JP2007152706A - Manufacturing method of alc panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily and inexpensively manufacture an ALC panel having good surface properties by reducing a linear flaw, which is formed when an ALC molded body is cut in a semi-plasticized state, to the utmost. <P>SOLUTION: In the manufacturing method of the ALC panel for manufacturing the ALC panel by relatively moving the ALC molded body 1 in the semi-plasticized state and a cutting wire W at a predetermined speed and cutting the ALC molded body into a panel shape, the wire is arranged in the direction almost vertical to the relative moving direction of the ALC molded body and the wire and the ALC molded body is cut while continuously moving the wire reciprocally or unidirectionally in its longitudinal direction to reduce the linear flaw formed at the time cutting. Further, the ratio of the longitudinal moving speed of the wire to the relative moving speed of the ALC molded body and the wire is set to 0.3 or above. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing an ALC (lightweight cellular concrete) panel. More specifically, the present invention relates to a method for manufacturing an ALC panel in which a semi-plastic ALC formed into a block shape or other desired shape with a mold or the like is cut into a panel shape with a wire such as a piano wire.

  When manufacturing an ALC panel as described above, conventionally, an ALC raw material slurry is generally poured into a mold to form an ALC molded body having a predetermined size and shape, and the molded body is solidified into a semi-plastic state having a predetermined hardness. By the way, the mold is removed, and the semi-plastic ALC molded body is cut into a predetermined panel shape with a wire such as a piano wire, and then steam-cured with an autoclave or the like to obtain an ALC panel having a predetermined size and shape. .

  In this case, as a method of cutting the uncured semi-plastic ALC molded body as described above with a wire, wire fixing is generally performed by moving the wire fixed in a tensioned state relative to the ALC molded body. Many cutting methods are used. However, simply moving the fixed wire relative to the ALC molded body has a problem that it cannot always be cut well.

  For example, ALC raw materials include silica, cement, lime, etc., which are the main raw materials, cutting scraps generated by cutting unnecessary parts before and after curing, and ALC recovered from defective panels and construction sites generated during the manufacturing process. So-called recycled raw materials such as pulverized scraps are also input. These raw materials are stored and transported as a single fine particle powder of several μm to 300 μm or a slurry in which this powder is suspended in water. Foreign materials that are not raw materials may be mixed.

  As an example of the above coarsening, there is a case where rainwater enters from a gap or the like and agglomerates and solidifies in a state where the cement stays in the silo or the transport facility. Examples of the foreign matter include wood such as phosphorus wood used when laminating ALC panels, and iron pieces peeled off from the inside of the material transport equipment due to wear or corrosion, and these are generally coarser than the raw materials. is there.

  When these coarse materials are mixed in the raw material and put into the mold, when the semi-plastic ALC molded body is cut with the wire, the wire hits the coarse material and is further caught so that the uncured semi-plastic A linear flaw (hereinafter referred to as a line flaw) is generated on the cut surface of the soft ALC molded body in a state. In particular, a problem arises when this line scar appears on the surface of the ALC panel instead of the facet.

  In general, in the case of shallow flaws, the dents of the flaws are filled with the paint and become invisible. However, in the case of deep flaws or when the coating is thin, the flaws will not be lost even after painting. I can see it. Further, when the panel surface is used without being painted on the surface of the panel, for example, inside a warehouse, the line remains as it is, which may impair the appearance.

  Therefore, in Patent Documents 1 and 2 below, in order to remove coarse substances mixed in the raw material slurry or the like, a net having an opening of about 1 mm is installed alone or in the middle of the transportation of each raw material or immediately before pouring into the formwork. Although a method has been proposed, it is difficult to completely remove coarse materials. In particular, it is known that a vertically long and coarse material passes if the width is less than 1 mm, and therefore many flaws are generated when a large amount of fibrous foreign matter enters the raw material. If the opening is reduced to increase the removal efficiency of the foreign matter, the residue increases, and it is necessary to dispose of the waste as industrial waste.

Japanese Patent Application Laid-Open No. 11-5111 Japanese Patent Laid-Open No. 8-300337

  The present invention has been proposed in view of the above problems, and has excellent surface properties by reducing as much as possible the above-mentioned line flaws that occur when cutting a semi-plastic ALC molded body as described above. An object of the present invention is to propose a method of manufacturing an ALC panel that can easily and inexpensively manufacture an ALC panel.

  In order to achieve the above object, a method for manufacturing an ALC panel according to the present invention has the following configuration. That is, in an ALC panel manufacturing method for manufacturing an ALC panel by relatively moving an ALC molded body in a semi-plastic state and a cutting wire at a predetermined speed to cut the molded body into a panel shape, The wire is arranged in a direction substantially perpendicular to the direction of movement relative to the wire, and the ALC molded body is cut while the wire is continuously reciprocated in the longitudinal direction or moved in one direction, thereby reducing the flaws. It is characterized by making it.

  As a result of diligent efforts to solve the above problems (problems), the inventors of the present invention have made the cutting wire the relative movement direction of the wire relative to the ALC molded body when cutting the semi-plastic ALC molded body. It has been found that the occurrence of the above-mentioned flaws can be reduced by cutting the ALC molded body while arranging the wire in a substantially vertical direction and continuously reciprocating or moving the wire in the longitudinal direction in one direction. is there. This is because even when a wire is coarse, the wire continuously moves in the longitudinal direction thereof, so the coarse material is instantaneously broken by the wire, or moves with the wire in a short time, and is detached or dropped. . Therefore, the amount of flaws generated when the wire is continuously moved in the longitudinal direction and cut can be greatly reduced as compared with the case where the wire is cut without moving.

  In addition, there is a correlation between the amount of flaw generation and the moving speed in the longitudinal direction of the wire, and the ratio of the moving speed in the longitudinal direction of the wire to the relative moving speed of the ALC molded body and the wire is It is desirable to be 0.3 or more. By doing so, it is possible to satisfactorily reduce the occurrence of flaws. The reason why the relative moving speed between the ALC molded body and the wire is used is that there are a case where the wire is moved and a case where the ALC molded body is moved depending on the manufacturing method. The moving speed of the wire in the longitudinal direction is a moving speed when the wire is continuously reciprocated or moved in one direction in the longitudinal direction, and the moving direction changes when reciprocating during cutting. Although it temporarily stops every time, there is no problem because it is usually instantaneous.

  According to the present invention, it is possible to reduce the amount of flaws as much as possible as described above, and the work and process for removing coarse materials in raw materials that require a great deal of labor are simplified or omitted. can do. Moreover, since it is easy and reliable as a measure against a flaw, the occurrence of a flaw can be easily and greatly suppressed. As a result, there is an effect that an ALC panel having excellent panel surface properties and appearance quality can be easily and inexpensively mass-produced.

  Hereinafter, the present invention will be specifically described based on the embodiments shown in the drawings, but the present invention is not limited to such embodiments.

  FIG. 1 shows an example of a state in which a semi-plastic ALC molded body 1 formed into a block shape with a mold or the like is cut into a panel shape with a cutting wire W such as a piano wire. In this embodiment, a predetermined state is shown. The ALC molded body 1 is moved at a predetermined speed in the direction of arrow a in the figure with respect to the wire W arranged at the position. The ALC molded body 1 is arranged at a predetermined position and the wire W is moved to the arrow in the figure. You may make it move to b direction. In any of the above cases, the relative moving speed between the ALC molded body 1 and the wire W is preferably about 2 to 7 m / min.

  Further, the wire W is disposed in a direction substantially perpendicular to the relative movement direction of the wire W and the ALC molded body 1, and the wire W is continuously reciprocated in the longitudinal direction (in the direction of arrow c in the figure). The ALC molded body 1 is cut while moving in one direction (arrow d or e direction in the figure). In this case, the moving speed in the longitudinal direction of the wire W is preferably set according to the relative moving speed between the ALC molded body 1 and the wire W, and in particular, the relative moving speed between the ALC molded body 1 and the wire W. The ratio (v / V) of the moving speed v in the longitudinal direction of the wire W to V is desirably 0.3 or more.

  The reason for the above conditions is based on examples and other experiments to be described later. When the speed ratio (v / V) is 0.3 or more, fibrous coarseness is present in the ALC molded body 1. Even if foreign matter is mixed in, it is possible to satisfactorily prevent the wire W from breaking instantaneously or being moved and removed together with the wire in a short time, resulting in almost no trouble as a panel product. This is because the flaws can be reduced to a lesser extent. If the speed ratio is set to 0.4 or more, the occurrence of flaws can be further reduced.

  As shown in FIG. 1, the ALC molded body 1 is moved relative to the wire W arranged at a predetermined position in the direction of arrow a in FIG. The ratio of the moving speed v in the longitudinal direction of the wire W to the relative moving speed (speed of 5 m / min in this example) V between the ALC molded body 1 and the wire W is continuously moved (downward in this example). The ALC molded body 1 was cut into a panel shape with various changes in (v / V).

  In addition, as a comparative example to the above example, the ALC molded body 1 was cut into a panel shape in a state where the wire W was fixed without moving in the longitudinal direction. And the ALC molded object 1 cut | disconnected in the panel shape in the said Example and comparative example was cured with an oak clave, and an ALC panel was manufactured, and the number of the wounds which arose on the cut surface by the said wire W of each ALC panel was shown. investigated. As a survey method, the panel is laid flat in a bright place indoors, and the number of flaws is visually counted from a place about 1 m away, and the total number of the panels is divided by the total area of the observation surface of the panel. The number of flaws per unit area was taken as the number of flaws per unit area in the above comparative example in which the wire was fixed and cut, and the ratio was calculated. The results are shown in Table 1 and FIG.

  As apparent from Table 1 and FIG. 2, the speed ratio, that is, the ratio (v / V) of the moving speed v in the longitudinal direction of the wire W to the relative moving speed V between the ALC molded body 1 and the wire W is set to 0. If it is 3 or more, the number of flaws can be suppressed to less than 30% compared to the case where the wire is fixed and cut, and if the speed ratio (v / V) is 0.4 or more, the wire is fixed. The number of flaws can be suppressed to less than 10% compared to the case of cutting. In the above embodiment, when the speed ratio (v / V) is about 0.6 or more, almost no flaws occur, and even if the speed ratio (v / V) is further increased, the flaw prevention effect is hardly changed. Since the surface property of the cut surface changes, a speed ratio corresponding to the desired appearance property may be selected as appropriate.

  In the above embodiment, the ALC molded body 1 is moved in the direction of the arrow a in FIG. 1 with respect to the wire W arranged at a fixed position. However, the ALC molded body 1 is fixed at a fixed position and the wire shown in FIG. Similar results can be obtained by moving in the direction of arrow b. Further, in the above embodiment, the wire W is moved downward as a direction in which the wire W is moved in the longitudinal direction. However, when the wire W is moved upward, almost the same result as described above was obtained. Furthermore, when the wire W was cut while reciprocating (vertically moving) in small increments with an amplitude of 60 mm (± 30 mm) in the longitudinal direction, the same result as above was obtained. The panel referred to in the present invention is not necessarily limited to a plate having a wide surface, and can be applied to columns and other various shapes.

  As described above, according to the present invention, when an ALC molded body is cut with a wire, the amount of generated flaws can be reduced as much as possible by a simple configuration in which the wire is reciprocated in the longitudinal direction or moved in only one direction. Therefore, the operation and process of removing coarse materials in the raw material that require a great deal of labor can be simplified or omitted. Therefore, it is effective for mass production of ALC panels having excellent surface properties and appearance quality easily and inexpensively, and has high industrial applicability.

The perspective view which shows an example of the state which cut | disconnects an ALC molded object in a panel form with a wire. The graph which shows the relationship between the wire speed ratio by the Example of this invention, and a flaw occurrence rate.

Explanation of symbols

1 ALC compact W wire

Claims (2)

  In an ALC panel manufacturing method for manufacturing an ALC panel by relatively moving an ALC molded body in a semi-plastic state and a cutting wire at a predetermined speed to cut the molded body into a panel shape, the ALC molded body and the wire The wire is arranged in a direction substantially perpendicular to the relative movement direction of the wire and the ALC molded body is cut while the wire is continuously reciprocated in the longitudinal direction or moved in one direction, thereby reducing the flaws. A method for producing an ALC panel characterized by the above.   The method for producing an ALC panel according to claim 1, wherein a ratio of a moving speed in the longitudinal direction of the wire to a relative moving speed between the ALC molded body and the wire is 0.3 or more.

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