JP2003291121A - Method for manufacturing gypsum board - Google Patents
Method for manufacturing gypsum boardInfo
- Publication number
- JP2003291121A JP2003291121A JP2002096662A JP2002096662A JP2003291121A JP 2003291121 A JP2003291121 A JP 2003291121A JP 2002096662 A JP2002096662 A JP 2002096662A JP 2002096662 A JP2002096662 A JP 2002096662A JP 2003291121 A JP2003291121 A JP 2003291121A
- Authority
- JP
- Japan
- Prior art keywords
- gypsum
- gypsum board
- board
- slurry
- base paper
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Panels For Use In Building Construction (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、石膏ボードの製造
方法に関する。TECHNICAL FIELD The present invention relates to a method for manufacturing a gypsum board.
【0002】[0002]
【従来の技術】近年、安価で防火性に富む建材として石
膏ボードが広く利用されている。その一方で、石膏ボー
ドを腰壁等として用いるために、表面に比較的大きな凹
凸模様を施したものを望む声がある。このような大きな
凹凸模様を施す石膏ボードの製造方法として、従来、ボ
ード用原紙の間に石膏スラリーを流し込み、石膏芯材の
含水率が3%以下となるようにほぼ完全に乾燥させてか
ら所定の寸法に裁断し、その後に型押しプレスを行う方
法があった。2. Description of the Related Art In recent years, gypsum board has been widely used as a building material which is inexpensive and rich in fire protection. On the other hand, in order to use the gypsum board as a waist wall or the like, there is a demand for a surface having a relatively large uneven pattern. As a method for producing a gypsum board having such a large uneven pattern, conventionally, a gypsum slurry is poured between base papers for a board, and the gypsum core material is almost completely dried so that the water content of the gypsum core material is 3% or less. There was a method of cutting into the size of, and then performing an embossing press.
【0003】[0003]
【発明が解決しようとする課題】ところで、石膏スラリ
ーが硬化して石膏芯材を形成する際には、スラリー状態
の焼石膏から針状結晶の二水石膏へ化学変化が生じる。
そして、この二水石膏がボード用原紙の繊維に絡み合う
ように結合することで、石膏芯材とボード用原紙との接
合がなされる。しかしながら、上記の従来の方法のよう
に石膏スラリーが完全に硬化した後、型押しプレスを行
って深い凹凸模様を施すと、石膏芯材の針状結晶とボー
ド用原紙の繊維との絡み合いが引き裂かれてしまい、石
膏芯材からボード用原紙が剥離してしまう問題があっ
た。このようにボード用原紙が剥離してしまうと石膏ボ
ードの強度が低下したり、凹凸模様が不鮮明となってし
まう等の問題を生じる。By the way, when the gypsum slurry is hardened to form a gypsum core material, a chemical change occurs from calcined gypsum in a slurry state to dihydrate gypsum in the shape of needles.
The gypsum core material and the board base paper are joined by binding the gypsum dihydrate to the fibers of the board base paper so as to be intertwined with each other. However, after the gypsum slurry is completely hardened as in the above-mentioned conventional method, when embossing press is performed to give a deep uneven pattern, the entanglement between the needle crystals of the gypsum core material and the fibers of the board base paper is torn. There is a problem that the base paper for board is peeled from the gypsum core material. If the base paper for the board is peeled off in this manner, the strength of the gypsum board is reduced, and the uneven pattern becomes unclear.
【0004】上記のような問題を回避するために、従来
の方法においても石膏スラリーが硬化した石膏ボードに
蒸気をあててから型押しプレスを行う方法もあったが、
焼石膏のほとんどが二水石膏に変化した後に型押しを行
うから、深い凹凸模様の形成には不向きであり、また、
石膏芯材とボード用原紙との剥離を防ぐことに対する本
質的な解決はできなかった。本発明は上記のような事情
に基づいて完成されたものであって、大きな凹凸模様を
施しても石膏芯材とボード用原紙との剥離を防いで強度
や外観に優れた石膏ボードの製造が可能な石膏ボードの
製造方法を提供することを目的とする。In order to avoid the above problems, there is also a conventional method in which steam is applied to the gypsum board in which the gypsum slurry is hardened and then the embossing press is performed.
Since most of the calcined gypsum is embossed after changing to dihydrate gypsum, it is not suitable for forming deep uneven patterns.
The essential solution to prevent the peeling of the gypsum core material and the board base paper could not be achieved. The present invention has been completed based on the above circumstances, the production of gypsum board excellent in strength and appearance by preventing peeling between the gypsum core material and the board base paper even if a large uneven pattern is applied. It is an object of the present invention to provide a gypsum board manufacturing method that can be used.
【0005】[0005]
【課題を解決するための手段】上記の目的を達成するた
めの手段として、請求項1の発明は、石膏芯材の原料で
ある焼石膏を水と混合してなるスラリーを、石膏ボード
の表裏面を形成するボード用原紙の間に流し込み、所定
形状に成形後、乾燥させる石膏ボードの製造方法におい
て、前記石膏ボードの含水率が50%以下の状態におい
て型押しして前記石膏ボードの凹凸模様を付すところに
特徴を有する。As a means for achieving the above object, the invention of claim 1 provides a slurry prepared by mixing calcined gypsum, which is a raw material of a gypsum core material, with water. In a method for producing a gypsum board, which is poured between base papers for forming a back surface, formed into a predetermined shape, and then dried, an embossing pattern of the gypsum board by embossing in a state where the water content of the gypsum board is 50% or less It has a feature in that it is attached.
【0006】請求項2の発明は、請求項1に記載のもの
において、前記石膏ボードの含水率が50%以下の状態
において第二次の型押しを行うところに特徴を有する。A second aspect of the invention is characterized in that, in the first aspect, the second embossing is performed in a state where the water content of the gypsum board is 50% or less.
【0007】請求項3の発明は、請求項1または請求項
2に記載のものにおいて、前記型押しの工程後に乾燥温
度が100℃以下で乾燥させるところに特徴を有する。A third aspect of the present invention is characterized in that, in the first or second aspect, drying is performed at a drying temperature of 100 ° C. or lower after the step of embossing.
【0008】[0008]
【発明の作用及び効果】<請求項1の発明>スラリー中
の二水石膏の反応が十分に進行しない過程において型押
しを行うので、凹凸模様を施した後にボード用原紙と石
膏芯材とが接合される。したがって、従来のように凹凸
模様を施した箇所のボード用原紙が石膏芯材から剥がれ
ることがなく、強度や外観に優れた石膏ボードを製造で
きる。<Operation and effect of the invention><Invention of claim 1> Since embossing is performed in a process in which the reaction of gypsum dihydrate in the slurry does not proceed sufficiently, the base paper for gypsum and the gypsum core material are provided after the uneven pattern is formed. To be joined. Therefore, it is possible to manufacture a gypsum board excellent in strength and appearance without causing the base paper for board in a portion having an uneven pattern as in the past to be separated from the gypsum core material.
【0009】<請求項2の発明>石膏ボードの凹凸模様
が多少戻り変形した場合でも第二次の型押しを行うので
凹凸模様の輪郭形状を一層鮮明にできる。<Invention of Claim 2> Even when the uneven pattern of the gypsum board is slightly returned and deformed, the second embossing is performed, so that the contour shape of the uneven pattern can be made clearer.
【0010】<請求項3の発明>型押しの工程後に10
0℃以下という比較的低温で乾燥するので、ボード用原
紙の熱膨張に起因した剥離を抑制できて外観品質の保護
が可能となる。<Invention of Claim 3> 10 after the embossing step
Since it is dried at a relatively low temperature of 0 ° C. or less, peeling due to thermal expansion of the board base paper can be suppressed, and the appearance quality can be protected.
【0011】[0011]
【発明の実施の形態】以下、本発明の実施形態を添付図
面に基づいて説明する。
<第1実施形態>本発明の第1実施形態を図1ないし図
3によって説明する。本実施形態は石膏芯材11の原料
と水とを混練して形成したスラリーを石膏ボードの表裏
を形成するボード用原紙(以下、単に「原紙」という)
12の間に流し込んで石膏ボード10を製造する製造方
法であり、図1には本実施形態に係る石膏ボード10の
製造ラインの概要図を示した。以下、製造方法について
詳述する。まず、焼石膏(半水石膏)、澱粉等の接着助
剤、発泡剤、無機繊維等の混和剤とに水を加えてミキサ
ーMにて混練してスラリーを形成する。本実施形態では
焼石膏(半水石膏)100重量部に対して水を76重量
部、酸化澱粉0.4重量部混合させると共に、微量のポ
リオキシエチレンアルキルエーテルサルフェートの泡
沫、ガラス繊維、凝結促進剤、凝結遅延剤を添加した。
尚、焼石膏は天然石膏或いは化学石膏から得られる二水
石膏を原料とし、この二水石膏を約150℃〜200℃
の温度で焼成して得られたものを使用した。また凝結促
進剤には二水石膏の微粉末や硫酸カリウムを使用した。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the accompanying drawings. <First Embodiment> A first embodiment of the present invention will be described with reference to FIGS. In the present embodiment, a base paper for board (hereinafter, simply referred to as “base paper”) for forming front and back surfaces of a gypsum board is a slurry formed by kneading the raw material of the gypsum core material 11 and water.
It is a manufacturing method for manufacturing the gypsum board 10 by pouring it between 12 and FIG. 1 shows a schematic view of a manufacturing line of the gypsum board 10 according to the present embodiment. Hereinafter, the manufacturing method will be described in detail. First, water is added to a calcined gypsum (hemihydrate gypsum), an adhesion aid such as starch, a foaming agent, an admixture such as an inorganic fiber, and the mixture is kneaded with a mixer M to form a slurry. In this embodiment, 76 parts by weight of water and 0.4 parts by weight of oxidized starch are mixed with 100 parts by weight of calcined gypsum (hemihydrate gypsum), and a trace amount of polyoxyethylene alkyl ether sulfate foam, glass fiber, and acceleration of setting. Agents and set retarders were added.
The calcined gypsum is made from gypsum dihydrate obtained from natural gypsum or chemical gypsum, and the gypsum dihydrate is about 150 ° C to 200 ° C.
The one obtained by firing at the temperature of was used. As the setting accelerator, fine powder of gypsum dihydrate or potassium sulfate was used.
【0012】ミキサーMで混練されたスラリーは、幅方
向の両側部を曲げ起こした下側原紙12L上に流し込ま
れる。スラリーが流し込まれると、上方から上側原紙1
2Uが宛がわれて接合された後、整厚板Fを通過するこ
とで所定厚さに成形される。尚、本実施形態では石膏ボ
ード10は整厚板Fで15mmの厚さに整形される。ま
た、原紙12の両側部を曲げ起こすために、原紙12の
両側部にはと石によって予め折溝が形成される(スコー
リング)。The slurry kneaded by the mixer M is poured onto the lower raw paper 12L whose both sides in the width direction are bent and bent. When the slurry is poured, the upper base paper 1
After 2U is applied and bonded, it passes through the thickness adjusting plate F to be molded into a predetermined thickness. In this embodiment, the gypsum board 10 is shaped by the thickness adjusting plate F to have a thickness of 15 mm. Further, in order to bend and bend both sides of the base paper 12, fold grooves are formed in advance on both sides of the base paper 12 by jewels (scoring).
【0013】さて、整厚板Fを通過した石膏ボード10
は、模様形成機Sへ移送されて板状型Pが押し当てられ
る。この板状型Pは模様形成機S内において昇降可能で
かつ長手方向に沿ってスライド可能に設けらており、か
つ、その下面は成形面となっており、内部のスラリーが
硬化する前の石膏ボード10に所望とする模様の付与を
行う。The gypsum board 10 which has passed through the thickness adjusting plate F
Is transferred to the pattern forming machine S and the plate-shaped die P is pressed against it. This plate-shaped mold P is vertically movable in the pattern forming machine S and slidable along the longitudinal direction, and the lower surface thereof is a molding surface, and the plaster before the internal slurry is hardened. A desired pattern is applied to the board 10.
【0014】板状型Pは石膏芯材(硬化する過程におけ
るスラリー)や原紙が破壊しないような比較的遅い速度
で押し当てられる。さらに、板状型Pは、押圧したまま
の状態でベルトコンベアの送り速度と同じ速度で石膏ボ
ード10の送り方向へ移動される。これにより、模様形
成機Sを通過するまでの時間をかけて石膏ボード10に
対する型押しを行うようになっている。ここで、板状型
Pが押し当てを開始する時の石膏ボードの含水率は30
〜50%程度である。そして板状型Pによる押し当てが
完了するまでの間にスラリー中の焼石膏が二水石膏へ化
学変化して原紙11の繊維に絡み合う。これにより、石
膏芯材11とボード用原紙12とは凹凸模様13に沿っ
た形状でもって接合する。ここで、凹凸模様13の形成
後、模様形成機Sを通過するときの石膏ボード10の含
水率は30〜50%であり、板状型Pの押圧を解除して
も容易に戻り変形しない程度に硬化している。尚、この
実施形態においては、石膏ボードの製造ラインのライン
スピードは3m/minであり、型押し加工がなされて
いる時間は5〜15分であり、さらにそのプレス圧は5
kg/cm2である。そして、板状型Pは所定時間押圧
を行うと上昇して所定位置まで戻り、次の箇所への型押
しを行う。The plate-shaped mold P is pressed at a relatively slow speed so that the gypsum core material (slurry in the hardening process) and the base paper are not destroyed. Furthermore, the plate-shaped die P is moved in the feeding direction of the gypsum board 10 at the same speed as the feeding speed of the belt conveyor while being pressed. As a result, the embossing of the gypsum board 10 is performed over a period of time until it passes through the pattern forming machine S. Here, the water content of the gypsum board when the plate-shaped die P starts pressing is 30.
It is about 50%. By the time the pressing by the plate-shaped mold P is completed, the calcined gypsum in the slurry chemically changes to gypsum dihydrate and entangles with the fibers of the base paper 11. As a result, the gypsum core material 11 and the base paper 12 for board are joined together in a shape along the uneven pattern 13. Here, the water content of the gypsum board 10 when passing through the pattern forming machine S after forming the uneven pattern 13 is 30 to 50%, and does not easily return and deform even when the pressing of the plate-shaped die P is released. It has hardened. In this embodiment, the line speed of the gypsum board production line is 3 m / min, the time during which the embossing process is performed is 5 to 15 minutes, and the pressing pressure is 5
It is kg / cm 2 . When the plate-shaped mold P is pressed for a predetermined time, the plate-shaped mold P moves up to a predetermined position, and the plate-shaped mold P is pressed to the next position.
【0015】型押し加工が施された石膏ボード10は、
乾燥機Dへ移送される。乾燥機Dでは、100℃以下の
乾燥温度で乾燥が行われる。ここで、本実施形態では1
00℃以下の温度で石膏ボード10の乾燥を行い通常の
乾燥温度(160℃〜100℃)に比べて低くしてあ
る。これにより、原紙12が膨張変形して浮上がること
を抑制している。さらに、乾燥機Dは図示しない他の製
造ラインで使用されている乾燥機の廃熱を熱源として利
用しているので、別途加熱装置を用いる必要がない。乾
燥が終了すると裁断機Cでもって必要部分が切断される
と図2、3に示すような凹凸模様13が施された石膏ボ
ード10がえられる。The embossed gypsum board 10 is
Transferred to the dryer D. In the dryer D, drying is performed at a drying temperature of 100 ° C. or lower. Here, in this embodiment, 1
The gypsum board 10 is dried at a temperature of 00 ° C. or lower to lower the temperature than the normal drying temperature (160 ° C. to 100 ° C.). This suppresses the base paper 12 from expanding and deforming and floating. Further, since the dryer D uses the waste heat of the dryer used in another manufacturing line (not shown) as a heat source, it is not necessary to use a separate heating device. After the drying is completed, when the necessary portion is cut by the cutter C, the gypsum board 10 having the concavo-convex pattern 13 as shown in FIGS. 2 and 3 is obtained.
【0016】以上のように製造された石膏ボード10は
含水率が50%以下といういわば半乾きの状態でプレス
を行い、二水石膏へ変化する前に模様が付されるので、
所望の深い凹凸模様13が得られる。これにより石膏芯
材11と原紙12との良好な絡み合いが保持されたまま
の状態で形成されるから原紙の浮上りがなく、鮮明な輪
郭の模様になる。The gypsum board 10 manufactured as described above is pressed in a so-called semi-dry state with a water content of 50% or less, and a pattern is applied before it is converted into dihydrate gypsum.
A desired deep concavo-convex pattern 13 is obtained. As a result, the gypsum core material 11 and the base paper 12 are formed in a state in which the good entanglement is maintained, so that the base paper does not float and has a clear contour pattern.
【0017】尚、本実施形態において、板状型Pを押し
当ててから石膏スラリーが硬化した後において、乾燥工
程の前に二次成形をおこなうようにしても良い。この場
合二次成形を行うにしても石膏ボード10の含水率が5
0%以下であることが望まれる。このように二次成形を
行うようにすれば、石膏芯材11の戻り変形を制限でき
凹凸模様13をより鮮明にすることができる。In this embodiment, after the plate-shaped die P is pressed, the gypsum slurry is hardened, and then the secondary molding may be performed before the drying step. In this case, the water content of the gypsum board 10 is 5 even if the secondary molding is performed.
It is desired to be 0% or less. By performing the secondary molding in this way, the return deformation of the gypsum core material 11 can be limited and the concavo-convex pattern 13 can be made clearer.
【0018】<第2実施形態>本実施形態では模様形成
機S内の板状型Pに代えて複数のローラーRを用いて凹
凸模様13を施す点が上記第1実施形態と異なる。他の
点は同様であり、同様の構成については同様の符号を付
して説明は割愛する。図4に示すように、本実施形態の
模様形成機Sには4個のローラーRが設置されている。
これらのローラーRはその周面が模様の成形面になって
おり、かつ、ローラーの上流側から下流側にいくに従っ
て形成面の模様系西部の突出高さが徐々に増すようにな
っており、次第に深絞り成形がなされるようになってい
る。このようなローラーRを用いることにより、石膏ボ
ード10に対して無理なく深い凹凸模様が形成できる。
また、本実施形態のようにローラーRを複数個用いるた
め、次のような使用法も可能である。ローラーRの成形
面に異なる模様を付すと共に、ローラーを選択的に押圧
或いは上方へ退避させれば、異なる模様を付した石膏ボ
ード10を容易に形成できる。<Second Embodiment> The present embodiment differs from the first embodiment in that the concavo-convex pattern 13 is provided by using a plurality of rollers R in place of the plate-shaped die P in the pattern forming machine S. The other points are the same, and the same reference numerals are given to the same configurations and the description thereof is omitted. As shown in FIG. 4, the pattern forming machine S of the present embodiment is provided with four rollers R.
The peripheral surface of each of these rollers R is a pattern forming surface, and the protruding height of the pattern surface west of the forming surface gradually increases from the upstream side to the downstream side of the roller, Deep drawing is gradually performed. By using such a roller R, a deep uneven pattern can be formed on the gypsum board 10 without difficulty.
Moreover, since a plurality of rollers R are used as in the present embodiment, the following usage is also possible. By forming a different pattern on the molding surface of the roller R and selectively pressing or retracting the roller upward, the gypsum board 10 having a different pattern can be easily formed.
【0019】<他の実施形態>本発明は上記記述及び図
面によって説明した実施形態に限定されるものではな
く、例えば次のような実施形態も本発明の技術的範囲に
含まれ、さらに、下記以外にも要旨を逸脱しない範囲内
で種々変更して実施することができる。
(1)上記第1実施形態において、板状型Pは石膏ボー
ド10に対して一旦押圧すると石膏ボード10が模様成
形機Sを通過するまで、この押圧状態を保持するもので
あったが、石膏ボード10が模様成形機Sを通過する過
程において、複数回押圧させるようにしても良い。<Other Embodiments> The present invention is not limited to the embodiments described above and illustrated in the drawings. For example, the following embodiments are also included in the technical scope of the present invention. In addition to the above, various modifications can be made without departing from the scope of the invention. (1) In the above-described first embodiment, the plate-shaped mold P, once pressed against the gypsum board 10, maintains this pressed state until the gypsum board 10 passes through the pattern forming machine S. The board 10 may be pressed a plurality of times during the process of passing through the pattern forming machine S.
【0020】(2)上記実施形態において、スラリーを
流し込む前の原紙12に対して凹凸模様13を予備成形
し、その後にスラリーを流し込むものであっても良い。
その場合、原紙12は形状保持機能の高いものであるこ
とが要求される。(2) In the above embodiment, the concavo-convex pattern 13 may be preformed on the base paper 12 before the slurry is poured, and then the slurry may be poured.
In that case, the base paper 12 is required to have a high shape retention function.
【図1】第1実施形態に係る石膏ボードの製造工程の概
要図FIG. 1 is a schematic diagram of a manufacturing process of a gypsum board according to a first embodiment.
【図2】石膏ボードの平面図[Fig. 2] Plan view of gypsum board
【図3】石膏ボードの断面図[Fig. 3] Sectional view of gypsum board
【図4】第2実施形態に係る石膏ボードの製造工程の概
要図FIG. 4 is a schematic diagram of a manufacturing process of a gypsum board according to a second embodiment.
10…石膏ボード 11…石膏芯材 12…ボード用原紙 13…凹凸模様 10 ... Gypsum board 11 ... Gypsum core material 12 ... Board base paper 13 ... uneven pattern
Claims (3)
してなるスラリーを、石膏ボードの表裏面を形成するボ
ード用原紙の間に流し込み、所定形状に成形後、乾燥さ
せる石膏ボードの製造方法において、 前記石膏ボードの含水率が50%以下の状態において型
押しして前記石膏ボードの凹凸模様を付すことを特徴と
する石膏ボードの製造方法。1. A gypsum board in which a slurry obtained by mixing calcined gypsum as a raw material for a gypsum core material with water is poured between base papers for forming the front and back surfaces of the gypsum board, formed into a predetermined shape, and then dried. The method for producing a gypsum board according to claim 1, wherein the gypsum board is embossed with a water content of 50% or less to give an uneven pattern to the gypsum board.
状態において第二次の型押しを行うことを特徴とする請
求項1記載の石膏ボードの製造方法。2. The method for producing a gypsum board according to claim 1, wherein the second embossing is performed in a state where the water content of the gypsum board is 50% or less.
℃以下で乾燥させることを特徴とする請求項1または請
求項2記載の石膏ボードの製造方法。3. The drying temperature is 100 after the embossing step.
The method for producing a gypsum board according to claim 1 or 2, which comprises drying at a temperature of not higher than ° C.
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JP2002096662A JP2003291121A (en) | 2002-03-29 | 2002-03-29 | Method for manufacturing gypsum board |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2002096662A JP2003291121A (en) | 2002-03-29 | 2002-03-29 | Method for manufacturing gypsum board |
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Publication Number | Publication Date |
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JP2003291121A true JP2003291121A (en) | 2003-10-14 |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005336996A (en) * | 2004-04-28 | 2005-12-08 | Yoshino Gypsum Co Ltd | Board building material, its manufacturing method, and board building material construction method |
EP2593282A1 (en) * | 2009-07-14 | 2013-05-22 | Sadler IP Pty Limited | Slab production and processing |
-
2002
- 2002-03-29 JP JP2002096662A patent/JP2003291121A/en active Pending
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2005336996A (en) * | 2004-04-28 | 2005-12-08 | Yoshino Gypsum Co Ltd | Board building material, its manufacturing method, and board building material construction method |
EP2593282A1 (en) * | 2009-07-14 | 2013-05-22 | Sadler IP Pty Limited | Slab production and processing |
EP2593282A4 (en) * | 2009-07-14 | 2014-02-26 | Abbey And Pride Ip Pty Ltd | Slab production and processing |
US9126351B2 (en) | 2009-07-14 | 2015-09-08 | Abbey And Pride Ip Pty Ltd. | Slab production and processing |
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