JP2637616B2 - Manufacturing method of inorganic foam board - Google Patents

Description

The present invention relates to a method for producing an inorganic foam board. More particularly, the present invention relates to a method for producing an inorganic foam board which can continuously produce an accessory made of an inorganic foam board, that is, a corner at an outer corner or an inner corner of a building by a single firing from raw materials.

[Problems to be Solved by Conventional Techniques and Inventions] Inorganic foam boards are easy to measure and handle, and have heat retention,
Due to its excellent fire resistance and durability, it has recently been used for prefabricated houses and the like.

Such an inorganic foamed board can be easily manufactured by laminating an inorganic granulated foamed raw material on a refractory and heat-resistant transporting belt installed in a furnace and subjecting the raw material to heat foaming.

On the other hand, when a house or the like is actually constructed using an inorganic foamed board, a substantially L-shaped member called a so-called corner role is required because a corner is formed at an inside corner or a corner at an outside corner.
In the construction of the building, it is preferable to use the corner material with the same material as the wall material, but it has been very difficult to continuously produce the corner material from the granulated raw material. That is, conventionally, for example, a flat plate that has been fired once is cut,
The two flat plates were put into a mold made of a refractory material and reheated, and a corner part was produced using the softening and bending of the foamed plate (see Japanese Patent Application No. 2-63772). At the same time as firing, uniform heat transfer cannot be performed when reheating because the foamed board is an object having high heat insulating properties. For this reason, cracks were generated during the temperature raising process, and the temperature raising temperature had to be reduced slowly in order to prevent this. As a result, there is a problem that time loss is extremely large.

In view of the circumstances described above, an object of the present invention is to provide a method for producing an inorganic foam plate that can continuously produce corner portions from raw materials in a single firing.

[Means for Solving the Problems] The method for producing an inorganic foamed board of the present invention is a method for producing an inorganic foamed board by heating and cooling an inorganic foamed granulated material on a heat-resistant transporting belt running in a furnace. A step of heating and foaming the inorganic foamable granules provided in a layer on the heat-resistant transporting zone, and forming a mold comprising an upper concave mold and a plurality of lower convex molds that can be raised and lowered. Using, the step of raising and lowering the inorganic foam plate transferred onto the plurality of lower convex molds, pressing the inorganic foam plate, and cooling the mountain-shaped inorganic foam plate. Features.

[Examples] Hereinafter, a method for producing an inorganic foam board of the present invention (hereinafter, referred to as a production method) will be described with reference to the accompanying drawings.

FIG. 1 is an explanatory longitudinal sectional view of one example of a firing furnace for carrying out the production method of the present invention.

In FIG. 1, (1) is a heat-resistant endless transfer belt disposed in a firing furnace (K), which is made of a heat-resistant material such as a stainless steel mesh belt, a steel belt, and a ceramic net. Things are used. The transport band (1) is run by a drive roll (2).

A supply hopper (3) is provided above the transport zone (1) in front of the firing furnace (K) to supply inorganic granules that are fired and foamed by heating onto the transport zone (1). As the inorganic granulated material, generally, Al ₂ O ₃ —SiO ₂ based minerals such as acid clay, shirasu, perlite, anti-firestone, feldspar, etc. are used as main raw materials, and soda ash, sodium nitrate, glass powder, boric acid, borax A granulated material obtained by granulating an auxiliary material such as a melting material such as dolomite, a foaming agent such as SiC, barium carbonate, and potassium carbonate is used. Further, (4) is a hopper for supplying granules for the surface decorative layer formed on the base layer. As the powdery raw material for the surface decorative layer, for example, a glaze such as a vitreous powder such as frit or feldspar, which is atomized to a particle size of about 0.5 to 2.0 mm by a bread granulator or the like is used. The number of the supply hoppers (3) and (4) may be appropriately selected according to the number of layers of the inorganic foam plate (5). Although not shown, it may be embedded in an inorganic granule such as a metal net for reinforcement.

On the side wall of the firing furnace (K), heating burners (6) (see FIG. 2) are provided at appropriate intervals.

In the firing furnace (K) shown in FIG. 1, a heating zone, a firing zone, a rapid cooling zone, a slow cooling zone, a heating / forming / cooling zone, and a cooling zone are formed.

The temperature rising zone is a zone for extracting moisture and organic substances in the raw material by heating, and is generally heated to 350 to 580 ° C., depending on the type of the raw material, the charge thickness and the like.

The inorganic expandable granules sent to the firing zone via the temperature raising zone are sequentially heated by the burner (6) to expand. The heating temperature varies depending on the type and composition of the raw materials, but is generally raised to 880 ° C.

In the example shown in FIG. 1, a quenching zone is provided immediately after the sintering zone, and the fired inorganic foam plate (5) is usually press-formed by a cooling roll (13) cooled by circulation of water. Is done.

The inorganic foam plate (5) formed by pressure by the cooling roll (13) is transferred to a slow cooling zone where the temperature is usually set to about 600 to 500 ° C, and is gradually cooled.

The inorganic foam plate (5) leaves the transport zone (1) in the middle of the slow cooling zone and is transported by the rotating roll (7) installed in the zone (A). In this case, in order to separate the inorganic foam plate (5) more quickly from the transport band (1), the moving speed by the rotating roll (7) can be made faster than the moving speed by the transport band (1).

Next, the inorganic foam plate (5) that has been gradually cooled moves to a heating / forming / cooling zone ((B) zone) where heating, molding, and cooling are performed.

(B) When the inorganic foam board (5) completely enters the zone,
The rotating roll (7) installed in the zone (B)
Stops. Next, the automatic door (8a) separating the zone (B) and the zone (A) is closed. At this time, the automatic door (8b) separating the zone (B) and the zone (C) is also closed. The arrival of the inorganic foam plate (5) at a predetermined position can be detected by, for example, a photoelectric tube or the like.
It is only necessary to stop the automatic door and close the automatic door (8a).

(B) The inorganic foam board (5) which has entered the zone is reheated to a temperature at which a bending process described later can be performed. The heating temperature varies depending on the thickness of the inorganic foam board and the softening temperature of the surface decorative layer, but is usually about 550 to 700 ° C. After the heating, the plurality of lower convex molds (9) disposed below the inorganic foam plate (5) and between the rotating rolls (7) are raised by the action of the pressing cylinder (12), and the inorganic foam is raised. The plate (5) is lifted and pressed against the upper concave mold (10) fixed upward (see FIG. 2. In FIG. 2, the lower convex mold (9) is in a state before ascending). It is in). The press cylinder (12) is driven by hydraulic pressure or the like, and usually has a pressing force of about 5 to 100 kg / cm ² and a pressing speed of about 0.2 to 1 m / min.

The inorganic foam plate (5) is formed into a chevron shape according to the shape of the mold by the mold pressing action. The shape of the mold is appropriately selected according to the shape and radius required for the corner part. The present invention is not particularly limited in the present invention. The lower convex mold (9) is preferably arranged to have a pitch of 10 to 30 cm in consideration of moldability. Also, upper concave mold (10) and lower convex mold (9)
In order to facilitate the release of the inorganic foam plate (5) from the mold, it is necessary to cool the internal foam plate (5) to about 50 to 100 ° C. lower than the ambient temperature by circulating cooling water inside. preferable. In addition, it is preferable to stop the operation of the burner at the time of lowering the lower convex mold (9) and at the time of pressing, in order to equalize the pressing conditions and protect the elevating section.

When the lower convex mold (9) is raised to a predetermined position and the inorganic foam plate (5) is pressed (press-formed), the exhaust fan (11) starts operating, and the (B) zone Exhaust of the heated air, that is, cooling is performed. Then, after cooling while applying pressure for a predetermined time (usually about 2 to 10 minutes), the lower convex mold (9) is processed, and the inorganic foam plate (5) formed into a mountain shape is turned into a rotating roll (7). Place on top. Then, the automatic door (8b) provided between the zone (B) and the zone (C) is released, and the rotating roll (7) in the zone (B) is driven to drive the inorganic foam plate (5). ) To (C) zone.

(C) The inorganic foam plate (5) which has entered the zone is gradually cooled, and is eventually carried out of the furnace. During this time, the inorganic foam board (5) is cooled while drawing a gentle downward curve,
When transported outside the furnace, it is usually cooled to about 400 to 600 ° C.

By manufacturing by the above-described method, it is possible to continuously obtain corner portions having the same quality as the flat plate in design from the granulated raw material. If such a corner accessory is constructed in a building, the aesthetic appearance can create an atmosphere (a sense of continuity or a sense of unity) not seen in a conventional building.

[Effects of the Invention] As described above, according to the production method of the present invention, an L-shaped corner or the like having the same quality as a flat plate can be continuously produced from inorganic granules by firing once. In addition, since the heating and molding are performed in the slow cooling region where the high temperature state 9 is still maintained, there is an effect that energy for heating can be reduced and energy can be saved.

[Brief description of the drawings]

FIG. 1 is an explanatory longitudinal sectional view of an example of a firing furnace for carrying out the production method of the present invention, and FIG. 2 is a partial sectional view taken along line (I)-(I) of FIG. (Main symbols in the drawings) (K): Firing furnace (1): Endless transport zone (3), (4): Supply hopper (5): Inorganic foam plate (6): Burner (7): Rotating roll (9) : Lower convex mold (10): Upper concave mold

Claims (1)

(57) [Claims] 1. A method for producing an inorganic foamed plate by heating and cooling an inorganic foamed granulated material on a heat-resistant transport zone running in a furnace, wherein the inorganic foamed granules are provided in layers on the heat-resistant transport zone. The step of heating and foaming the formed inorganic foamable granules, and using a molding die comprising an upper concave mold and a plurality of lower convex molds that can be raised and lowered, were transferred onto the plurality of lower convex molds. A method for producing an inorganic foam board, comprising: a step of raising and lowering the inorganic foam board to press-mold the inorganic foam board; and a step of cooling the mountain-shaped inorganic foam board.