JPH0717038B2 - Large foam panel - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a large-sized foam panel, and more particularly to a large-sized foam panel that solves the problem of warpage of a foam panel whose one surface is covered with a large porcelain plate.

[Prior Art] In recent years, as shown in FIG. 2, a surface decorative lightweight panel 10 in which a surface decorative material such as a large porcelain plate 11 and a foam 13 reinforced with a reinforcing bar 12 are integrally bonded is provided. It is used as a building or floor building material.

2. Description of the Related Art Conventionally, a surface decorative lightweight panel is manufactured by integrally adhering a surface decorative material such as a large ceramic plate to the surface of a foam with an adhesive or the like. However, this method requires two steps, that is, a step of producing a foam and a step of adhering the foam and the surface decorative material, which has a drawback of low productivity.

For such problems, a method for simultaneously foaming a foam and adhering a surface decorative material has been developed (Japanese Patent Application No. 57-21667).
2) The productivity of surface decorative lightweight panels has been greatly improved.

That is, a large porcelain board or the like is placed on the front side of the foamed material to foam the foamed material, and at the same time, the large porcelain board and the foam are fused and integrated by the binder component in the foamed material to reduce the number of processing steps. In this case, two layers simultaneously expand or contract during heating / cooling.

[Problems to be Solved by the Invention] In the foam panel in which the foam reinforced with the reinforcing bar and the large porcelain plate are fused and integrated by such a method, the thermal expansion of the large porcelain plate, the foam and the reinforcing bar is performed. Since the respective rates are different, there is a problem that the strain due to the difference in thermal expansion or contraction between the foam and the large porcelain plate in the heating / cooling process remains at the fixed interface, and the manufactured foam panel is warped. . Particularly in a large panel using a large porcelain plate, the difference in the amount of thermal expansion and the amount of contraction is amplified and concentrated on the layer interface between the porcelain plate and the foam, and the warpage is large.

[Means for Solving the Problems] The present invention is to solve the above-mentioned conventional problems, in which a large porcelain plate is provided on one surface of an intermediate foamed body having reinforcing bars inside.
A large foam panel in which a high specific gravity material is arranged on the other surface and integrated, wherein the high specific gravity material has a specific gravity of 0.2 or more higher than the specific gravity of the intermediate foam, and The thickness is 1 / th of the total thickness of the intermediate foam and the high specific gravity material.
The gist of the large foam panel is characterized by being 10 to 1/4.

That is, the inventors of the present invention have conducted extensive studies in order to solve the problem of warpage of the foam panel, and as a result, on the surface of the foam panel opposite to the surface on which the large porcelain plate is welded, a high specific gravity and a predetermined thickness are provided. It has been found that a foam panel without warping can be obtained by a method in which a specific gravity material is installed and a backing layer of a large porcelain plate has a two-layer structure, and a method of simultaneously performing foaming and bonding of the large porcelain plate can provide a foamed panel. Completed .

Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 1 is a partially cutaway perspective view showing an embodiment of a large foam panel of the present invention.

As shown in the figure, the large-sized foam panel 1 of the present invention is one in which a large porcelain plate 4 is arranged on one surface of an intermediate foamed body 3 in which a reinforcing bar 2 is arranged, and a high specific gravity material 5 is arranged on the other surface. The high specific gravity material 5 satisfies the following conditions.

The specific gravity of the intermediate foam body 3 is 0.2 or more.

The thickness of the high specific gravity material 5 is 1/10 to 1/4 of the total thickness of the intermediate foam 3 and the high specific gravity material 5.

When the specific gravity of the high specific gravity material is not larger than the specific gravity of the intermediate foam by 0.2 or more, it is not possible to sufficiently prevent the foamed panel from warping.

In addition, the thickness of the high specific gravity material is 1 / of the total thickness with the intermediate foam.
If it is less than 10, the warp cannot be sufficiently prevented, and conversely 1 /
If it exceeds 4, warpage in the opposite direction will occur.

In the present invention, as the high specific gravity material 5, basically any material may be used as long as it has a specific gravity higher than that of the intermediate foam 3 by 0.2 or more. However, in consideration of the compatibility (adhesiveness) between the high specific gravity material 5 and the intermediate foam 3, it is preferable that the materials are of the same kind. Therefore, as the high specific gravity material 5, the specific gravity is adjusted by adding a frit agent, glass powder or the like to the foam material of the intermediate foam body 3, or the specific gravity is reduced by reducing the expansion ratio of the foam material of the intermediate foam body 3. And the like are preferred.

The specific gravity and thickness of the intermediate foam 3 of the foamed panel 1 are appropriately determined according to the weight of the foamed panel 1, required characteristics such as heat insulation characteristics, and the like depending on the purpose of use of the foamed panel 1. Since the specific gravity of 3 is about 0.3 to 0.7, the specific gravity of the high specific gravity material 5 is preferably about 0.5 to 1.5. Moreover, since the thickness of the intermediate foam 3 is generally set to about 20 to 100 mm, the thickness of the high specific gravity material is preferably set to about 3 to 20 mm.

On the other hand, the large porcelain plate 4 has a thickness of 30 x 30 cm or more and a thickness of 3 ~.
A 10 mm one is commonly used.

Such a foamed panel of the present invention can be extremely efficiently manufactured by a manufacturing method in which foaming of a foamed body and welding of a large porcelain plate are simultaneously performed.

Hereinafter, for a preferred production example of the foamed panel of the present invention,
This will be described in detail with reference to FIGS.

In this method, as the foam material of the intermediate foam body 3, one containing a binder component is used. As the foaming material, for example, hard pearlite is used as an aggregate, and PVA (polyvinyl alcohol) as a binder is added to the mixture and water is kneaded. Further, a calcined material composed of siliceous earth, soda ash, sodium nitrate, and dolomite is added. An example is one in which a binder is mixed and the surface of the aggregate is coated with these sintering agents.
In such a foam material, a large porcelain plate can be fixed and integrated by the binder action of the glassy component contained in the sintering agent.

In the method shown in FIGS. 3 to 5, first, as shown in FIG. 3, a large porcelain plate 4 having reinforcing bars 2 arranged on a belt conveyor (mesh belt) 22 coated with a release agent 21. Place and move (step I). At this time, the frit or the frit-mixed foam material is sprinkled on the surface of the large porcelain plate 4 to enhance the adhesive force between the large porcelain plate 4 and the intermediate foam body 3. The large porcelain plate 4 on which the reinforcing bars 2 are arranged is moved, the foam material 24 is dropped from the hopper 23, and the surface of the foam material 24 is pressed by the rolling roller 25 to make its thickness uniform and smooth the surface. (Step II). Furthermore,
Move the large porcelain board 4 on which the foam material 24 is laminated (Step II
I) In the same manner as in step II, the high specific gravity foam material 24 is dropped onto the foam material 24 from the hopper 26, the thickness is made uniform by the rolling roller 28, and the surface is smoothed (step IV).
In this state, it is further moved (step V), placed in the firing furnace 29 and subjected to heat treatment (for example, 820 ° C.) to foam the foamed materials 24 and 27 and at the same time weld them to the large porcelain plate 4 (step V).
I). That is, the binder component in the foam material 24 is the large porcelain plate 4
Then, the intermediate foam 3 and the large porcelain plate 4 and the layer of the high specific gravity material 5 are fixed and integrated by fusion bonding to the foam material 27. At the outlet of the firing furnace 29, the foamed laminated product is pressed by the rolling roller 30 to keep the foamed thickness constant, the surface of the foamed body is smoothed, and then cooled to room temperature in a cooling step to obtain a product. (Step VII).

By such a method, the foaming of the intermediate foam 3 and the high specific gravity material 5 and the welding and unification of the large porcelain plate 4 can be performed in a single process, and extremely efficient manufacturing can be performed.

When a foam panel is manufactured by such a method, in a foam panel composed of a conventional large porcelain plate and a foam, expansion and contraction occur in the heating and firing and the subsequent cooling process, resulting in a large porcelain plate and a foam layer. Is warped in the panel due to the difference in the amount of thermal expansion and the amount of contraction, but in the case of a three-layer structure lined with a material having a higher specific gravity as in the present invention, the high specific gravity material layer is warped. It effectively acts on the stress that gives and prevents this.

[Operation] Since the foam panel of the present invention has a three-layer structure of a large porcelain plate, an intermediate foam, and a high specific gravity material having a specific gravity and a specific thickness, the large porcelain plate and the intermediate foam by heating and cooling in the manufacturing process. The presence of the high specific gravity material layer effectively prevents distortion and warpage due to the difference in thermal expansion and contraction with the body.

Therefore, a high-quality foam panel without product defects can be efficiently produced by adopting a manufacturing method in which foaming and welding are performed at the same time.

[Examples] Examples and comparative examples will be described below.

Examples 1 to 6 Foamed panels (size: 600 × 1800 × 45 mm) of the present invention as shown in FIG. 1 were manufactured by the method shown in FIGS.

The following materials were used as the foaming material and the high specific gravity material of the intermediate foam, and the thickness and the specific gravity were adjusted to those shown in Table 1, respectively.

A large porcelain plate with a thickness of 3 mm was used.

Intermediate foam material Hard perlite as aggregate and PVA as binder
And kneaded with water, and then mixed with a sintering agent consisting of siliceous earth, soda ash, sodium nitrate, and dolomite, coated on the surface of the aggregate, and then air-dried. .

High specific gravity material The above foam material with frit and glass powder added.

The degree of warpage of the produced foam panel was measured by the degree of warpage 1 (see FIG. 6) with respect to a foam panel having a width of 1 m, the state of warpage was examined, and the results are shown in Table 1.

Comparative Examples 1 to 5 A foam panel was produced in the same manner as in Example 1 using no high specific gravity material (Comparative Example 1) or using a high specific gravity material whose specific gravity or thickness is out of the range of the present invention. The state of the warp was investigated. The results are shown in Table 1.

From Table 1, it is clear that the foamed panel of the present invention has almost no warpage due to thermal expansion and contraction and has an extremely high quality.

[Effects of the Invention] As described in detail above, in the foam panel of the present invention, since warpage due to the difference in thermal expansion and contraction between the large porcelain plate and the foam is prevented from occurring, the foaming of the foam material and the large porcelain plate are prevented. By the method of simultaneously performing the fusion integration with the foam and the foam, it is possible to extremely advantageously manufacture without causing product defects such as defective adhesion and warpage.

Therefore, the foamed panel of the present invention can be easily and efficiently manufactured with a small number of steps, and by the simplification of the manufacturing process,
It is possible to improve productivity and reduce costs.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view of a foam panel according to an embodiment of the present invention, FIG. 2 is a partially cutaway perspective view showing a conventional example, and FIGS. 3 and 4 are manufacturing of the panel of FIG. FIG. 5 is an explanatory view for explaining the procedure, FIG. 5 is an explanatory view showing the process II of FIG. 3 in an enlarged manner, and FIG. 6 is a view showing a method for measuring the warpage of the example and the comparative example. 1 ... foam panel, 2 ... reinforcing bar, 3 ... intermediate foam, 4 ... large porcelain plate, 5 ... high specific gravity material.

Front page continuation (72) Inventor Hiroaki Motoki 1 179, Nitta, Nitta, Mishima, Kawashima-cho, Asa-gun, Tokushima

Claims (1)

[Claims] 1. A large foam panel in which a large porcelain plate is arranged on one surface of an intermediate foam body having reinforcing bars inside and a high specific gravity material is arranged on the other surface of the intermediate foam body, the high specific gravity material comprising: It has a specific gravity greater than that of the intermediate foam by 0.2 or more, and
A large foam panel, wherein the thickness of the high specific gravity material is 1/10 to 1/4 of the total thickness of the intermediate foam and the high specific gravity material.