JP2004058307A - Method for manufacturing light-weight foam block - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a light-weight foam block which is reduced in cost by remarkably decreasing the number of forms and in which a separation of a material, a separation of an aggregate and clogging with cement component or the like in foam in the aggregates are prevented without a deformation or a collapse of the aggregate such as a foamed material or the like. <P>SOLUTION: The method for manufacturing the light-weight foam block includes the steps of filling a porous stiff consistency concrete (1) obtained by kneading the aggregate (2) containing a resin foamed material and/or a light weight and porous structure inorganic material, a cement, water and an admixture as main components in a form (5), molding the block (3) by adding a vibration to the foam and compacting the concrete, releasing the block from the form and then curing the block. The vibration is preferably applied while a pressure of 0.98 to 39.2 kPa is applied to the concrete. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a lightweight foam block using a resin foam or the like as an aggregate.
[0002]
[Prior art]
Conventionally, as a method of manufacturing a concrete block, there are a high-pressure press molding method in which a high pressure is applied to concrete charged into a mold to form a block, and a pressure vibration molding method in which vibration is applied together with pressure. In such a method of manufacturing a pressure-type block, since the block can be immediately removed from the block, there is an advantage that the number of molds required for manufacturing can be reduced. However, the lightweight cell block disclosed in, for example, Japanese Patent Application Laid-Open No. 11-246253 and using a polystyrene foam (styrene foam) as an aggregate can further reduce the weight by increasing the expansion rate, while having a high deformation strength. Becomes smaller. For this reason, if the above-described high-pressure press molding, pressure vibration molding, or the like is used for molding the lightweight cell block, the pressing force is too large, and as shown in FIG. 10 is deformed or crushed. Further, after the mold is released, the block expands, which causes a crack or break of the block.
[0003]
Therefore, molding of a lightweight cell block using a resin foam or the like as an aggregate has been conventionally performed by a casting method into a mold. In the casting method, concrete is charged into a mold, and the concrete is hardened in the mold and then removed from the mold to form a block.
[0004]
[Problems to be solved by the invention]
As described above, in the conventional method for manufacturing a lightweight cell block, concrete is charged into a mold, and after the concrete is hardened in the mold, the block is released. Therefore, in order to manufacture a large number of blocks, a large number of molds must be prepared, and there is a problem that the cost is increased. In addition, since the concrete used is relatively stiff, material separation and aggregate separation occur due to the difference in density of the concrete component during hardening, or the cement component etc. is clogged in bubbles in the foam or the like, There is a problem that the quality of the block is deteriorated.
[0005]
The present invention has been made in order to solve such a problem, and it is possible to reduce the number of molds required at the time of manufacturing, to achieve a large cost reduction, and to deform or crush aggregates such as foam. A method for manufacturing a lightweight foam block capable of producing a high-quality foam block that is free of material separation, hardly causes material separation, aggregate separation, and hardly causes clogging of bubbles in the aggregate with a cement component or the like. The task is to
[0006]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the means adopted by the present invention is a resin-based foam and / or an aggregate containing a lightweight inorganic material having a porous structure, and kneaded with cement, water and an admixture as main components. The object is to fill a mold with porous hardened concrete, apply vibration to the mold, compact the concrete, form a block, remove the block, and then cure it. Here, the porous hardened concrete refers to hardened concrete in which the continuous porosity of the ready-mixed concrete is about 15 to 70%.
[0007]
In the present means, since the block is released from the mold and then cured immediately after the block is removed, the number of molds required for production can be greatly reduced. In addition, since vibration is applied to the formwork to compact the concrete and form the block, the particles of cement and aggregate in the concrete are settled in a more stable position among the particles by this vibration, and a foam or the like is formed. Almost no deformation or crushing occurs due to external pressure. In addition, the contact area between the particles is increased, and the expansion and deformation of the block after demolding is reduced. Furthermore, since concrete is hardened, air bubbles in the aggregate are less likely to be clogged with cement or the like.
[0008]
Preferably, vibration is applied to the form while applying a pressure of 0.98 kPa or more and 39.2 kPa or less to concrete. This prevents the concrete from jumping due to the vibration, and at such a low pressure, the aggregate such as the foam hardly deforms or collapses. More preferably, the vibration frequency is 15 Hz or more and 120 Hz or less, the gravitational acceleration is 49 m / s ² or more and 294 m / s ² or less, and the amplitude is 0.3 mm or more and 3.0 mm or less. Vibrations below these lower limits may result in insufficient compaction of the concrete, while vibrations above these upper limits may cause deformation or collapse of aggregates such as foams.
[0009]
For example, the resin-based foam is made of any one of polystyrene, polyethylene, polyvinyl chloride, and polyurethane, or a mixture of two or more foams. For example, the inorganic material is composed of any one of zeolite, shirasu balloon, perlite, and vermiculite, or a mixture of two or more.
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the method for manufacturing a lightweight bubble block according to the present invention will be described in detail with reference to FIG.
[0011]
Porous stiffening in which all or part of the mixture is a resin-based foam or a lightweight inorganic material having a porous structure, or an aggregate containing a mixture thereof, and Portland cement, water and an admixture as main components. Prepare concrete. Here, the porous hardened concrete refers to hardened concrete in which the continuous porosity of the ready-mixed concrete is about 15 to 70%.
[0012]
As the resin foam, for example, any one of polystyrene, polyethylene, polyvinyl chloride, and polyurethane, or a mixture of two or more foams can be used. Further, as the inorganic material having a lightweight and porous structure, for example, any one of granular zeolite, shirasu balloon, perlite, and vermiculite, or a mixture of two or more thereof can be used. It is desirable that these particle diameters are not less than 0.1 mm and not more than 15.0 mm. If the particle size is less than the lower limit, the weight cannot be reduced, and if the particle size exceeds the upper limit, the strength may be insufficient. Further, the above-mentioned aggregate may be a mixture of inorganic materials such as silica sand and crushed stone in addition to the above materials.
[0013]
Among resin foams, polystyrene foams having high strength and excellent workability are particularly useful. In the case of the polystyrene foams, the particle density is 80 kg / m ³ to 80 kg from the viewpoint of strength and weight reduction. It is desirable to be about 250 kg / m ³ . As the polystyrene foam, it is possible to collect and use the expanded polystyrene used in the cushioning material, the heat insulating material, the packing material, the concrete decorative formwork for civil engineering, and the like, and the collected expanded polystyrene is generally used. The foaming ratio is 30 to 70 times, which is too wide to handle. Also, the particle density is very light, about 10 kg / m ^{3 to} 50 kg / m ³ , and there is a problem in strength.
[0014]
However, it is possible to adjust the particle density within the above-mentioned particle density by crushing the waste polystyrene foam and blowing hot air of about 120 ° C. on the crushed body for a certain period of time to uniformly reduce the volume. , Can be changed to a foam that can be used as an aggregate. Further, since it is a pulverized body, it is also excellent in bonding with cement particles and the like. Of course, it is also possible to use a polystyrene foam which has been adjusted to the above particle density in advance.
[0015]
Next, as shown in FIG. 1A, a mold 5 including a bottom frame 6 and a side frame 7 is prepared. The hardened concrete 1 described above is charged and filled into the formwork 5. As shown in FIG. 1B, a pressure of 0.98 kPa (0.01 kg / cm ² ) or more and 39.2 kPa (0.40 kg / cm ² ) or less is applied to the concrete 1 charged and filled. Place the upper die 8 weighing as much as possible.
[0016]
The vibrator 9 has a frequency of 15 Hz to 120 Hz, a gravitational acceleration of 49 m / s ² (5.0 G) to 294 m / s ² (30.0 G), and an amplitude of 0.3 mm to 3.0 mm. Vibration is applied to the mold 5 to compact the concrete 1 and form the block 3. Vibrations below these lower limits may result in insufficient compaction of the concrete 1, while vibrations above these upper limits may cause deformation or collapse of aggregates such as foam. is there. At this time, the upper mold 8 prevents the concrete 1 from jumping due to vibration of the mold. However, at such a low pressure, there is almost no deformation or collapse of the aggregate such as a foam.
[0017]
Moreover, the frequency of the mold 5 and 25Hz or 60Hz or less, and the gravitational acceleration and 78.4m ^/ s 2 (8.0G) or 245m ^/ s 2 (25.0G) or less and 1.5mm amplitude By setting the thickness to 2.5 mm or less, a higher-quality bubble block can be obtained. Pressure also, 14.7kPa (0.15kg / cm ²⁾ or more 29.4kPa it is desirable that the (0.30kg / cm ²⁾ or less. Then, as soon as the block 3 is compacted, it is released from the mold, and then the block 3 is cured.
[0018]
As described above, in the present manufacturing method of the lightweight bubble block, since the block 3 is removed from the mold and cured immediately after the removal, the number of the molds 5 can be greatly reduced. In addition, since the block 3 is compacted by applying vibration to the form 5, the particles of cement and aggregate in the concrete 1 are settled at a more stable position among the particles by the vibration, and the particles are subjected to external pressure. The deformation area is small and the contact area between the particles is large. For this reason, the expansion deformation of the block 3 after the mold release is reduced. Further, since the concrete 1 is hardened, the air bubbles in the aggregate are hardly clogged with cement or the like.
[0019]
The above-mentioned concrete 1 is mainly composed of a resin foam or a lightweight inorganic material having a porous structure, or an aggregate 2 obtained by mixing silica sand, crushed stone, etc., with Portland cement and water. However, it is not limited to this, or other types of cement or other types of cement, silica fume, blast furnace slag, reactive powder such as fly ash, water reducing agent, It may contain an auxiliary material such as a thickener, a reinforcing fiber, and a synthetic resin.
[0020]
The method of pressing the concrete 1 is not limited to the method using only the upper mold 8 described above, but may be a method using another pressing device or a combination thereof. Furthermore, resin-based foams and lightweight inorganic materials having a porous structure are not necessarily limited to the above-described polystyrene foams, zeolites, and the like, and other resin-based foams and other lightweight and porous structures can be used. Of course, an inorganic material can be used. Further, the frequency, gravitational acceleration, amplitude, and pressing force on the concrete of the formwork are not limited to those described above.
[0021]
The light-weight bubble block molded in this manner is lightweight and has a large porosity, so that it is a multifunctional block excellent in heat insulation, sound absorption, water retention, moisture retention, water permeability, and the like. Further, by selecting zeolite or the like, a function of adsorbing harmful substances can be added. Applications include a wide range of applications such as heat insulating materials and sound absorbing materials as building materials, greening blocks on building roofs, and heat island prevention blocks.
[0022]
When a resin foam is used, it is widely used as a heat insulating material, a sound absorbing material, a water retaining material, a moisturizing material, and the like. In addition, by crushing the lightweight bubble block itself after use, it can be used as a recycled material again, contributing to a recycling-oriented society.
[0023]
【Example】
Hereinafter, the method for manufacturing a lightweight cell block according to the present invention will be described with reference to five examples, and the results will be described based on the physical properties of each block.
(Example 1)
Concrete mix (parts by mass)
Portland cement: 100 parts polystyrene foam aggregate (particle size 1-3 mm): 55
Water: 40
Water reducing agent: 0.8
Methyl cellulose: 0.1
Acrylic resin (water dispersion type): 3
Vinylon single fiber (0.05 mm in diameter, 6 mm in length): 0.3
Molding conditions Frequency: 60Hz
Gravitational acceleration: 196 m / s ² (20 G)
Amplitude: 1.8mm
Pressure: 22.54 kPa (0.23 kg / cm ² )
Mold dimensions: 60 cm long, 30 cm wide, thickness (6 cm) () indicates the thickness of the block when compacted at a compression ratio of 40%.
[0024]
Physical properties of block Compressive strength: 2.94 MPa (30 kg / cm ² )
Porosity: 30%
Density: 600 kg / m ³ (0.6 g / ml)
(Example 2)
Concrete mix (parts by mass)
Portland cement: 100 parts polystyrene foam aggregate (particle size 1-3 mm): 15
Zeolite aggregate (particle size 1-3 mm): 50
Water: 32
Water reducing agent: 3
Methyl cellulose: 0.3
Acrylic resin (water dispersion type): 0.5
Vinylon single fiber (diameter 0.05mm, length 6mm): 0.2
Molding conditions Frequency: 60Hz
Gravitational acceleration: 156.8 m / s ² (16G)
Amplitude: 2.0mm
Pressure: 16.66 kPa (0.17 kg / cm ² )
Mold size: 75 cm long, 50 cm wide, thickness (5 cm) () indicates the thickness of the block when compacted at a compression ratio of 40%.
[0025]
Physical properties of block Compressive strength: 3.92 MPa (40 kg / cm ² )
Porosity: 40%
Density: 800 kg / m ³ (0.8 g / ml)
(Example 3)
Concrete mix (parts by mass)
Portland cement: 100 parts polystyrene foam aggregate (particle size 1-3 mm): 22
Silica sand (particle size 1-3 mm): 24
Water: 21
Water reducing agent: 3
Acrylic resin (water dispersion type): 1.5
Vinylon single fiber (0.05 mm in diameter, 6 mm in length): 0.1
Molding conditions Frequency: 30 Hz
Gravitational acceleration: 78.4 m / s ² (8G)
Amplitude: 2.4mm
Pressure: 27.44 kPa (0.28 kg / cm ² )
Mold size: 30cm long, 30cm wide, thickness (2.5cm)
It shows the thickness dimension of the block when compacted in%.
[0026]
Physical properties of block Compressive strength: 2.94 MPa (30 kg / cm ² )
Porosity: 23%
Density: 500 kg / m ³ (0.5 g / ml)
(Example 4)
Concrete mix (parts by mass)
Portland cement: 100 parts polyurethane foam aggregate (particle size 1-3 mm): 35
Zeolite aggregate (particle size 1-3 mm): 10
Water: 30
Water reducing agent: 1
Methyl cellulose: 0.1
Acrylic resin (water dispersion type): 3
Vinylon single fiber (0.05 mm in diameter, 6 mm in length): 0.3
Molding conditions Frequency: 60Hz
Gravitational acceleration: 156.8 m / s ² (16G)
Amplitude: 2.0mm
Pressure: 16.66 kPa (0.17 kg / cm ² )
Mold size: 75 cm long, 50 cm wide, thickness (5 cm) () indicates the thickness of the block when compacted at a compression ratio of 35%.
[0027]
Physical properties of block Compressive strength: 3.43 MPa (30 kg / cm ² )
Porosity: 36%
Density: 800 kg / m ³ (0.8 g / ml)
(Example 5)
Concrete mix (parts by mass)
Portland cement: 100 parts zeolite aggregate (particle size 1-3 mm): 70
Perlite aggregate (particle size 1-3 mm): 50
Water: 45
Water reducing agent: 1
Methyl cellulose: 0.2
Molding conditions Frequency: 30 Hz
Gravitational acceleration: 78.4 m / s ² (8G)
Amplitude: 2.4mm
Pressure: 27.44 kPa (0.28 kg / cm ² )
Mold dimensions: 30 cm long, 30 cm wide, thickness (6 cm) () indicates the thickness of the block when compacted at a compression ratio of 40%.
[0028]
Physical properties of block Compressive strength: 4.9 MPa (50 kg / cm ² )
Porosity: 28%
Density: 800 kg / m ³ (0.8 g / ml)
As shown by the physical properties of each of the above blocks, in each case, the compressive strength, porosity, and density of the block are extremely good, and the method for producing a lightweight cell block of the present invention is a method for producing a lightweight cell block. It turns out that it is excellent. In addition, the internal inspection of the block also confirmed that there was almost no deformation or crushing of the aggregates such as foams, and that there was almost no clogging of the cement components and the like in the material separation, aggregate separation, and bubbles in the aggregates. Was.
[0029]
【The invention's effect】
As described in detail above, the method for producing a lightweight foam block of the present invention comprises a resin-based foam and / or an aggregate containing a lightweight, inorganic material having a porous structure, and cement, water and an admixture as main components. Filling the mold with the kneaded porous hardened concrete, applying vibration to the mold, compacting the concrete to form a block, curing the block after demolding, reducing the number of molds required for production It is possible to greatly reduce the cost, and there is no deformation or crushing of aggregates such as foam, and it is also possible to separate materials, aggregates, cement components to bubbles in the aggregates, etc. An excellent effect that a high-quality bubble block that hardly causes clogging can be manufactured can be obtained.
[Brief description of the drawings]
FIG. 1A is a cross-sectional view showing a first half of a process of a method for manufacturing a lightweight bubble block according to the present invention, and FIG. 1B is a cross-sectional view showing a latter half.
FIG. 2 is a cross-sectional view illustrating a conventional method for manufacturing a lightweight bubble block.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Concrete 2 Aggregate 3 Block 5 Form 6 Bottom frame 7 Side frame 8 Upper mold 9 Exciter 10 Foam

Claims (5)

Porous hardened concrete (1) obtained by kneading resin-based foam and / or aggregate (2) containing an inorganic material having a light-weight and porous structure, cement, water and an admixture as main components into a mold (5). A method for manufacturing a lightweight foam block, comprising: filling the mold, applying vibration to the formwork, compacting the concrete, forming a block (3), removing the block, and curing the block. The method according to claim 1, wherein the vibration is applied while applying a pressure of 0.98 kPa to 39.2 kPa to the concrete (1). 2. The method according to claim 1, wherein a frequency of the vibration is 15 Hz or more and 120 Hz or less, a gravitational acceleration is 49 m / s ² or more and 294 m / s ² or less, and an amplitude is 0.3 mm or more and 3.0 mm or less. Or the manufacturing method of the lightweight cell block as described in 2. 4. The resin foam according to claim 1, wherein the foam comprises at least one of polystyrene, polyethylene, polyvinyl chloride, and polyurethane, or a mixture of two or more foams. 5. A method for producing a lightweight foam block according to any one of the above. 5. The light-weight bubble block according to claim 1, wherein the inorganic material is made of one or a mixture of two or more of zeolite, shirasu balloon, perlite, and vermiculite. Method.

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