JP2000109354A - Production of building board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a lightweight/inexpensive board which can be easily processed and which is excellent in sound insulating property and workability by adding and kneading vermiculite and/or pearlite material, cement and carbon fiber to water, casting the kneaded material into a die, pressing, drying and curing. SOLUTION: This carbon fiber material is produced by aggregating extremely thin fibers and cutting the aggregate into chips. Or, by another method, water is added to vermiculite and/or pearlite material and cement and kneaded, and the kneaded material is partly cast into a die and flattened, on which the carbon fiber material is mounted. Then the rest of the kneaded material is cast into the die and flattened, and then pressed, dried and hardened. The carbon fiber material is produced by aggregating extremely fine threads and cut into strips. The carbon fiber material in stripes is mounted at a same distance parallel to each other, or may be arranged in a lattice state.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a building board which is lightweight, can be manufactured at a low cost, is easy to process, and has excellent sound absorption and workability.

[0002]

2. Description of the Related Art Various types of cement boards used for construction have been proposed and put into practical use.

[0003]

However, such a construction board is heavy in weight due to the use of a large amount of cement in its entirety, and it is difficult to cut other than an electric saw. In addition to the inconvenience that cannot be obtained, there are disadvantages such as the necessity of dust prevention measures at the time of cutting, and the cost is high.

The present invention has been made in view of such a viewpoint, and proposes a method of manufacturing an inexpensive architectural board which is particularly lightweight, can be easily processed, and has excellent sound absorption and workability. Is the task.

[0005]

According to a first aspect of the present invention, there is provided a method of manufacturing a building board, comprising: a vermiculite material, a perlite material, or both materials, a cement material and a carbon fiber. The material is kneaded by adding water, poured into a mold, leveled, pressed by a pressing means, and dried and cured by a drying means.

In a second aspect of the present invention, a vermiculite material or a perlite material or both materials and a cement material are kneaded by adding water, and a part of the kneaded material is poured into a mold and leveled. Further, after the carbon fiber material is placed thereon, the remaining part is poured into a mold, leveled, and then pressed by a pressing means, and further dried and cured by a drying means.

[0007] The carbon fiber material may be formed by gathering very thin yarns, and may have a chip-like form.

[0008] The carbon fiber material may be formed by gathering very thin yarns, and may have a strip shape.

[0009] The carbon fiber material having a strip shape may be arranged in parallel at equal intervals or in a lattice shape.

[0010]

Embodiments of the present invention will be described below with reference to the drawings.

In FIG. 4, reference numeral 1 denotes an architectural board manufactured by the method of manufacturing an architectural board according to the present invention, and the architectural board 1 is formed in a rectangular shape in plan view.

Next, a method of manufacturing the building board 1 will be described with reference to FIGS. Here, the building board 1 has a length of 500 mm, a width of 500 mm,
This is an example of manufacturing a 12-mm-thick material. First, the fired vermiculite material 2, cement material 3, and carbon fiber material 4 are sufficiently kneaded in a mixer 6 after adding water 5. At this time, since the vermiculite material 2 itself in the kneaded state has many fine spaces, it is kneaded from the mixer 6 because water is absorbed and kept in the fine spaces. When the material 7 is taken out, the material 7 has almost no fluidity.

When the vermiculite material 2 is passed through a high-temperature baking furnace, the moisture contained in the crystal layer instantaneously turns into water vapor to expand rapidly through delamination. As a result, the vermiculite material after firing 2 has the property that many microspaces are created.

By the way, when the building board 1 is manufactured, the amount of each material to be charged into the mixer 6 is as follows:
Vermiculite material 2 is 600-700 g, cement material 3 is 800-1000 g, and carbon fiber material 4 is 5-5.
What is necessary is just to adjust suitably 10 g and water 5 in the range of 1400-2000 g.

As shown in FIG. 5, the carbon fiber material 4 is formed by gathering very thin yarns 4a.
This is cut into a chip-like form. As the carbon fiber material 4, a trader chopped fiber having a trade name "Treca" of Toray Industries, Inc. is used.
It is not necessarily limited to this, and other carbon fiber materials may be used.

Next, the material 7 after kneading in the mixer 6 is poured into a mold 8 and the poured material has no fluidity, so that the mold 7 is formed by an appropriate means such as a shovel (not shown) or the like. Equalize the whole of 8 Then, formwork 8
After the material 7 is pressed by a press machine 9 (pressing means) provided above, the material 7 is taken out of the mold frame 8, stored in a drying chamber 10 (drying means), and dried and cured by a heater. The building board 1 can be manufactured.

The press pressure of the press 9 for press working is usually preferably 2 to 3 tons. At this time, the water absorbed in the micro space of the vermiculite material 2 is pushed out. Further, the drying may be solar drying without using a heater provided in the drying chamber 10.

According to the above-described method for manufacturing a building board,
The vermiculite material 2, the cement material 3, and the carbon fiber material 4 are kneaded in a mixer 6 by adding water 5. next,
The kneaded material 7 is poured into a mold 8 and leveled. Then, after performing press working with the press machine 9 from the formwork 8,
The architectural board 1 is manufactured by taking out the material 7 from the mold 8 and drying and curing it in the drying chamber 10.

Therefore, according to the above-mentioned manufacturing method, the cement material 3 is lightweight and tough, and the amount of the cement material 3 is small relative to the total mixing amount. Building boards can be manufactured.

Further, since the building board 1 has excellent sound absorbing properties, it is also suitable to be used as a sound absorbing material.
In addition, the manufacturing cost can be kept low.

In this embodiment, the vermiculite material 2 is used. However, the present invention is not limited to this. For example, a perlite material or a vermiculite material and a pearlite material 2 may be used.
May be used. In this case, the compounding amount is appropriately adjusted in the range of 800 to 1000 g when the perlite material alone is used, and in the range of 350 to 450 g for the vermiculite material and 400 to 500 when both the vermiculite material and the perlite material are used. Is preferred. The amounts of the other materials are not changed at all as described above.

Next, FIGS. 9a and 9b show a building board 1 manufactured by a method of manufacturing a building board of another invention, and the building board 1 is formed in a rectangular shape in plan view.

A method of manufacturing the building board 1 of the other invention will be described with reference to FIGS. Here, the building board 1 has a length of 500, as shown in FIGS.
This is an example in the case of manufacturing a device having a diameter of 500 mm, a width of 500 mm and a thickness of 12 mm.

First, the vermiculite material 2 and the cement material 3 are sufficiently kneaded in the mixer 6 with the addition of water 5. In the kneaded state at this time, the vermiculite material 2 itself has many microspaces, and the moisture is absorbed and maintained in the microspaces. When the kneaded material 7 is taken out from the inside, there is no fluidity.

By the way, when the building board 1 is manufactured, the mixing amount of each material put into the mixer 6 is as follows.
Vermiculite material 2 is 600-700 g, cement material 3 is 800-1000 g, and water 5 is 1400-2.
It is preferable to adjust appropriately within the range of 000 grams.

Next, half of the kneaded raw material 7 in the mixer 6 is poured into the mold 8 and the poured raw material 7 has no fluidity, so that the raw material 7 is molded by a suitable means such as a shovel (not shown) or the like. Equalize the whole inside the frame 8. Thereafter, the carbon fiber material 12 having a strip shape is placed on the carbon fiber material 12 at equal intervals, and the remaining material 7 is further poured from the carbon fiber material 12 and leveled. Then, a press 9 (pressing means) provided on the form 8 in this state
After pressing, the building board 1 can be manufactured by taking it out of the mold frame 8, storing it in the drying chamber 10 (drying means), and drying and curing it with a heater.

As shown in FIG. 5, the carbon fiber material 4 is formed by assembling very thin yarns 4a, and is cut into a strip shape. The carbon fiber material 4
May be arranged in a grid as shown in FIG. 9b. In addition, the carbon fiber material 4 uses the trade name chopped fiber of the trade name "Treca" of Toray Industries, Inc.
It is not necessarily limited to this, and other carbon fiber materials may be used.

The pressing pressure of the pressing machine 9 for performing the press working is usually preferably 2 to 3 tons. Further, at this time, the moisture absorbed and maintained in many micro spaces of the vermiculite material 2 is extruded. Further, the drying may be solar drying without using a heater provided in the drying chamber 10.

According to the method for manufacturing a building board as described above, the vermiculite material 2 and the cement material 3 are kneaded in the mixer 6 with the addition of water 5. Next, half of the kneaded material 7 is poured into a mold 8 and leveled.
After the carbon fiber material 12 formed in a belt shape is placed thereon at equal intervals, the entire remaining material 7 is poured into the mold 8 and pressed from above by a pressing means. Thereafter, the building board 1 is manufactured by taking out from the mold 8 and drying and hardening it in the drying chamber 10.

Therefore, according to the above-mentioned manufacturing method, the ratio of the cement material 3 is small relative to the total mixing amount, so that the processing can be easily carried out by the cutter, so that the workability is excellent and the building is easy to use. Board can be manufactured. Further, the product itself can be provided with a lightweight and tough product.

Further, since the building board 1 contains the carbon fiber material 12 formed in a band shape, it is very resistant to bending and very excellent in sound absorption. In addition, the manufacturing cost can be kept low.

In this embodiment, the vermiculite material 2 is used. However, the present invention is not limited to this. For example, a perlite material or both a vermiculite material and a pearlite material may be used. The compounding amount in this case is
800-1000 grams when using only perlite,
For both vermiculite and perlite,
It is preferable to appropriately adjust the amount of the vermiculite material in the range of 350 to 450 g and the amount of the pearlite material in the range of 400 to 500. The amounts of the other materials are not changed at all as described above.

FIG. 10 shows an example in which the architectural board 1 of the present invention is used for waterproofing a veranda. In this example, the board 1 is placed on a veneer plywood (control panel) 15 and nails, screws, etc. (Not shown).
Then, FRP waterproofing 16 may be applied on the board 1.

In the FRP waterproofing 16, a primer layer is provided on the board 1, a resin layer is provided on the primer layer, and a glass mat layer is provided on the resin layer. A resin layer is provided on the glass mat layer, and a colored polyester layer is provided on the resin layer.

Thus, the processing can be easily performed by the cutter, and the workability can be improved, and the working period can be shortened. In addition, the manufacturing cost can be kept low, which is economical.

The architectural board 1 is also excellent in sound absorption, so that it is suitable for use as a wall member.

[0037]

As described above, according to the method for manufacturing a building board according to the first aspect of the present invention, the vermiculite material or the perlite material or both of them, the cement material and the carbon fiber material are kneaded by adding water. Since it is poured into a mold and leveled, it is subjected to press working from above by press means, and further dried and cured by drying means to produce a board,
Thus, the material is lightweight and tough, and the ratio of the cement material is small relative to the entire mixing amount, so that the material can be easily processed by a cutter even at the time of processing, so that excellent workability can be obtained. Further, since this architectural board has excellent sound absorbing properties, it is suitable for use as a wall member. Further, the manufacturing cost can be kept low, which is economical.

Further, according to the invention of claim 2, a vermiculite material or a perlite material or both materials and a cement material are kneaded by adding water, and a part thereof is poured into a mold and leveled.
Further, after the carbon fiber material is placed thereon, the remaining part is poured into a mold, subjected to press working from above by a pressing means, and further dried and cured by a drying means to produce a board. Therefore, since the ratio of the cement material is small relative to the total mixing amount, the processing can be easily performed by the cutter at the time of processing, so that excellent workability can be obtained. Further, since it is lightweight, tough, and excellent in sound absorption, it is suitable for use as a wall member, and in addition, the production cost can be reduced.

Further, according to the third aspect of the present invention, since the carbon fiber material is formed by gathering very thin yarns and has a chip-like form, it can be kneaded uniformly and evenly. Thereby, a tougher building board can be manufactured.

Further, according to the invention of claim 4, since the carbon fiber material is formed by gathering very thin yarns and has a belt-like form, a building board resistant to bending is manufactured. can do.

According to the fifth aspect of the present invention, since the carbon fiber material having a belt-like shape is arranged at equal intervals in parallel or in a lattice, it is more tough against bending. With it, lightweight architectural boards can be manufactured.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a state in which a vermiculite material, a cement material, and a carbon fiber material are added to a mixer, added with water, and kneaded in the method for manufacturing a building board of the present invention.

FIG. 2 is an explanatory view showing a state in which the mixture is poured into a mold frame after kneading, leveled, and then pressed by a pressing means.

FIG. 3 is an explanatory view showing a state where the sheet is taken out of a mold, stored in a drying chamber, and dried and cured by a heater.

FIG. 4 is a perspective view of a building board manufactured by the method for manufacturing a building board of the present invention.

FIG. 5 is a perspective view of a carbon fiber material.

FIG. 6 is an explanatory view showing a state in which a vermiculite material and a cement material are added to a mixer, added with water, and kneaded in another example of the method of manufacturing a building board.

FIG. 7 is an explanatory view showing a state in which the mixture is poured into a mold frame after kneading, leveled, and then pressed by a pressing means.

FIG. 8 is an explanatory view showing a state where the sheet is taken out of a mold, stored in a drying chamber, and dried and cured by a heater.

9A and 9B are perspective views of a building board manufactured by another example of a method of manufacturing a building board.

FIG. 10 is an explanatory view of a state in which a building board is used for waterproofing a veranda.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Building board 2 Vermiculite material 3 Cement 4 Carbon fiber material 5 Water 8 Formwork 9 Press machine (Press means) 10 Drying room (Dry means)

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) E04C 2/06 E04C 2/06 // C04B 111: 40 111: 52

Claims (5)

[Claims] Claims 1. A vermiculite material or a perlite material or both materials, a cement material and a carbon fiber material are kneaded by adding water, poured into a mold, leveled, and then subjected to press working by a press means. A method for producing an architectural board, comprising drying and curing by a drying means. 2. A vermiculite material or a perlite material or both materials and a cement material are kneaded by adding water, and a part of the kneaded material is poured into a mold, leveled, and further a carbon fiber material is placed thereon. A method for manufacturing an architectural board, characterized in that the rest is poured into a mold, leveled, pressed by a pressing means, and dried and cured by a drying means. 3. The building board according to claim 1, wherein the carbon fiber material is formed by gathering very thin yarns, and has a chip-like form. Method. 4. The method for manufacturing a building board according to claim 2, wherein the carbon fiber material is formed by gathering very thin yarns, and has a strip shape. . 5. The method for manufacturing a building board according to claim 2, wherein the carbon fiber materials having a band shape are arranged at equal intervals in parallel or in a lattice.