ー法による繊維強化コンクリート板（比重2.35）
に比して大幅に軽量になる。 (Industrial Application Field) The present invention relates to a lightweight panel that is lightweight, has heat insulating and sound absorbing properties, and is stronger than ordinary concrete plates, and a method for manufacturing the same. (Prior Art) For example, gypsum boards and aerated concrete boards are known as panels having heat insulating properties. When using gypsum board as a partition wall, it is necessary to increase the board thickness to some extent in order to provide sound absorption, but this increases the importance and causes problems in terms of workability, etc. On the other hand, aerated concrete plates have many air bubbles inside, so they have not only heat insulation properties but also sound absorption properties, are lightweight, and do not have the above-mentioned problems. However, aerated concrete boards tend to absorb moisture, and once moisture is trapped in the bubbles, it becomes difficult for the moisture to escape, creating a problem in which mold and the like are likely to grow. In addition, the bending strength was 10 to 13 Kgf/cm ² , about one-third of that of an ordinary concrete plate (bending strength 30 to 35 Kgf/cm ² ), so there was a problem that the strength was not sufficient. Therefore, it may be possible to cover the surface of the aerated concrete board with fiber-reinforced concrete. In this way, there is no risk of moisture being taken in, and a panel with sufficient strength can be obtained. However, because the mechanical strength and other properties of the aerated concrete plates that serve as the inner panels and the fiber-reinforced concrete plates that serve as the outer panels are significantly different, there is a risk of delamination. In addition, there is a problem in terms of weight that it is heavier than aerated concrete plates. (Problems to be Solved by the Invention) The present invention has been made in view of the above circumstances, and its purpose is to be lightweight, have heat insulating and sound absorbing properties, and be stronger than ordinary concrete plates. To provide a lightweight panel that is large and has high adhesion strength between an aerated concrete plate serving as an inner plate and a fiber-reinforced concrete plate serving as an outer plate, and a method for manufacturing the same. (Means for Solving the Problems) In order to achieve the above object, the present invention spreads a formwork, spreads a flexible sheet on the formwork, and pours sand or the like over the flexible sheet. Instead, a fiber-reinforced concrete layer is formed by a spray method using mortar mixed with microvoids made of shirasu and reinforcing fibers, and the formwork is erected from the unfolded state before the fiber-reinforced concrete layer hardens. After assembly, a mixture of the cement slurry and the foamed synthetic resin grains, which are made by mixing the foamed synthetic resin grains into the cement slurry with fine air bubbles and are uniformly dispersed, is poured into the cement slurry, and then the mixture is placed in the formwork. A fiber mortar made by mixing reinforcing fibers with a mortar containing microscopic hollow bodies made of whitebait instead of sand, etc. is poured onto the top surface, the mold is covered, and the mold is then steam-cured. . (Example) An example of the present invention will be described below with reference to the drawings. 1 to 4 show an example of the method for manufacturing a lightweight panel of the present invention. First, as shown in Fig. 1, the left and right side plates 1a, 1b of the formwork 1 are laid down horizontally to make the formwork 1 in an unfolded state, a vinyl sheet 2 is spread on the inner surface of the formwork 1, and the vinyl sheet 2 is Mortar and alkali-resistant glass fiber are sprayed onto the sheet 2 and lightly leveled with a roller to form a fiber-reinforced concrete layer 3 that will serve as an outer panel. At this time,
Alkali-resistant glass fibers are made to fluff on the surface of the fiber-reinforced concrete layer 3. The above mortar contains micro hollow bodies made of whitebait (average diameter 36-189μm, specific gravity 0.11-100μm) instead of sand etc.
0.3, manufactured by Ijichi Seed Farm Co., Ltd., product name Winlight)
is mixed in. This mortar (cement,
The blending ratio of the alkali-resistant glass fiber and the alkali-resistant glass fiber is set as shown in Table 1, for example. In the case of this mixing ratio, the specific gravity of fiber reinforced concrete layer 3 is 1.45, and the fiber reinforced concrete plate made by the conventional spray method (specific gravity 2.35)
It is significantly lighter than the .

【表】次いで、繊維強化コンクリート層３が硬化する
前に第２図に示すように、左右側板１ａ，１ｂを
水平面に対し略80度の角度をすようにして起立さ
せる。このとき、型枠１の底板１ｃと左右側板１
ａ，１ｂとの枢着部上に位置する部分を折ローラ
で軽く押える。繊維強化コンクリート層３はスプ
レー法により形成したものであり、左右側板１
ａ，１ｂを起立させても流れ落ちるおそれがな
い。そして、セメントスラリーと発泡スチロール
ビーズ（以下、ビーズと略記する）４（第５図、
第６図ａ，ｂ参照）と混合物５を第２図に示す状
態の型枠１の内容積のほぼ70％を占めるように投
入する。上記セメントスラリーは、ミキサー内に原液
（混練水、起泡剤、減水剤）を入れて発泡させ、
次いでこの原液にセメントと高強度混和剤を入れ
てミキサーを高速回転させて混練することにより
製造される。ビーズ４はこのセメントスラリー中
に微細な気泡が多数生じている状態のときに混入
する。これにより、ビーズ４がセメントスラリー
中に均一に分散して混ざる。従来、コンクリート中にビーズ４を均一に分散
させることは難しく、ビーズ４が表面側に偏在す
る問題があつた。これは、コンクリートスラリー
（セメント、混練水、砂等を混練したもの）の比
重が2.30以上で、ビーズ４の比重0.02との差が大
きすぎるためであつた。本発明では、上述の如く
セメントスラリー中に微細な気泡を多数発生させ
て比重を小さくした状態、すなわちビーズ４との
比重差を小さくした状態でビーズ４を混入するこ
とにより、ビーズ４が偏在しないようにしてい
る。ビーズ４は、内板６となる気泡コンクリートを
軽量にし、断熱性を向上させる。高強度混和剤（日本セメント(株)製、商品名スパ
ーミツクス）は、気泡により強度が低下するのを
阻止し、またセメントとビーズ４との付着強度が
低下するのを阻止する。上記セメントスラリーとビーズ４の配合比は、
例えば表−２に示すように設定される。この配合
比の場合には、混合物５の比重は0.5程度になる。[Table] Next, before the fiber-reinforced concrete layer 3 hardens, the left and right side plates 1a and 1b are erected at an angle of approximately 80 degrees with respect to the horizontal plane, as shown in FIG. At this time, the bottom plate 1c of the formwork 1 and the left and right side plates 1
Lightly press the portion located above the pivot joint with a and 1b with a folding roller. The fiber-reinforced concrete layer 3 is formed by a spray method, and the left and right side plates 1
Even if a and 1b are stood up, there is no risk of them falling down. Then, cement slurry and expanded polystyrene beads (hereinafter abbreviated as beads) 4 (Fig. 5,
(see FIGS. 6a and 6b) and the mixture 5 are charged into the formwork 1 in the state shown in FIG. 2 so as to occupy approximately 70% of the internal volume. The above cement slurry is made by putting the stock solution (kneading water, foaming agent, water reducing agent) into a mixer and foaming it.
Next, cement and a high-strength admixture are added to this stock solution, and a mixer is rotated at high speed to knead the mixture. The beads 4 are mixed into the cement slurry when a large number of fine air bubbles are generated therein. As a result, the beads 4 are uniformly dispersed and mixed in the cement slurry. Conventionally, it has been difficult to uniformly disperse beads 4 in concrete, and there has been a problem that beads 4 are unevenly distributed on the surface side. This was because the specific gravity of the concrete slurry (mixed with cement, mixing water, sand, etc.) was 2.30 or more, and the difference from the specific gravity of beads 4, which was 0.02, was too large. In the present invention, as described above, beads 4 are mixed in a state in which a large number of fine air bubbles are generated in the cement slurry and the specific gravity is reduced, that is, a difference in specific gravity between the beads 4 and the beads 4 is reduced, so that the beads 4 are not unevenly distributed. That's what I do. The beads 4 make the aerated concrete that becomes the inner plate 6 lighter and improve its heat insulation properties. The high-strength admixture (manufactured by Nippon Cement Co., Ltd., trade name: Supermix) prevents the strength from decreasing due to air bubbles, and also prevents the adhesion strength between the cement and the beads 4 from decreasing. The mixing ratio of the cement slurry and beads 4 is as follows:
For example, the settings are as shown in Table 2. In the case of this blending ratio, the specific gravity of the mixture 5 is about 0.5.

【表】次いで、第３図に示すように、左右側板１ａ，
１ｂを水平面に対し90度の角度をなすように起立
させて、型枠１を本来の形状に組み立てる。これにより、型枠１内の混合物５がせり上が
り、型枠１の内容積をほぼ占める。このとき、混
合物５の比重は例えば0.5程度であるため、入力
だけでもすむ。この後、繊維強化コンクリート層３と同じ組成
の繊維モルタルを投入して混合物５の上面を覆
う。このようにしてから、第４図に示すように、
型枠１に蓋７を取付けて、例えば温度70℃で４時
間蒸気養生する。この蒸気養生に際しては、温度
上昇に伴ないセメントスラリー中に気泡が発生
し、またセメントスラリーが膨張して繊維強化コ
ンクリート層３や繊維モルタルに圧着する。養生
後はビニートシート２が付着したまま脱型する。このようにして第５図に示すような軽量パネル
が製造される。この軽量パネルは、気泡コンクリ
ートからなる内板６が繊維強化コンクリート層３
や繊維モルタルからなる外板８で覆われていて、
外板８中の耐アルカリガラス繊維の一部が内板６
中に埋め込まれて内板６に対し外板８が強固に付
着している。また、外板８の表面には、ビニール
シート２が付着している。内板６の内部は、第６図ａに示すようにビーズ
４と気泡９とが混在した状態となつていて、断熱
性及び遮音性（吸音性）が優れている。また、ビ
ーズ４は気泡９により取り囲まれていて、仮りに
熱でビーズ４からガスが発生しても、同図ｂに示
すように気泡９に吸収され外部に漏れるおそれが
ない。ビーズ４が熱で溶融してガス化すると、ビ
ーズ４があつた部分に空洞が生ずるが、この空洞
は気泡９と同様に断熱、吸音の作用をする。前述の表１、２に示す配合比で軽量パルスを製
造した場合には、寸法−2500ｍ／ｍ×900ｍ／ｍ×60ｍ／ｍ曲げ強度−40Kgｆ／cm²以上比重（絶乾重量）−0.54 比重（気乾重量）−0.63 気泡径−0.5〜1.0ｍ／ｍとなる。なお、軽量パネルの表面のビニールシート２は
保管時、運搬時等には付着したままにしておき、
施工時直前に剥離する。（発明の効果）以上説明したように本発明によれば、内板とな
る気泡コンクリートと外板となる繊維強化コンク
リート層を同時に養生するために付着性が良く、
また強化繊維が内板と外板を接合する作用をし、
このため機械的強度等が相違していても外板が剥
離するおそれがなく、内板に対し外板が強固に付
着した複合体となる。また、内板と外板を別々に
製造してから両者を接合したり、あるいは外板を
製造してから型枠内にセツトして内板を形成する
セメントスラリーを投入するような場合に比して
作業性、生産性が良く、コストダウンを図ること
ができる。また、外板となる繊維強化コンクリート層や繊
維モルタルには砂等の代わりにシラスからなる微
小中空体が混入され、また内板となる気泡コンク
リートには合成樹脂発泡粒が混入されていること
から、内板を外板で覆つて複合体にしても気泡コ
ンクリート単独の場合に比して重量増加は少なく
てすむ。また、型枠に可撓性シートを敷くことから、脱
型が容易で、脱型後、可撓性シートを付着したま
まにしておけば、養生が続行されて品質が安定
し、また出荷時等に傷付くおそれがない。また、
パネルの表面がきれいに仕上がり、そのまま塗装
を施すことができる。したがつて、本発明によれば、軽量で断熱生及
び吸音生を有しかつ普通のコンクリート板よりも
強度の大きく、内板となる気泡コンクリート板と
外板となる繊維強化コンクリート板との付着強度
の大きい軽量パネルが得られる。[Table] Next, as shown in Fig. 3, the left and right side plates 1a,
1b is erected so as to make an angle of 90 degrees with respect to the horizontal plane, and the formwork 1 is assembled into its original shape. As a result, the mixture 5 inside the mold 1 rises up and almost occupies the internal volume of the mold 1. At this time, since the specific gravity of the mixture 5 is, for example, about 0.5, only the input is sufficient. Thereafter, fiber mortar having the same composition as the fiber reinforced concrete layer 3 is introduced to cover the upper surface of the mixture 5. After doing this, as shown in Figure 4,
A lid 7 is attached to the formwork 1, and steam curing is performed at a temperature of, for example, 70° C. for 4 hours. During this steam curing, bubbles are generated in the cement slurry as the temperature rises, and the cement slurry expands and presses against the fiber reinforced concrete layer 3 and the fiber mortar. After curing, the mold is removed with the vinyl sheet 2 still attached. In this way, a lightweight panel as shown in FIG. 5 is manufactured. This lightweight panel has an inner plate 6 made of aerated concrete and a fiber-reinforced concrete layer 3.
It is covered with an outer panel 8 made of fiber mortar and
A part of the alkali-resistant glass fiber in the outer panel 8 is part of the inner panel 6.
The outer plate 8 is embedded in the inner plate 6 and firmly attached to the inner plate 6. Furthermore, a vinyl sheet 2 is attached to the surface of the outer panel 8. The inside of the inner plate 6 has beads 4 and air bubbles 9 mixed therein, as shown in FIG. 6a, and has excellent heat insulation and sound insulation (sound absorption). Furthermore, the beads 4 are surrounded by air bubbles 9, so that even if gas is generated from the beads 4 due to heat, it will be absorbed by the air bubbles 9 and there is no risk of it leaking to the outside, as shown in FIG. When the beads 4 are melted and gasified by heat, a cavity is formed in the area where the beads 4 are heated, and this cavity has the function of heat insulation and sound absorption in the same way as the bubbles 9. When lightweight pulses are manufactured using the compounding ratios shown in Tables 1 and 2 above, dimensions - 2500 m/m x 900 m/m x 60 m/m Bending strength - 40 Kgf/cm ² or more Specific gravity (absolute dry weight) - 0.54 Specific gravity (Air dry weight) -0.63 Cell diameter -0.5 to 1.0 m/m. Please note that the vinyl sheet 2 on the surface of the lightweight panel should remain attached during storage and transportation.
Peel off immediately before construction. (Effects of the Invention) As explained above, according to the present invention, the aerated concrete layer serving as the inner panel and the fiber-reinforced concrete layer serving as the outer panel have good adhesion and are cured at the same time.
In addition, the reinforcing fibers act to join the inner and outer panels,
Therefore, even if the mechanical strength etc. are different, there is no risk of the outer panel peeling off, resulting in a composite body in which the outer panel is firmly attached to the inner panel. In addition, compared to cases where the inner and outer panels are manufactured separately and then joined together, or where the outer panels are manufactured and then set in the formwork and cement slurry is added to form the inner panel. As a result, work efficiency and productivity are improved, and costs can be reduced. In addition, the fiber-reinforced concrete layer and fiber mortar that make up the outer panel contain microscopic hollow bodies made of shirasu instead of sand, and the cellular concrete that makes up the inner panel contains foamed synthetic resin particles. Even if the inner plate is covered with an outer plate to form a composite, the increase in weight will be smaller than in the case of aerated concrete alone. In addition, since a flexible sheet is placed on the formwork, it is easy to remove the mold, and if you leave the flexible sheet attached after removing the mold, curing will continue and quality will be stable. There is no risk of injury. Also,
The surface of the panel is beautifully finished and can be painted as is. Therefore, according to the present invention, it is lightweight, has heat insulation and sound absorption properties, and has greater strength than ordinary concrete plates, and is capable of adhering the aerated concrete plate serving as the inner plate and the fiber-reinforced concrete plate serving as the outer plate. A lightweight panel with great strength can be obtained.

[Brief explanation of drawings]

図面は本発明の一実施例を示すもので、第１図
〜第４図は製造工程を示す斜視図、第５図は本発
明の方法で製造された軽量パネルの斜視図、第６
図ａは内板の内部を拡大して示した部分拡大断面
図、同図ｂは合成樹脂発泡粒から発生したガスが
気泡に吸収される状態を示す説明図である。１……型枠、２……可撓性シート（ビニールシ
ート）、３……繊維強化コンクリート層、４……
合成樹脂発泡粒、５……混合物、６……内板、７
……蓋、８……外板、９……気泡。 The drawings show one embodiment of the present invention, and FIGS. 1 to 4 are perspective views showing the manufacturing process, FIG. 5 is a perspective view of a lightweight panel manufactured by the method of the present invention, and FIG.
Figure a is a partially enlarged cross-sectional view showing the inside of the inner plate, and Figure b is an explanatory view showing a state in which gas generated from foamed synthetic resin particles is absorbed by air bubbles. 1... Formwork, 2... Flexible sheet (vinyl sheet), 3... Fiber reinforced concrete layer, 4...
Synthetic resin foam particles, 5...Mixture, 6...Inner plate, 7
... Lid, 8 ... Outer plate, 9 ... Air bubbles.

Claims

[Claims]

1. With the formwork in an expanded state, a flexible sheet is laid on the formwork, and on top of the flexible sheet, mortar mixed with micro hollow bodies made of whitebait and reinforcing fibers are used instead of sand, etc. A fiber-reinforced concrete layer is formed by a spray method, and before the fiber-reinforced concrete layer hardens, the formwork is erected from the unfolded state and assembled, and then synthetic resin is foamed into the cement slurry in which fine air bubbles are generated. A mixture of cement slurry and synthetic resin foam particles mixed with grains and uniformly dispersed is added, and then fiber mortar is made by mixing reinforcing fibers into mortar in which micro hollow bodies made of shirasu are mixed instead of sand etc. A method for manufacturing lightweight panels, which comprises charging the formwork with a lid, and steam-curing it.