JP2009138476A - Lightweight cement panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight cement panel lightweight, high in strength with excellent durability, causing neither strength degradation nor deformation by water absorption and atmospheric temperature variation, excelling in workability of nailing or the like and usable for a concrete form and a building floor, wall, ceiling or the like. <P>SOLUTION: The panel 1E is lightweight with specific gravity of 0.5-2.0, wherein the side end faces of a panel body 2 formed of lightweight cement are covered with side part foam layers 4 formed of foam synthetic resin, and the surface of the panel body 2 is covered with a surface resin layer 4A in which a surface reinforcing sheet 13 is embedded. The panel 1E has high toughness, excels in impact resistance by the side part foam layer 4, has excellent appearance and high strength by the surface reinforcing sheet 13 and the surface resin layer 4A, is suitable for use as a building material such as a wall material, a floor material, a ceiling material of a building as a substitute of plywood, and has excellent mold release property when used as a sheathing board of a concrete form. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a lightweight cement panel, and more specifically, for example, as a concrete formwork panel or as a wall material, floor material, ceiling material, etc. of a building, and further, a heat insulating material incorporated in a partition partitioning the room The present invention relates to a lightweight cement panel that can be widely used in the construction field, civil engineering field, and the like.

  Conventionally, wood plywood (hereinafter simply referred to as “plywood”) has been frequently used as a concrete formwork panel. However, plywood has low durability and water resistance, and has a problem that it absorbs water due to surplus water at the time of placing concrete or rains at the time of storage, resulting in an increase in weight and a decrease in strength. Less than ~ 7 times. For this reason, a large amount of used plywood becomes building waste, and not only is it time consuming to incinerate it, but also the use of plywood consumes a large amount of wood resources obtained from tropical forests, Leads to worsening. Therefore, there is a demand for reducing the use of plywood. Furthermore, the plywood is usually formed by laminating about 6 single plates and bonding them with a vinyl acetate adhesive. For this reason, harmful gases are generated from the vinyl acetate adhesive during plywood incineration, causing environmental pollution. In addition, when a plywood using a vinyl acetate adhesive is used for a house building or the like, there is a problem of a sick house, and the plywood cannot be used particularly in a clean room or the like.

  In concrete formwork panels, various synthetic resin formwork panels have been proposed in view of the above-mentioned problems of plywood (for example, see Patent Documents 1 to 4). Some of these synthetic resin panels do not consume wood resources and can be used repeatedly 20 to 30 times, and there is no problem of weight increase or strength reduction due to water absorption. However, a synthetic resin panel has a greater variation in strength, particularly bending stiffness, due to changes in temperature than plywood. For this reason, at the time of concrete placement in summer, the bending rigidity of the panel may be reduced and the concrete may be deformed by the placement concrete pressure. Further, depending on the structure of the synthetic resin panel, there is a limited range in which nailing is possible, and it is difficult to say that the workability like a plywood is sufficient.

  Moreover, what consists of inorganic materials, such as a cement type and a concrete type, is also known as a panel used at the time of concrete placement. For example, a discarded frame made of a cement-based composite material using glass fiber, a nonwoven fabric made of glass fiber or the like as a reinforcing material (see Patent Document 5), a discarded frame made of a reinforced glass fiber mixed concrete plate (GRC) (Patent Document) 6), a concrete structure (see Patent Document 7) using a permanent form plate formed of fiber reinforced cement such as glass fiber, a cement-based cured body, and a (foamed) concrete-based cured body. Ready-made concrete board mixed with cast-in type frame material (refer to Patent Document 8) made of a composite material sandwiched between inorganic fiber mesh such as fiber, metal mesh made of stainless steel, iron, etc., and bonded, lightweight aggregate, and foam agent Discarded formwork for placing concrete, consisting of lightweight concrete board covered with cement paste with mesh reinforcing fiber sheets embedded and integrated on both sides of the main body (See Patent Document 9.) Are known. However, all of these conventional panels for placing concrete made of inorganic materials are discarded frames (permanent molds), and after the concrete is cast, these structures are integrated with the cast concrete structure. It constitutes a part of the body and is not used repeatedly like a concrete formwork panel made of plywood.

  A number of panels made of inorganic materials using concrete or cement reinforcing fibers such as polyvinyl alcohol fibers (vinylon) have also been proposed. For example, a concrete casting form panel (see Patent Document 10) formed from a composition containing gypsum and quartzite powder, glass fiber, a water reducing agent and polyvinyl alcohol with respect to alumina cement, a hydraulic inorganic material, and polyvinyl A dense substrate layer made of an extrusion-molded / cured body of a hydraulic admixture containing alcohol fiber, polyolefin fiber, polyamide fiber, hemp, glass fiber, carbon fiber, pulp fiber, and other reinforcing fiber materials; A composite panel material (see Patent Document 11), a synthetic fiber A, and a polyvinyl alcohol, which are laminated and combined on one surface of the dense substrate layer and have a porous filling layer having a specific gravity of 0.6 or less. A fiber-reinforced cement molded body containing reinforcing fibers in which the synthetic fiber B is mixed so that the weight ratio A / B between A and B is 0.1 to 3 ( (See Permissible Document 12), a fiber reinforced board material based on a hydraulic substance using a mesh-like tissue body made of spun yarn such as polyvinyl alcohol synthetic fiber as a reinforcing material (see Patent Document 13), a hydraulic material A mold made of a hydraulic paste containing at least reinforcing fibers and water, wherein at least a part of the reinforcing fibers is a polyvinyl alcohol fiber (see Patent Document 14), a polyvinyl alcohol-based main body. A hard board made of fiber entanglement including fibers, wherein the main fibers are joined by a polyvinyl alcohol-based binder (see Patent Document 15), reinforcing reinforcing bars are embedded, and formed by hardening of concrete The main body of the structure body and cement integrated as a permanent mold on the outer surface of the structure body, A hydraulic composition containing a concrete structure having a fiber-reinforced high-toughness cement board having a strength vinylon fiber as a reinforcing fiber (see Patent Document 16), a reinforcing fiber made of polyvinyl alcohol fiber and / or polyolefin fiber. A precast concrete molded body obtained by molding the material by centrifugal molding (refer to Patent Document 17), and a glass mesh or carbon mesh and urethane foam are laminated on one side of a papermaking plate in which the reinforcing fiber contains a polyvinyl alcohol-based synthetic fiber. A fiber-reinforced outer heat insulating material (see Patent Document 18) formed by laminating glass mesh or carbon mesh and urethane foam on one side of a high-strength, high-toughness fiber-reinforced cement board is proposed.

  However, conventionally, there has been no panel that has durability that can be used repeatedly as well as or higher than that of plywood, and that has the same processability, lightness, workability, and handleability as plywood.

JP-A-6-66021 JP-A-8-207190 JP-A-11-182029 JP 2003-161037 A JP 55-95728 A Japanese Patent Publication No. 61-28511 Japanese Patent Laid-Open No. 9-13486 JP-A-9-76404 JP-A-9-287239 JP-A-5-340090 JP-A-5-18042 Japanese Patent Laid-Open No. 5-139803 JP-A-8-91911 JP 2001-252916 A JP 2001-355171 A JP 2004-36253 A JP 2005-81657 A JP 2006-112038 A

  The present invention is made of an inorganic material in view of the problems in the above-described conventional concrete formwork panels and the like, and has no decrease in strength, deformation, and weight increase due to water absorption or temperature fluctuations, and has workability such as nailing. Good, lightweight, easy to handle, high strength, excellent durability, can be used repeatedly as a panel for concrete formwork, and building materials such as building floor materials, wall materials, ceiling materials, partitions, etc. The purpose of the present invention is to provide a panel that can be used as a substitute for plywood.

  In order to achieve the above object, in the lightweight cement panel according to the present invention, the side end face of the panel body made of lightweight cement is integrally covered with the side foam layer made of foamed synthetic resin, and the specific gravity is 0.00. It is in the range of 5 to 2.0. As a preferred embodiment, the panel body is composed of a porous molded body obtained by filling a mold for cement with a kneaded product obtained by kneading foam formed by cement, water, reinforcing fibers and a foaming agent, and curing and solidifying the mold. The reinforcing fiber and the foam are contained in a dispersed state in the molded body, and the specific gravity is in the range of 0.5 to 2.0.

  It is preferable that a surface reinforcing sheet made of woven fabric or nonwoven fabric is integrally coated on the surface of the lightweight cement panel. In another preferred embodiment, a surface resin layer made of a synthetic resin is integrally coated on the surface of the lightweight cement panel, and the surface reinforcing sheet is embedded in the surface resin layer. Furthermore, a side reinforcing sheet made of a woven fabric or a non-woven fabric is provided in an embedded state between the side end surface of the panel main body and the side foam layer, and the strength rigidity against torsion of the panel main body can be increased.

When such a surface reinforcing sheet or side reinforcing sheet is provided, a nonwoven fabric made of glass fiber having a basis weight of 50 to 1000 g / m ² is used to suppress an increase in manufacturing cost and prevent delamination. preferable.

  It is also preferable that the surface of the lightweight cement panel is integrally covered with a surface protective layer. In this case, the surface protective layer can be composed of a film, sheet or board made of non-foamed synthetic resin. Moreover, it is a preferable embodiment that the outer peripheral end of the lightweight cement panel is integrally covered with the end protective layer so that the surface protective layer does not peel from the outer peripheral end.

  The cement panel of the present invention as described above can be widely used for building materials and civil engineering applications. In particular, as a panel for concrete formwork, it is used repeatedly in the same manner as plywood instead of plywood that has been used conventionally. can do.

  In particular, a kneaded product obtained by kneading foams preformed with cement, water, reinforcing fibers, and a foaming agent is filled in a closed cement mold and cured and solidified. A panel body made of a lightweight cement having a specific gravity of 0.5 to 2.0 and a foamed synthetic resin that integrally covers the side end surfaces of the panel body. The side foam layer made of, the side reinforcing sheet made of a woven or non-woven fabric embedded in a side end surface of the panel body and the side foam layer, and the surfaces of the panel body and the side foam layer are integrated. A preferred embodiment of the lightweight cement panel according to the present invention includes a surface resin layer made of a synthetic resin to be coated and a surface reinforcing sheet made of a woven fabric or a non-woven fabric embedded in the surface resin layer.

  The first lightweight cement panel manufacturing method according to the present invention includes filling a foamable synthetic resin into a lower part of a mold for product that can be sealed and having a slightly larger internal space than the panel main body. Place a surface reinforcing sheet made of woven or non-woven fabric with the same plane dimensions as the internal space of the product mold on the resin in an embedded state, and then position and place the panel body at the center of the product mold. The panel body is filled with foaming synthetic resin on the outer peripheral side and upper side, and a surface reinforcing sheet made of woven or non-woven fabric having substantially the same planar dimensions as the internal space of the product molding die is embedded in this foamed synthetic resin. Then, in a state where the product mold is sealed, the filled foaming synthetic resin is foamed and cured, so that the side end surface of the panel body is covered with the side foam layer and the surface reinforcing sheet is embedded. Characterized by coating the surface of the panel and the side foam layer at the surface resin layer.

  A surface reinforcing sheet is embedded in the inner surface of the mold for product, with the side end face of the panel body covered with a side foam layer in a state where a film, a sheet or a board serving as a surface protection layer is previously arranged. Cover the surface of the panel body and the side foam layer with the surface resin layer, and adhere the film, sheet or board to be the surface protection layer to the panel body with the foaming synthetic resin constituting the surface resin layer. It is a preferred embodiment to use a panel body in which a side reinforcing sheet made of woven fabric or nonwoven fabric is fixed in advance on the side end surface.

In the first method for manufacturing a lightweight cement panel, any one of the following two methods for manufacturing a panel body can be employed as a method for manufacturing a panel body made of the lightweight cement.
The method for producing the first panel main body includes a step of filling a kneaded product obtained by kneading foam pre-formed with cement, water, reinforcing fibers, and a foaming agent into a closed mold for cement, and curing and solidifying. One panel body is molded in one cement mold.

  The second panel body is manufactured by filling a kneaded mixture of cement, water, reinforcing fiber and foamed foam into a closed cement mold, curing and solidifying the porous mold. A step of producing a body and a step of slicing the porous molded body to produce a panel body, producing a block-shaped porous molded body larger than the panel body in a cement mold, A panel body is manufactured by slicing this to a set thickness.

  The second method for producing a lightweight cement panel according to the present invention comprises filling a kneaded product obtained by kneading foam pre-formed with cement, water, reinforcing fibers and a foaming agent into a closed mold for cement, and curing and solidifying. And producing a block-shaped porous molded body, and foaming by filling a foamable synthetic resin between the outer peripheral side surface of the porous molded body and the foam molding mold in a closed foam molding mold A step of curing and integrally covering the outer peripheral side surface of the porous molded body with a foamed synthetic resin layer; and slicing the porous molded body coated with the foamed synthetic resin layer to form a side portion made of the foamed synthetic resin A process for manufacturing a panel body with a set thickness with the side edges covered with a foam layer, and filling the foamable synthetic resin into the lower part of a mold for product that can be sealed, and molding the product into this foamable synthetic resin Plane dimensions approximately the same as the mold interior space A surface reinforcing sheet made of woven fabric or non-woven fabric is placed in an embedded state, and then the panel body is positioned and placed in the product mold, and then the foamed synthetic resin is filled on the upper side of the panel body and the foam is expanded. A foam-reinforced synthetic resin filled with a surface reinforcing sheet made of woven or non-woven fabric having the same plane dimensions as the interior space of the product mold, and then sealed with the product mold The surface of the panel main body and the side foam layer is covered with a surface resin layer in which a surface reinforcing sheet is embedded by foaming and curing the resin.

  The third method for producing a lightweight cement panel according to the present invention comprises filling a kneaded product obtained by kneading foam pre-formed with cement, water, reinforcing fibers and a foaming agent into a closed cement mold, and curing and solidifying. The step of producing a block-shaped porous molded body, the step of temporarily fixing a reinforcing sheet made of woven fabric or non-woven fabric on the outer peripheral side surface of the porous molded body, and the reinforcement in a sealed foam molding mold A foamable synthetic resin is filled between the outer peripheral side surface of the porous molded body on which the sheet is temporarily fixed and the foaming mold, and the foamed and cured resin is formed. The reinforcing sheet and the foamed synthetic resin layer are formed on the outer peripheral side surface of the porous molded body. A step of covering integrally, slicing the porous molded body covered with the reinforcing sheet and the foamed synthetic resin layer, a side reinforcing sheet made of the reinforcing sheet, and a side foamed layer made of the foamed synthetic resin Side end face The process of manufacturing the coated panel body with the set thickness, and filling the foamable synthetic resin into the lower part of the mold for the product that can be sealed, and this foamable synthetic resin is substantially the same as the interior space of the product mold A surface reinforcing sheet made of woven or non-woven fabric with a planar dimension is placed in an embedded state, and then the panel body is positioned and placed in a product mold, and then the upper surface of the panel body is filled with a foaming synthetic resin. Then, a surface reinforcing sheet made of woven or non-woven fabric having substantially the same plane dimensions as the internal space of the product mold is embedded in this foamable synthetic resin, and then filled with the product mold sealed. The surface of the panel body and the side foam layer is covered with the surface resin layer in which the surface reinforcing sheet is embedded by foaming and curing the foamable synthetic resin.

  In the step of coating the panel main body and the side foam layer with the surface resin layer in the second and third production methods, a film, sheet or board serving as a surface protective layer is formed on the inner surface of the mold for product that can be sealed. In the state of being placed in advance, the surface of the panel body is integrally covered with a surface resin layer made of foamed synthetic resin in the product mold, and at the same time, a film, sheet or board serving as a surface protective layer is covered with the surface resin. The layer can be glued to the panel body.

  In the second and third lightweight cement panel manufacturing methods, after the step of manufacturing the panel body, the surface of the panel body and the side foam layer is covered with a surface resin layer in which a surface reinforcing sheet is embedded. In this case, instead of foaming and curing the foamable synthetic resin in the product mold, the panel body is overlaid with a surface reinforcing sheet made of a woven or non-woven fabric with the foamable synthetic resin attached thereto, and heated. You may make it coat | cover the surface of a panel main body and a side part foaming layer with the surface resin layer by which the surface reinforcement sheet was embed | buried by carrying out pressure molding and foam-hardening a foamable synthetic resin.

  In the first to third manufacturing methods, a step of covering outer peripheral ends of the panel main body and the side foam layer with an end protective layer can be provided.

  According to the lightweight cement panel of the present invention, the side end face of the panel body made of lightweight cement, that is, the so-called end face of the panel body is protected by the side foam layer made of foamed synthetic resin. The impact when the cement panel falls can be absorbed, and the panel can be prevented from being broken or broken.

  The lightweight cement panel according to the present invention is lightweight and high in strength, has good workability, and can be used as a substitute for plywood. Moreover, since the light-weight cement panel of the present invention uses cement as a main material and does not use wood resources like wooden plywood, it can reduce the use of wood resources from tropical forests and can contribute to environmental conservation. In addition, the lightweight cement panel of the present invention has higher durability than a plywood and can be used repeatedly many times. Therefore, if it is used instead of plywood as a concrete formwork panel, the amount of building waste materials can be reduced. In addition, construction costs can be reduced. In addition, when used as a concrete formwork, there is no occurrence of poor hardening of the concrete surface due to the acuity unlike plywood. In addition, since vinyl acetate adhesive is not used like plywood, no toxic gas is generated during waste material processing as in the case of incineration of plywood. Can also be used.

  Further, the lightweight cement panel of the present invention is a panel body made of a porous molded body having a large number of bubbles formed by dispersing foam of foam, for example, a foaming agent, and a side covering the side end face of the panel body. It consists of a part foam layer and a surface protective layer that covers the surface of the panel body, and can be made as light as plywood with a specific gravity of 2.0 or less, and it is excellent in handleability and workability, as in plywood There is no increase in weight or decrease in strength due to water absorption.

  Further, the lightweight cement panel according to the present invention has a structure in which the porous molded body is reinforced by entanglement of reinforcing fibers contained in a dispersed state. In addition, the driven-in nail and the like are firmly held by the reinforcing fiber contained in the molded body.

  Therefore, the lightweight cement panel according to the present invention can be suitably used for building materials such as building wall materials, flooring materials, ceiling materials, and heat insulating materials for partitions, and further for concrete formwork.

  In the lightweight cement panel of the present invention, the amount of reinforcing fiber contained in the lightweight cement constituting the panel body is not particularly limited, but by blending about 0.5 to 5 parts by weight with respect to 100 parts by weight of cement. A reinforcing structure is formed by entanglement of reinforcing fibers contained in a dispersed state in the molded body. For example, even when used as a concrete formwork, sufficient strength against cast concrete pressure can be ensured. The type of the reinforcing fiber is not particularly limited, and examples thereof include vinylon which is a polyvinyl alcohol fiber, polyolefin fiber such as polypropylene fiber and polyethylene fiber, aramid fiber, carbon fiber, steel fiber, and glass fiber.

  The panel body of the present invention may be manufactured by forming a cement kneaded product into a plate shape of a desired size, but after forming into a large block shape, it is sliced into a plate shape of a desired thickness and size. It can also be manufactured, or after forming into a large block shape, a foamed synthetic resin layer can be coated on the outer peripheral side surface and sliced into a plate having a desired thickness and size. Further, after forming into a large block shape, a foamed synthetic resin layer is covered with a reinforcing sheet serving as a side reinforcing sheet temporarily fixed on the outer peripheral side surface and sliced into a plate having a desired thickness and size. Can also be produced. In the case of slicing into a plate after forming into a block shape, many panels can be formed at one time with a single mold for cement, and curing and solidification can be performed together. Improves. In addition, when slicing an outer peripheral side coated with a foamed synthetic resin layer after molding into a large block shape, productivity can be further improved and a foamed synthetic resin layer is formed in advance on the side end face of the panel body. Therefore, the positioning operation of the panel body with respect to the product mold is facilitated.

  When the surface of the lightweight cement panel is integrally covered with a surface reinforcing sheet made of woven fabric or nonwoven fabric, the bending strength of the lightweight cement panel can be improved and the reinforcing performance of the surface of the panel body can be improved. The surface reinforcing sheet of the present invention can be adhered to the panel main body with an adhesive, but the surface of the panel main body is integrally covered with a synthetic resin layer, and the surface reinforcing sheet is embedded in the synthetic resin layer. The surface reinforcing sheet can be bonded to the panel body by the synthetic resin constituting the synthetic resin layer. Further, when the surface resin layer covering the surface of the panel main body is provided in this way, the surface resin layer prevents water absorption from the panel surface and can improve the water resistance of the lightweight cement panel. When the panel is used for concrete formwork, excess water at the time of placing concrete and water absorption due to rainfall are prevented, and an increase in panel weight due to water absorption can be reliably prevented. Further, the surface resin layer can improve the impact resistance performance of the panel body surface, and can effectively prevent the panel body surface from being damaged. Furthermore, the finish of the concrete placement surface is also improved by the surface resin layer, and the releasability of the lightweight cement panel from the cast concrete is improved. Furthermore, since the surface resin layer functions as an adhesive for bonding the surface reinforcing sheet to the panel body, a plurality of functions can be imparted to the surface resin layer.

Further, by providing a side reinforcing sheet made of woven fabric or non-woven fabric between the side end surface of the panel main body and the side foam layer, the strength rigidity against bending and twisting of the lightweight cement panel can be further improved. Further, when a surface reinforcing sheet or a side reinforcing sheet is provided, by using a nonwoven fabric made of glass fiber having a basis weight of 50 to 1000 g / m ² , bending and twisting are suppressed while suppressing an increase in manufacturing cost of the panel. The strength and rigidity against can be improved.

  When the surface of the panel body is covered with the surface protective layer, the surface protective layer prevents water absorption from the panel surface more effectively, and the water resistance of the lightweight cement panel can be improved. The surface protective layer can be composed of a non-foamed synthetic resin. When the surface protective layer is made of non-foamed synthetic resin, the non-foamed synthetic resin layer can more reliably prevent water absorption from the panel surface, and a smooth and clean concrete placement surface can be obtained. The releasability from the finished concrete is also improved.

  Furthermore, when the outer peripheral edge of the lightweight cement panel is integrally covered with the edge protective layer, water absorption from the outer peripheral edge of the surface resin layer and the surface protective layer can be prevented, and the water resistance and durability can be further improved. Separation of the surface resin layer and the surface protective layer from the end can be effectively prevented. The edge protection layer is formed by sticking a watertight sealing tape, or a film or sheet made of a synthetic resin material compatible with the surface protection layer is formed by heat sealing, or surface protection. It can be formed by any method such as immersing in a synthetic resin material having compatibility with the layer.

  FIG. 1 is a cross-sectional view showing an embodiment of a lightweight cement panel 1 according to the present invention. A lightweight cement panel 1A according to the embodiment shown in FIG. 1 is obtained by integrally covering a surface 2a of a panel body 2 made of lightweight cement with a surface protective layer 3, and forming a side end surface 2b of the panel body 2 on a side portion made of a foamed synthetic resin. The outer peripheral end of the surface protective layer 3 and the side foamed layer 4 are covered with the end protective layer 5 and are integrally covered with the foam layer 4. However, those in which at least one of the surface protective layer 3 and the end protective layer 5 is omitted are also within the scope of the present invention.

  The panel body 2 made of the lightweight cement includes, for example, a porous molded body 7 containing reinforcing fibers 6 and a large number of bubbles (not shown) in a dispersed state. The porous molded body 7 can be obtained, for example, by filling a cement mold with a kneaded product obtained by kneading foam obtained by preforming cement, water, reinforcing fibers, and a foaming agent, and curing and solidifying the mixture.

  The cement is not particularly limited, and various cements such as ordinary Portland cement, early-strength Portland cement, and ultra-early-strength Portland cement can be used.

  The blending ratio of cement and water is preferably in the range of 20 to 100 parts by weight, more preferably 20 to 50 parts by weight of water with respect to 100 parts by weight of cement. If there is too much water, the strength tends to decrease, and if there is too little water, the fluidity of the cement kneaded product at the time of molding tends to deteriorate and the moldability tends to be impaired.

  Examples of the reinforcing fibers 6 include polyvinyl alcohol fibers (vinylon), polyolefin fibers such as polypropylene fibers and polyethylene fibers, aramid fibers, carbon fibers, steel fibers, and glass fibers. Among these fibers, vinylon fibers are preferable because of their high durability and excellent affinity with cement. The fiber length of the reinforcing fiber 6 is not particularly limited, but is preferably a short fiber, for example, a range of 4 to 35 mm is preferable. If the fiber length of the reinforcing fiber 6 is less than 4 mm, the reinforcing effect tends to be insufficient. A longer fiber length of the reinforcing fiber 6 is advantageous in terms of reinforcing effect, but on the other hand, the longer the fiber length, the lower the dispersibility, and the reinforcing fiber 6 is unevenly distributed in the molded body, thereby improving the panel strength. It may be lowered. Moreover, although there is no limitation in particular also in the thickness of the reinforcing fiber 6, a thing of 10-200 micrometers is used normally.

  The panel main body 2 can obtain a reinforcing structure by entanglement of the reinforcing fibers 6 as shown in FIG. 1 simply by uniformly dispersing the reinforcing fibers 6 such as vinylon and glass chop during cement kneading. Therefore, when manufacturing a panel, a complicated operation such as a positioning operation when embedding a reinforcing material such as a net-like reinforcing material is unnecessary, and a panel having no variation in strength can be easily manufactured.

  The blending amount of the reinforcing fiber 6 is preferably 0.5 to 5 parts by weight with respect to 100 parts by weight of the cement. When the amount of the reinforcing fiber 6 is small, the reinforcing effect is low and the panel strength is also low. Although the greater the amount of the reinforcing fiber 6 is, the more advantageous the panel reinforcement effect is. However, when the amount of the reinforcing fiber 6 is excessive, the dispersibility in the cement kneaded product is deteriorated, and the reinforcing fiber 6 is unevenly distributed. There is a possibility that the strength of the panel becomes uneven and the strength of the panel is lowered. From such a viewpoint, the more preferable range of the compounding amount of the reinforcing fiber 6 is 0.5 to 3 parts by weight with respect to 100 parts by weight of cement.

  The foaming agent is not particularly limited, and various well-known foaming agents such as a protein-based, surfactant-based, and resin-based foaming agents can be used. Furthermore, metal foaming agents such as aluminum powder can be used together with the foaming agent. The amount and method of addition of the foaming agent are not particularly limited. Usually, the target value is 0.1 to 3 parts by weight with respect to 100 parts by weight of cement, and the specific gravity of the obtained panel is 2.0 or less. What is necessary is just to adjust suitably so that. The specific gravity of the panel is preferably 0.5 to 2.0, more preferably in the range of 0.5 to 1.0, and particularly preferably about the same as that of wood plywood. The smaller the specific gravity, the lighter the panel and the more advantageous the handling. However, as the specific gravity decreases, the porosity increases and the strength of the panel decreases. On the other hand, the greater the specific gravity, the heavier the panel and the lower the handleability.

  In kneading a kneaded material composed of the above-mentioned cement, water, foams pre-formed with a reinforcing fiber and a foaming agent, and other additives, a conventionally known cement mixer or concrete mixer can be used. It is necessary to uniformly knead the whole without damaging the foam (bubbles) pre-formed with the foaming agent and the reinforcing fibers. If the foam (bubbles) of the foaming agent is damaged during kneading, the size of the bubbles in the panel after molding becomes nonuniform, and the panel strength may vary. Further, if the reinforcing fiber is damaged, it may break and the desired reinforcing effect may not be obtained.

  Whether the panel body 2 is kneaded with foams pre-formed with cement, water, reinforcing fibers and foaming agent as described above, filled in a molding die for cement, and molded into a plate shape having a size suitable for the purpose of use. After molding into a block shape larger than that, and curing, the cement milk containing bubbles hardens by a hydration reaction between cement and water, and contains reinforcing fibers and a large number of bubbles in a dispersed state. A lightweight porous molded body is obtained. The thickness of the panel body 2 is not particularly limited, and is, for example, 2 to 50 mm, and usually about 8 to 30 mm.

  An example of a specific manufacturing method of the panel body 2 made of lightweight cement is as follows. Water and a water reducing agent are mixed in cement, and reinforcing fibers are added thereto and kneaded. On the other hand, air is introduced into the foaming agent and preformed at a predetermined magnification. The foam obtained by preforming the foaming agent is added to the kneaded product and kneaded. In addition, the specific gravity of the kneaded product may be appropriately measured during the kneading, and foam pre-formed with a foaming agent may be further added and kneaded so as to approach the target value. The cement kneaded material is filled into a metal pressure-resistant molding die, for example, and molded into a plate shape having a predetermined thickness of, for example, 600 mm (width) × 1800 mm (length), and this is cured and solidified. Thereby, as shown in FIG. 1, the panel main body 2 which consists of the porous molded object 7 which the cement solidified and consists of the lightweight cement reinforced by the entanglement of the reinforcing fiber 6 disperse | distributed in the molded object 7 is obtained. Further, as shown in FIG. 11, after forming into a large block-shaped porous molded body 7A made of lightweight cement reinforced with reinforcing fibers 6, and curing and solidifying, it is cut into a plate shape having a desired thickness and size. The panel body 2 may be obtained. The curing may be ordinary curing, steam curing, or a combination of both. In addition, curing is not completed in the mold for cement, but is steam-cured in the mold for cement and solidified to some extent, usually after several hours, and then cured for further curing. The molding cycle in the mold is shortened and productivity is improved.

  In the lightweight cement panel 1 according to the present invention, the four side end surfaces 2b of the panel main body 2 made of the lightweight cement as described above are integrally covered with the side foam layer 4, and the outer side of the panel main body 2 is disposed on the side. The partial foam layer 4 is formed in a frame shape.

  The foamed synthetic resin constituting the side foam layer 4 is not particularly limited. For example, polystyrene foam, polyethylene foam, rigid polyurethane foam, flexible polyurethane foam, rigid vinyl chloride foam, urea foam, phenol foam, acrylic foam, Examples thereof include cellulose acetate foam and other foamed synthetic resins.

  As a method of forming the side foam layer 4, a generally known method can be applied. Among these, three types of foaming methods of polyurethane foam, urea foam, and phenol foam are exemplified below as representative examples.

  Polyurethane foam is obtained from raw materials such as polyol, excess diisocyanate, cross-linking agent, foaming agent, catalyst, cell size adjuster, etc., and carbon dioxide, methylene dichloride, pentane, and mechanical mixing by reaction of water and isocyanate as foaming agent. Other decomposable organic foaming agents such as air to be used are used. Silicone resins and emulsifiers can be used as the bubble size adjusting agent, and amines and organotin compounds can be used as the catalyst.

  The urea foam is a low temperature or 2-30 parts foaming agent such as propane, butane, butene, hexane, methyl chloride in 100 parts of a viscous urea-formaldehyde aqueous solution (resin content 50-90%) having a viscosity of about 1000 cp. After dispersing in a closed container and adding an acid catalyst in the presence of an emulsifier, the temperature is increased to 15 to 115 ° C. Further, the urea resin initial condensate containing the emulsifier may be discharged while mechanically foaming while mixing the hydrochloric acid solution with an in-situ foaming machine.

  The phenol foam is obtained by adhering or filling a target part by mixing a curing agent with stirring while blowing into the resol-type precondensate with air using a foaming machine. Furthermore, about 1% of sodium bicarbonate may be added at the time of creaming to help foaming. According to this method, it hardens | cures rapidly after addition of a hardening | curing agent. As the oxidation catalyst, benzenesulfonic acid, toluenesulfonic acid, sulfuric acid, phosphoric acid and the like are used. In addition, if a volatile foaming agent is blended, the first foaming is not necessary because foaming occurs due to reaction heat. A phenolic resin suitable for foaming is also commercially available, but a tough foam can also be prepared by copolymerizing 5 parts of polyamide obtained from adipic acid and hexamethylenediamine with 85 parts of resole, polyvinyl alcohol, About 5 to 20 parts of vinyl chloride resin can be blended to supplement toughness and elasticity.

  Although there is no limitation in particular in the expansion ratio of the side part foam layer 4, about 2 to 30 times may be sufficient normally. The panel strength increases as the expansion ratio of the side foam layer 4 decreases, but the panel weight also increases. Moreover, although the panel is reduced in weight as the expansion ratio of the side foam layer 4 increases, on the other hand, the panel strength tends to decrease. Therefore, the expansion ratio of the side foam layer 4 is appropriately determined from the viewpoint of the lightness, strength, impact resistance, etc. of the panel. Further, the thickness of the side foam layer 4 is set to be substantially the same as that of the panel body 2, and the width is not particularly limited, and depends on the thickness of the panel body 2, but when the lightweight cement panel 1 is dropped. It is set to about 2 to 50 mm so that the impact can be effectively absorbed.

  The method of integrally covering the side end surface 2b of the panel body 2 with the side foam layer 4 is not particularly limited. For example, in the mold for product that can be sealed, around the panel body 2 made of lightweight cement. The side foam face 4 of the panel body 2 is integrally covered with the side foam layer 4 by foaming and curing the filled foamable synthetic resin. More specifically, first, the panel body 2 is positioned and placed in the center of the product mold having a slightly larger internal space than the panel body 2, and then a foaming synthetic resin is placed on the outer peripheral side of the panel body 2. The side foam layer 4 is coated on the side end surface 2 b of the panel body 2 by filling and then foaming and curing the filled synthetic resin in a state where the product mold is sealed. In this way, by foaming and curing the foamable synthetic resin in the sealed product mold, the side foam layer 4 is provided, so that the surface of the side foam layer 4 is covered with a skin layer without bubbles. It is formed on a smooth surface. The side foamed layer 4 is composed of closed cells with few or no open cells, water resistance, surface properties, releasability from cast concrete when used for concrete formwork, etc. It is preferable because of its excellent resistance. Moreover, as shown in FIG. 12, the panel main body 2A in which the side foam layer 4 is previously formed on the side end surface of the panel main body 2 can be used. As a specific manufacturing method of such a panel main body 2A, the porous molded body 7A is formed at the center of a closed foam molding mold having a larger internal space than the block-shaped porous molded body 7A. The foamed synthetic resin is filled in the gap between the porous molded body 7A and the mold for foam molding and foamed and cured, and as shown in FIG. It can be produced by being coated with a partial foam layer 4 and sliced into a plate having a desired thickness and size. The side foam layer 4 only needs to be provided on at least the outer peripheral surface of the porous molded body 7A, and a blade such as a circular saw or a band saw so that the side foam layer 4 is disposed on the outer periphery of the panel body 2A. Slice with.

  In the lightweight cement panel 1 </ b> A of the present embodiment, the surface 2 a of the panel body 2 is integrally covered with the surface protective layer 3. The surface protective layer 3 increases the strength of the lightweight cement panel 1A, and also improves the surface properties, water resistance, and releasability from the cast concrete when used as a concrete formwork. The surface protective layer 3 is preferably provided so as to cover both the front and back surfaces of the panel body 2, but the surface protective layer 3 provided so as to cover only one surface 2 a is also within the scope of the present invention.

  The material of the surface protective layer 3 is not particularly limited, but can be composed of a non-foamed synthetic resin. The method of providing the surface protective layer 3 with a non-foamed synthetic resin is not particularly limited. For example, a method of bonding a synthetic resin film, sheet, or board to the surface 2 a of the panel body 2, Examples include a method of applying a synthetic resin. As the synthetic resin, in addition to polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, ABS, MMA, etc., when used for concrete molds, good releasability from cast concrete Synthetic resins are preferred. Films, sheets or boards made of these synthetic resins can be bonded to the surface of the panel body 2 with an adhesive. Further, the surface of the film, sheet or board made of a synthetic resin constituting the surface protective layer 3 is subjected to corona discharge processing, or the surface thereof is treated with an acid, etc. You may make it improve adhesiveness with the surface 2a. The synthetic resin film, sheet or board constituting the surface protective layer 3 may be a single layer or multiple layers.

  As shown in FIG. 1, the surface protective layer 3 is set to the same size as the entire surface of the lightweight cement panel 1 </ b> A, and the outer peripheral end of the surface protective layer 3 is disposed along the outer peripheral end of the side foam layer 4. Has been. By configuring in this way, the length of the overlapping portion of the end protective layer 5 provided so as to cover the outer peripheral portion of the surface protective layer 3 and the surface protective layer 3 is set to be as large as possible. It is possible to effectively prevent water from entering from the outer peripheral end of the panel 1A. However, the outer peripheral end portion of the surface protective layer 3 can be provided up to the middle portion of the side foam layer 4 or the outer peripheral end portion of the panel body 2. It is also a preferred embodiment that the outer peripheral end of the surface protective layer 3 is covered with the side foam layer 4.

  In the lightweight cement panel 1 </ b> A, the outer peripheral end portion and the side foam layer 4 of the surface protective layer 3 are integrally covered with the end protective layer 5. And by this edge part protective layer 5, while being able to prevent water absorption from the outer peripheral end surface of the surface protective layer 3, while being able to improve the water resistance and durability of lightweight cement panel 1A further, the surface protective layer 3 is from the outer peripheral edge part. It can prevent that it peels or the side foam layer 4 falls off from the panel main body 2. FIG. However, the end protective layer 5 is preferably provided to prevent the surface protective layer 3 from peeling off and the side foamed layer 4 from falling off, but the omitted one is also within the scope of the present invention.

  The edge protective layer 5 is formed by sticking a sealing tape having water tightness, or formed by bonding or heat-sealing a synthetic resin film or sheet, or on the outer peripheral edge of the panel body 2. It can be formed by any method such as applying a synthetic resin. Alternatively, a frame material having a U-shaped cross section made of synthetic resin can be fitted along the side end portion of the panel body 2 and fixed with an adhesive. As the synthetic resin constituting the end protective layer 5, ABS, MMA, and the like are preferable in addition to polyolefin resins such as polyethylene and polypropylene, and polyester resins such as polyethylene terephthalate. The polymerization width of the end protective layer 5 and the surface protective layer 3 can be arbitrarily set, but can be set to about 3 to 10 mm, and in order to increase the attachment strength of the side foam layer 4 to the panel body 2, at least the panel It is preferable to provide the edge part protective layer 5 so that the boundary part of the main body 2 and the side part foam layer 4 may be included. Furthermore, when the edge protective layer 5 that integrally covers the outer peripheral edge of the surface protective layer 3 is provided on the side foam layer 4 on the side edge surface of the panel body 2, the edge protective layer 5 is combined with the side foam layer 4. It is preferable because molding can be performed at the same time, and an increase in manufacturing cost can be suppressed.

  FIG. 2 shows another embodiment of the lightweight cement panel 1 according to the present invention. A lightweight cement panel 1B according to the present embodiment has a non-foamed synthetic resin layer 10 and paper 11 on the surface 2a of the panel body 2 instead of the surface protective layer 3 made of non-foamed synthetic resin in the lightweight cement panel 1A. The surface protective layer 3 is provided, and the others are configured in the same manner as the lightweight cement panel 1A. Examples of the non-foamed synthetic resin layer 10 include various synthetic resins such as polyethylene, polypropylene, and polyethylene terephthalate described above. This non-foamed synthetic resin layer 10 may be directly bonded to the surface of the paper 11 by thermal lamination or the like, and, like a lightweight cement panel 1C shown in FIG. A film-like, sheet-like or board-like non-foamed synthetic resin may be adhered to the paper 11. The type of the adhesive is not particularly limited, and it is appropriately selected from known adhesives in consideration of adhesiveness to both the synthetic resin material constituting the non-foamed synthetic resin layer 10 and the paper 11. be able to. Further, as the adhesive for bonding the non-foamed synthetic resin layer 10 and the paper 11, the same foamable synthetic resin as the foamable synthetic resin constituting the side foam layer 4 is used, and the surface of the panel body 2 is formed in the mold. 2a and side end face 2b are coated with side foam layer 4; paper 11 is adhered to side foam layer 4; and non-foamed synthetic resin layer 10 (film, sheet, or board) is adhered to paper 11. Can also be performed in the same process. 2 and 3 that are the same as those shown in FIG.

  The surface protection layer 3 is provided on the surface 2a of the panel body 2 as described above, and in particular, the outermost layer is bonded to a film, sheet or board made of a non-foamed synthetic resin, or a synthetic resin is applied to protect the surface. By providing layer 3, water absorption from the panel surface can be reliably prevented, and when used as a concrete formwork, a smooth and clean concrete placement surface is obtained, and separation from the cast concrete is obtained. The moldability is also good. Further, when the surface protective layer 3 includes the paper 11, the bending rigidity, elasticity and impact resistance of the lightweight cement panel 1 are further increased, and the pullout strength of the nail driven into the lightweight cement panel 1 is increased. It is preferable because it increases and nailability improves. In this embodiment, the side foam layer 4 is responsible for all of the waterproof performance and impact resistance imparted to the panel body 2 and the adhesion function of the surface protective layer 3 to the panel body 2. It is possible to efficiently produce lightweight cement panels with excellent water resistance and impact resistance.

  FIG. 4 shows still another embodiment of the lightweight cement panel 1 according to the present invention. In the lightweight cement panel 1D according to this embodiment, the surface 2a of the panel body 2 in the lightweight cement panel 1A is covered with a surface resin layer 4A made of a foamed synthetic resin, and a surface protective layer 3 is provided thereon. In other respects, the configuration is the same as that of the lightweight cement panel 1A. 4 that are the same as those in FIG. 1 are given the same reference numerals, and descriptions thereof are omitted.

  The thickness of the surface resin layer 4A is not particularly limited, and is usually set to about 0.1 mm to 3 mm. In the embodiment shown in FIG. 4, the surface resin layer 4 </ b> A is provided on both the front and back surfaces of the panel body 2, but it may be provided only on one of the surfaces depending on the use of the panel.

  The synthetic resin constituting the surface resin layer 4A is not particularly limited. For example, polystyrene foam, polyethylene foam, rigid polyurethane foam, flexible polyurethane foam, rigid vinyl chloride foam, urea foam, phenol foam, acrylic foam, cellulose acetate Examples thereof include foams and other foamed synthetic resins. Further, polystyrene resin, polyethylene resin, hard polyurethane resin, soft polyurethane resin, hard vinyl chloride resin, urea resin, phenol resin, acrylic resin, cellulose acetate resin, and other non-foamed synthetic resins may be employed.

  The surface resin layer 4A and the side foam layer 4 on the side end face of the panel body 2 can be made of different materials, but are preferably made of the same material and simultaneously or separately formed. In the case of simultaneous molding, for example, the foamable synthetic resin filled around the panel main body 2 made of lightweight cement is foam-cured in a mold for product that can be sealed, so that the surface 2a and the side of the panel main body 2 are The end surface 2 b is integrally covered with the surface resin layer 4 </ b> A and the side foam layer 4. More specifically, first, a foamable synthetic resin is filled in the lower part of the product mold having a slightly larger internal space than the panel body 2, and then the panel body 2 is placed in the center of the product mold. Positioned and placed, then filled with foamable synthetic resin on the outer peripheral side and upper side of the panel body 2, filled with foamable synthetic resin so as to wrap the panel body 2, and then sealed with a product mold Thus, the panel main body 2 can be covered with the surface resin layer 4 </ b> A and the side foam layer 4 by foaming and curing the filled foamable synthetic resin. Thus, the surface resin layer 4A is provided with the surface resin layer 4A and the side foam layer 4 by foaming and curing the foamable synthetic resin in a sealed product mold, so that the surface resin layer 4A has a surface free of bubbles. The pores on the surface of the panel body 2 made of the porous molded body 7 are also sealed, and water absorption from the panel surface is prevented. It should be noted that the surface resin layer 4A and the side foam layer 4 are composed of closed cells with few open cells or closed cells without open cells, which are used for water resistance, surface properties, and concrete molds. It is preferable because of its excellent releasability. When the surface resin layer 4A and the side foam layer 4 are separately molded, the panel body 2A having the side foam layer 4 molded on the outer periphery as shown in FIG. With the foamed synthetic resin filled in the lower part of the mold for molding, the panel body 2A is positioned and placed at the center of the product mold, and then the foamed synthetic resin is filled on the upper side of the panel body 2A. Then, in a state where the product mold is sealed, the filled foamable synthetic resin is foamed and cured, so that the surface resin layer 4A and the side foam layer 4 can be separately provided on the panel body 2. .

  The surface protective layer 3 can be adhered to the surface resin layer 4A with an adhesive, but when the surface resin layer 4A is molded, the foamable synthetic resin constituting the surface resin layer 4A is subjected to foam curing. The surface protective layer 3 can be directly adhered to the panel body 2 by the foamable synthetic resin. For example, in a state where the sheet, film, or board to be the surface protective layer 3 is disposed on the inner surface of the mold, the foamable synthetic resin filled around the panel body 2 is foamed and cured, whereby the surface 2a of the panel body 2 In addition, the surface protective layer 3 can be bonded to the side end surface 2b by the surface resin layer 4A and the side foam layer 4 at the same time, and the foamable synthetic resin as an adhesive.

  FIG. 5 is a cross-sectional view showing another embodiment of the lightweight cement panel 1 according to the present invention. In the lightweight cement panel 1E according to this embodiment, the surface protective layer 3 and the edge protective layer 5 in the lightweight cement panel 1D are omitted, and the surface reinforcing sheet 13 made of woven fabric or nonwoven fabric is embedded in the surface resin layer 4A. The other components are configured in the same manner as the lightweight cement panel 1D. 5 that are the same as those in FIG. 4 are given the same reference numerals, and descriptions thereof are omitted.

As the surface reinforcing sheet 13, a woven or non-woven fabric made of a fiber material such as polyvinyl alcohol fiber (vinylon), polyolefin fiber such as polypropylene fiber or polyethylene fiber, aramid fiber, carbon fiber, steel fiber, glass fiber or the like can be adopted. . In particular, a chopped strand mat made of glass fibers having a basis weight of 50 to 1000 g / m ² is preferable because it can be obtained at a low cost and the strength and rigidity of the lightweight cement panel 1 can be greatly improved. The surface reinforcing sheet 13 only needs to be provided embedded in the surface resin layer 4A, and is preferably provided embedded in the middle of the surface resin layer 4A in the thickness direction. It can also be embedded in the main body 2 side portion.

  As described above, when the surface reinforcing sheet 13 is embedded in the surface resin layer 4A, the strength and rigidity against bending and twisting of the lightweight cement panel 1E can be further increased, and the protection performance of the panel body 2 is further improved. it can. Moreover, since the surface reinforcing sheet 13 is composed of a woven fabric or a nonwoven fabric, the adhesion of the surface resin layer 4A disposed on the front surface side and the back surface side of the surface reinforcing sheet 13 can be sufficiently ensured.

  The manufacturing method of the lightweight cement panel 1E will be described. First, the foamable synthetic resin is filled in the lower part of the mold for product that can be sealed and has a slightly larger internal space than the panel body 2, and the foamed synthetic resin is filled with the foamed synthetic resin. A surface reinforcing sheet 13 made of a woven or non-woven fabric having substantially the same planar dimensions as the internal space of the product mold is placed in an embedded state. Next, the panel body 2 is positioned and placed at the center of the product mold, and then the foamed synthetic resin is filled on the outer peripheral side and the upper side of the panel body 2, and the foamed synthetic resin is filled with the product mold. A surface reinforcing sheet 13 made of a woven fabric or a non-woven fabric having substantially the same planar dimensions as the internal space is disposed in an embedded state. Next, the foamed synthetic resin filled is foamed and cured in a state where the product mold is sealed, so that the side end surface of the panel body 2 is covered with the side foam layer 4 and the surface reinforcing sheet 13 is embedded. The light-weight cement panel 1E is manufactured by covering the surface of the panel body 2 and the side foam layer 4 with the surface resin layer thus formed.

  Another manufacturing method is to use a sealable product mold having an internal space of the same size as the lightweight cement panel 1E, and fill the lower part of the product mold with a foamable synthetic resin, A surface reinforcing sheet 13 made of a woven fabric or a non-woven fabric having substantially the same planar dimensions as the internal space of the product mold is placed in the synthetic resin in an embedded state. Next, after placing the panel body 2A having the side foam layer 4 formed on the outer periphery in a product mold, the foam body is filled with a foaming synthetic resin, and the foamed synthetic resin. A surface reinforcing sheet 13 made of a woven fabric or a non-woven fabric having substantially the same planar dimensions as the internal space of the product mold is disposed in an embedded state. Next, it is also possible to adopt a manufacturing method in which the foamable synthetic resin is foamed and cured while the product mold is sealed.

  In addition, like the lightweight cement panel 1H shown in FIG. 8, the surface protective layer 3 and the edge part protective layer 5 can also be provided with respect to the said lightweight cement panel 1E. In order to manufacture such a lightweight cement panel 1H, in the product mold, in the same manner as described above, with the sheet, film or board serving as the surface protective layer 3 disposed on the inner surface of the product mold. The panel body 2 and the side reinforcing sheet 14 are integrally covered with the surface resin layer 4A and the side foam layer 4, and then a sealing tape having water tightness is attached to the outer peripheral end of the molded product. It can be manufactured by forming the end protective layer 5.

  FIG. 6 is a cross-sectional view showing another embodiment of the lightweight cement panel 1 according to the present invention. In the lightweight cement panel 1F according to this embodiment, a side reinforcing sheet 14 made of woven fabric or non-woven fabric is embedded between the side end surface 2b of the panel body 2 and the side foam layer 4 in the lightweight cement panel 1E. In other respects, the construction is the same as that of the lightweight cement panel 1E. In FIG. 6, structures that are the same as those in FIG. 5 are given the same reference numerals, and descriptions thereof are omitted.

The side reinforcing sheet 14 is made of a fiber material such as polyvinyl alcohol fiber (vinylon), polyolefin fiber such as polypropylene fiber or polyethylene fiber, aramid fiber, carbon fiber, steel fiber, glass fiber, etc., similarly to the surface reinforcing sheet. A woven or non-woven fabric can be employed. In particular, a chopped strand mat made of glass fibers having a basis weight of 50 to 1000 g / m ² is preferable because it can be obtained at a low cost and the strength and rigidity of the lightweight cement panel 1 can be greatly improved.

  Thus, when the side reinforcing sheet 14 is provided in the side end face 2b of the panel body 2 in an embedded state, the strength and rigidity against bending and twisting of the lightweight cement panel 1F can be further enhanced. In addition, also about the lightweight cement panels 1A-1E, the side reinforcement sheet 14 can be provided in an embedded state between the panel body 2 and the side foam layer 4, and the strength rigidity of the panel against torsion can be improved.

  The manufacturing method of the lightweight cement panel 1F will be described. First, a panel body 2 made of lightweight cement is manufactured in the same manner as the panel body 2 of the lightweight cement panel 1A, and a strip-shaped side reinforcing sheet 14 is attached to the side end face 2b. And temporarily fix with temporary fixing tape. Next, the foamable synthetic resin is filled in the lower part of the product mold having a slightly larger internal space than the panel main body 2, and the surface reinforcing sheet 13 having the same area (planar shape) as the panel main body is provided. It is embedded in a foamable synthetic resin. Next, the panel body 2 on which the side reinforcing sheet 14 is temporarily fixed is positioned and placed at the center of the product mold, and then the outer peripheral side and the upper side of the panel body 2 are filled with foaming synthetic resin, The foamable synthetic resin is filled so as to wrap the main body 2, and the surface reinforcing sheet 13 is embedded in the foamable synthetic resin on the upper side of the panel main body 2. Next, a lightweight cement panel 1F is manufactured by foaming and curing the filled foamable synthetic resin in a state where the product mold is sealed.

  As another manufacturing method, as shown in FIG. 13, a large block-shaped porous molded body 7A made of lightweight cement is molded, and the reinforcing sheet 14B is used as a material of the side reinforcing sheet 14 of the porous molded body 7A. Temporarily fixed to the outer peripheral side with an adhesive or a temporary fixing tape 15, and this is loaded into the center of the foam molding mold, and a foamable synthetic resin is placed in the gap between the porous molded body 7 A and the foam molding mold. As shown in FIG. 14, the outer peripheral side surfaces of the porous molded body 7A and the reinforcing sheet 14B are covered with the side foam layer 4, and this is a plate having a desired thickness and size. The panel main body 2B having the side foam layer 4 in which the side reinforcing sheet 14 is embedded in the outer peripheral portion is manufactured. In the same manner as described above, the foamable synthetic resin is filled in the lower part of the product mold, and the surface reinforcing sheet 13 is embedded in the foamable synthetic resin. Next, after placing the panel body 2B on the product mold, the upper surface of the panel body 2B is filled with the foaming synthetic resin, and the surface reinforcing sheet 13 is provided in the foaming synthetic resin so as to be embedded. Next, the lightweight cement panel 1F can be manufactured by foaming and curing the filled foamable synthetic resin in a state where the product mold is sealed.

  In addition, the surface protective layer 3 and the edge part protective layer 5 can also be provided with respect to the said lightweight cement panel 1F like the lightweight cement panel 1J shown in FIG. When manufacturing such a lightweight cement panel 1J, the lower part in the product mold is formed in the same manner as described above with the sheet, film, or board serving as the surface protective layer 3 disposed on the inner surface of the product mold. The foamable synthetic resin is filled therein, and the surface reinforcing sheet 13 is embedded in the foamable synthetic resin, and then the panel body 2B is placed on the product mold. Next, the foamable synthetic resin is filled on the upper side of the panel main body 2B, and the surface reinforcing sheet 13 is embedded in the foamable synthetic resin, and then the foamed foam is filled in a state where the product mold is sealed. It is possible to manufacture by forming the end protective layer 5 by foaming and curing the synthetic resin and finally sticking a sealing tape having water tightness to the outer peripheral end.

  Further, in manufacturing the lightweight cement panel 1E (FIG. 5), 1F (FIG. 6), and 1H (FIG. 8), after manufacturing the panel body 2 whose side end surface is covered with the side foam layer 4, the surface reinforcing sheet 13 is manufactured. When covering the surface of the panel body 2 and the side foam layer 4 with the surface resin layer 4A embedded with foam, instead of foaming and curing the foamable synthetic resin in the product mold, the panel body 2 is foamed. A surface resin layer 4A in which the surface reinforcing sheet 13 is embedded by stacking the surface reinforcing sheet 13 made of a woven or non-woven fabric to which an adhesive synthetic resin is attached, heating and pressing to cure the foamable synthetic resin. You may make it coat | cover the surface of the panel main body 2 and the side part foam layer 4.

  FIG. 7 is a cross-sectional view showing another embodiment of the lightweight cement panel 1 according to the present invention. In the lightweight cement panel 1G according to this embodiment, the surface resin layer 4A in the lightweight cement panel 1F is omitted, and the surface reinforcing sheet 13 is integrally bonded to the panel main body 2 with an adhesive. It is comprised similarly to the lightweight cement panel 1F. In this case, the lightweight cement panel 1G can be easily manufactured by adhering the surface reinforcing sheet 13 to the surface of the panel main body 2B manufactured as described above in an adhesive layer. In addition, like the lightweight cement panel 1K shown in FIG. 10, the surface protective layer 3 and the edge part protective layer 5 can also be provided with respect to the lightweight cement panel 1G. The surface protective layer 3 can be adhered to the panel body 2 together with the surface reinforcing sheet 13, and the end protective layer 5 can be formed by sticking a sealing tape having watertightness.

  The lightweight cement panel 1 of the present invention as described above is widely used in the construction field and civil engineering field, such as for concrete formwork, building wall materials, flooring materials, ceiling materials, partitions, and heat insulating materials incorporated in them. it can. For example, what is shown in FIG. 15 is an example used as a concrete formwork panel. The concrete formwork 20 is nailed with a nail n to a predetermined position in the periphery and in the middle of the back surface of the lightweight cement panel 1 of the present invention which serves as a dam plate. The lightweight cement panel 1 serving as a dam plate has sufficient strength to withstand the cast concrete pressure, and is lightweight and easy to handle, and more frequently than a wooden dam plate, It will also lead to a reduction in construction costs for concrete placement work. In addition, the crosspiece 21 may be a porous body obtained by foaming cement as in the lightweight cement panel 1.

It is sectional drawing which shows one Embodiment of the lightweight cement panel of this invention. It is sectional drawing of the panel provided with the surface protection layer which consists of paper on which the non-foaming synthetic resin was laminated which is other embodiment of the lightweight cement panel of this invention. It is sectional drawing of the panel provided with the surface protection layer which consists of paper to which the non-foaming synthetic resin film was adhere | attached which is further another embodiment of the lightweight cement panel of this invention. It is sectional drawing of the panel which coat | covered the surface of the panel main body with the surface resin layer, and provided the surface protective layer on it as further another embodiment of the lightweight cement panel of this invention. It is sectional drawing of the panel by which the surface reinforcement sheet was provided in the surface resin layer in the embedding form which is further another embodiment of the lightweight cement panel of this invention. Sectional drawing of the panel which is still another embodiment of the lightweight cement panel of this invention, the surface reinforcement sheet was provided in the embedding form in the surface resin layer, and the side reinforcement sheet was provided in the embedding form between the panel main body and the side surface foaming layer. It is. FIG. 6 is a cross-sectional view of a panel in which a surface reinforcing sheet is bonded to a panel body with an adhesive, and a side reinforcing sheet is embedded in an embedded manner between the panel body and a side foam layer, which is still another embodiment of the lightweight cement panel of the present invention. is there. It is sectional drawing of the panel by which the surface reinforcement sheet was provided in the surface resin layer in the embedding form which is further another embodiment of the lightweight cement panel of this invention. Sectional drawing of the panel which is still another embodiment of the lightweight cement panel of this invention, the surface reinforcement sheet was provided in the embedding form in the surface resin layer, and the side reinforcement sheet was provided in the embedding form between the panel main body and the side surface foaming layer. It is. In another embodiment of the lightweight cement panel of the present invention, the surface protective layer and the surface reinforcing sheet are bonded to the panel body with an adhesive, and the side reinforcing sheet is embedded in the embedded form between the panel body and the side foam layer. It is sectional drawing of a panel. It is explanatory drawing when cutting a panel main body from the block-shaped porous molded object which is other embodiment of the manufacturing method of the panel main body of the lightweight cement panel of this invention. It is explanatory drawing when cutting a panel main body from the block-shaped porous molded object which coat | covered the side part foam layer which is further another embodiment of the manufacturing method of the panel main body of the lightweight cement panel of this invention. It is explanatory drawing of the block-shaped porous molded object to which the side surface reinforcement sheet was temporarily fixed which is further another embodiment of the manufacturing method of the panel main body of the lightweight cement panel of this invention. It is explanatory drawing when a panel main body is cut out from the block-shaped porous molded object which is the same embodiment, and the surface part of the side reinforcement sheet was further coat | covered with the side part foam layer. It is a perspective view which shows one Embodiment of the concrete formwork using the lightweight cement panel of this invention, (a) is a surface side, (b) is a back surface side.

Explanation of symbols

1, 1A, 1B, 1C, 1D, 1E Lightweight cement panel 1F, 1G, 1H, 1J, 1K Lightweight cement panel 2, 2A, 2B Panel body 2a Panel body surface 2b Panel body side end surface 3 Surface protective layer 4 side Partial foam layer 4A Surface resin layer 5 End protective layer 6 Reinforcing fiber 7, 7A Porous molded body (lightweight cement)
DESCRIPTION OF SYMBOLS 10 Non-foaming synthetic resin layer 11 Paper 12 Adhesive 13 Surface reinforcement sheet 14 Side reinforcement sheet 14B Reinforcement sheet 15 Temporary fixing tape 20 Concrete formwork 21 Pier

Claims (22)

  A lightweight cement panel in which a side end face of a panel body made of lightweight cement is integrally covered with a side foamed layer made of foamed synthetic resin and has a specific gravity in the range of 0.5 to 2.0. .   The panel body is composed of a porous molded body in which a kneaded product obtained by kneading foam formed by cement, water, reinforcing fibers, and a foaming agent is filled in a closed cement mold and cured and cured. The lightweight cement panel according to claim 1, wherein the reinforcing fiber and foam are contained in a dispersed state in the body, and the specific gravity is in the range of 0.5 to 2.0.   The lightweight cement panel according to claim 1 or 2, wherein a surface reinforcing sheet made of a woven fabric or a nonwoven fabric is integrally coated on a surface of the lightweight cement panel.   The lightweight cement panel according to claim 3, wherein a surface resin layer made of a synthetic resin is integrally coated on a surface of the lightweight cement panel, and the surface reinforcing sheet is embedded in the surface resin layer.   The lightweight cement panel according to any one of claims 1 to 4, wherein a side reinforcing sheet made of a woven fabric or a nonwoven fabric is provided in an embedded state between a side end surface of the panel body and a side foam layer. At least one of a lightweight cement panel according to any one of claims 3 to 5 comprising a glass fiber nonwoven fabric having a basis weight of 50 to 1000 g / m ² of said surface reinforcing sheet and the side reinforcing sheet.   The lightweight cement panel according to any one of claims 1 to 6, wherein a surface of the lightweight cement panel is integrally covered with the surface protective layer.   The lightweight cement panel according to claim 7, wherein the surface protective layer is made of a non-foamed synthetic resin.   The lightweight cement panel according to any one of claims 1 to 8, wherein an outer peripheral end portion of the lightweight cement panel is integrally covered with an end protective layer.   The lightweight cement panel according to any one of claims 1 to 9, which is for construction or civil engineering.   The lightweight cement panel according to claim 10, which is used for concrete formwork. A kneaded product obtained by kneading foam formed by cement, water, reinforcing fiber and foaming agent is filled into a closed cement mold and cured and solidified. A panel body made of lightweight cement containing reinforcing fibers and foam in a dispersed state and having a specific gravity in the range of 0.5 to 2.0;
A side foam layer made of a synthetic foam resin that integrally covers a side end surface of the panel body;
A side reinforcing sheet made of a woven fabric or a non-woven fabric embedded in a side end surface of the panel main body and the side foam layer; and
A surface resin layer made of a synthetic resin that integrally covers the surfaces of the panel body and the side foam layer; and
A surface reinforcing sheet made of a woven fabric or a non-woven fabric embedded in the surface resin layer; and
A lightweight cement panel for concrete formwork characterized by comprising   A foamable synthetic resin is filled in the lower part of a sealable product mold having a slightly larger internal space than the panel body, and the foamed synthetic resin has a woven fabric having substantially the same plane dimensions as the internal space of the product mold. Or a surface reinforcing sheet made of non-woven fabric is placed in an embedded state, and then the panel body is positioned and placed at the center of the product mold, and then the outer peripheral side and upper side of the panel body are filled with foaming synthetic resin The foamed synthetic resin is filled with a surface reinforcing sheet made of a woven or non-woven fabric having the same plane dimensions as the interior space of the product mold, and then filled with the product mold sealed. The side end surface of the panel body is covered with the side foam layer and the surface of the panel body and the side foam layer is covered with the surface resin layer in which the surface reinforcing sheet is embedded. This Method for manufacturing a lightweight cement panel according to claim.   A surface reinforcing sheet is embedded in the inner surface of the mold for product, with the side end face of the panel body covered with a side foam layer in a state where a film, a sheet or a board serving as a surface protection layer is previously arranged. The surface of the panel main body and the side foam layer is covered with a surface resin layer, and a film, sheet or board that serves as a surface protective layer is bonded to the panel main body with a foamable synthetic resin constituting the surface resin layer. Item 14. A method for producing a lightweight cement panel according to Item 13.   The method for manufacturing a lightweight cement panel according to claim 13 or 14, wherein a side reinforcing sheet made of a woven fabric or a nonwoven fabric is fixed to the side end surface in advance as the panel main body.   As a step of producing a panel body made of the lightweight cement, a step of filling a kneaded product obtained by kneading foam pre-formed with cement, water, reinforcing fibers, and a foaming agent into a closed mold for cement and curing and solidifying. The manufacturing method of the lightweight cement panel in any one of Claims 13-15 provided.   As a process for producing a panel body made of the lightweight cement, a kneaded product obtained by kneading foam pre-formed with cement, water, reinforcing fibers, and a foaming agent is filled in a closed mold for cement and cured and solidified. The manufacturing method of the lightweight cement panel in any one of Claims 13-15 provided with the process of manufacturing a porous molded object, and the process of slicing the said porous molded object and manufacturing a panel main body.   Filling a kneaded mixture of foams preformed with cement, water, reinforcing fibers and foaming agent into a closed cement mold, and curing and solidifying to produce a block-shaped porous molded body; In a closed foam molding mold, a foamable synthetic resin is filled between the outer peripheral side surface of the porous molded body and the foam molding mold and foam-cured, and the outer peripheral side surface of the porous molded body is foamed synthetic resin. A panel body having a set thickness in which a porous molded body covered with a foamed synthetic resin layer is sliced and the side end faces are covered with side foamed layers made of the foamed synthetic resin. And a foamable synthetic resin is filled in the lower part of the mold for product that can be sealed, and the foamed synthetic resin is made from a woven or non-woven fabric having substantially the same plane dimensions as the interior space of the product mold. A surface reinforcing sheet Next, the panel body is positioned and placed in the product mold, and then the upper side of the panel body is filled with a foaming synthetic resin, and the foaming synthetic resin is substantially the same as the internal space of the product molding die. A surface reinforcing sheet made of a woven or non-woven fabric having a planar dimension is placed in an embedded state, and then the foamable synthetic resin is foamed and cured in a state where the product mold is sealed, whereby the surface reinforcing sheet is embedded. A method for producing a lightweight cement panel, wherein the surface of the panel body and the side foam layer is covered with a surface resin layer.   Filling a kneaded mixture of foams preformed with cement, water, reinforcing fibers and foaming agent into a closed cement mold, and curing and solidifying to produce a block-shaped porous molded body; Temporarily fixing a reinforcing sheet made of woven or non-woven fabric on the outer peripheral side surface of the porous molded body, and the outer peripheral side surface of the porous molded body temporarily fixing the reinforcing sheet in a sealed foam molding mold and foam molding Filling a foamable synthetic resin between molding dies for foaming and curing, and integrally covering the reinforcing sheet and the foamed synthetic resin layer on the outer peripheral side surface of the porous molded body; and the reinforcing sheet and the foamed synthetic resin layer A step of slicing the porous molded body covered with the above and manufacturing a panel body having a set thickness in which the side end face is covered with the side reinforcing sheet made of the reinforcing sheet and the side foam layer made of the foamed synthetic resin. And dense A foamable synthetic resin is filled in the lower part of a possible product mold, and a surface reinforcing sheet made of a woven or non-woven fabric having substantially the same planar dimensions as the internal space of the product mold is embedded in the foamable synthetic resin. Next, the panel body is positioned and placed in the product mold, and the upper side of the panel body is filled with a foaming synthetic resin, and the foaming synthetic resin is filled with the internal space of the product molding die. A surface reinforcing sheet made of woven or non-woven fabric having substantially the same plane dimensions is arranged in an embedded state, and then the foamable synthetic resin is foamed and cured in a state where the product mold is sealed, so that the surface reinforcing sheet is obtained. A method for producing a lightweight cement panel, wherein the surface of the panel main body and the side foam layer is covered with an embedded surface resin layer.   In the step of coating the panel main body and the side foam layer with a surface resin layer, a film, a sheet or a board serving as a surface protective layer is arranged in advance on the inner surface of a mold for product that can be sealed. In the mold, the surface of the panel body is integrally covered with a surface resin layer made of foamed synthetic resin, and at the same time, a film, a sheet or a board serving as a surface protective layer is bonded to the panel body with the surface resin layer. Item 20. A method for producing a lightweight cement panel according to Item 18 or 19.   After the step of manufacturing the panel body, when the surface of the panel body and the side foam layer is covered with the surface resin layer in which the surface reinforcing sheet is embedded, the foamable synthetic resin is foam-cured in the product mold. Instead of letting the surface of the panel body, a surface reinforcing sheet made of a woven or non-woven fabric with the foamable synthetic resin attached thereto is stacked, heated, and pressure-molded to foam and cure the foamable synthetic resin. The method for producing a lightweight cement panel according to claim 18 or 19, wherein the surface of the panel body and the side foam layer is covered with a surface resin layer in which a reinforcing sheet is embedded. The manufacturing method of the lightweight cement panel in any one of Claims 13-21 provided with the process of coat | covering the outer peripheral edge part of the said panel main body and a side part foam layer with an edge part protective layer.

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