JP3408210B2 - Building board manufacturing equipment - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building board suitable for use as an outer wall of a building, and more particularly to an apparatus for manufacturing a building board having an improved waterproof function on its back surface.

[0002]

2. Description of the Related Art Conventionally, at the beginning of a building board coating process, back sealer coating is applied to the back surface of the board of the building board in order to impart some waterproofness. The coating amount in that case is about 45 to 55 g / m ² in the wet state, and the thickness of the sealer coating film after drying is about 10 to ²⁰ μm. Since the sealer is adhered to the back surface of the plate, the film thickness is reduced by the amount of the sealer impregnated inside the porous plate. The term "sealer" as used herein refers to a paint that is used to fill the pores of the porous, highly absorbable surface to be painted, and normally a colorless and transparent acrylic urethane-based paint is often used. .

[0003]

By the way, although the back surface of the cement substrate (which is a plate in a state before coating) manufactured in the substrate manufacturing line is formed to be substantially flat, the whole substrate is It is difficult to say that the density of the plate in the thickness direction is not always uniform, because there are fine irregularities and a large number of voids. Therefore, in terms of the sealer permeability in the back sealer application process in the continuous coating process of the building board,
Inevitably, the problem of partial coating unevenness is unavoidable, and in such a case, the desired waterproof effect cannot be sufficiently exerted.

On the other hand, increasing the coating amount of the sealer on the back surface of the building board, which is not directly visible in normal use, causes a large increase in product cost. Absent. Originally, unlike the coating layer on the surface, the function that the sealer layer should exhibit is that it is not the part that is directly exposed to rainwater, so it is sufficient if the sealer layer can exhibit a certain degree of waterproofness as the back surface of the substrate. The current situation is that painting is done. Therefore, little attention is paid to other physical properties such as scratch strength, and the film is not strong in terms of strength.

Due to this, there is a sufficient risk that scratches will occur during distribution or at the construction site, and if scratches occur once,
Penetration of water from that part is inevitable. In some cases, some kind of shock may cause a fatal defect such as a loss of the real part.

In view of the above situation, the applicant of the present invention has previously applied for "building board, its manufacturing apparatus and pre-expanded plastic" in which a foamed plastic sheet is lined with a cement substrate material (Japanese Patent Application No. 11- 242022).
In order to line the cement substrate material with the foamed plastic, this building board first laminates the polyethylene foam on the cement substrate material together with the recycled PET nonwoven fabric while foaming polyethylene on the recycled PET nonwoven fabric,
After that, the recycled PET nonwoven fabric is manufactured through a process of separating it. Therefore, an extra step of removing the recycled PET non-woven fabric is required. Further, if the step is unsuccessful, the surface of the foamed plastic backed will be damaged, or in the worst case, the foamed plastic backed will peel off. I was afraid.

In view of the above problems, the present invention eliminates the back sealer application and the subsequent drying step, and effectively exerts the waterproof function of the sealer layer conventionally formed on the back surface of a building board. It is an object of the present invention to provide a building board manufacturing apparatus that can be manufactured simply and reliably.

[0008]

Means for Solving the Problems] building board manufacturing apparatus of the present invention, non-foamed on non-foamed plastic sheet
A sheet of plastic foam state during the process of foam molding, a foamed plastic and non-foamed plastics, as non-foamed plastic on the outside, is intended to obtain Bei backing means lining cement substrate fabric. Also before
The backing means is backing the building board after clear coating.
By doing so, the plate temperature of the discharged building board can be utilized for foaming the foamed plastic, and since there is no subsequent step of heating to high temperature, the backed plastic sheet is not damaged.

[0009]

[0010]

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Figure 1
Is a building board manufacturing apparatus according to an embodiment of the present invention .
It is a figure which shows the partial cross-section of the building board manufactured by this .
The building board 1 has a surface coating layer 3 on the front surface of a cement base material 2, and on the back surface thereof, a foamed plastic, preferably a PE (polyethylene) foaming layer 4, and outwardly from the back surface of the board. , Non-foamed plastic, preferably recycled PET (polyethylene terephthalate) sheet layer 5 backed. In addition, when viewed in detail, the layers are not clearly distinguished from each other, but the components of the adjacent layers are fused, and the PE-impregnated layer 6 in which the foamed PE is impregnated in the cement substrate 2, And foamed PE and recycled PE
The mixed layer 7 in which T is mixed may exist.

The cement base material 2 is formed by pressing and curing a raw material mat formed by forming or extruding a raw material slurry on a porous support. The raw material slurry is, for example, Portland cement, or blast furnace cement in which blast furnace slag is mixed in Portland cement, fly ash cement in which fly ash is mixed, volcanic ash, silica fume, silica cement in which silica materials such as clay are mixed, alumina cement, blast furnace slag. Cement-based inorganic hydraulic materials such as wood powder, wood wool, wood chips, wood fibers, wood pulp, softwood pulp, hardwood pulp, wood fiber bundles, waste paper pulp, hemp fiber, bacas, chaff, rice straw, bamboo fiber, etc. Wood reinforcements and, if desired, accelerated hardening of aggregates such as pearlite, silas balloons, expanded shale, expanded clay, calcined diatomaceous earth, fly ash, coal debris, crushed foam concrete, and alkali metal silicates. Agents, waxes, waxes, paraffins, surfactants, waterproof agents such as silicone, and water repellents The dispersed in water usually 5 solids
It is adjusted to about 20% by weight.

The PE foam layer 4 is preferably made of resin foamed by an atmospheric pressure foaming method. Linear polyethylene is preferable because it has excellent chemical resistance. Non-crosslinked ones are preferable because they can be regenerated. By adjusting the material density, a wide range of PE foam layers 4 from soft types to semi-hard types can be manufactured. In addition, by adjusting the kneading amount of the foaming agent,
The E foam layer 4 can be molded. The thickness of the PE foam layer 4 is
0.5-3.0 mm is suitable. When the thickness is less than 0.5 mm, a problem occurs in strength, and the waterproof property cannot be sufficiently exerted. Conversely, 3.
If the thickness exceeds 0 mm, the building board as a whole will be unnecessarily bulky and the commercial value will decrease.

In the normal pressure foaming method, for example, an olefin resin composition for foaming such as polyethylene or polypropylene mixed with a heat-decomposable foaming agent such as azodicarbonamide in advance is extruded at a temperature at which the foaming agent does not decompose. Melt kneading with a roll or a roll, and the kneaded product is preformed into an appropriate shape such as a sheet by extrusion molding, press molding, or other appropriate means, and the preformed product is introduced into a heating chamber to decompose the foaming agent. It is a method of foaming the resin under normal pressure by heating above. In addition, known foaming methods such as extrusion foaming and pressure foaming can be applied.

In the extrusion foaming method, for example, a resin composition for foaming is melt-kneaded by an extruder, and an expansive liquid such as dichlorotetrafluoroethane is injected from a foaming agent injection port provided in the kneading section of the extruder. Type foaming agent or an inert gas type foaming agent such as carbon dioxide gas is pressed into a molten resin, or the above resin composition for foaming is mixed with a pyrolytic foaming agent such as azodicarbonamide in advance. Melt and knead at
This is a method of extruding this while foaming it into an appropriate shape from an extrusion die.

In the pressure-foaming method, for example, the foaming resin composition is melt-kneaded by an extruder or a roll, and the kneaded product is extruded, press-molded or other suitable means to prepare a sheet or other suitable shape. After molding, the preform is placed in a pressure chamber such as an autoclave and heated under pressure, and an expansive liquid foaming agent such as dichlorotetrafluoroethane or an inert gas foaming agent such as carbon dioxide is added to the preform. This is a method in which the surface is impregnated and then the pressure in the pressure chamber is released to cause foaming.

Further, the foaming agent used in each of the above-mentioned foaming methods is not particularly limited, and is an expansive liquid type foaming agent such as a low boiling point organic solvent or a swelling agent, an inert gas type foaming agent, or a thermal decomposition type. Any foaming agent such as a foaming agent can be used. As the recycled PET sheet layer 5, a plastic sheet that does not deform as a whole even when the temperature exceeds the temperature at which the PE foam layer 4 foams is used. It does not matter that the mixed layer 7 in which the foamed PE and the recycled PET are mixed is formed by softening to some extent.

FIG. 2 is a top view for explaining the laminated sheet 11. This laminated sheet 11 is for backing the cement base material 2. For example, on the surface of a long heat-resistant recycled PET sheet (nonwoven fabric or woven fabric) 12, the width is narrower than that of the recycled PET sheet 12. The PE laminate layer 13 which is not expanded and is wider than the cement base material 2 is coated.

FIG. 3 is a flow chart for explaining the laminated sheet backing process of the building board manufacturing apparatus of this embodiment. The process within the broken line is the process according to the present invention and is inserted into the conventional process. In addition to the fact that the sealer is not lined, the plate a that has come out with the surface (handle surface) facing up is reversed from the drying process after clear coating in a normal building board manufacturing device (step S101). From (step S102), the plate a to be processed is supplied and subjected to lamination processing (step S103). On the other hand, the laminate sheet 11 coated with the PE laminate layer 13 in an unfoamed state is supplied (step S104), and the PE laminate layer 13 is heated, melted and foamed by subjecting the laminate sheet 11 to the first stage heat treatment. (Step S105), the laminate sheet 11 and the plate a to be processed are laminated (step S106), rapidly cooled (step S107), and the plate a is carried out and inverted again (step S108). Cooling (step S109), which is a process of a normal building board manufacturing apparatus, and cutting or trimming the excess laminate sheet 11 protruding from the contour boundary portion of the plate a to be processed (step S110), the inspection plate (step S11).
1) and shipping (step S112).

FIG. 4 is a diagram for explaining the processing principle of the building board manufacturing apparatus of this embodiment. FIG. 5: is a figure which shows the structure of a corresponding concrete building board manufacturing apparatus. The inverted plate to be processed a is placed on the carry-in conveyor 31 with its longitudinal direction being the traveling direction A, and is conveyed to the laminating section.

FIG. 6 is a view for explaining the building board 1 of the present embodiment, the carry-in conveyor 31, and the belt conveyor serving as the carry-out conveyor. FIG. 6A is a plan view and a side view as seen from the back side of the building board 1. Building board 1 is male part 5
1 and the female part 52, and the plate surface handle 53 has a large number of irregularities in recent years from the aspect of designability, so in place of a normal conveying roller, here, a belt conveyor is used. It is supposed to be used. The work plate a is shown in FIG.
(b) and FIG. 6 (c) show the side view and the plan view of the belt conveyor 54.
It is carried into the laminating section with the back side of the sheet facing upward.

On the other hand, the laminated sheet 11 wound in a roll shape is unrolled from the sheet roll 21, and then the recycled PET sheet 12 is placed on the upper side and the PE laminated layer 13 is placed on the lower side. Is heated by the far-infrared heater 22 from the lower side to the first stage, and the PE laminate layer 13 starts melting. When the PE laminated layer 13 reaches the position immediately before the laminating section, the PE laminated layer 13 starts foaming. The seat surface temperature at this time is
For example, it is 175 ° C. The carry-in of the laminate sheet 11 into the laminating section is performed by the feed roll 32, and the carry-in angle is adjusted by the guide roll with an adjuster (preferably made of a silicon rubber roll) 33.

In the laminating section, first, the plate a that has been carried in is subjected to feed heating and press working. In this, the heating press roll 34 and the lower backup sponge roll 35 arranged to face the heating press roll 34 convey the substrate a while heating it. The backup sponge roll 35 is made of a heat-insulating sponge roll (having elasticity), absorbs the irregular shape of the surface of the plate a to be processed so as not to crush the handle, and the plate a holds. It does not let away the heat you make. This heating further raises the temperature of the sheet to, for example, 200 ° C.

During the feed heating and press working, the laminate sheet 11 partially impregnates the face layer on the back surface of the plate a to form the PE impregnated layer 6 (see FIG. 1). By this impregnation, the adhesive strength of the sheet is greatly improved. During this period, foaming is progressing microscopically, but it is macroscopically suppressed because press pressure is applied. That is, the PE foam layer 4 does not become thicker than necessary.

After the press working is completed, the PE is continued.
The foam sheet is guided forward by the auxiliary heating Teflon-coated endless belt 36 arranged above the plate a to be processed with a clearance corresponding to the designed thickness of the foam layer 4. Auxiliary heating Teflon coated endless belt 3
In No. 6, auxiliary heating is performed by bringing the heat roll 37 into contact with the back surface of the belt so that the sheet surface temperature is kept at, for example, 185 ° C., during which PE foaming is completed.

Further, the plate a to be processed after completion of the feed heating press working is immediately carried out by a carry-out conveyor 38 running below the plate a.
It is moved and placed on top and transported forward. The feeding roll 32, the heating press roll 34, the Teflon coat endless belt 36 for auxiliary heating, and the carry-out conveyor 38
And are operated synchronously.

A heater retracting mechanism 39 is provided so that when the rear end of the plate a to be processed passes through the feed roll 32, the far infrared heater 22 is turned off and at the same time retracted to a predetermined position. Further, the feeding roll 32
The sheet gripping roll (for example, a silicone rubber roll) 40 that has been retracted to a lower position opposite to the upper side rises to come into contact with the feeding roll 32, and thus the laminated sheet 11
Is gripped by both rolls 32, 40,
A sheet gripping roll retracting mechanism 41 is provided.

When the laminated sheet 11 is gripped, the laser knife 42 is used to cut the sheet at a high speed at the laser receiving stage 43 located slightly in front of the laminated sheet 11 (by reciprocating the sheet portion). The laminate sheet 11 is cut slightly diagonally. Here, the plate a to be processed which has been laminated is completely independent.

The laminated plate to be processed a which has become an independent body is carried to the next cooling zone by the carry-out conveyor 38. In the cooling zone, a cooling process is performed in which cold air is blown against the back surface of the sheet and ducts are sucked from both sides. After that, the plate a to be processed is inverted again, and with the plate surface handle 53 facing upward, is placed on a normal conveying roller or a chain conveyor and is carried out from the laminating system, and the next processing is performed. Move to the process.

FIG. 7 is a diagram showing the overall construction of a building board manufacturing apparatus according to an embodiment of the present invention. The main controller 100 controls the following units. First, a sheet for detecting the passage of the plate a to be processed by the passage detection switches S1 and S2 at the front end of the plate to control the heater retreat mechanism 39 to measure the surface temperature of the laminate sheet 11 heated by the far infrared heater 22. The surface thermometer 61 controls the far infrared heater controller 62 that controls the heating of the far infrared heater 22. The heating of the heating press roll 34 is controlled by a roll surface thermometer 63 that measures the surface temperature of the heating press roll 34 and a sheet surface thermometer 64 that measures the surface temperature of the laminate sheet 11 heated by the heating press roll 34. The heating press roll temperature controller 65 is controlled. Heat roll 3
A sheet surface thermometer 66 that measures the surface temperature of the laminate sheet 11 that is heated by 7 controls a heat roll controller 67 for heating the Teflon-coated endless belt back surface that controls heating of the heat roll 37.
The above is the heating control system. The carry-in conveyor 31, the carry-out conveyor 38, the heating press roll 34, the backup sponge roll 35, and the transport controller 68 for synchronously controlling the rotation of the auxiliary heating Teflon-coated endless belt 36 are controlled. This is a plate conveyance control system. The press roll pressure adjustment 69 that adjusts the press pressure of the heating press roll 34, the sheet gripping roll retracting mechanism 41, the sheet feeding motor 70 that rotates the sheet roll 21, and the sheet supply controller 71 that controls the feeding roll 32 are controlled. Passage detection switch S3 at the rear end of the plate
The laser knife controller that controls the laser knife reciprocating drive motor 72 that causes the laser knife 42 to reciprocate, and the laser generator 73 that generates a laser, by detecting that the plate a to be processed has been completely carried into the laminating section. Control 74. These are sheet supply systems.

FIG. 8 is a flow chart for explaining the operation of the building board manufacturing apparatus of this embodiment. First, the laminate sheet 11 is pulled out from the sheet roll 21 by an operator, and in a state where the front end portion thereof is placed on the laser receiving stage 43, by the feed roll 32 and the sheet gripping roll 40 that is in contact with this, It is in a gripped state. The penetration angle of the laminate sheet 11 is adjusted by moving the guide roll 33 with an adjuster forward and backward.

Further, the far infrared heater 22 is
The installation angle is adjusted according to the adjustment of the penetration angle of the laminate sheet 11, and the laminate sheet 11 is placed in a standby state facing the surface side of the laminate sheet 11 and approaching the laminate sheet 11 for a predetermined distance. (An angle adjustment and distance adjustment mechanism are not shown.) The above is manually performed by the operator. Further, rotation of the heating press roll 34 and the auxiliary heating Teflon-coated endless belt 36 and control of heating are started.

Then, the operation of the carry-in conveyor 31 and the carry-out conveyor 38 in the plate transfer control system is started. Thus
From the standby state where the laminate sheet 11 can be supplied and is stopped (step S1), the carry-in conveyor 31
When the detection switch S1 detects that the front end of the plate a has passed the predetermined position (step S2), the far infrared heater 22 is turned on (step S3).

At the same time or after a slight delay, the rotation of the sheet feeding motor 70 and the feeding roll 32 is started (step S4). The tip of the laminate sheet 11 has a curved guide 44 provided slightly in front of the laser receiving stage 43.
Is guided to the lower collecting basket 45 along with, and the unnecessary laminate sheet 11 at the start of processing is collected. When the detection switch S2 detects that the front end of the plate a has passed a predetermined front position near the front end of the carry-in conveyor 31 (step S5), the sheet gripping roll 40 is retracted to a predetermined position below. (Step S6).

At the same time, the laser knife 42 is run to the opposite position to cut the sheet (step S7). (First Front End Cut) The plate a to be processed is further pushed forward by the carry-in conveyor 31, and subsequently, is fed forward while being held by the heating press roll 34 and the backup sponge roll 35. . During this time, foaming laminating is performed.

When the detection switch S2 detects that the rear end of the plate a to be processed has passed the predetermined position near the front end of the carry-in conveyor 31 (step S8), the far infrared heater 22 is turned off. At the same time (step S
9) The far infrared heater 22 is retracted to a predetermined retracted position (step S10). When the detection switch S3 detects that the rear end of the plate a has passed a predetermined position before the heating press roll 34 (step S
11), run the laser knife 42 to the original position and cut the laminate sheet 11 (step S12). (1
(Cut the rear edge of the first sheet)

The rotation of the sheet feeding motor 70 and the feeding roll 32 is stopped (step S13). At the same time, the sheet gripping roll 40 in the retracted position is raised and brought into contact with the feed roll 32 to grip the laminate sheet 11 (step S14).

During this period, if there is no abnormality (step S1
5) The processed plate a that has undergone the laminating process is moved forward by the carry-out conveyor 38 and proceeds to the next processing step. If there is an abnormality, the main controller 10
0 is notified (step S16), stop processing is executed, and the flow ends (step S17). The present invention is not limited to the above embodiment.

[0039]

As described above, according to the present invention (1), since water absorption from the back surface of the building board is effectively prevented,
The dimensional change of the whole plate is reduced. (2). Since the invasion of CO ₂ from the back surface of the building board is considerably prevented, carbonation and neutralization of the cement board are prevented. (3). As water is prevented from absorbing water from the backside of the building board, chlorine ions will not flow out from the inside, so when it is fastened to a steel frame foundation, oxidation of iron (generation of rust) is prevented. .

(4) Since the film strength (tear strength, burst strength, etc.) is greater than in the case of applying a sealer, the occurrence of scratches, cracks and chips (particularly, the real part) is suppressed. (5). Since the back sealer coating step and the subsequent dry operation step are eliminated, the energy cost can be greatly reduced and the total coating cost can be significantly reduced. (6). The construction method of fastening the building board to the steel frame foundation prevents squeaking noise of the building board.

(7). In the construction method in which nails (or screws) are driven in from the surface of the building board and fastened, the vicinity of the protruding portion of the nail is protected by the foamed plastic with a high degree of elasticity of closed cells, so rainwater can be protected. It is possible to block it to some extent. As a result, it is possible to prevent rainwater from flowing around to the back surface of the plate much more effectively. (8) .Because the foamed plastic is formed on the back side,
A certain degree of shock absorption is exhibited, and the phenomenon that fine cracks occur even when an external force is applied is considerably alleviated. (9). Since the plastic to be foamed is lined with the foamed plastic, a product with considerably improved strength can be obtained.

[Brief description of drawings]

FIG. 1 is an apparatus for manufacturing a building board according to an embodiment of the present invention.
It is a figure which shows the partial cross-section structure of the building board manufactured by .

FIG. 2 is a top view illustrating a laminate sheet used in this embodiment.

FIG. 3 is a flowchart illustrating a laminated sheet lining process step of the building board manufacturing apparatus according to the present embodiment.

FIG. 4 is a diagram illustrating a processing principle of the building board manufacturing apparatus according to the present embodiment.

FIG. 5 is a diagram showing a configuration of a building board manufacturing apparatus according to the present embodiment.

FIG. 6 is a diagram illustrating a building board and a belt conveyor according to the present embodiment.

FIG. 7 is a diagram showing an overall configuration of a building board manufacturing apparatus according to the present embodiment.

FIG. 8 is a flowchart illustrating the operation of the building board manufacturing apparatus according to the present embodiment.

[Explanation of symbols]

1 Building Board 2 Cement Base Material 3 Surface Coating Layer 4 PE Foam Layer 5 Recycled PET Sheet Layer 6 PE Impregnation Layer 7 Mixed Layer 11 Laminated Sheet 12 Recycled PET Sheet 13 PE Laminated Layer 21 Sheet Roll 22 Far Infrared Heater 31 Carry In Conveyor 32 Feeding roll 33 Guide roll with adjuster 34 Heating press roll 35 Backup sponge roll 36 Teflon coated endless belt for auxiliary heating 37 Heat roll 38 Carry-out conveyor 39 Heater retracting mechanism 40 Sheet gripping roll 41 Sheet gripping roll retracting mechanism 42 Laser knife 43 Laser receiving stage 44 Curved guide 45 Recovery basket 51 Male part 52 Female part 53 Plate surface handle 54 Belt 55 Fixing pin 56 Guide block 61 Seat surface thermometer 62 Far infrared heater controller 63 Surface thermometer 64 sheet surface thermometer 65 heating press roll temperature controller 66 sheet surface thermometer 67 Teflon coat endless belt back side heating heat roll controller 68 transport controller 69 press roll pressure adjustment 70 sheet feeding motor 71 sheet feeding controller 72 laser knife reciprocating Dynamic drive motor 73 Laser generator 74 Laser knife controller 100 Main controller a Work plate S1, S2, S3 Detection switch

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ identification code FI C04B 41/71 C04B 41/71 E04C 2/04 E04C 2/04 E (58) Fields investigated (Int.Cl. ⁷ , DB name) ) E04F 13/08-13/18 B32B 1/00-35/00

Claims (2)

(57) [Claims] 1. On a sheet of non-foamed plastic
A sheet of foam plastic unfoamed state when the process of foam molding, a foamed plastic and non-foamed plastic, non-foamed plastic so that the outer side, and wherein the obtaining Bei backing means lining cement substrate fabric Building board manufacturing equipment. 2. The backing means after clear coating
The backing of the building board according to claim 1,
Building board manufacturing equipment.