JP2001065112A - Construction plate, its manufacturing device, and preparatory foamed plastic - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce a cost and improve waterproof performance by eliminating coating and drying of a rearview mirror, and lining the foaming plastic of prescribed thickness on the material of a cement baseboard in a state where the remaining heat of a surface coating process is held. SOLUTION: A ground fabric comprising PET as a main component is supplied to a construction plate-manufacturing device, a non-foaming plastic comprising polyethylene as a main component is heated by far infrared ray heater and laminated on a surface in the form of the island of the shape and size of substantially a construction plate 1 at intervals. The material 2 of a cement baseboard is supplied on an island-like preparatory foaming plastic in a state where the remaining heat of the drying process of a surface coating layer 3 is held, and heated by a heating roll to be foamed so as to be lined. The thickness of a foaming plastic is adjusted in 0.5-3.0 mm by an adjusting roll, and the remaining ground fabric is peeled to be cooled and trimmed so as to manufacture the construction plate 1. Since the coating and drying process of a back sealer is eliminated, a cost is reduced, and a resilient foaming layer 4 effectively suppresses the leakage of rainwater by riveting from the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building board suitable for use as an outer wall of a building, and more particularly to a building board having an improved waterproof function on a back surface thereof, an apparatus for manufacturing the same, and a prefoamed plastic therefor.

[0002]

2. Description of the Related Art Conventionally, at the beginning of a building board coating process, back sealer coating is performed to impart a certain degree of waterproofness to the back surface of a board of a building board. The coating amount in that case is about 45 to 55 g / m ² in a wet state, and the thickness of the dried sealer coating is about 10 to 20 μm. Since the sealer is adhered to the back surface of the plate, the film thickness is reduced by the amount of the sealer impregnated inside the porous plate. Here, the sealer refers to a paint used to fill the pores of the surface to be coated which is porous and large in absorbency, and a colorless and transparent acrylic urethane-based paint is often used in general. .

[0003]

By the way, the back surface of a cement substrate (which is a plate before painting) manufactured on a substrate manufacturing line is formed almost flat, There are fine irregularities and a large number of voids, and the density in the thickness direction of the plate is not always uniform. Therefore, in terms of sealer permeability in the back sealer coating step in the continuous coating step of the building board,
It is unavoidable that a problem of partial application unevenness is inevitable. In such a case, the desired waterproof effect cannot be sufficiently exhibited.

On the other hand, increasing the amount of sealer applied to the back of a building board, which is not directly visible in normal use, greatly increases the cost of the product. Absent. Originally, the function that the sealer layer should exhibit is that, unlike the surface coating layer, it is not the part that is directly exposed to rainwater. At present it is being painted. For this reason, little attention has been paid to other physical properties such as scratching strength, and the strength has never been a strong film.

[0005] Due to this, there is a sufficient risk that a scratch or the like will occur during distribution or on the construction site. If a scratch or the like occurs once,
Infiltration of water from that part is inevitable anymore. In addition, there is no need to occasionally cause a catastrophic failure such as a real part being chipped due to a certain impact. In view of this situation, the present applicant has previously filed an application for "building board and its manufacturing apparatus" in which a plastic sheet is lined with a cement substrate fabric (Japanese Patent Application No. 11-185410).

However, the following problems remain in the invention of this application. In other words, as shown in FIG. 2A, in the construction method in which nails 5 (or screws) are driven into the building board 201 from the surface thereof, the nails 5 project from the back of the building board 201. The vicinity 206 of the part is in a crack state, and the cement substrate 202 is broken. Therefore, the rainwater that has penetrated into the back surface of the building board 201 from the nailed portion of the nail 5 (that is, a small gap between the nail and the screw and the plate) is applied to the conventional sealer layer 204 or to the previously proposed plastic sheet backing. In this case, it is not possible to avoid going around the back surface of the cement substrate 202.

In view of the above problems, the present invention eliminates the application of a back sealer and a subsequent drying step, and effectively exerts the waterproof function of a sealer layer conventionally formed on the back of a building board. An object of the present invention is to provide a building board, a manufacturing apparatus thereof, and a pre-foamed plastic for the same, which can still protect the back surface of the building board even after nailing.

[0008]

A building board according to the present invention is a construction board in which a foamed plastic is lined with a cement substrate cloth. Furthermore, when the foamed plastic contains polyethylene as a main component, it is possible to provide a building board having particularly excellent low-temperature properties, flexibility, and toughness. Further, when the thickness of the foamed plastic is 0.5 to 3.0 mm, it is preferable in terms of strength and shape scale.

Further, the building board manufacturing apparatus of the present invention is provided with a backing means for backing the foamed plastic to the cement substrate cloth in the process of foam molding of the foamed plastic. Thereby, good adhesive properties can be obtained. In addition, the backing means backs the building board after the clear coating, so that the plate temperature of the carried-out building board can be used for the foaming treatment of the foamed plastic. No damage to the backing foam plastic.

Further, the present invention is a pre-foamed plastic in which unfoamed plastic having substantially the shape and size of a building board is laminated on a plastic sheet in an island shape continuous at intervals. Thereby, the prefoamed plastic lining the building board can be effectively used without wasting. In addition, the plastic sheet is mainly composed of PET (polyethylene terephthalate), and the unfoamed plastic is mainly composed of polyethylene, so that a low-cost, harmless building board with particularly excellent low-temperature properties, flexibility and toughness can be obtained. Can be provided.

[0011]

Preferred embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG.
1 is a diagram showing a partial cross-sectional structure of a building board according to an embodiment of the present invention. The building board 1 has a structure in which a cement substrate 2 has a surface coating layer 3 on the surface and a foamed plastic, preferably a polyethylene (PE) foamed layer 4 on the back surface. The cement substrate 2 is prepared by pressing and curing a raw material mat formed by forming or extruding a raw material slurry on a porous support.
The raw material slurry is, for example, Portland cement, blast furnace cement in which blast furnace slag is mixed with Portland cement, fly ash cement in which fly ash is mixed, silica cement in which silica materials such as volcanic ash, silica fume, and clay are mixed, alumina cement, blast furnace slag Such as cement-based inorganic hydraulic materials, wood flour, wood wool, wood chips,
Wood fiber, wood pulp, softwood pulp, hardwood pulp,
Wood fiber bundle, waste paper pulp, hemp fiber, bacas, fir,
Wood reinforcement such as rice straw and bamboo fiber, and aggregates such as pearlite, shirasu balloon, expanded shale, expanded clay, calcined diatomaceous earth, fly ash, coal gala, foamed concrete, and alkali silicate Curing accelerators such as metal salts,
The solid content is usually 5 to 2 by dispersing a waterproofing agent such as wax, wax, paraffin, surfactant, silicone, or a water repellent agent in water.
It is adjusted to about 0% by weight.

The PE foam layer 4 preferably uses a resin foamed by a normal pressure foaming method. Linear polyethylene is preferred because of its excellent chemical resistance. Non-crosslinked ones are preferred because they can be regenerated. By adjusting the material density, a wide variety of PE foam layers 4 from a soft type to a semi-hard type can be manufactured. Further, by adjusting the amount of the foaming agent kneaded, the P of any thickness can be adjusted.
The E foam layer 4 can be formed. The thickness of the PE foam layer 4 is
0.5 to 3.0 mm is preferred. If the thickness is less than 0.5 mm, a problem occurs in terms of strength, and the function of waterproofness cannot be sufficiently exhibited. Conversely, 3.
When the thickness exceeds 0 mm, the building board as a whole becomes unnecessarily bulky and its commercial value is reduced.

In the normal pressure foaming method, for example, an extruder is prepared by mixing a foaming olefin resin composition such as polyethylene or polypropylene with a pyrolytic foaming agent such as azodicarbonamide at a temperature at which the foaming agent is not decomposed. The mixture is melt-kneaded with a roll or the like, and the kneaded material is preformed into a sheet or other appropriate shape by extrusion molding, press molding, or other appropriate means, and the preformed product is introduced into a heating chamber, and the decomposition temperature of the foaming agent is increased. This is a method of foaming the resin at normal pressure by heating.

Other known foaming methods such as an extrusion foaming method and a pressure foaming method can be applied. The extrusion foaming method is, for example, melt-kneading a resin composition for foaming with an extruder, and an expanding liquid foaming agent such as dichlorotetrafluoroethane through a foaming agent injection port provided in the middle of the kneading section of the extruder. Alternatively, an inert gas type foaming agent such as carbon dioxide is injected into the molten resin, or a mixture obtained by previously mixing a thermally decomposable foaming agent such as azodicarbonamide with the above foaming resin composition is melted by an extruder. It is a method of kneading and extruding this while foaming it into an appropriate shape from an extrusion die.

In the pressure foaming method, for example, a resin composition for foaming is melt-kneaded with an extruder or a roll, and the kneaded material is preliminarily formed into a sheet or other appropriate shape by extrusion molding, press molding or other appropriate means. The preform is placed in a pressure chamber such as an autoclave and heated under pressure, and an inflatable liquid foaming agent such as dichlorotetrafluoroethane or an inert gas foaming agent such as carbon dioxide is charged into the preform. It is a method of impregnating from the surface and then foaming by releasing the pressure in the pressure chamber. Further, the foaming agent used in each of the above foaming methods is not particularly limited, and a low-boiling organic solvent,
Inflatable liquid foaming agents such as swelling agents, inert gas foaming agents,
Any blowing agent, such as a pyrolytic blowing agent, can be used.

FIG. 2 is a view for explaining the situation of cracks on the back of the building board in the case of nailing. As described above, in the case of applying the conventional sealer layer 204 shown in FIG. 2 (a) or in the case of the plastic sheet backing proposed previously, the rainwater that has entered the backside of the building board 201 goes around to the backside of the cement substrate 202. Can not be avoided. However, as shown in FIG. 2B, in the case of the present invention, cracking and chipping on the back of the building board 1 are prevented.

FIG. 3 is a flow chart for explaining the PE foam layer backing process of the building board manufacturing apparatus according to the present embodiment.
The process within the broken line is the process according to the present invention and is inserted into the conventional process. Except that the sealer is not lined, the drying process after clear coating of a normal building board manufacturing apparatus (step S10)
1), the supply of the work plate a is received (step S10).
2) Supply a base cloth 11 (described later) coated with an unfoamed foamed plastic (step S10).
3) By heating the base cloth 11, the foamed plastic is heated, melted, and foamed (Step S104), and the base cloth 11 and the work board a are laminated (Step S1).
05), rapidly cooling (step S106),
Is carried out (step S107), and cooling (step S10), which is a process of a normal building board manufacturing apparatus, is performed again.
8), the excess foamed plastic protruding from the contour boundary of the plate a to be processed is cut or trimmed (step S109), and the inspection plate (step S110) is shipped (step S111).

FIG. 4 is a top view showing the structure of the building board manufacturing apparatus according to the present embodiment, and FIG. 5 is a side view thereof. The work plate a is transported along a predetermined transport path by a carriage cart CC (described in detail in FIG. 8 and thereafter).
In FIG. 4, the position at which the workpiece a moves is indicated by a two-dot chain line. The special laminated sheet wound in a roll shape (hereinafter referred to as “base cloth 11, specifically, shown in FIG. 6)
After being unwound from the base fabric roll 12, the front rotating roller 1
3 and a pin tenter 16 driven by a rear rotating roller 14, the pin tenter 16 is hung by a pin holding roll 15, and is wound around a residue cloth roll 17. First, base cloth 1
When 1 passes through the far-infrared heating zone ZA, the far-infrared heater 18 receives a non-contact heating process from above. Here, for example, by subjecting the base cloth 11 to a heat treatment at 175 ° C. for 10 seconds, the P on the base cloth 11 is reduced.
The temperature of the E-coated portion 32 is raised from room temperature (30 ° C.) to 165 ° C. As the temperature rises, the PE coating portion 32 on the base cloth 11 undergoes a state change from softening to melting. Then, it moves to the subsequent laminating zone ZB in the molten state.

A plate supply zone ZC is provided on the side of the laminating zone ZB, and a plate a to be processed, which has exited the dryer after the clear coating, is moved by a carriage cart CC described later.
It is carried in the state set in. From the plate position (1) to the plate position (2), a laminating process of placing the plate a to be processed on the base cloth 11 is performed. In the case of laminating, usually, it is easier to support the plate a to be processed, the laminating process itself is easier, and the device configuration is often simpler if the back surface of the plate a is processed upward. However, for example, in the case of using a transport roller, it is inevitable that the plate surface may be damaged (in the case of the processed plate a having severe irregularities, it is hopeless). Usually, the sheet comes out with the surface of the plate facing upward, so that the laminating process is performed with the surface of the plate facing upward.

In this laminating process, the laminating process is performed by placing the back surface of the plate a to be processed on the PE coating portion 32 already in the foamed state. At the same time, the back surface of the base fabric 11 applied to the pin tenter 16 is Heating is performed by the heat roll 19, and control is performed so that the temperature of the PE coating portion 32 rises from 165 ° C. to 185 ° C., for example. The heating curve at this time is determined by actually performing a test, but the foaming is started slowly by initially gradually increasing the temperature. Then, at a position immediately before reaching the bonding position, for example, the temperature is raised so as to have a foaming degree of about 60%,
At the bonding position, the foaming degree has reached about 80%, and immediately after that, the foaming degree control with the lapse of time, such as reaching 100%, is performed, and the temperature rise curve is determined in consideration of the running speed of the pin tenter 16. After the lamination, the thickness of the foamed PE coating portion 32 is adjusted to a desired value by the clearance adjusting roll 20, and cool air is applied from the cold air supply duct 21 toward the back surface of the base cloth 11 applied to the pin tenter 16, and provided on both sides. The first-stage cooling process is performed by exhausting the exhaust gas from the exhaust duct 22, for example, when the PE coating portion 32 has a temperature of 185 ° C. →
Control is performed so that the temperature drops to 140 ° C.

Subsequently, the work piece a which has exited the laminating zone ZB (the state at that time is that the work piece a is placed on the PE coating portion 32 on the long continuous base cloth 11).
Is transported to a further cooling zone ZD in that state, where the cooling process is performed on the front and back surfaces of the plate a to be processed.
Control is performed so that the temperature drops from 70 ° C. to 70 ° C. Then, at the plate position (3), the pin tenter 1
The base cloth 11 with the PE foam layer 4 formed on the back surface is separated from the base cloth 11.

In this case, the base cloth 11 is pushed up by the pin removing roll 24 whose position is adjusted by the adjuster 23 so that the base cloth 11 is not wound around the pin tenter 16. At the same time, the plate a to which the PE foam layer 4 is adhered to the back is separated from the base cloth 11 by the separate blade 25 (see FIG. 7). The remaining base cloth 11 from which the PE foam layer 4 has been separated is wound up around the residue cloth roll 17.

The laminated work plate a conveyed to the plate position (4) is removed from the carriage cart CC there, is placed on the lower conveyance roller 26, and is cooled by the cooling zone Z.
Unloaded from D. Here, the upper surface position of the transport roller 26 is installed so as to be lower than the base fabric surface position transported by the pin tenter 16. In the cooling zone ZD, cooling air is actively blown from the upper cool air supply duct 27 and the lower cool air supply duct 28 to the front and back surfaces of the plate a to be processed, and the air after blowing is provided on both sides. From the exhaust duct 29. Carriage cart CC is in cart return zone ZE
To the start position in the plate supply zone ZC.

FIG. 6 is a view for explaining the base cloth 11. The base cloth 11 is, for example, partially rectangularly formed on the surface of a long heat-resistant regenerated PET (polyethylene terephthalate) non-woven fabric (or woven cloth) 31 with an area slightly protruding from the back surface of the work piece a. Unfoamed PE coating 32
Are coated at predetermined intervals. If the surface of the base cloth 11 is thinly coated with a heat-resistant release agent so as not to hinder the coating, the PE foam layer 4 of the building board 1 is formed.
The operation of detaching the recycled PET non-woven fabric 31 from the can be performed more smoothly. The interval between the PE coated portions 32 on the base cloth 11 is determined according to the processing speed. For example, when the plate position (2) in FIG. The interval is set so that the position of the coating portion 32 becomes the plate position (0) in front of the far-infrared heating zone ZA.

FIG. 7 is a diagram showing a state in which the work plate a and the remaining base cloth 11 are detached from the pin tenter 16. Base cloth 11
A separate blade 25 having a moderately rounded tip at the tip is brought into contact with the boundary between the base cloth 11 and the PE foam layer 4 at a moderately adjustable angle so as not to break, and the two are separated.

FIG. 8 is a diagram showing a drive system on the back surface of the carriage cart CC, FIG. 9 is a side view showing the configuration of the carriage cart CC, and FIG. 10 is a front view showing the configuration of the carriage cart CC. It is a traveling vehicle driven by an electric motor of a four-wheel drive system. Front wheel 41 and rear wheel 4
The four wheels (tires) consisting of two run on the flat plate transport path 51 (see FIG. 9). The propeller shaft 44 is driven by the motor 43, and the front wheel 41 and the rear wheel 42 are driven by the front differential 45 and the rear differential 46, respectively. A center guide roll 47 is attached to the center of the center line in the traveling direction, and rotates and slides on a center guide rail 52 formed on the center line of the flat plate transport path 51. Prevents meandering. As shown in FIGS. 8 and 9, on both sides of the center guide rail 52 of the flat plate transport path 51, a long hole through which a pipe-shaped suspender 48 attached to the back of the carriage of the carriage cart CC passes. 53 are formed (note that the four corners are cut out in an L-shape).

The operation of the hanging hand 48 (the descending operation and the ascent / return operation) is performed by operating the rack gear 54 attached to the upper part of the pipe of the hanging hand 48. The driving is performed by the stepping shown in FIGS. The rotation and the rotation direction are controlled by a pinion gear 56 interlocked with the motor 55 in accordance with a pulse conversion program created based on a locus curve shown in FIG. Carriage cart CC
A controller 58 for controlling the whole of the carriage cart CC, a battery 57 as a power supply for the carriage cart CC, and a double-acting air cylinder connected via a hinge 59 from the suspender 48 are provided on the base 40 of the vehicle. 64,
Two single-acting air cylinders 61 provided at a predetermined distance from the end of the piston rod 60 are connected to an air hose 62.
And a small compressor 63 that is driven through the compressor.

FIG. 11 is a plan view of the building board 1. When the building board 1 to be subjected to this laminating processing is, for example, a work board a having a four-way joint shape, a pattern portion (painted surface) of the work board a
In order to work with 67 up, a single-acting type in which the female part 68 on the left side and the male part 69 on the right side are positioned on each side as shown in FIG. A holder 66 attached to the tip of the piston rod of the air cylinder 61 (in addition,
The surface is coated with rubber to increase the frictional force).
1, P2, P3, and P4 support both ends of the plate a to be processed. The vertical position of the single-acting air cylinder 61 may be adjusted by a double-acting air cylinder 64 or the like.

FIG. 12 shows the plate supply zone ZC shown in FIG.
It is a figure showing all the conveyance systems of carriage cart CC installed in laminating zone ZB, cooling zone ZD, and cart return zone ZE. The entire transport system is formed by connecting four rectangular transport paths in a ring shape, but is composed of two opposing transport paths, one of which is two flat plate transport paths 51 and the other one. Are two chain conveyors 72 and 76
Is a transport path for supporting both end portions of the back surface of the cart base 40 formed by the above. For convenience, the rectangular carriage cart CC is shown as being located at the four corners of the transport path, but the travel position of each carriage cart CC and the carriage cart CC used on all transport paths are shown.
The number varies depending on the processing conditions, and the computer is controlled so that the processing is smoothly performed in each case.

FIG. 13 is a diagram for explaining the operation of the transport system shown in FIG. 1. When the cart CC arrives at the position (1), the cart drive motor is stopped. 2. Turn on the board conveyor chain conveyor 71 to turn on the work board a
To the position (1), and the plate carry-in chain conveyor 71
Is turned off. 3. Turn the solenoid valve of the single-acting air cylinder 61 to O.
N, and the work plate a is set on the carriage cart CC in a suspended state. 4. By using the limit switch, the lifters (1) L, R supporting the back surface of the base 40 of the carriage cart CC are provided.
The carriage cart CC is raised to the upper chain running position of the carry-in chain conveyor 72 installed above by raising and lowering 73.

5. By moving the pusher A 74 forward and backward and pushing the carriage cart CC forward, the carriage cart CC is placed on the carrying-in chain conveyor 72 in operation from the position (1). 6. By using the limit switch, the carriage cart C is moved to the position (2) by the carry-in chain conveyor 72.
Carry C. 7. By using the limit switch, lifter (2)
The carriage cart CC is lowered on the flat plate transport path 51 by lowering and raising L and R75.

8. By moving the motor 43 in the forward direction in the direction of acceleration → constant speed → deceleration → stop, the carriage cart CC runs from the position (2) to the position (3). 9. The work plate a is moved from the carriage cart CC by the rack gear 54 of the suspender 48 to the transport roller 26 (FIGS. 4 and 5).
See)). The solenoid valve of the single acting air cylinder 61 is turned off. 10. The work plate a is carried out by operating and stopping the transport roller 26. 11. Lifter (3) by using limit switch
The carriage cart CC is raised to the upper chain running position of the carry-out chain conveyor 76 installed above by raising and lowering L and R77.

12. The pusher B 78 is moved forward and backward, and the carriage cart CC is put on the running carry-out chain conveyor 76 from the position (3). 13. The carriage cart CC is transported to the position (4) by the unloading chain conveyor 76 by using the limit switch. 14． Lifter (4) by using limit switch
The carriage cart CC is lowered onto the flat plate transport path 51 by lowering and raising L and R79. 15. Accelerate the motor 43 in the reverse direction → constant speed → decelerate →
By stopping, the carriage cart CC travels from the position (4) to the position (1). 16.1. Return to the operation of.

FIG. 14 shows a PE coated portion 32 (◆
FIG. 5 is a diagram illustrating a traveling timing of a carriage cart CC (represented by ◇) that conveys a work plate a to be laminated on the back surface. The horizontal axis indicates the traveling path of “◆”, and “◇” joins from the junction y. (0) indicates the plate position (0) shown in FIG. 4. At the detection point x, the passage of the tip of “◆” is detected by a color mark sensor or the like. In order to laminate the PE-coated portion 32 and the plate a to be processed, they must both travel substantially at the same position and at the same speed during lamination. However, while “◆” is traveling at a constant speed on the base cloth 11, “を” starts traveling directly for lamination processing from the junction y, so “◇” comes with “◆”. It is necessary to start running at the previous timing.

FIG. 15 is a diagram for explaining the speeds of “◆” and “◇”. Time is plotted on the horizontal axis, and both speeds are plotted on the vertical axis. “◆” travels at a constant speed v1 (travel speed of the pin tenter 16), while “◇” increases smoothly from the initial speed 0 and accelerates to the speed v1,
After that, a state of running at a constant speed is shown. Since the traveling distance until the two speeds match is the time integral of the speed, "◆" travels about twice as long in the illustrated case. Therefore, this distance difference v1 × t1 (sec)
Is detected at a position x corresponding to
If "◇" is started from the departure position (1) and accelerated at the timing when "◆" is detected, when the speed of "◇" coincides with the speed of "◆", both of them are in the same position. You will run at speed. Thereafter, when “$ 2” passes the detection position x at time t2 seconds after “$ 1” is detected, the cart 2 “$ 2” is similarly departed from the departure position (1) at the detection time. Shall be. As a result, the preceding cart and the succeeding cart are controlled such that the inter-vehicle distance equivalent to the lapse of t2 seconds is always obtained when each of the carts passes the departure position (1).

In this way, as long as the pin tenter is operating at a constant speed and the "◆" is coated on the base cloth at a predetermined interval, the above-described transport / running control can be performed for the running of the cart. Yes, the laminating process can be performed smoothly. The departure position (1), the length of each part of the transport path, and the like are set to an error in the transporting movement of the cart and an optimum length within an allowable adjustment range in the timing operation with the pin tenter 16.

FIGS. 16 and 17 are views for explaining the operation of the hanging hand 48 during the laminating process. While the carriage cart CC travels from the plate position (1) shown in FIG. 4 to the plate position (2), the front and rear suspenders 48 are shown in FIG. The rack gear 54 is controlled to change its length so as to draw a trajectory. By controlling in this way, it approaches the upper surface of the base cloth 11 traveling below the work plate a while gradually decreasing the inclination angle. Then, at the board position (2), the back surface of the work board a is completely landed on the PE-coated portion 32. So-called work plate a
The soft landing on the PE coated portion 32 is realized, and a reliable lamination can be performed without involving air as much as possible.

The operation of the hanging hand 48 (the descending operation and the ascent / return operation) is performed by operating the rack gear 54 attached to the upper part of the pipe of the hanging hand 48. The driving is performed by the stepping shown in FIGS. The control is performed by the motor 55, and the number of rotations and the direction of rotation are controlled in accordance with a pulse conversion program created based on a locus curve shown in FIG.

FIG. 18 is a diagram showing the overall configuration of a building board manufacturing apparatus according to an embodiment of the present invention. Memory 1 for storing the moving schedule 101 of the carriage cart CC and the like
02, and a wireless unit 1 that performs wireless communication with the antenna 103
The main controller 100 having the position sensor 04 detects a position on the transport path of the carriage cart CC by a color mark sensor 105 for detecting the passage of the PE coating portion 32 at a predetermined position, a photoelectric switch or the like.
06, keyboard 10 for inputting necessary data
7 and a display 108 for displaying desired data
Is connected. The main controller 100 controls the following units. First, the work board a
, And controls a cool air / exhaust controller 84 that controls the blower blower 82 and the exhaust blower 83. A pin tenter & residue cloth roll controller 85 for controlling the pin tenter 16 and residue cloth roll 17 is controlled. A sheet temperature controller 88 for controlling the far-infrared heater 18 and the heat roll 19 by detecting the surface temperature of the base cloth 11 by the sheet surface thermometer 86 and detecting the surface temperature of each heat roll 19 by each roll surface thermometer 87. Control. The carry-in chain conveyor 72 and the carry-out chain conveyor 76 are controlled. The board loading & cart transport sequence controller 89 for controlling the transport of the board loading conveyor 71 and the carriage cart CC is controlled.

A cart controller 110 having a memory 113 for storing a travel control program 111, a lifting hand control program 112, etc., a timer 114 for counting time, and a wireless unit 116 for wirelessly communicating with an antenna 115 detects the landing of the carriage cart CC. The movement of itself is detected by a limit switch 117 and a proximity switch 118 that detects the arrival of a corner of the carriage cart CC, the air cylinders 61 and 64 are controlled by an air cylinder control solenoid valve 120, and stepping is performed by a front and rear rack gear driving driver 121. The motor 55 is controlled, the compressor 63 is controlled, and the driving motor 43 is controlled by the DC motor driver 119.

The pusher A control unit 134
1, a pusher A operation switch 13 for driving a pusher A74 for changing the transport direction of the carriage cart CC and a receiver 132 for wirelessly receiving the corresponding wireless signal.
3 The pusher B control unit 138 controls the antenna 13
5, a pusher B operation switch 13 for driving a receiver 136 for wirelessly receiving the corresponding radio signal and a pusher B78 for changing the transport direction of the carriage cart CC.
Seven.

Each carriage cart CC to be used is given an ID number and registered in the main controller 100 in advance. The main controller 100 wirelessly manages the operation status of each carriage cart CC. Specifically, in accordance with the detection information of the PE-coated portion 32 by the color mark sensor 105, departure is instructed to the carriage cart CC at the departure position (1). In addition, for example, if each carriage cart CC is configured to wirelessly notify the main controller 100 that it has arrived at the four corners of the cart transport path, the main controller 100 causes all the carriage carts CC to change over time. Since the position on the cart transport path can be roughly grasped, the information can be converted into display information, created and displayed on the display 108, and an abnormal situation can be found.

FIG. 19 is a diagram showing a method of recognizing that each carriage cart CC has arrived at the corner.
Each carriage cart CC travels along four cart transport paths in a direction indicated by an arrow. Therefore, 4 of cart base 40
Proximity switches Sa, Sb, Sc, Sd
Attach. The proximity switch Sa can recognize arrival at the corner part (1) by detecting the metal surface 141 facing the traveling direction. Similarly, the proximity switch Sb is connected to the corner
The proximity switch Sc to (2) can recognize the arrival to the corner (3), and the proximity switch Sd can recognize the arrival to the corner (4).

FIGS. 20 and 21 are flowcharts for explaining the operation of the cart controller 110 according to the present embodiment. First, it is determined whether or not the system power is ON (step S1). If NO, the process waits until the system power is turned ON. If YES, an initial setting including a wireless communication setting with the main controller 100 is performed (step S2). Next, in step S3, it is determined whether or not there is a system stop instruction from the main controller 100. If YES, the system stop processing is performed (step S3).
4) End the flow. If NO and there is no system stop instruction, it is determined whether there is an abnormality in itself (step S).
5) If YES is found, an abnormality is notified to the main controller 100 (step S6), and the process proceeds to step S4. If there is no abnormality in NO, it is determined whether or not there is a position inquiry from the main controller 100 (step S7). If there is an inquiry in YES, a response message relating to position information is sent to the main controller 100 (step S8). ), And proceed to step S7. If there is no inquiry at NO, it is determined whether or not it has arrived at the position (1) (step S9). If it has not arrived at NO, it waits until it arrives.
A message to the effect that the vehicle has arrived at the position (1) is sent to the main controller 100 (step S10), and the work board a is set (step S11).
It is determined whether there is a departure instruction from 00 (step S).
12) If NO, and there is no departure instruction, wait until there is an instruction, and if YES, there is support for departure, drive pusher A 74 to get on carry-in chain conveyor 72. Next, it is determined whether or not the vehicle has arrived at the position (2) (step S1).
4) If not arrived at NO, wait until it arrives, and if arrived at YES, send a notification message to the main controller 100 indicating that it has arrived at position (2) (step S15), and proceed to FIG. It is determined whether the carriage cart CC has landed on the flat plate transport path 51 (step S1).
6) If NO, the landing waits until the landing, and if YES, the traveling of the carriage cart CC is controlled (step S17), and the front and rear hanging hands 48 are controlled.
Is controlled (step S18). And the position
It is determined whether or not (3) has been reached (step S19).
If it has not arrived at O, wait until it arrives, YES
, A message is sent to the main controller 100 indicating that the vehicle has arrived at the position (3) (step S2).
0), the workpiece a is lowered onto the transport roller 26 (Step S21), and the return transport and return travel of the carriage cart CC are controlled (Step S22), and it is determined whether or not the workpiece has arrived at the position (4). (Step S23) If the vehicle has not arrived at NO, the return transport and return traveling control of the carriage cart CC is continued (Step S22). If the vehicle arrives at YES, the vehicle has arrived at the position (4) at the main controller 100. A message to the effect is sent (step S24), and it is determined whether or not the vehicle has arrived at the position (1) (step S25).
If the vehicle has not arrived at NO, the return transport and return traveling control of the carriage cart CC (Step S22) is continued, and if the vehicle arrives at YES, the process returns to Step S10 (FIG. 20).

FIG. 22 is a flowchart illustrating the operation of main controller 100 according to the present embodiment. The details of each control item are executed by a dedicated controller.
Therefore, it is assumed that an appropriate instruction is given to each of these controllers. First, it is determined whether or not the system power is ON (step S31). If NO, the process waits until the system power is turned ON. If YES, initial settings including wireless communication settings with each cart controller 110 are performed (step S32).

Next, in step S3, it is determined whether or not there is an abnormality in itself, and if there is an abnormality, the system is stopped (step S34), and the flow is terminated. If there is no abnormality in NO, the cart controller 110
It is determined whether or not there is a notification of the occurrence of an abnormality (step S
35) If there is an abnormality in YES, the abnormality is notified by broadcast to the cart controller CC of each carriage cart CC (step S36), and the process proceeds to step S34. If there is no notification of the occurrence of an abnormality in NO, management control of the movement position of each carriage cart CC (step S37),
The control of traveling and winding of the base cloth 11 (step S38), the control of loading and unloading of the workpiece a (step S39), the heating control of the base cloth 11 (step S40), and the control of the base cloth 11 and the base The cooling control of the work plate a (step S41) is performed, and the process returns to step S33.

The management of the movement position of each carriage cart CC (step S37) will be described in detail with reference to FIGS. Control of running and winding of the base cloth 11 (step S3
In 8), the synchronous operation of the pin tenter 16 and the residue cloth roll 17 is instructed. In the control of loading and unloading of the plate a to be processed (step S39), a timing operation of the loading chain conveyor 72 and the unloading chain conveyor 76 is instructed.
Further, according to the detection of the corresponding base cloth 11 by the color mark sensor 105, the carriage cart CC at the departure position (1) is provided.
Is instructed to depart to the cart controller 110.

The heating control of the base cloth 11 (step S4)
0), the corresponding base cloth 1 by the color mark sensor 105 is used.
In accordance with the detection of 1, the control unit instructs the sheet temperature controller 88 to start / stop heating. In the sheet temperature controller 88, the temperature of the base cloth 11 immediately after leaving the heating zone ZA is constantly measured by the sheet surface thermometer 86. For example, the heating condition is maintained by PID control, and the next PE coating portion is maintained. By the time 32 arrives, the heating conditions are corrected. In the cooling control of the base cloth 11 and the plate a to be processed (step S41), the laminating zone ZB
And the timing at which the workpiece a passes through the cooling zone ZD. The cool air / exhaust controller 84 measures the surface temperature of the object to be cooled at the outlet of each processing zone, and controls the air volume of the blower blower 82 and the exhaust blower 83.

FIG. 23 is a flowchart for explaining the details of the management control (step S37) of the movement position of each carriage cart CC according to the present embodiment. First, based on the departure time of the first carriage cart CC, each carriage cart CC
Is created and recorded in the memory 102 (step S51). Next, each carriage cart CC
It is determined whether or not there is a notification that the vehicle has arrived at the position (1) (step S52). If NO, the communication waits. If YES, the color mark sensor 10
In step S5, it is determined whether or not the corresponding PE coating portion 32 has been detected (step S53). If NO, the process waits until it is detected. If YES, the process returns to the cart controller 110 at the position (1). To departure (step S54). Then, an inquiry is made to each cart controller 110 at a predetermined polling speed as to whether or not it has arrived at any one of the corners (step S5).
5) It is determined whether there is a response (step S56),
If there is no answer in NO, any cart controller 1
It is determined whether or not there is an interruption notification from step 10 (step S57), and if there is no interruption notification, the process returns to step S55. If there is a response or an interruption is made in step S56 or S57, the corresponding notification is made. Each ID number of each corner and the arrival time of each carriage cart CC are received from the cart controller 110 and recorded in the memory 102 (step S58). Then, it is checked whether or not each carriage cart CC is moving on the transport path as scheduled according to the record (step S5).
9) It is determined whether there is any abnormality (step S60),
If there is no abnormality in NO, the process returns to step S55 to continue the process, and if there is an abnormality in YES, step S34 (FIG. 22)
And shut down the system.

The problem that a plurality of carriage carts CC simultaneously arrive at two or more (or four in many cases) corners and radio communication from each cart controller 110 to the main controller 100 is eliminated. For this purpose, in the present embodiment, the main controller 100 calls each cart controller 110 at a predetermined polling speed, and inquires about each arrival time at each corner. In response to the inquiry, if there is uncontacted arrival information in each cart controller 110, the “own ID number”, the “arrival time to the corner that just passed”, and the “corner number” As a response message to the main controller 100.

Further, in the main controller 100, if a notification message indicating that the cart has arrived at the corner is received from any of the cart controllers 110 during the inquiry by polling,
It is assumed that the contact message is received as interrupt input data. In this case, each cart controller 11
The contact message from 0 is "your ID number"
"The arrival time of the arrived corner" and "the corner number".

When the measurement data of the elapsed time from the arrival time at each corner is included in the message from the carriage cart CC, the approximate current position of each cart on the transport / running path can be ascertained. The response message and the contact message are distinguished by, for example, setting a flag for the former message data. If the response message is a response message, the check in step S59 indicates whether or not the corner section contacted as the corner section that has just passed has arrived according to the movement schedule table. In this case, it is checked "whether or not the contacted corner has arrived according to the transfer schedule table". Specifically, for the arrival time we contacted,
For the scheduled arrival time shown in the transfer schedule table,
With the allowable range in the system operation as OK, the scheduled arrival time close to the notified arrival time in the column of the corresponding corner number in the movement schedule table which was contacted is searched, and the scheduled arrival ID number is notified. It is to be checked whether the ID number matches the ID number.

Therefore, if they do not match, the carriage cart CC that has contacted or responded to the inquiry has not been conveyed or traveled according to the movement schedule table. System stop processing. " In the system stop processing, each cart controller 110 is instructed to execute the system stop processing by broadcast communication by wireless communication. Also,
Emergency stop is applied to other drive systems. After that, a system stop process on software is executed.

FIG. 24 shows a step S51 of the present embodiment.
It is a figure which shows the example of the movement schedule table created in (refer FIG. 23). As described above, each ID number of each corner and the estimated arrival time of each carriage cart CC are recorded. Note that the present invention is not limited to the above embodiment.

[0055]

As described above, according to the present invention, (1) water absorption from the back of a building board is effectively prevented,
The dimensional change of the entire plate is reduced. (2). Since the intrusion of CO ₂ from the back of the building board is considerably prevented, carbonation and neutralization of the cement board are prevented. (3). Since the absorption of chlorine ions from the inside is prevented by preventing water absorption from the back of the building board, oxidation (rust generation) of iron is prevented when fastening to the steel frame base etc. . (4). Compared with the case of sealer coating, the film strength (tear strength,
(Burst strength, etc.) is large, so the occurrence of scratches, cracks and chips (particularly, real parts) is suppressed.

(5) Since the application step of the back sealer and the subsequent drying operation are eliminated, the energy cost is greatly reduced, and the total coating cost can be significantly reduced. (6). The construction method in which the building board is fastened to the steel frame base set prevents the squeaking noise of the building board. (7). In the construction method in which nails (or screws) are driven in from the surface of the building board and fastened, the foam near the protrusions of the nails is protected by a foam layer with high elasticity of closed cells. It becomes possible. As a result, it is possible to much more effectively prevent rainwater from flowing to the back surface of the board. (8) Since the foamed layer is formed on the back surface, a certain degree of shock absorption is exhibited, and the phenomenon of fine cracking even when an external force is applied is considerably reduced.

[Brief description of the drawings]

FIG. 1 is a diagram showing a partial cross-sectional structure of a building board according to an embodiment of the present invention.

FIG. 2 is a diagram for explaining a situation of cracks on the back of a building board in the case of nailing.

FIG. 3 is a flowchart illustrating a PE foam layer backing process of the building board manufacturing apparatus according to the present embodiment.

FIG. 4 is a top view illustrating a configuration of a building board manufacturing apparatus according to the present embodiment.

FIG. 5 is a side view illustrating a configuration of a building board manufacturing apparatus according to the present embodiment.

FIG. 6 is a diagram illustrating a base fabric.

FIG. 7 is a diagram showing a state in which a work plate and a remaining base cloth are detached from a pin tenter.

FIG. 8 is a diagram showing a drive system on the back surface of the carriage cart.

FIG. 9 is a side view showing the configuration of the carriage cart.

FIG. 10 is a front view showing a configuration of a carriage cart.

FIG. 11 is a plan view of a building board.

FIG. 12 is a diagram showing the entire transport system of the carriage cart.

FIG. 13 is a diagram illustrating the operation of the transport system.

FIG. 14 is a diagram for explaining a traveling timing of a PE coating portion and a carriage cart.

FIG. 15 is a diagram illustrating the speeds of the PE coating portion and the carriage cart.

FIG. 16 is a diagram (part 1) for explaining the operation of the hanging hand during the laminating process.

FIG. 17 is a diagram (part 2) for explaining the operation of the hanging hand during the laminating process.

FIG. 18 is a diagram showing an overall configuration of a building board manufacturing apparatus according to the present embodiment.

FIG. 19 is a diagram illustrating a method of recognizing that each carriage cart has arrived at a corner.

FIG. 20 is a flowchart (part 1) for explaining the operation of the cart controller of the present embodiment.

FIG. 21 is a flowchart (part 2) for explaining the operation of the cart controller of the embodiment.

FIG. 22 is a flowchart illustrating an operation of the main controller according to the present embodiment.

FIG. 23 is a flowchart illustrating details of management control of the movement position of each carriage cart CC according to the present embodiment.

FIG. 24 is a diagram illustrating an example of a movement schedule table according to the present embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Building board 2 Cement board 3 Surface coating layer 4 PE foam layer 11 Base cloth 12 Base cloth roll 13 Front rotation roller 14 Rear rotation roller 15 Pin holding roll 16 Pin tenter 17 Residue cloth roll 18 Far infrared heater 19 Heat roll 20 Clearance Adjusting Roll 21 Cold Air Supply Duct 22 Exhaust Duct 23 Adjuster 24 Pin Removal Roll 25 Separate Blade 26 Transport Roller 27 Upper Cold Air Supply Duct 28 Lower Cold Air Supply Duct 29 Exhaust Duct 31 Recycled PET Nonwoven Fabric 32 PE Coated Part 40 Base 41 Front Wheel 42 Rear Wheel 43 Motor 44 Propeller shaft 45 Front differential 46 Rear differential 47 Center guide roll 48 Hanging hand 51 Flat plate transport path 52 Center guide rail 53 Long hole 54 Rack gear 55 Stepping motor 56 pinion gear 57 battery 58 controller 59 hinge 60 the piston rod 61 acting type air cylinder 62 the air hose 63 compressor 64 double-acting air cylinder

Continued on front page F-term (reference) 2E162 CA01 CD01 CD11 FA05 FA09 FC01 FC02 FC03 FC04 FC06 FC08 4F100 AE00B AK04A AT00B BA02 CA01A DJ01A GB07 JD02 JD05 JL05

Claims (7)

[Claims] 1. A building board characterized in that a foamed plastic is lined with a cement substrate cloth. 2. The building board according to claim 1, wherein the foamed plastic contains polyethylene as a main component. 3. The thickness of the foamed plastic is 0.5
The building board according to claim 1, wherein the thickness is from 3.0 mm to 3.0 mm. 4. An apparatus for manufacturing a building board, comprising backing means for backing a foamed plastic to a cement substrate cloth during a process of foaming and molding the foamed plastic. 5. The building board manufacturing apparatus according to claim 4, wherein the backing means backs the building board after the clear coating. 6. A pre-foamed plastic, characterized in that unfoamed plastic having a shape and a size of a building board is laminated on a plastic sheet in an island shape continuous at intervals. 7. The pre-foamed plastic according to claim 6, wherein the plastic sheet has PET (polyethylene terephthalate) as a main component, and the unfoamed plastic has polyethylene as a main component.