JP2931746B2 - Method for producing inorganic molded plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an inorganic molded plate having an uneven pattern on one or both sides.

[0002]

2. Description of the Related Art In a dry or semi-dry production method of an inorganic molded plate, as shown in FIG. 7, a raw material mixture mainly composed of a self-hardening inorganic material such as cement and a wood reinforcing material.
(10) is sprayed on a lower mold plate (3) having a concavo-convex pattern (3A) on the mold surface to form a mat, and the upper mold plate is brought into contact with the mat to perform compression hardening and curing to form a plate. Mold into Conventionally,
When spraying the raw material mixture (10) on the lower template (3), wind is selected by blowing air in a direction (arrow arrow) opposite to the moving direction of the lower template (3) (arrow 板), fine raw material mixture (10) is allowed to fall in from the rear, coarse raw material mixture (10) is by dropping in from the front, to increase the density of the lower surface or the front surface or back surface section, the density of the inner part There has been provided a method of obtaining a molded plate which is lowered to make the front and back surfaces dense and lightweight.

[0003]

However, according to the above-mentioned conventional method, however, the projections (31A) of the concavo-convex pattern (3A) of the lower mold plate (3) are provided.
The back rear side is a blind spot of the flow of raw material mixture (10) by wind, the packing density of the raw material mixture (10) is lowered in this section,
Even in the resulting molded plate, the surface structure of this portion is roughened, and the mechanical strength and water resistance are reduced, and the number of burrows is increased and the appearance is deteriorated. Produces a point.

[0004]

According to the present invention, as a means for solving the above-mentioned conventional problems, an uneven pattern (3A) is formed on a mold surface.
The lower die plate (3) is moved along the line, the main blower having
(7) from the direction opposite to the moving direction of the lower mold plate (3)
The lower mold plate (3) is moved by blowing air and by the auxiliary blower (7A).
Forming a mat from moving direction by dispersing a raw material mixture consisting mainly of a by blowing wind self-hardening inorganic materials and wood reinforcement on the lower mold plate with the wind selection (3) in the lower mold plate (3) When the upper mold plate (11) is brought into contact with the mat and subjected to compression hardening to produce an inorganic molded plate, at least a wood reinforcement of 2 mm or less is used as a wood reinforcing material for the front and back layers of the inorganic molded plate. 30 powder
An object of the present invention is to provide a method for producing an inorganic molded plate using 5 to 15% by weight of a material containing 70 to 70% by weight. In the present invention, branching and / or
Or wood fiber bundles that have been bulked by bending and / or bending, rigid bamboo or hemp fibers or
It is desirable to use wood chips . Hereinafter, the present invention will be described in detail. The inorganic molded plate of the present invention is mainly made of a self-hardening inorganic material and a wood reinforcing material.

[Self-hardening inorganic material] Examples of the self-hardening inorganic material used in the present invention include cements such as Portland cement, blast furnace cement, silica cement, fly ash cement, alumina cement, gypsum dihydrate, hemihydrate gypsum, and anhydrous gypsum. Mixtures of activated lime-containing substances such as gypsum, slaked lime, quick lime and silica-containing substances such as silica sand, silica stone sand, silica fume, blast furnace slag, fly ash, shirasu balloon, perlite, etc., the above cements and the above silica And the like are exemplified.The cements are hardened by a hydration reaction in the presence of water, and the activated lime-containing material and the silicic acid-containing material mixture become a cured product of calcium silicate by a hydrothermal reaction. .
In the case of the cement-silicic acid-containing substance mixture, the weight ratio of the cement and the silicic acid-containing substance is usually 40:60 to 70: 3.
Mix to about 0.

[Wood Reinforcing Material] Examples of the wood reinforcing material used in the present invention include wood flour, wood fiber, pulp, wood fiber bundle, wood wool, wood chip, bamboo fiber, hemp fiber and the like. Particularly desirable as a wood reinforcement for the core layer is a bundle of wood fibers that has been bulked by branching and / or bending and / or bending. The bulky wood fiber bundle desirably has a main trunk diameter of about 0.1-2.
0mm, the actual length of the main trunk is about 2-35mm, more preferably 10mm
３０30 mm and the bulk specific gravity is about 0.03-0.05.
g / cm ³ . To manufacture the bulky wood fiber bundle, wood is immersed in a chemical such as sodium hydroxide, sodium sulfite, calcium sulfite, or the wood is heated with steam, or the chemical immersion and steam heating are used in combination. By swelling without completely dissolving ligulin, hemicellulose, resin, etc., which serves as a binder for woody monofilaments contained in wood, the above binder is left and defibrated. Yes,
The diameter of the binder is larger than that of pulp fibers which are definitively removed by removing lignin almost completely. The defibration is performed by, for example, a grinding disk, and the degree of defibration is adjusted by adjusting the interval between the grinding disks. The bulky wood fiber bundles are branched and / or curved and / or bent so that the excluded volume is large, thus providing a bulky and low density core layer, but the interlocking is strong but the density is small. A structure with high strength is obtained. Other desirable materials for the wood reinforcing material in the core layer are rigid fibers such as wood chips , bamboo fibers, and hemp fibers. Like the bulky wood fiber bundle, the rigid fiber gives a structure having a small density but a large strength due to its rigidity.

[Third component] In addition to the self-hardening inorganic material and the wood reinforcing material, the inorganic molded plate of the present invention further comprises magnesium chloride,
Magnesium sulfate, calcium chloride, calcium sulfate,
Hardening accelerators such as sodium aluminate, potassium aluminate, aluminum sulfate, and water glass; mineral powders such as vermiculite and bentonite; water repellents such as wax, paraffin and silicone; reinforcing materials such as synthetic resin emulsions; Plastic beads, plastic foams and the like may be added. The above examples do not limit the invention.

[Composition of Inorganic Molded Plate] In the inorganic molded plate of the present invention, the density of the front and back layers is increased to form dense front and back surfaces having high strength and water resistance, and the density of the core layer is decreased. It is desirable to have a lightweight and cushioning property. For this purpose, use wood flour of 2 mm or less as a wood reinforcement
It is preferable to use one containing 0 to 70% by weight, and it is preferable to use a bulky wood fiber bundle, a rigid fiber such as a bamboo fiber, a hemp fiber or the like as described above as a wood reinforcing material for the core layer. Inorganic fine hollow bodies such as ash, shirasu balloon, perlite and glass balloon, and organic hollow bodies such as expandable thermoplastic plastic beads and plastic foam may be used. In consideration of the noncombustibility of the molded plate, it is preferable to use an inorganic fine hollow body rather than an organic hollow body. In the inorganic molded board of the present invention, the wood reinforcing material is usually added in a range of 5 to 15% by weight. If the added amount of the wood reinforcing material is less than 5% by weight, the reinforcing effect is small, and if it exceeds 15% by weight, the fire resistance is reduced. Desirable compositions of the main materials of the front and back layers and the core layer are as follows. Front and back layers: Cement and activated lime-containing substance 30 to 60% by weight Silicic acid-containing substance 30 to 55 〃 Wood flour (sieve 2 mm or less) 5 to 10 〃 Other wood reinforcing material 5 to 10 芯 Core layer: Cement and Activated lime-containing material 30-60% by weight Silicic acid-containing material 25-55 Hollow body 0-15 Wood reinforcement 5-15

[Manufacture of Inorganic Molded Plate] As a method of manufacturing an inorganic molded plate of the present invention, it is desirable to adopt a dry manufacturing method in which the steps can be easily made continuous and the equipment is simple. In step 1 of the dry production method, the raw material mixture of the front and back layers (hereinafter, referred to as mixture A) is spread in a mat shape on a lower mold plate, and then the raw material mixture of the core layer (hereinafter, referred to as mixture B) is spread thereon. ) In the form of a mat, and the mixture A is further scattered in the form of a mat. At this time, 30 to 45% by weight of water is added to each of the mixture A and the mixture B for a curing reaction. deep. When the above-mentioned branched and / or curved and / or bent bulky wood fiber bundle is used as the wood reinforcing material of the mixture B, the mixture B is easily loosened and easily spread on the lower mold plate. In the continuous manufacturing method, a large number of the lower mold plates are placed on a belt conveyor, moved along a line, and moved by a main blower.
Towards the opposite direction to the moving direction from the moving direction of the lower die plate (front)
The material mixture A is sprayed while blowing wind (rearward).
Then, the mixture A is air-selected and a fine mixed
The compound A is arranged to increase the density. And only, the unevenness of the lower die plate
The back side of the convex portion of the pattern is a mixture by the wind from the main blower.
It becomes the blind spot of the flow of A. Therefore, in the present invention, the auxiliary blower is used.
And blow the wind just above the lower mold plate from back to front
You. Then , wood flour of the mixture A, in particular, having a sieve of 2 mm or less,
The back side of the convex part of the uneven pattern of the lower mold plate is efficiently filled.
You. The raw material mixture sprayed on the lower mold plate is slightly pressed by a roll or the like, if desired, and the upper mold plate is then placed on the upper surface of the mat, pressed and pre-cured in step 2 in the presence of moisture in step 2, and Molded into shape. The pressing conditions are usually a pressing pressure of 10 to 20 kg / cm ² , a temperature of 60 to 80 ° C., and a time of 1 hour.
The heating is performed in about 0 to 30 hours, and the heating is usually performed with steam. Pressing is performed by pressing the mat between two upper and lower mold plates, and a predetermined uneven pattern is provided on the template surface of the upper mold plate and / or the lower mold plate. The pre-cured product obtained by the pressing pre-curing in step 2 is
Cured in an autoclave. The curing conditions are usually 160-200 ° C. for 5-10 hours.
By the above autoclave curing, the calcium silicate reaction between the activated lime-containing substance and the silicic acid-containing substance is completely performed. In this way, the inorganic molded plate of the present invention having an uneven pattern obtained by reverse-transferring the uneven pattern of the upper mold plate and / or the lower mold plate on both surfaces or one surface is produced, and the front and back layers of the inorganic molded plate of the present invention are produced. Is usually 10 to 30% of the total thickness
And

[0010]

In the inorganic molded plate of the present invention, on the lower mold plate
From the front in case of cloth dispersed raw material mixture towards the rear in
That the blowing wind by the main blower Therefore, the raw material mixture
And finely distribute the raw material mixture on the lower surface to achieve high density.
And 緻 close-packed structure. However, the back of the convex part of the concave and convex pattern of the lower mold plate
The rear side has a blind spot in the flow of the raw material mixture.
The lower die plate straight in I'm toward from the rear to the front in the sub-blower
By blowing air onto the mixture,
mm of fine wood powder on the back side of the convex part of the uneven pattern of the lower mold plate
Filling efficiently. Therefore in the present invention inorganic molding
The surface of the plate has a substantially uniform and dense structure, and a rough structure portion is not formed. In particular, a bulky wood fiber bundle or bamboo fiber which is made bulky by branching and / or bending and / or bending as a wood reinforcing material for the core layer portion,
When a rigid fiber such as hemp fiber is used, the structure becomes coarse and the density becomes low, but a large mechanical strength is obtained due to the entanglement and rigidity of the fiber.

[0011]

Examples [Examples 1 to 3] (1) The composition of mixture A (front and back layers) is as follows. Porutoran de cement 50 wt% silica sand 32 〃 wood reinforcement * ₁ 15 〃 magnesium chloride (curing accelerator) 1 〃 paraffin emulsion (waterproofing agent) 2 〃 * _1: The wood reinforcement and less wood flour sieve 2mm , An average sieve of 4.5 mm and an average thickness of 0.6 mm with a wood chip in a weight ratio of 4
0:60 (Example 1), 47:53 (Example 2), 6
6:33 (Example 3). (2) The composition of the mixture B (core layer) is as follows. Porutoran de cement 44 wt% silica sand 29 〃 wood reinforcement * ₂ 10 〃 magnesium chloride (curing accelerator) 1 〃 paraffin emulsion (waterproofing agent) 2 〃 * _2: Average diameter 1.0mm as wood reinforcement, average length Sa2
A 0 mm branched and / or curved and / or bent bulky wood fiber bundle is used. (3) FIGS. 1 to 6 show a method for producing an inorganic molded plate using the above mixtures A and B. In the forming apparatus shown in the figure, (1) is a forming chamber, and a conveyor belt conveyor is provided at the bottom of the forming chamber (1).
(2) A lower mold plate (3) having a concavo-convex pattern (3A) on its surface is arranged thereon, and the lower mold plate (3) is conveyed by the conveyor belt conveyor (2) in the direction of arrow a. The forming chamber
(1) A supply belt conveyor (4) is arranged above, and a supply brush (5) is provided at an upper end at an end of the supply belt conveyor (4).
A cleaning brush (6) is arranged on the lower side to constitute a spraying device. Lower mold plate (3) of the forming chamber (1)
A blower (72) housed in a casing (71) and a pair of upper and lower blow ports (73, 73) communicating with the blower (72) via a distribution duct (74) on the transport direction side ( front ). A main air blower (7) is disposed, and the air blow ports (73, 73) blow air into the forming chamber (1) in a direction ( rearward ) opposite to the conveying direction of the lower mold plate (3). as since is, the forming chamber (1) conveying direction air blowing port in the side of Gyakukata direction is (73, 73) to recover the air that has been blown from the blower (7
The circulation path (8) for circulation to 2) is open. Further, a blow port (73A) communicating with a blower (72) through a duct (74A) branched from a distribution duct (74) is provided at a lower portion of the forming chamber (1) on a side opposite to a transfer direction. ) Is provided, and the blower port (73A) is directly connected to the lower mold plate (3).
So that the blowing direction selfish style to the front from the rear at the top. Air flow control valves (76A, 76A) operated by handles (75A, 75A) are attached to the air outlet (73) of the main air blower (7) and the air outlet (73A) of the sub air blower (7A). ing. Further, the blowing port is provided in the forming chamber (1).
A sieve frame (9) is provided so as to be adjustable in inclination angle and to be movable back and forth, as opposed to (73). A dispersing device similar to the above-described forming device including a supply belt conveyor (4), a supply brush (5), and a cleaning brush (6) is disposed at a stage subsequent to the forming device, and further, at a subsequent stage, before and after the forming device. The above-described forming device in which the direction is reversed is arranged. In the former forming apparatus, a mixture (10) obtained by mixing the mixture A with 40% by weight of water is conveyed on a supply belt conveyor (4) in the direction of arrow B, and an arrow is provided at the end of the supply belt conveyor (4). by supplying brush which rotates in c direction (5) to drop into from the front of the mixture (10) One loosenedゝforming chamber (1). The mixture (10) that has fallen into the forming chamber (1) first flows through the air outlet (73) of the main air blower (7) as shown by the arrow d.
The wind attached toward selfish blown from the front to the rear brought oriented rearwardly as indicated by arrow E, after being sieved by the sieve frame (9), it is winnowing the wind blown from the further air blowing port (73) The finer powder in the mixture (10) in the forming chamber (1) in the direction opposite to the conveying direction.
Falls deposited on the lower mold plate (3) located, coarser powder more conveying direction in the forming chamber (1) in
Although falling deposited on the lower die plate for position on the side (3), this time a fine powder the lower mold plate (3) air blowing port of the auxiliary blower (7A) immediately above (7
From 3A), the wind is directed slightly forward as shown by the arrow H due to the wind blown from the rear to the front as shown by the arrow G. The coarsest powder remains on the sieve frame (9)
(9) is deposited on the lower mold plate (3) is also highest in fall and forming a chamber (1) in as indicated by an arrow F is positioned in the conveying direction from above. The lower mold plate (3) is formed by the conveyor belt conveyor (2) as described above.
(1) As it is conveyed from the rear to the front , the finest powder is deposited at the bottom on the lower mold plate (3), and the coarser powder is deposited at the top Will be. In this way, as shown in FIG. 3, the surface mat (10A) having a structure in which the grain size becomes finer as it goes down is formed. The thickness of the surface mat (10A) is 8 mm. In the surface mat (10A), as described above, the fine powder is blown immediately above the lower mold plate (3) into the air outlet (73A) of the sub-blower (7A).
As it is oriented slightly forward by the wind blown from above, as shown in FIG. 3, the projections of the uneven pattern (3A) on the lower mold plate (3)
The fine powder to the rear side of the (31A) is filled. In this manner, the surface mat (10A) is produced. In the same manner, a mixture obtained by mixing 40% by weight of water with the mixture B is sprayed on the surface mat (10A) by an intermediate spraying device. Form a core layer mat (20A) as shown in (1). The thickness of the core layer mat (20A) is 50 mm. In addition the
The mixture (10) is similarly sprayed by a second forming device following the forming position to form a backing mat (30A) as shown in FIG. The thickness of the back layer mat (30A) is 8 mm. As described above, since the second forming device is disposed with the front and rear directions reversed with respect to the first forming device, the back layer mat (30A) is a surface layer mat.
Contrary to (10A), it has a structure in which the coarsest powder is deposited at the bottom and the particle size becomes finer toward the top. Thus, the surface layer mat (10A), the core layer mat (20A), and the back layer mat (30A) are formed. As shown in FIG.
The upper mold plate (A) having the above (A) is brought into contact with the upper mold plate, and after press molding, pressure hardening is performed at a pressure of 10 kg / cm ^{2 at} a temperature of 70 ° C. for 25 hours. The obtained laminated molded body is a plate-like body having a thickness of 18 mm,
The laminated molded body is then placed in an autoclave at 165 ° C.
After curing for 7 hours, the cement and silica sand in the laminated molded product are hardened by a calcium silicate reaction. Table 1 shows the evaluation of physical properties of the inorganic molded plates of Examples 1 to 3 manufactured as described above.

[Table 1] * ₁ : Specimen No. 3 * ₂ : Measured after 24 hours according to JIS A 1414 As shown in Table 1, the inorganic molded plates of Examples 1 to 3 of the present invention are lightweight, have high mechanical strength, and have a uniform surface. It is dense and has a good appearance.

[Comparative Examples 1 and 2] In Comparative Example 1, the wood flour used in Examples 1 to 3 and the wood chips used in Examples 1 to 3 were used as wood reinforcing materials in a weight ratio of 20:
80, and the other steps were the same as in Examples 1 to 3 to produce an inorganic molded plate. In Comparative Example 2, only wood flour used in Examples 1 to 3 was used as a wood reinforcing material.
Other than that produced the inorganic molded board like Example 1-3. Table 2 shows the physical properties and evaluation of the inorganic molded plate.

[Table 2] * ₁ : Specimen No. 3 * ₂ : Measured after 24 hours according to JIS A 1414 As shown in Table 2, Comparative Examples 1 using wood flour in an amount of less than 30% by weight as a wood reinforcing material were Examples 1 to 3. The surface water absorption is large compared to the molded plate, and the surface is rough,
It has many burrows and is inferior in appearance to the molded plates of Examples 1 to 3. Comparative Example 2 using only wood flour as a wood reinforcing material
Has insufficient breaking strength.

[Examples 4 and 5] In Example 4, as the wood reinforcing material of the mixture B of Example 2, a mixture of the bulky wood fiber bundle used in Example 2 and bamboo fiber in a 5: 5 weight ratio was used. Other than that, an inorganic molded plate was manufactured in the same manner as in Example 2. In Example 5, hemp fiber was used as a wood reinforcing material in place of the bulky wood fiber bundle of Example 2, and the other conditions were the same as in Example 2. To produce an inorganic molded plate. Table 3 shows the physical properties and evaluation of the inorganic molded plate.

[Table 3] * ₁ : Specimen No. 3 * ₂ : Measured after 24 hours according to JIS A 1414 As shown in Table 3, even if part or all of the bulky wood fiber bundle of Example 2 was replaced with bamboo fiber or hemp fiber, the mechanical strength was maintained. And an inorganic molded plate having a uniform appearance, a dense surface and a good appearance.

[0014]

[Effect of the Invention] In the present invention, therefore, the surface
An inorganic molded plate having a clear uneven pattern, a uniform and dense surface, and a high mechanical strength can be obtained.

[Brief description of the drawings]

 1 to 6 show one embodiment of the present invention.

FIG. 1 is an explanatory side view of the apparatus.

FIG. 2 is an explanatory plan view of the apparatus.

FIG. 3 is an explanatory diagram of a state of a formed surface mat.

FIG. 4 is an explanatory diagram of a state of a formed surface layer and core layer mat.

FIG. 5 is an explanatory diagram of a state of a formed surface layer, core layer, and back layer mat.

FIG. 6 is an explanatory view of a state where an upper mold plate is placed on the three-layer mat.

FIG. 7 is an explanatory view of a conventional example.

[Explanation of symbols]

 3 Lower mold plate 11 Upper mold plate 3A, 11A Uneven pattern 10A Surface mat 20A Core layer mat 30A Back layer mat

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ identification symbol FI // (C04B 28/18 16:02 22:12 24:26) (58) Investigated field (Int.Cl. ⁶ , DB name) ) B28B 1/52 B28B 3/02 C04B 28/18 C04B 40/02

Claims (5)

(57) [Claims] 1. A line of a lower mold plate having an uneven pattern on a mold surface.
Moving along the main mold and the moving direction of the lower mold plate
Lower by spraying and Fukuoku blower wind from a direction opposite to the
A wind is blown directly above the lower template from the moving direction of the template to select a raw material mixture mainly composed of self-hardening inorganic material and wood reinforcing material.
While forming the mat by spraying on the lower mold plate, when producing the upper die plate abuts inorganic molded plate by performing pressing hardening and curing it on to the mat, at least the inorganic molded plate front and back layers 30 pieces of wood flour with a sieve mesh of 2 mm or less as wood reinforcement
A method for producing an inorganic molded plate, comprising using 5 to 15% by weight of one containing 70 to 70% by weight. 2. The inorganic material according to claim 1, wherein a part or all of the wood reinforcing material other than the wood flour is made of a wood fiber bundle which has been bulked by branching and / or bending and / or bending. Manufacturing method of molded plate 3. The method according to claim 1, wherein bamboo fiber is used for a part or all of the wood reinforcing material other than the wood flour. 4. The method according to claim 1, wherein hemp fibers are used for part or all of the wood reinforcing material other than the wood flour. 5. A part or all of a wood reinforcing material other than the wood flour.
Made in the inorganic molded plate according to claim 1 that use wood to section
Construction method