JPH0620738B2 - Lightweight cellular concrete panel manufacturing method and pre-cutting jig - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing an autoclave-cured lightweight cellular concrete panel (hereinafter referred to as an ALC panel).

[Prior Art] ALC panels widely used for outer walls, partitions, roofs, floors, etc. of buildings are generally manufactured by the following steps.
Many are manufactured in a cycle.

(1) In a formwork having a length more than twice the length of the ALC panel, a plurality of reinforcing bars are arranged in parallel to form a reinforcing bar group, and two or more groups of the reinforcing bar group are spaced apart from each other. The step of arranging in series. By using such a long frame and arranging the reinforcing bars not only in parallel but also in series, a large number of reinforcing bars can be arranged at one time.

(2) A step of injecting the ALC raw material slurry into the mold to foam and solidify the slurry to form a long semi-cured green cake including all reinforcing bar groups.

(3) A step of demolding the green cake.

(4) As shown in FIGS. 11 and 12, a step of gripping the green cake 51 by the sandwich plate 53 of the moving device 52 and moving it to the pre-cutting device. This pre-cutting device is generally provided separately from the main cutting device.

(5) A step of pre-cutting the green cake between the reinforcing bar groups by a pre-cutting device to divide the green cake into two or more small cakes each containing the reinforcing bar group.

(6) A step of moving the small cake to a main cutting device by a moving device.

(7) A step of cutting the small cake into a predetermined width and thickness by a main cutting device and dividing the cake into a plurality of uncured panels each including one reinforcing bar.

(8) A step of autoclaving the uncured panel.

[Problems to be Solved by the Invention] According to the method for manufacturing an ALC panel described above, it is possible to manufacture a large number of ALC panels in one cycle.
On the other hand, there were the following problems.

Since ALC has a brittle and fragile property in a semi-cured state, a long green cake 5 containing two or more reinforcing bar groups 55 in series as shown in FIGS. 11 and 12.
When 1 is gripped by the sandwich plate 53 and moved to the pre-cutting device, a shearing force is applied between the reinforcing bar groups 55 in the green cake 51, which do not work to reinforce the inside, and cracks 54 or chips may occur. there were.

Further, as a dedicated machine for pre-cutting the green cake into two or more small cakes, it is necessary to provide a large-scale pre-cutting apparatus in addition to the main cutting apparatus, resulting in an increase in equipment cost.

In addition, the pre-cutting step and the cake moving step before and after the pre-cutting step require time, and the production efficiency cannot be increased by that much.

An object of the present invention is to solve the above problems, first to prevent cracks and chips between the reinforcing bar groups of the green cake, to simplify the pre-cutting process of the green cake and reduce the moving process to improve the manufacturing efficiency. Another object of the present invention is to provide a new method for manufacturing an ALC panel that can be further raised and can reduce the equipment cost. Another object is to provide a useful pre-cutting jig that has a simple structure and can reduce the equipment cost, and can easily perform the setting work on the mold and the pre-cutting work of the green cake. It is in.

[Means for Solving the Problems] In order to achieve the above object, the method for manufacturing an ALC panel according to claim 1 is configured such that a plurality of reinforcing bars are arranged in parallel in a mold to form a reinforcing bar group, and the reinforcing bars are formed. A step of arranging two or more groups in series at intervals with respect to each other, a step of setting a pre-cutting jig in the mutual pipe of the reinforcing bar group in the formwork, and an ALC raw material slurry in the formwork. A step of forming a semi-cured green cake including all reinforcing bar groups by pouring and foaming and solidifying, and before or after demolding the green cake from the mold, for pre-cutting A step of pre-cutting the green cake between the reinforcing bar groups by raising the jig, and dividing the green cake into two or more small cakes containing the reinforcing bar groups one by one; And then transfer to the main cutting device. A step of moving, a step of cutting the small cake into a predetermined width and thickness by a main cutting device, dividing into a plurality of uncured panels each containing one reinforcing bar, and autoclaving the uncured panel It consisted of a process and.

The jig for pre-cutting according to claim 2, wherein the pair of support rods hang down along the inner surface of the mold, the support bar supporting the upper ends of both support rods, and the cutting stretched between the lower ends of both support rods. And a supporting member for supporting the pre-cutting jig on the mold.

Further, the pre-cutting jig according to claim 3 is configured such that a cutting wire that is bent and arranged along an inner bottom surface and an inner side surface of the mold and a rising portion of the cutting wire is arranged along the inner side surface of the mold. And a wire holding member that is detachably held.

[Operation] According to the method for manufacturing an ALC panel of claim 1, the green cake is pre-cut between the reinforcing bar groups to be divided into two or more small cakes, and then the small cakes are gripped by the sandwich plate. Therefore, there is no possibility that a shearing force is exerted between the reinforcing bar groups and cracks or chips occur as in the conventional case. Also, without using a large-scale pre-cutting device different from the main cutting device as in the past, it is easy to pre-cut the green cake with a pre-cutting jig with a simple structure that can be set in the formwork. In addition to being possible (simplification of the pre-cutting step), the step of moving the green cake to the pre-cutting device as in the past is not necessary (reduction of the moving step).

According to the pre-cutting jig of the second aspect, the green cake can be easily pre-cut by the stretched portion of the cutting wire simply by pulling up the support bar straight.

According to the pre-cutting jig of claim 3, first, both wire holding members are pulled out from the green cake, and then the cutting wire is pulled straightly to easily pre-cut the green cake with the cutting wire. can do.

EXAMPLES Examples of ALC panel manufacturing methods and pre-cutting jigs embodying the present invention will be described below with reference to FIGS. 1 to 10.

First, the ALC panel manufactured by this method will be briefly described with reference to FIG. 10. This ALC panel 41 is used for an outer wall, a partition, a ceiling, a floor, etc. of a building. Size range is length 6
00-4200mm, width 400-900mm, thickness 40-2
It is 00 mm. A reinforcing bar 5 is arranged inside the ALC panel 41. The reinforcing bar 5 has two frame bodies 6 formed by welding a main bar and a sub bar vertically and horizontally and arranged at a predetermined interval. The spacer 7 is bridged over and welded to form a cage.

Now, a method of manufacturing the ALC panel 41 of this embodiment will be described below in the order of steps.

(1) First, as shown in FIG. 1 and FIG. 2, a plurality of reinforcing bars 5 are arranged in parallel in the formwork 1 to form a reinforcing bar group 55, and two or more groups of the reinforcing bar group 55 are mutually connected. They are arranged in series at intervals.

Here, the formwork 1 is formed in a rectangular box shape whose upper surface is opened by a bottom plate 2, side plates 3 and end plates 4 which stand upright from the edge thereof, and particularly the length thereof is the length of the ALC panel 41. More than twice. The side plate 3 and the end plate 4 are pivotally attached to the edge of the bottom plate 2 so as to be openable and closable, and the lower ends of the side plate 3 and the end plate 4 are
As shown in FIG. 2, when the formwork 1 is closed, it comes into contact with the bottom plate 2 in a sealed state, and when the formwork 1 is opened, as shown in FIG. 6, it is slightly separated from the edge of the bottom plate 2. ing.

Further, each reinforcing bar 5 spans a plurality of support bars 8 on the upper surfaces of both side plates 3 of the form 1, and a support rod (not shown) fixed to the support bars 8 in a suspended state can be detachably attached to the spacer 7. By fitting and locking, it is accurately supported at a predetermined position in the mold 1.

(2) Next, as shown in FIG. 1 to FIG. 3 or FIG. 4 to FIG. 5, set the pre-cutting jigs 10 or 15 between the reinforcing bar groups 55 in the formwork 1. To do. Also, the formwork 1
Due to the combination of the reinforcing bar 5 and the reinforcing bar 5, if an unnecessary vacant part 9 is formed between the one reinforcing bar group 55 and the end plate 4 of the form 1, the pre-cutting jig 10 is also provided in the vacant part 9. Or set 15 beforehand.

The step (2) can be performed before the step (1).

The pre-cutting jig 10 shown in FIGS. 1 to 3 is provided with a support bar 11 having an I-shaped cross-section that is laid across the upper surfaces of the side plates 3 of the mold 1, and both ends thereof are stably attached to the upper surfaces of the side plates 3. A downwardly widened mounting portion 12 is provided as a supporting member to be mounted on the substrate. Two support rods 1 are provided near both ends of the support bar 11.
3, the support rods 13 are adapted to hang down along the inner side surfaces of the side plates 3 of the formwork 1 to the vicinity of the inner bottom surface of the bottom plate 2. A cutting wire 14 is stretched between the lower ends of both support rods 13, and both ends of the cutting wire 14 extend upward along the support rod 13 and are fixed to the lower ends of both ends of the support bar 11. Examples of the cutting wire 14 include various metal wires, synthetic resin wires, chemical fiber threads, etc. In this embodiment, a general piano wire is used.

The pre-cutting jig 10 configured as described above is accurately positioned between the reinforcing bar groups 55 (usually at the center position) and in the vacant space 9, and then the above-described mounting portion 12 is provided on both side plates 3. The cutting wire 14 is set by being placed on the upper surface of the bottom plate 2, and the stretched portion of the cutting wire 14 is located immediately above the inner bottom surface of the bottom plate 2. In order to completely prevent the pre-cutting jig 10 from unintentionally moving in the next step of injecting and foaming the ALC raw material slurry, the pre-cutting jig 10 should be fixed to the mold 1 or its periphery. Is preferred.

Next, the pre-cutting jig 15 shown in FIGS. 4 to 5 has always free flexibility and is bent along the inner bottom surface of the bottom plate 2 of the formwork 1 and the inner side surfaces of both side plates 3. And a wire holding member 17 for removably holding the rising portion of the cutting wire 16 along the inner side surfaces of the side plates 3. The wire holding member 17 includes a holding rod 18 that can hang down to the vicinity of the bottom plate 2 along the inner side surfaces of the side plates 3, and the cutting wire 16 is inserted into the convex portions 19 provided at the upper and lower ends of the holding rod 18. A guide groove 20 is formed. The protrusion 19 has a magnet 21 attracted to the inner surface of the steel side plate 3.
Other suction means is attached to hold the cutting wire 16 inserted into the guide groove 20 between the cutting wire 16 and the inner surface of the side plate 3. A ring-shaped handle member 22 is attached to the upper end of the holding rod 18.

In order to set the pre-cutting jig 15 configured as described above between the reinforcing bar groups 55 and in the empty space 9, the form 1
With the open state, the cutting wire 16 is arranged at a predetermined position so as to cross the inner side surfaces of the both side plates 3 and the inner bottom surface of the bottom plate 2, and the cutting wire 16 is inserted into the guide groove 20. A convenient method is to suck 17 onto the inner surface of both side plates 3 and close the formwork 1 and then stretch the cutting wire 16 between the lower ends of the wire holding members 17 straight. Of course, while guiding the cutting wire 16 in the guide groove 20 with the form 1 closed, the wire holding member 17 is lowered into the form 1 and adsorbed on the inner side surfaces of the side plates 3, and then both wires are held. Alternatively, the cutting wire 16 between the lower ends of the members 17 may be stretched straight. Pre-cutting jig 15 set in this way
The magnet 21 and the like prevent the ALC raw material slurry from moving in the subsequent step of injecting and foaming the slurry by the attraction force.

As described above, the structure of each of the pre-cutting jigs 10 and 15 is much simpler than that of the conventional pre-cutting device.
The equipment cost can be greatly reduced, and the work of setting the mold 1 can be easily performed.

(3) Next, as shown in FIG. 2 or FIG.
By injecting the ALC raw material slurry 23 therein to foam and solidify it, the semi-cured green cake 24 including all the reinforcing bar groups 55 is formed.

The ALC raw material slurry 23 injected into the mold 1 is 2 to
While standing still for 3 hours, it expands so as to wrap around all the reinforcing bars 5 while generating innumerable bubbles, and eventually solidifies to a semi-hardened state, and an integrated rectangular green cake 2
4 is formed.

(4) Next, as shown in FIG. 2, FIG. 4 and FIG. 6, the pre-cutting jigs 10, 15 are cut before or after the green cake 24 is removed from the mold 1. Is raised, the green cake 24 is pre-cut between the reinforcing bar groups 55 and divided into two or more small cakes 25 each containing the reinforcing bar group 55. Similarly, the green cake 24 is pre-cut in the empty space 9 to divide the surplus block 26 formed in the empty space 9.

The pre-cutting needs to be performed when the green cake 24 is in a proper semi-cured state. This is because if the green cake 24 is too soft, it reattaches after pre-cutting and loses the effect of pre-cutting, while if it is too hard, the cutting resistance becomes large, which causes breakage of the cutting wires 14 and 16 and cake breakage. .

It is most preferable that the pre-cutting is performed before the green cake 24 is removed from the mold 1 and before it is conveyed together with the mold 1 to the mold removing position. This is to prevent the reinforcing bars 55 of the green cake 24 from being impacted by the transportation between them. Needless to say, pre-cutting can be performed after this conveyance and before or after demolding, but it is necessary to perform at least before gripping with the sandwich plate in the next step.
This is because no shearing force is applied between the reinforcing bar groups 55 of the green cake 24 or the like.

Regarding the pre-cutting jig 10, its supporting bar 11
Is raised straight together with the plurality of support bars 8 by using a publicly known lifting device (not shown).
The green cake 24 can be easily precut by the stretched portion of No. 4.

Regarding the pre-cutting jig 15, the operator first pulls out both wire holding members 17 from the green cake 24, and then pulls up the cutting wire 16 straightly upward. The cake 24 can be easily pre-cut.

As described above, according to the present invention, the green cake 24 can be provided by the pre-cutting jigs 10 and 15 having a simple structure without using a large-scale pre-cutting device different from the main cutting device as in the related art.
Can be easily pre-cut (simplification of the pre-cutting process) and the process of moving the green cake 24 to the pre-cutting device unlike the conventional case is not necessary (reduction of the moving process), so that the manufacturing efficiency is further improved. be able to.

As shown in FIG. 6, when the mold 1 is demolded after pre-cutting, if the length of the excess block 26 is 200 mm or less, the excess block 26 may fall down and stain the vicinity of the mold 1. . Therefore, the pressing plate 2 is provided above the surplus block 26.
7 and a fluid pressure cylinder for performing the pressing operation, a fall prevention device 29 including a pressing means 28 using an electric motor, etc. is provided, and the fall prevention device 29 gently presses the excess block 26 during the mold release to remove the mold. This pressure is released later to prevent the surplus block 26 from tipping over.

In this embodiment, the size of the pressing plate 27 is 100 mm × 5.
It is set to about 00 mm so that the surplus block 26 is uniformly applied with force. An air cylinder was used as the pressing means 28, the stroke thereof was 300 mm, and the pressing force was about 0.01 kg / cm ^{2 at} which the surplus block 26 in the semi-cured state was not broken.

(5) Next, as shown in FIG. 7 and FIG.
The small cakes 25 are gripped one by one or at the same time by two or more sandwiching plates 31 and moved to the main cutting device in the next step.

As described above, in the present invention, the green cake 24 is pre-cut between the reinforcing bar groups 55 to be divided into two or more small cakes 25, and the small cakes 25 are gripped by the sandwich plate 31. As described above, the shearing force is exerted between the reinforcing bar groups 55 to eliminate the possibility of cracking.

In addition, the small cake 25 and the surplus block 26 are provided by the sandwich plate 31.
When both and are gripped at the same time, it is difficult to apply a uniform force to the surplus block 26 located at the end portion and having a short length. Therefore, the surplus block 26 may be broken or slipped off from the sandwich plate 31 to cause a process trouble. There is. Therefore, a fall prevention device 35 including a pressing plate 32 on the end surface of the surplus block 26, a fluid pressure cylinder for performing the lifting and pressing operations of the pressing plate 32, a lifting unit 33 using an electric motor, and a pressing unit 34.
The fall prevention device 35 lightly presses the end surface of the moving surplus block 26 and releases the pressing after the movement to prevent the surplus block 26 from falling.

In this embodiment, air cylinders are used as the elevating means 33 and the pressing means 28.

(6) Next, as shown in FIG. 9, the small cake 25 is cut into a predetermined width and thickness by a known main cutting device 36,
It is divided into a plurality of uncured panels 39 each containing one reinforcing bar 5.

In this main cutting device 36, the small cake 25 is placed on a carrying table 37 and carried, and a plurality of uncured panels 39 are provided by passing through vertical and horizontal decision wires 8 stretched reciprocally in a frame (not shown). It is divided into two parts, and unnecessary parts of the outer surface are cut off.

(7) By putting the uncured panel 39 in a known autoclave (not shown) and curing it under high temperature and high pressure steam,
As shown in FIG. 10, a large number of completely cured ALC panels 41 can be obtained.

When the dimensional accuracy of the ALC panel 41 is further required, a sufficient cutting margin may be previously provided between the reinforcing bars 5, and the dimensional cutting may be performed in the length direction after the curing. Further, even when the small edge surface of the ALC panel 41 is chipped, the chipping can be cut off and dealt with.

The present invention is not limited to the configurations of the above-described embodiments, but may be embodied by being arbitrarily modified within the scope of the gist of the invention as follows, for example.

(1) In the pre-cutting jig 10, the support bar 11
It is also possible to increase the number of the support rods 13 in the central portion of and to support the central portion of the stretched portion of the cutting wire 14 by the lower end thereof. When the width of the mold 1 is large and therefore the stretched portion of the cutting wire 14 becomes long, the cutting wire 14
It has the effect of restricting the bending and preventing breakage.

(2) In the pre-cutting jig 10, the support rod 1
A plate-shaped cutting blade may be attached between the lower ends of the wires 3 instead of the cutting wire 14. The cutting wire 14 has a lower cutting resistance and a more accurate cutting surface, but the cutting blade is characterized by being less likely to break.

(3) The shape and mounting structure of the support bar 11 or the support rod 13 of the pre-cutting jig 10, or the cutting wire 1
The fixing structure of 4 and the like can be changed as appropriate.

(4) The shape of the holding rod 18 of the pre-cutting jig 15 and the position, quantity, shape, etc. of the protrusion 19, the guide groove 20, or the magnet 21 can be changed as appropriate.

[Effects of the Invention] As described in detail above, according to the method for manufacturing an ALC panel of claim 1, cracks and chips between the reinforcing bar groups of the green cake are prevented, and the pre-cutting step of the green cake is simplified. Therefore, it is possible to further reduce the number of moving steps, further improve the structural efficiency, and reduce the facility cost.

Further, according to the pre-cutting jig of claim 2 or claim 3, the structure is simple and the facility cost can be reduced, and the setting work to the formwork and the pre-cutting work of the green cake can be easily performed. It has an excellent effect that

[Brief description of drawings]

1 to 10 show an embodiment embodying the present invention.
The figure is a plan view when the reinforcing bar and the pre-cutting jig are set in the form, Fig. 2 is a cross-sectional view when the ALC raw material slurry is injected into the form, and Fig. 3 is the pre-cutting jig. Fig. 4 is a perspective view of the tool, Fig. 4 is a cross-sectional view when another pre-cutting jig is set in the mold and ALC raw material slurry is injected, and Fig. 5 is a perspective view of the pre-cutting jig. 6 is a perspective view when the mold is removed from the green cake, FIG. 7 is a front view when the small cake is gripped by the plate, and FIG. 8 is a right side view of the same.
FIG. 9 is a cross-sectional view when cutting a small cake into a panel shape,
FIG. 10 is a perspective view of the ALC panel after curing. FIG. 11 is a front view of a conventional ALC panel manufacturing method in which a green cake is held by a sandwich plate, and FIG.
The figure is also a right side view. 1 ... Formwork, 5 ... Reinforcing bar, 10 ... Pre-cutting jig, 11 ... Support bar, 13 ... Support rod, 14 ... Cutting wire, 15 ... Pre-cutting jig, 16 ...... Cutting wire, 17 ...... Wire holding member, 23 ...... ALC raw material slurry, 24 ...... Green cake, 25 ...... Small cake, 30 ...... Moving device, 31 ...... Cutting plate, 36 ...... Main cutting device , 39 ... uncured panel, 41 ... ALC panel, 55 ... Reinforcing bar group.

Claims (3)

[Claims] 1. A plurality of reinforcing bars (5) are arranged in parallel in a form (1) to form a reinforcing bar group (55), and the reinforcing bar group (55).
The step of arranging two or more groups in series at intervals with respect to each other and the step of setting the pre-cutting jigs (10, 15) between the reinforcing bar groups (55) in the form (1). And a lightweight cellular concrete raw material slurry (23) is injected into the mold (1) to foam and solidify, thereby forming a semi-hardened green cake (24) containing all reinforcing bar groups (55). And a step of performing the pre-cutting jigs (10, 15) before or after removing the green cake (24) from the mold (1) to remove the green cake (24). Reinforcing bar group (55)
Pre-cut between the two and divide it into two or more small cakes (25) each containing a group of reinforcing bars (55), and sandwiching the small cakes (25) with a sandwich plate (31) of a transfer device (30). ) To move to the main cutting device (36), and the small cake (25) is cut into a predetermined width and thickness by the main cutting device (36) and includes one reinforcing bar (5) at a time. A method for manufacturing a lightweight cellular concrete panel, which comprises a step of dividing into a plurality of uncured panels (39) and a step of curing the uncured panels (39). 2. A pair of support rods (13) hanging along the inner surface of the mold (1), a support bar (11) for supporting the upper ends of both support rods (13), and both support rods (13). )
A pre-cutting jig comprising a cutting wire (14) stretched between lower ends of the pre-cutting tool and a support member (12) for supporting the pre-cutting jig (10) with respect to the mold (1). 3. A cutting wire (16) arranged by bending along an inner bottom surface and an inner side surface of the mold (1), and a rising portion of the cutting wire (16) are provided inside the mold (1). A pre-cutting jig comprising a wire holding member (17) which is detachably held along the side surface.