JP2000271924A - Manufacture of inorganic formed plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide the manufacturing method of an inorganic formed plate, in which a special cement utilizing the powder mainly consists of γ-2CaOSiO2 and 12CaO7Al2O3 representing the reduction stage slug in a steel making is applied, and the manufacturing method of an inorganic formed plate, within which fixing members are embedded and which is made of an arbitrary kind of cement. SOLUTION: In this manufacturing method, in which an inorganic formed plate is manufactured by forming a composition, which is prepared by adding 1-12 pts.wt. of reinforcing fibers, 0.1-3 pts.wt. of a water holding agent, 30-70 pts.wt. of water and a foaming agent and arbitrarily water reducing agent, fine aggregate and filler to 100 pts.wt. of cement mainly consisting of 2-100 pts.wt. of gypsum to 100 pts.wt. of basic powder including 10-80 pts.wt. of γ-2 CaOSiO2 and 90-20 pts.wt. of 12CaO7Al2O3 and then kneaded, with a press made of air permeable material and then steam-curing and drying and, in addition, an inorganic formed plate, within which fixing members are embedded, is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a cement made from gypsum as a raw material and a base powder mainly composed of γ-2CaOSi ₂ and 12CaO7Al ₂ O ₃ typified by, for example, slag for reducing steelmaking.
Compared to the case of using ordinary ordinary cement (Portland cement), a method of manufacturing an inorganic molded plate that enables manufacturing with a lower capital investment amount, and using a cement (the type of cement is not specified) and a fixing bracket inside The present invention relates to a method for producing an embedded inorganic molded plate.

[0002]

2. Description of the Related Art In the past, most of exterior wall materials for houses were made by a wet construction method characterized by earth walls, but recently, a large number of materials have been used.
Among them, the production has rapidly increased since the mid-1950s, and a fiber-reinforced cement board called nitrogen-based siding has attracted attention. However, most of the cements used in fiber reinforced cement boards that have been conventionally produced are Portland cements, and this cement takes time to harden, which may hinder mass production of cement boards. is there. To accelerate curing,
In some cases, high-strength cement or jet cement, which hardens faster than ordinary Portland cement, or a hardening accelerator such as calcium chloride, magnesium chloride, sodium carbonate, or sodium aluminate is used, but the cost is high. There's a problem. Further, the pH of the composition obtained by the hydration reaction of the above-mentioned commercially available cement is as high as about 12, and there is a problem that a reinforcing fiber weak to alkali such as E-glass cannot be used. Furthermore, in order to obtain excellent performance in a short period of time, it is often necessary to perform autoclave treatment (treatment using a steam pot, to quickly cure cement products by applying pressure with steam), in which case a large amount of money is required. Capital investment had to be made. On the other hand, the present applicants have already succeeded in developing a cement obtained by making effective use of the steelmaking reduction period slag generated in large quantities during the production of steel materials, and have clarified the contents thereof (Japanese Patent Publication No. 62-47827). This cement is γ-2CaOSiO ₂ ,
The 12CaO7Al ₂ O ₃ and gypsum to a cement raw material,
Early strength development, weak alkali, can be cured at low temperature and atmospheric pressure,
Although it has excellent features such as small dimensional changes, it was necessary to develop further applications that take advantage of these features. Also, Japanese Utility Model Publication No. 59-22817, Japanese Patent Application Laid-Open No. 60-23540.
Japanese Patent Application Publication No. 6-41703 and Japanese Patent Application Laid-Open No. Hei 9-13573 have already proposed a structure in which a fixing member is buried inside a wall material in order to fix the wall material at a predetermined position. However, in these publications, although the fixing member is described in detail, a method of efficiently forming the pattern on the front side and burying the fixing member efficiently at the same time, ensuring excellent transferability to a model mold. There is no description about a method and a method for securing the fixing strength of the fixing member without reinforcement, and there is no sufficient proposal for utilizing it as a wall material.

[0003]

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and proposes a new use of slag in the steelmaking reduction stage (slag in the electric furnace deoxidation stage). Γ-2CaOSiO ₂ and 12Ca typified by slag in steelmaking reduction period
To provide a method for producing an inorganic molded plate utilizing a special cement using powder containing O7Al ₂ O ₃ as a main component and a method for producing an inorganic molded plate (an arbitrary type of cement) having a fixing member embedded therein. With the goal.

[0004]

The present invention to achieve the above object is as follows. (1) 10 to 80 parts by weight of γ-2CaOSiO ₂ and 12CaO7Al ₂ O ₃
Cement 100 mainly composed of 100 parts by weight of substrate powder containing 90 to 20 parts by weight and 2 to 100 parts by weight of gypsum
1 to 12 parts by weight of the reinforcing fiber and 0.
1 to 3 parts by weight, 30 to 70 parts by weight of water, a foaming agent, and optionally a water reducing agent, fine aggregate, a composition kneaded by adding a filler, press-molded with a material having air permeability, A method for producing an inorganic molded plate, comprising drying after steam curing. (2) The inorganic molded plate produced by press-molding a material having air permeability has a dense layer having a higher specific gravity at the surface than at the center, and a difference in specific gravity between the surface and the center is zero. The method for producing an inorganic molded plate according to (1), which is 0.05 or more. (3) A hydraulic raw material mixture containing cement, reinforcing fibers, a water retention agent, and water, and further optionally adding a foaming agent, a water reducing agent, fine aggregate, and a filler, and kneading the mixture, is passed through the entire bottom surface. Inorganic molding characterized by filling in a formwork on which a permeable material is laid and a fixing member installed at an arbitrary position above it, press-molding from the upper surface with a breathable material, drying after steam curing Plate manufacturing method. (4) An inorganic molded plate manufactured by press-molding with a breathable material and having a fixing member embedded therein has a dense layer having a higher specific gravity than a central portion on a surface portion, and a surface portion and a central portion. (3), wherein the difference in specific gravity is 0.05 or more.

According to the above method (1), γ-2CaOSiO ₂ and 12
CaO7Al ₂ O ₃ to a novel use of steelmaking reduction period slag can be newly proposed having as main mineral composition, contributes to effective use of waste in a steel mill by an electric furnace. Also,
The inorganic molded plate of the present invention is quickly cured despite the use of inexpensive cement, can be quickly demolded, requires a small pressing force, and can be cured and dried at low temperature and atmospheric pressure. Therefore, it is possible to manufacture an inorganic molded plate with a small capital investment. Furthermore, the inorganic molded plate manufactured by the method (2) or (4) has a dense layer on the surface, and thus has an advantage that lightweight and excellent performance can be secured. According to the above method (3), since a press-molding is performed with a breathable material, a pattern having good transferability can be formed on the front side, and the fixing member can be easily embedded at a predetermined position. In addition, the shaping of the pattern and the embedding of the fixing member can be performed simultaneously. Since the periphery of the fixing member is filled with the raw material containing the reinforcing fiber by press molding, and the dense layer is formed on the surface by the breathable material, the strength required by curing can be easily secured thereafter. . Therefore, it is not necessary to use a reinforcing material such as a reinforcing bar. Since the fixing portion of the fixing member is exposed on the back side of the plate, the work of mounting the plate can be easily performed. Since it can be fixed from the back side of the board, there is no need to damage the pattern side of the front. As if screwing from the front side (pattern side),
Reinforcement work (putty filling) to make screw stop marks inconspicuous becomes unnecessary.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The first invention of the present invention is an inorganic molded plate and a method for producing the same. The inorganic molded plate of the first invention of the present invention has a dense layer having a higher specific gravity than the center of the inorganic molded plate on the surface of the inorganic molded plate, and the difference in the ratio between the surface and the center is 0.05. It is composed of the above-mentioned inorganic molded plate. Further, the inorganic molded plate of the first invention of the present invention is characterized in that γ-2CaOSiO
Against ₂ 10-80 parts by weight 12CaO7Al ₂ O ₃ 90~20 cement 100 parts by weight of the substrate powder 100 parts by weight, gypsum 2-100 parts by weight and the major component containing parts, the reinforcing fibers 1-12 Parts by weight, 0.1-3 parts by weight of water retention agent, water 3
0 to 70 parts by weight, a foaming agent, and a water-reducing agent, fine aggregate, and a composition obtained by adding and kneading a filler, and kneading the mixture. It has a high density layer and the difference between the ratio of the surface part and the center part is 0.05
It is composed of the above-mentioned inorganic molded plate. In addition, the first aspect of the present invention
As shown in FIG. 1, the method for producing an inorganic molded plate according to the invention (corresponding to claims 1 and 2) comprises a substrate containing 10 to 80 parts by weight of γ-2CaOSiO ₂ and 90 to ₂₀ parts by weight of 12CaO7Al ₂ O _3. 100 parts by weight of cement containing 100 parts by weight of powder and 2 to 100 parts by weight of gypsum as main components, 1 to 12 parts by weight of reinforcing fiber, 0.1 to 3 parts by weight of water retention agent, 30 to 70 parts by weight of water,
A method comprising press-molding a composition obtained by adding a foaming agent and optionally a water reducing agent, a fine aggregate, and a filler and kneading the same with a material having air permeability, followed by steam curing and drying. Among the cements used in the method of the present invention, γ-2CaOSiO ₂ and 12CaO7
As a raw material of Al ₂ O ₃ , it is recommended that CaO, SiO ₂ , and slag in the steelmaking reduction period in which Al ₂ O ₃ is stabilized within a certain range are the most easily available. In particular, slag that causes dusting upon cooling is suitable as a raw material. The substrate powder is γ
-2CaOSiO ₂ from 10 to 80 parts by weight, 90 to the 12CaO7Al ₂ O ₃
It is necessary to use a powder containing 20 parts by weight. If the ratio is outside the above range, sufficient strength as cement cannot be obtained. In particular, powder having a ratio of 20 to 70 parts by weight of γ-2CaOSiO ₂ and 80 to 30 parts by weight of 12CaO 7 Al ₂ O ₃ is more preferable. The substrate powder is γ-2Ca
It may be composed only of OSiO ₂ and 12CaO 7 Al ₂ O ₃ , but it can be used without any problem even if it contains a small amount of other oxides such as MgO or sulfides as impurities.

As the gypsum, calcined gypsum, gypsum hemihydrate or gypsum or an intermediate or mixture thereof can be used. For example, desulfurized gypsum generated in large quantities in a thermal power plant or the like can be used as a raw material. The amount of the gypsum is 2 to 100 parts by weight, preferably 20 to 50 parts by weight, based on 100 parts by weight of the substrate powder. When the amount of gypsum is less than 2 parts by weight, ettringite (mineral name) is not sufficiently generated by the hydration reaction, and thus sufficient strength cannot be obtained. As the gypsum is increased from 2 parts by weight, high strength is obtained, and the highest strength is obtained at 20 to 40 parts by weight.

The cement used in the present invention contains the above-mentioned γ-2CaOSiO ₂ , 12CaO7Al ₂ O ₃ and gypsum as main components. In addition, another commercial cement is mixed with 100 parts by weight of the cement. To 100 parts by weight or less. When commercial cement is added in excess of 100 parts by weight with respect to 100 parts by weight of the cement,
This is because the characteristics of the cement such as early strength development, weak alkalinity, and the above-mentioned curing at low pressure and atmospheric pressure (details will be described later) are lost, and the cost is increased as described above. Therefore, the mixing amount of the commercially available cement is more preferably 30 parts by weight or less based on 100 parts by weight of the cement. Examples of the cement that can be mixed include ordinary portland cement, early-strength cement, jet cement, blast-furnace slag cement, fly ash cement, alumina cement, and the like, and one or a mixture of two or more of these cements can be used.

As the reinforcing fibers, pulp fibers, waste paper defibrated materials, polyester fibers, polyamide fibers, acrylic fibers, acetate fibers, polyethylene fibers, polypropylene fibers, glass fibers, carbon fibers, ceramic fibers, rock wool, vinylon fibers, etc. The reinforcing fibers used in the reinforced cement board can be used. Particularly mainly used in the present _{invention, γ-2CaOSiO 2, 12CaO7Al 2} O 3 and a cement made of gypsum, since the calcium hydroxide by a hydration reaction does not produce, pH of about 10.5 and other commercial cement Cement Mortar Since it shows weak alkalinity as compared with pH of 12 to 12.5, it is possible to reinforce it with inexpensive E-glass among glass fibers. E-glass reinforcement is γ-2CaOSiO ₂ , 12
Cement consisting CaO7Al ₂ O ₃ and plaster even when mixed a small amount of other commercial cement, it is likewise possible. Also, the fact that using longer fibers has a greater strength improvement effect,
It is as conventionally known.

The compounding amount of the reinforcing fibers is in the range of 1 to 12 parts by weight based on 100 parts by weight of the cement powder (substrate powder + gypsum). The reason for the above range is that a sufficient strength improvement effect cannot be obtained with less than 1 part by weight,
This is because, even if added in excess of 12 parts by weight, the effect of improving strength is saturated, and the fluidity of the kneaded raw material is reduced, making it difficult to form a pattern described later. In consideration of both strength and cost, it is more preferable to add the reinforcing fiber in the range of 2.5 to 8 parts by weight.

In the present invention, a desired pattern or the like is formed on the surface by press molding after kneading the raw materials in the above-mentioned composition. The kneaded raw material contains a large amount of water and air bubbles (generated by a foaming agent), but when pressed, the air bubbles and cement water existing inside are separated, and an inorganic plate having the target specific gravity and strength is obtained. No longer available. In the present invention, a water retention agent is added to solve the problem. As the water retention agent, methylcellulose, hydroxypropismethylcellulose, hydroxyethylmethylcellulose, oxypromethylcellulose and the like can be used, and they are used alone or in combination.

It is necessary to add an appropriate amount of a water retention agent to such an extent that cement water does not separate during press molding (water does not exude when pressed). Specifically, 0.1 to 3 parts by weight, preferably 0.3 to 3 parts by weight based on 100 parts by weight of cement powder
1.5 parts by weight is preferred. The lower limit was set to 0.1 part by weight because a smaller amount would not provide a sufficient water retention effect, and the upper limit was set to 3 parts by weight even if added in an unnecessarily large amount. There is no change, just higher costs.

The foaming agent is added to reduce the weight of the produced inorganic molded plate. Many foaming agents are commercially available, and any foaming agent can be used as long as it can be put into a mixer and foamed by kneading, and the type thereof is not particularly limited. Therefore, since the optimal amount differs depending on which product is used,
In the present invention, the amount is not particularly limited. However, since ceramic-based siding is required to have a specific gravity of about 1.0, it is necessary to select a foaming agent capable of reducing the specific gravity of the kneaded composition after drying to less than 1.0. is there.

In kneading the cement composition of the present invention, 3 parts are added to 100 parts by weight of the cement powder.
0-70 parts by weight, preferably 40-60 parts by weight, of water are added. When the amount of water added is large, the strength of the cured body is reduced, but when the amount is too small, the fluidity is reduced, and when a pattern is formed by press molding, a defect such as a crack or a lack of a wall is generated. there is a possibility. Therefore, it is necessary to add an appropriate amount of a water reducing agent as needed in order to secure the required fluidity with a smaller amount of water. Since various kinds of water reducing agents are commercially available, a suitable one may be arbitrarily selected from them.

In addition, as a raw material for the inorganic molded plate of the present invention, a fine aggregate, a filler and the like may be arbitrarily added in addition to those described above. For example, one or two of light aggregate such as perlite, shirasu balloon, fly ash balloon, expanded styrene beads, sand, lime sand, granulated blast furnace sand, silica, fly ash, sepiolite, silica fume, wollastonite, mica, etc. More than one species can be added. However, it is necessary to adjust the addition amount of the lightweight aggregate in combination with the effect of the foaming agent so that the cost is not increased as much as possible. By kneading the above-described raw materials, the raw materials for the inorganic molded plate according to the present invention can be prepared.

In the method for producing an inorganic molded plate of the present invention, the above-mentioned raw materials are sufficiently kneaded and then press-molded with a material having air permeability. For example, in the case of an ordinary outer wall material for a house, a pattern is formed only on one side, and the other side has a flat shape.
In the case of manufacturing a plate having such a shape, the mold 11 is prepared, and an iron plate or an acrylic plate 12 having a hole having a diameter of about 1 mm is placed as shown in FIG. The sheet 13 is laid, and the raw material 14 is put thereon. In this case, it is essential that the air-permeable sheet used has air permeability over the entire surface. If there is a part that does not have air permeability even partially, if air is trapped between that part and the raw material, the air will not be discharged to the outside, so there is a possibility that it will remain as a defect after press molding. At the same time, a dense layer described later is not formed at that portion. By using a sheet having air permeability on the entire surface, the air sandwiched at the time of charging the raw material easily passes through the air permeable sheet and is discharged to the outside at the time of pressing, so that a defect-free plate can be manufactured.

The air-permeable sheet may be of any type as long as it has strength not to break by pressing and has sufficient air-permeability. Long-fiber nonwoven fabric that has been used can be used. After the raw material 14 is put on the air permeable sheet as described above, a pattern is formed on the surface from the top as shown in FIG. The press forming force at this time must be a pressing force necessary to sufficiently fill all corners of the material surrounded by the mold, the permeable sheet, and the permeable material without causing underfill of the raw material. And the pressure is 0.5-10.0
kgf / cm ² (1 kg / cm ² is 98 kPa), preferably 1.0-7.
It is good to be 0 kgf / cm ² . If the pressing pressure is too low, it may not be possible to press-mold sufficiently to a predetermined thickness or the plate may be underfilled.If the pressing pressure is too high, water inside the raw material is separated, and a plate having excellent characteristics is obtained. This is because it cannot be generated.

The air-permeable mold having a pattern needs to have air-permeability on the entire surface, similarly to the air-permeable sheet.
And such a breathable mold is, for example, 10 to 10
A sample of 0 μm powder, a resin binder for binding the powders, and a solvent for the resin binder are kneaded, filled into the upper part of the master-shaped mold housed in the mold, and the binder is dried and cured. Can be manufactured.

That is, powders having a size of several tens of μm are combined with a resin binder in such an amount that a space is formed between the powders, and the presence of the space ensures air permeability. The type of the powder is not particularly limited as long as the adhesive strength with the resin binder to be used is good, and is not particularly limited. Use of metal powder such as Al, brass, iron sulfide, reduced iron, etc., ceramic particles, glass particles, etc. Is possible.

The particle size of the powder used is 10 to 100 μm
And a particle size of 20 to 50 μm is particularly preferred. If it is too fine, it is difficult to secure sufficient air permeability.On the other hand, if it is too large, the production of an inorganic molded plate having an excellent-looking pattern with the grain shape transferred to the molded plate in a size that can be visually confirmed on the molded plate Becomes difficult. However, it is possible to use a grain having a larger diameter only in a portion that does not directly contact the raw material. In order to improve the durability of the mold, a reinforcing layer may be provided on the side not directly contacting the raw material. For example, a method of sandwiching a glass cloth and bonding urethane foam can be applied. In this case, it is necessary to make holes in a plurality of locations of the reinforcing layer to secure air permeability.

The type of the resin binder is not particularly limited as long as it has good adhesive strength to the powder used, and a thermosetting resin such as an epoxy resin or a phenol resin can be used. In order to ensure excellent air permeability, the amount of the resin is preferably as small as possible as long as the adhesive strength required for the mold can be secured.

The air-permeable mold can be manufactured by a porous electroforming method in addition to the resin mold. The method of producing a mold by electroforming is a method of producing a mold by inverting the shape and surface irregularities of the matrix by applying electroplating to the matrix (mandrel) to a thickness of several mm. Also known as a mold. As a metal to be plated, nickel, copper, a nickel alloy or the like can be used. The electroformed shell manufactured after the electroplating process on the mother die is removed from the mother die, and can be used by being attached to a mold base or the like.

In FIGS. 2 and 3 described above, the pattern mold is shown as the upper surface, but it is possible to manufacture the pattern mold upside down. However, if it is possible to remove the mold in a short time by heating at the time of pressing and rapidly curing the pattern surface, it is possible to mass-produce with a small number of pattern molds with the pattern on the top side,
It is more advantageous.

During the kneading and during the charging of the raw material on the air-permeable material, it is desirable to carry out the reaction in an atmosphere of 20 ° C. or less. This is because the cement using the slag in the steelmaking reduction period has a rapid hardening reaction as described above, and the hardening reaction becomes more remarkable as the ambient temperature is higher, and the fluidity required for press molding may not be sufficiently secured. If necessary, the curing rate can be adjusted using a retarder such as sodium gluconate.

The case where a pattern is formed on one side to produce an inorganic plate having a flat one side has been described as an example.
When a pattern is formed on both surfaces, even when both surfaces are flat surfaces, production can be performed by using a gas-permeable material such as a gas-permeable mold or a gas-permeable sheet according to the shape of the surface. Also, the example in which the air permeable sheet is used on the side where the flat surface is manufactured has been described. However, if the air permeable flat material is sufficiently small in deformation due to a predetermined press pressure, other materials may be used. It is needless to say that it can also be used (for example, a mold in which the above-mentioned powder is solidified with a resin binder and flattened).

After a predetermined pattern is formed by press molding, it is removed from the mold and steam cured. When using the cement limited in the present invention, curing is not required to be performed at a high pressure as in an autoclave or the like, and sufficient strength can be obtained only by curing with steam at atmospheric pressure. The processing can be performed at a relatively low temperature of 30 to 60 ° C. Conversely, if the treatment is carried out at a high temperature such as in an autoclave, the crystallization water of ettringite will be dehydrated as described later. Therefore, the treatment is preferably carried out at a low temperature of 80 ° C. or lower.

[0027] The processing time of steam curing is added as a raw material.
Γ-2CaOSiO added_Two And 12CaO7Al_TwoO _ThreeAnd gypsum are hydrated
It is desirable that the time be sufficient to end the response. An example
For example, when processing at 50 ° C, it is sufficient to process for 8 hours or more.
It is.

Finally, the inorganic molded plate of the present invention is obtained by drying. The drying process can be performed in a shorter time if the temperature is high, which is convenient for mass production.However, if the temperature is too high, the crystal water of the ettringite crystals generated by the hydration reaction is dehydrated and the crystal structure changes. However, it is desirable to perform the drying treatment at a low temperature of 80 ° C. or less, since it causes the strength to decrease. By further painting this board,
It is possible to manufacture an inorganic plate that can be used as an outer wall material for a house.

When the inorganic molded plate is manufactured by the above-described method, the composition after kneading with the mixer becomes a state in which a large amount of air bubbles are retained inside by adding a foaming agent. When the composition is press-molded by the method described above, only air bubbles near the surface pass through a gas-permeable material such as a gas-permeable sheet or a gas-permeable mold material and are discharged to the outside. A dense plate is formed, and a molded plate composed of a porous layer in which a composition containing a large amount of air bubbles that has been kneaded in a mixer and cured as it is is manufactured. Therefore,
As a result, it is possible to produce an inorganic plate having a specific gravity difference of 0.05 or more between the surface portion and the central portion, and 0.20 or more depending on the pressing conditions.

As described above, since the inorganic molded plate of the present invention has a dense layer only in the surface layer, a high bending strength can be ensured in spite of the small specific gravity of the whole, and the adhesiveness of the paint,
By increasing the specific gravity of the dense layer, excellent characteristics of water permeability and freeze-thaw properties can be secured. In addition, since the inside has a small specific gravity, the weight of the plate can be reduced and the cost of raw materials can be reduced, which is advantageous in terms of cost.

The second invention of the present invention is an inorganic molded plate and a method for producing the same. An inorganic molded plate according to a second aspect of the present invention is an inorganic molded plate in which a fixing member is embedded therein, and has a dense layer having a higher specific gravity than a central portion on a surface portion, and a surface portion and a central portion. Is an inorganic molded plate having a specific gravity difference of 0.05 or more. Further, as shown in FIG. 4, the inorganic molded plate of the second invention of the present invention contains cement, reinforcing fibers, a water retention agent, and water, and further optionally includes a foaming agent, a water reducing agent, a fine aggregate, and a filler. The hydraulic raw material mixture 14 to which the material has been added and kneaded is filled into a mold 11 in which a gas permeable material 13 is spread over the entire bottom surface and a fixing member 16 is installed at an arbitrary position thereon,
An inorganic molded plate manufactured by a method of press-molding the upper surface with a breathable material 15 and drying after steam curing.
An inorganic molded plate having a fixing member embedded therein, a dense layer having a higher specific gravity at the surface than at the center, and a difference in specific gravity between the surface and the center of 0.05 or more. Second embodiment of the present invention
As shown in FIG. 4, the method for producing an inorganic molded plate according to the invention (corresponding to claims 3 and 4) includes cement, reinforcing fibers, a water retention agent and water, and further optionally comprises a foaming agent, a water reducing agent, Fine aggregate,
A hydraulic raw material mixture 14 kneaded by adding a filler,
A gas-permeable material 13 is spread over the entire bottom surface, and is filled in a mold 11 in which a fixing member 16 is installed at an arbitrary position thereon, and is press-formed with the gas-permeable material 15 from the upper surface, and after steam curing. It consists of a method of drying.

In the second invention, the type of cement is not limited, and any type of cement can be used. Commercial cement such as ordinary Portland cement, early-strength cement, jet cement, blast-furnace slag cement, fly ash cement, alumina cement, etc. Cement composed of slag and gypsum in the steelmaking reduction period disclosed in JP-B-62-47827 (the cement used in the first invention of the present invention) can also be used. As the breathable material, the inorganic molded plate described in the first invention can be used. Curing and drying conditions are performed in a humid atmosphere. At room temperature, autoclaving may be performed to accelerate the curing reaction. However, Japanese Patent Publication 62-
When using the cement disclosed in 47827, it is desirable to carry out at a temperature of 80 ° C. or less.

The fixing member is as follows. Regarding the type of fixing member, a U-shaped cross section provided with flanges at both ends to prevent detachment (cross section is hat type), a simple nut may be used, and a washer with a washer prevents the detachment. desirable. As shown in FIG. 5, the fixing portion of the fixing member is provided on the back side of the plate (in the case of a hat-shaped bracket, a screwing point at the center of the bracket, and in the case of a nut, a central screw hole).
Is buried so that is exposed. Regarding the embedding method of the fixing member, a permeable material is laid on the entire bottom surface in the mold, the fixing member is installed at a predetermined position on the permeable material, press-formed after charging the raw material, and the periphery of the fixing member is filled with the kneaded material. It is cured in a state where it has been made Further, by embedding the fixing member 16, FIG.
As shown in the figure, the formed plate can be fixed to the U-shaped bracket 17 with screws 18 from the back side of the plate. By press molding with a breathable material, the inorganic molded plate in which the fixing member is buried inside has a dense layer with a higher specific gravity than the central part on the surface,
The difference in specific gravity between the surface part and the center part is 0.05 or more.

[0034]

Next, the features of the first invention of the present invention will be clarified by examples. (Example 1 Influence of cement composition) 100 parts by weight of steelmaking reduction period slag having the chemical composition and mineral composition shown in Table 1, hemihydrate gypsum, and other commercially available cements added in various ratios as shown in Table 2 5 parts by weight of glass fiber (E-glass) having a length of 25 mm, 1 part by weight of a water retention agent, 50 parts by weight of water, 1 part by weight of a foaming agent, 1 part by weight of a water reducing agent,
The parts by weight were added and kneaded with an omni mixer (trade name of Chiyoda Giken Kogyo). The water retention agent used was METROZE 90SH-15000 manufactured by Shin-Etsu Chemical Co., Ltd., the foaming agent used was Emal D-3-D manufactured by Kao Corporation, and the water reducing agent used was SMF-PG manufactured by Nissan Chemical Industries, Ltd. .

The kneaded material was filled in a mold having a grooved iron plate provided with a large number of air vent holes having a diameter of 1.5 mm on the lower side and a gas permeable sheet made of long-fiber nonwoven fabric. c
Press molding was performed with a force of m ² to form a flat plate having a length of 300 mm, a width of 400 mm and a height of 20 mm. This plate was cured for 8 hours in a case filled with moist air at a temperature of 50 ° C., and dried at a temperature of 50 ° C. In press molding, the height of the press mold after placing the kneaded material and the height after pressing are 8 mm.
(Hereinafter referred to as “push allowance”). The higher the pressing margin is set, the higher the specific gravity of the dense layer generated on the surface portion and the thicker the dense layer. The pressing was performed using a 10-ton hydraulic jack, and the pressing force was checked with a hydraulic meter of a hydraulic pump. In addition, a jig having a structure in which a press die hits a press allowance adjusting bolt when a predetermined press allowance was pressed and the press could not be performed any more. Therefore, it should be added that the entire press force shown in the table does not contribute to sheet forming.

The plate produced under these conditions was measured for flexural strength immediately after the drying treatment, and was subjected to a sealer coating to test the adhesion, water permeability and freeze-thaw resistance of the coating film. Further, the specific gravity and the average specific gravity of the central portion and a portion 2 mm from the surface were measured at the same time. Adhesion of coating film, water resistance,
The freeze-thaw test was performed by a method based on JISA5422. The results shown in Table 3 show the results evaluated according to the evaluation criteria shown in Table 3 of JISA5422. Regarding the adhesion of the coating film, ○ indicates that the film meets the JIS A5422 standard (peel area of 5% or less), X indicates that the film does not satisfy the criterion, and ◎ indicates that the film has a peel area of 0% among those that satisfy the standard. did.
As is clear from Table 3, it was found that all of the inorganic plates of the present invention had a high strength of about 10 MPa and also had excellent coating performance. In addition, it has a dense layer with a high specific gravity on the surface and has excellent performance despite its low specific gravity at the center, which is extremely useful for reducing raw material costs. Further, it can be seen that particularly excellent strength can be obtained in a certain range of the ratio of the slag and the gypsum in the steelmaking reduction period. Therefore, it is desirable to manufacture from a raw material having a composition range in which high strength can be obtained.

(Example 2) Influence of composition other than cement
Next, an example in the case where the addition ratio of raw materials other than cement is changed will be described. For the cement, the same raw material as in Experiment No. 7 in which excellent strength was obtained in Example 1 was used, and the addition ratio of the other raw materials was changed as shown in Table 4, and an inorganic molded plate was prototyped. Table 5 shows the evaluation results. The trial production method and evaluation method of the plate are the same as those in the first embodiment. As is clear from Table 5, it was found that No. 16 with a small amount of water added and No. 17 with a small amount of water retention agent could not be molded due to problems such as fluidity and water separation. In addition, it was found that in No. 18 with a large amount of reinforcing fiber added, high strength was obtained, but fluidity was lowered, and a clean surface skin was not obtained after press molding. On the other hand, the examples in which the raw materials were added within the range limited by the present invention all had high bending strength, excellent coating performance and clean surface skin.

Example 3 Influence of Steam Curing and Drying Conditions Next, the same raw materials as in Experiment No. 7 were kneaded, and the bending strength measurement results when steam curing conditions and drying conditions were changed are shown in Table 6. Show. The other conditions are the same as in the first embodiment. As is clear from Table 6, in order to obtain excellent strength, 80 ° C.
It can be seen that it is better to process at the following low temperature.

Example 4 Influence of Air Permeability and Influence of Press Molding Conditions In the same manner as in Example 3, the raw materials of Experiment No. 7 (except for Experiment No. 35) were kneaded, and the air permeable material and press molding conditions were changed. The results of examining the surface skin and the surface denseness were shown in Table 7 while changing the shape of the plate as shown in Table 7. As is clear from Table 7, a clean surface skin can be obtained by pressing with a material having only a part of air permeability, such as making a hole for air release or using a mold in which a material having air permeability is partially embedded. It turns out there is no. In the case of press-molding with a material having no air permeability, normal press-molding could not be performed because the internal air could not be discharged. Furthermore, even when pressed with a material having air permeability, if the pressing margin is small, the sharpness may not completely disappear, and the specific gravity of the dense layer does not become sufficiently high, and excellent performance is obtained. It turns out there is no. Experiment No. 35 is an example in which the amount of the foaming agent added was reduced to 1/4 and the press allowance was reduced, but the adhesion of the flexural strength coating film was good, but the press allowance was low. The small size made it impossible to completely remove the sharps. Therefore, in order to obtain an excellent inorganic plate, it was found that it was necessary to press the entire surface with a material having air permeability and a sufficient press allowance for forming a dense layer.

Example 5 Molding of a Patterned Inorganic Plate In the above-described example, a test was performed in which a flat plate was molded in order to evaluate basic characteristics. In order to confirm the above, a molding test of an inorganic plate with a single-sided pattern was performed. The test knead the raw materials of Experiment No. 7,
A gas permeable sheet made of a long-fiber nonwoven fabric was laid on the lower surface, and after kneaded material was filled, a gas permeable pattern was press-molded from the upper surface. The air-permeable pattern mold was manufactured by hardening glass particles having an average particle diameter of 30 μm with an appropriate amount of epoxy resin, and a reinforcing layer was provided by sandwiching a glass cloth and bonding urethane foam. The test was carried out on both a plate having the same size as that of the above example and a plate having a size of 1 m × 3 m. After press molding, the surface texture and characteristics of the formed plate were confirmed. It was confirmed that molding was possible.

An embodiment of the second invention of the present invention will be described. (Example 6: Molding of metal-molded inorganic molded plate embedded in metal) Raw materials such as cement or ordinary Portland cement and reinforcing fibers made of steelmaking reduction slag and dihydrate gypsum having the chemical components shown in Table 8 were mixed with the raw materials as shown in Table 9. The raw material was prepared and kneaded with an omni mixer, and the raw material was filled in a mold in which a permeable sheet and a fixing member were set at predetermined positions, followed by press molding. As the fixing member, a hat-shaped bracket and a nut with washer were used. Table 10 shows the dimensions of the bracket. Press pressure is 3.0
The test was performed under the condition of kgf / cm ² . As shown in the figure below, a U-shaped fitting was overlapped and screwed, and the tensile load of the U-shaped fitting was measured. For comparison, a similar test was performed for a case where a commercially available outer wall plate was screwed from the front side as in the related art. The experimental results (Table 10) are as follows. Table 10 shows the results in the case of the raw material No. 1. The average specific gravity of the test pieces after pressing was 1.42 at the surface and 0.85 at the center. Select nuts with washers or metal hats with appropriate dimensions of hat-shaped cross section (select appropriate plate thickness, collar depth, and collar length)
As a result, it was confirmed that the same or higher strength can be obtained as compared with a case where a commercially available plate was fixed with screws from the front side. In particular, when a foaming agent is used as in this experiment, a dense layer is formed on the surface and bubbles remain inside to form a lightweight porous layer. The strength is excellent, and the strength of the fixing member can be ensured to be excellent. Similarly, when the raw materials Nos. 2 and 3 were used, high fixing strength was obtained.

[0042]

[Table 1]

[0043]

[Table 2]

[0044]

[Table 3]

[0045]

[Table 4]

[0046]

[Table 5]

[0047]

[Table 6]

[0048]

[Table 7]

[0049]

[Table 8]

[0050]

[Table 9]

[0051]

[Table 10]

[0052]

According to the method for producing an inorganic molded plate of the first aspect, it is possible to newly propose a new use of the steelmaking reduction period slag having γ-2CaOSiO ₂ and 12CaO7Al ₂ O ₃ as main mineral compositions. The contribution of electric furnaces to the effective use of waste in steel mills is extremely large. In addition, the inorganic molded plate of the present invention can be quickly cured in spite of using an inexpensive cement, can be quickly demolded, requires a small pressing force, and is cured and dried at low temperature and atmospheric pressure. Therefore, it is possible to manufacture an inorganic molded plate with a small capital investment. According to the method for producing an inorganic molded plate according to claims 2 and 4, since the inorganic molded plate produced by the method of the present invention has a dense layer on its surface, it has an advantage that lightweight and excellent performance can be secured. . According to the method of manufacturing an inorganic molded plate according to the third aspect, since press molding is performed using a breathable material, it is possible to form a pattern having good transferability on the front side, and the fixing member can be easily embedded at a predetermined position. . In addition, the shaping of the pattern and the embedding of the fixing member can be performed simultaneously. Since the periphery of the fixing member is filled with the raw material containing the reinforcing fiber by press molding, and the dense layer is formed on the surface by the breathable material, the strength required by curing can be easily secured thereafter. . Therefore, it is not necessary to use a reinforcing material such as a reinforcing bar. Since the fixing portion of the fixing member is exposed on the back side of the plate, the mounting work of the plate can be simplified. Since it can be fixed from the back side of the board,
There is no need to damage the pattern side of the table. Repair work (putty padding) for making screw fixing traces inconspicuous as in the case of screwing from the front side (pattern side) becomes unnecessary.

[Brief description of the drawings]

FIG. 1 is a process chart of a method for producing an inorganic molded plate according to the first invention of the present invention.

FIG. 2 is a cross-sectional view of an apparatus when pouring a material into a mold according to the first invention of the present invention.

FIG. 3 is a sectional view of the apparatus when a material is being pressed in the first invention of the present invention.

FIG. 4 is a cross-sectional view of an apparatus at the time of raw material pouring and pressing in the method for producing an inorganic molded plate according to the second invention of the present invention.

FIG. 5 is a partial cross-sectional view of a formed plate near an embedded metal fitting.

FIG. 6 is a sectional view of a forming plate and a U-shaped fitting in the vicinity of a fitting when the forming plate is screwed.

[Explanation of symbols]

 11 Formwork 13 Breathable sheet 14 Raw material 15 Breathable mold 16 Fixing member

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C04B 7: 153 18:14) 111: 40 (72) Inventor Katsutoshi Noda 1st Toyota Town, Toyota City, Aichi Prefecture Toyota Inside Motor Co., Ltd. (72) Inventor Sadazo Hase 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Co., Ltd. (72) Inventor Satoshi Gota 1 Toyota Town, Toyota City, Aichi Prefecture Inside Toyota Motor Co., Ltd. (72 Inventor Yasuhiko Kojima 1 Aomachi Wanowari, Tokai City, Aichi Prefecture Inside Aichi Steel Co., Ltd. (72) Inventor Kei Muroga 1 Aomachi Wanowari Arachi Town, Tokai City, Aichi Prefecture Aichi Steel Co., Ltd. (72) Inventor Tanaka Tatsuo 1 Wanowari, Arao-cho, Tokai-shi, Aichi Prefecture Within Aichi Steel Co., Ltd. (72) Inventor Kazuya Sano 41-1, Yokomichi, Yakumichi, Nagakute-cho, Aichi-gun, Aichi Prefecture F-term in Toyota Central Research Laboratory Co., Ltd. (reference) 4G012 PB03 PB06 PB11 PD03 4G054 AA01 AA15 AC04 BA02 BA43 BA62 4G058 GA02 GC01 GE01

Claims (4)

[Claims] 1. 10 to 80 parts by weight of γ-2CaOSiO ₂ and 12CaO7
Al ₂ O ₃ and 90 to 20 the substrate powder 100 parts by weight containing parts and plaster 2-100 parts by weight relative to the cement 100 parts by weight of a main component, reinforcing fibers 1-12 parts by weight, water retention agents 0. 1 to 3 parts by weight, 30 to 70 parts by weight of water, a foaming agent, and optionally a water reducing agent, fine aggregate, a composition kneaded by adding a filler, press-molded with a material having air permeability, A method for producing an inorganic molded plate, comprising drying after steam curing. 2. An inorganic molded plate manufactured by press-molding a material having air permeability has a dense layer having a higher specific gravity at the surface than at the center, and a difference in specific gravity between the surface and the center. 2. The method for producing an inorganic molded plate according to claim 1, wherein is not less than 0.05. 3. A hydraulic raw material mixture containing cement, reinforcing fibers, a water retention agent, and water, and optionally kneaded with a foaming agent, a water reducing agent, a fine aggregate, and a filler, is mixed with the entire bottom surface. The air-permeable material is laid on the mold, the mold is placed in a mold where a fixing member is installed at an arbitrary position on the air-permeable material, the air-permeable material is press-molded from the upper surface, and steam curing is performed, followed by drying. A method for producing an inorganic molded plate. 4. An inorganic molded plate manufactured by press-molding with a breathable material and having a fixing member embedded therein has a dense layer having a higher specific gravity than a central portion at a surface portion thereof. 4. The method according to claim 3, wherein the difference in specific gravity at the center is 0.05 or more.