JP3682144B2 - Manufacturing method of inorganic board - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing an inorganic board used as a building material such as an outer wall material, a roof material, an exterior member, and an interior wall material.
[0002]
[Prior art]
Conventionally, a wet method and a dry method have been adopted in manufacturing inorganic plates such as ceramics. The manufacturing method of the inorganic board by the wet method is called the round net type paper making method or the long net type paper making method. The solid content such as reinforcing fiber such as cement and pulp and filler such as silica is dispersed in water. An inorganic board made by preparing a slurry cement material and forming it into a plate-like hydrous cement board by rolling it up with a round net or a long net, dehydrating the hydrous cement board and curing it after curing. Is to be manufactured.
[0003]
In this wet method, by using a slurry-like cement material having a solid content concentration as low as 4 to 12% by weight, a plate-like water-containing cement board can be easily formed without being connected to the solid content itself. I am doing so. However, the wet method using a cement material having a low solid content has a problem that a large-scale water treatment facility for treating a large amount of water and a great amount of labor for maintaining the water treatment facility are required. In addition, the water-containing cement board is low in strength and easily cut, and there is a problem that an inorganic board having a uniform thickness and good texture (surface smoothness) cannot be obtained.
[0004]
On the other hand, the manufacturing method of the inorganic board by a dry method does not require a large-scale water treatment facility in order to mix solid content in a dry state. However, mixing solids in a dry state has a problem that the dispersed state of solids, particularly the dispersed state of reinforcing fibers, is not good, and it is not possible to obtain a high-strength inorganic plate. There is a problem that a special material is required to secure the material, resulting in a high material cost.
[0005]
[Problems to be solved by the invention]
Therefore, the present invention provides an inorganic board that does not require a large-scale water treatment facility and can obtain an inorganic board having a uniform thickness and a good texture even in a wet method in which the solid content is well dispersed. An object of the present invention is to provide a manufacturing method.
[0006]
[Means for Solving the Problems]
Method for producing inorganic board according to claim 1 of the present invention, the sheet 1 and can proceed in the same direction thickness adjusting sheet 2 provided above the molded sheet 1 traveling in one direction, the thickness adjusting sheet 2 The lead-out port 17 formed on the surface of the supply box 8 that faces the direction of travel of the molded sheet 1 and is introduced from the opening of the upper surface of the cylindrical supply box 8 that is provided on the upper side of the molded sheet 1 and whose upper and lower surfaces are open. The cement material 3 having a solid content concentration of 20 to 55% by weight consisting of a solid content containing cement and water is supplied to the supply box 8 through the supply box 8 as derived from the supply box 8. fed onto and the driving belt 25 connecting the small rotary roll 24 and large rotation rolls 26, a portion of the outer wall of the side surface of the supply box 8 above the outlet 17 of the feed box 8 Placed into the defect portion is damaged cement material 3 is contacted to the thickness adjusting sheet 2 in the feed box 8 in contact with the upper surface of the thickness adjusting sheet 2 an outer surface of the drive belt 25 in the feed box 8, the drive belt 25 is advanced between the small rotating roll 24 and the large rotating roll 26 to drive the thickness adjusting sheet 2 and advance in the same direction as the forming sheet 1 so as to proceed from the small rotating roll 24 toward the large rotating roll 26, The cement material 3 is formed into a hydrous cement board 4 by applying vibration to the cement material 3 through the thickness adjusting sheet 2 while holding the cement material 3 between the forming sheet 1 and the thickness adjusting sheet 2. It is.
[0007]
Moreover, the manufacturing method of the inorganic board of Claim 2 of this invention WHEREIN: In addition to the structure of Claim 1, the thickness adjustment sheet | seat 2 is formed with a sheet | seat with air permeability, It is characterized by the above-mentioned. Moreover, in addition to the structure of Claim 1 or 2, the manufacturing method of the inorganic board of Claim 3 of this invention supplies water to the location where the cement material 3 and the thickness adjustment sheet 2 contact. Is.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below.
[0009]
FIG. 1 shows a reference example of an inorganic plate manufacturing apparatus. The molded sheet 1 is formed of a water-permeable sheet such as felt, and is stretched between a pair of rolls 5 and 5 in an infinite loop shape (partially omitted in FIG. 1). Further, the molded sheet 1 is formed so as to advance in one direction (indicated by an arrow in FIG. 1) by rotating the rolls 5 and 5, for example. A supply box 8 is provided on the upper side of the molded sheet 1. The supply box 8 is formed in a cylindrical shape whose upper and lower surfaces are open, and a lead-out port 17 is provided on the surface of the supply box 8 facing the direction of travel of the molded sheet 1. The thickness adjustment sheet 2 is passed through the supply box 8 so as to be introduced from the opening on the upper surface and led out from the outlet 17.
[0010]
The thickness adjusting sheet 2 is formed of a polyester sheet using polyethylene terephthalate or the like, and is supported on a plurality of support rolls 6, 6... Yes. Further, a part of the thickness adjusting sheet 2 is disposed so as to face the molded sheet 1 with a predetermined interval, and a thickness adjusting portion 7 is formed between the facing portions. The thickness adjusting sheet 2 is formed so as to advance in the same direction as the molded sheet 1 at the thickness adjusting portion 7. A vibrator 15 is disposed above the thickness adjustment sheet 2 at the location of the thickness adjustment section 7, and the diaphragm 16 that vibrates up, down, left and right by driving the vibrator 15 contacts the upper surface of the thickness adjustment sheet 2. Are arranged to be. The vibration of the diaphragm 16 may be adjusted as appropriate according to its weight and the traveling speed of the molded sheet 1, but it is appropriate to set the vibration to about 20 to 180 Hz.
[0011]
A head tank 9 communicates with the supply box 8 through a supply pipe 10, and a pump 11 is disposed in the middle of the supply pipe 10. A plurality of suction boxes 12 are arranged in the traveling direction of the molded sheet 1, and each suction box 12 is connected to a decompression device. Reference numeral 13 denotes a cleaning box, in which a pair of upper and lower sprays 14 are disposed, and the thickness adjusting sheet 2 is disposed so as to cross between the sprays 14. And the thickness adjustment sheet | seat 2 is wash | cleaned by injecting cleaning fluids, such as water, to the thickness adjustment sheet | seat 2 from the spray 14. FIG.
[0012]
Hereinafter, the manufacturing method of the inorganic board using the said manufacturing apparatus is demonstrated. First, the cement material 3 stored in the head tank 9 is supplied to the supply box 8 through the supply pipe 10 by driving the pump 11. The cement material 3 is prepared by dispersing in water water a solid content composed of reinforcing fibers such as cement and pulp, a filler such as silica, and an admixture such as fly ash. At this time, the solid content concentration of the cement material 3 is set to 20 to 55% by weight. If the solid content concentration of the cement material 3 is less than 20% by weight, the shape retaining property of the cement material 3 is lowered, and an inorganic plate having a uniform thickness cannot be obtained, and the solid content concentration of the cement material 3 is 55% by weight. If the content exceeds 50%, the dispersion state of solids, particularly the dispersion state of reinforcing fibers, will be low, and it will not be possible to obtain a homogeneous and high-strength inorganic board, and only obtain an inorganic board with a non-uniform thickness and poor texture. I can't.
[0013]
By using the cement material 3 having a solid content concentration of 20 to 55% by weight in this way, it is possible to make the dispersion state of the solid content, particularly the dispersion state of the reinforcing fibers, higher than that of the dry method of the above-described conventional example. The strength of the plate can be prevented from being lowered. Moreover, a special material for securing the solid content connection as in the dry method is not required, and the material cost can be prevented from becoming high. Furthermore, the total amount of water can be reduced as compared with the papermaking method, and a large-scale water treatment facility can be eliminated. Moreover, since the shape retention of the cement material 3 is higher than that of the papermaking method, it becomes easier to control the thickness of the hydrous cement board 4 described later.
[0014]
The cement material 3 supplied to the supply box 8 as described above is supplied onto the molded sheet 1 that proceeds from the opening on the lower surface of the supply box 8 and contacts the thickness adjusting sheet 2 in the supply box 8. The cement material 3 on the molded sheet 1 travels together with the molded sheet 1. At this time, since the cement material 3 is in contact with the thickness adjusting sheet 2, the thickness adjusting sheet 2 is also formed by the friction between them. It will proceed at the same speed in the same direction as the material 3). Thereafter, the cement material 3 is led out of the supply box 8 through the outlet 17 and introduced into the thickness adjusting unit 7. The cement material 3 introduced into the thickness adjusting unit 7 proceeds while being sandwiched between the thickness adjusting sheet 2 and the forming sheet 1 and is formed into a plate shape having a thickness close to the inorganic plate of the final product. Further, vibration is applied to the cement material 3 in the thickness adjusting unit 7 from the diaphragm 16 through the thickness adjusting sheet 2. In this way, by applying vibration to the cement material 3 from above, the cement material 3 is formed into a hydrous cement board 4 having a thickness of an inorganic board as a final product.
[0015]
Thereafter, the water-containing cement board 4 is carried above the suction box 12 and dehydrated in the suction box 12 until the moisture content is such that the shape does not collapse. Next, the water-containing cement board 4 is removed from the molded sheet 1 and dehydrated and pressed by a press machine or the like to adjust the water content necessary for curing. Thereafter, the hydrous cement plate 4 is subjected to wet heat curing or wet heat curing and autoclave curing to be cured, and further subjected to necessary processing such as surface decoration to form the inorganic plate of the present invention. Simultaneously with the dehydration press, the water-containing cement plate 4 may be patterned or shaped, or the water-containing cement plate 4 may be cut into a desired size.
[0016]
As described above , in the above reference example , the cement material 3 is applied to the water-containing cement plate 4 by applying vibration to the cement material 3 through the thickness adjusting sheet 2 while sandwiching the cement material 3 between the molded sheet 1 and the thickness adjusting sheet 2. Since molding is performed, the cement material 3 is sandwiched between the molding sheet 1 and the thickness adjusting sheet 2 to hold the cement material 3 so that shearing force is not applied to the cement material 3 as much as possible, and the cement material 3 is pressed and solidified by vibration to improve solid content. Thus, the water-containing cement board 4 can be prevented from being cut. Moreover, the surface (upper surface) of the water-containing cement board 4 can be smoothed by vibration. Therefore, the hydrous cement board 4 having a good texture with a uniform thickness can be formed. As a result, the inorganic board also has a good texture with a uniform thickness.
[0017]
When manufacturing a thick inorganic board, if the thickness adjusting sheet 2 exists from the inside of the supply box 8 to the lower side of the diaphragm 16, the cement material 3 becomes laminar and becomes easy to handle, and manufacture of the inorganic board (hydrous cement board 4). Can be done easily.
[0018]
In the reference example of FIG. 1 described above, it is preferable to use a breathable sheet as the thickness adjusting sheet 2. By using the thickness adjusting sheet 2 having air permeability as described above, air that enters between the cement material 3 and the thickness adjusting sheet 2 when the thickness adjusting sheet 2 is brought into contact with the cement material 3 passes through the thickness adjusting sheet 2. It can be made to discharge | release, and the trace of air can be made not to remain depressed like a crater on the surface of the water-containing cement board 4. FIG. Therefore, the appearance of the inorganic plate can be prevented from being deteriorated.
[0019]
In the present invention, in the reference example of FIG. 1 described above, the thickness adjusting sheet 2 is advanced by the thickness adjusting portion 7 in the same direction as the molded sheet 1 at the same speed . The advancement of the thickness adjusting sheet 2 can be performed using the driving device 18 .
[0020]
The driving device 18 shown in FIG. 2 has a rotating shaft 21 and a small rotating roll 24 of a driving generator 19 such as a motor connected by a belt 27, and a small rotating roll 24 and a large rotating roll 26 connected by a driving belt 25. It is. Then, a part of the outer wall on the side surface of the supply box 8 is lost above the outlet 17 of the supply box 8, and the drive belt 25 is disposed in the missing part , and the thickness of the outer surface of the drive belt 25 is adjusted in the supply box 8. By contacting the upper surface of the sheet 2 and transmitting the rotational drive of the rotary shaft 21 to the small rotary roll 24 via the belt 27, the drive belt 25 is advanced between the small rotary roll 24 and the large rotary roll 26. The thickness adjusting sheet 2 is advanced.
[0021]
Thus, by causing the thickness adjusting sheet 2 to advance by the drive device 18, it is possible to reduce the sliding resistance caused by the friction between the thickness adjusting sheet 2 and the cement material 3, and the thickness adjusting sheet 2 is generated by providing the thickness adjusting sheet 2. The load on the molded sheet 1 can be reduced.
[0022]
Incidentally, Te form smell above you facilities, it is effective to also obtain inorganic board having a uniform thickness and good formation applying multistage vibrating with a plurality of vibrator 15. Further, in the above embodiment, after passing through the first suction box 12a, the thickness adjusting sheet 2 is bent upward so as to be separated from the cement material 3, but before the vacuum dehydration is performed in the suction box 12. Alternatively, the thickness adjusting sheet 2 may be separated from the cement material 3, or after the vacuum dehydration is performed in the suction box 12, the thickness adjusting sheet 2 may be separated from the cement material 3.
[0023]
【The invention's effect】
According to a first aspect of the present invention as described above, the sheet and advanceable thickness adjusting sheet in the same direction over the molded sheet traveling in one direction is provided, the thickness adjusting sheet, the formed sheet The supply box is introduced from the opening on the upper surface of the cylindrical supply box which is provided on the upper side and the upper surface and the lower surface are open, and is led out from the outlet opening formed on the surface of the supply box facing the direction of travel of the molded sheet. A cement material having a solid content concentration of 20 to 55% by weight consisting of a solid content containing cement and water is supplied to the supply box and supplied onto the molded sheet from the supply box, and a small rotating roll and a large rotating roll the drive belt for coupling, arranged to fracture portion obtained by deleting a part of the outer wall of the side surface of the feeding box above the outlet of the supply box subjected to outer surface of the drive belt The thickness adjustment sheet is driven by abutting the upper surface of the thickness adjustment sheet in the box, bringing the cement material into contact with the thickness adjustment sheet in the supply box, and advancing the drive belt between the small rotation roll and the large rotation roll. Proceeding in the same direction as the molded sheet so as to proceed from the small rotating roll to the large rotating roll, and by applying vibration to the cement material through the thickness adjusting sheet while sandwiching the cement material between the forming sheet and the thickness adjusting sheet, Since the material is formed into a water-containing cement board, the use of a cement material having a solid content concentration of 20 to 55% by weight makes it possible to increase the dispersion state of the solid content as compared with the dry method, and the total water content as compared with the papermaking method. The amount can be kept small so that a large-scale water treatment facility is not required. Furthermore, by holding the cement material between the molded sheet and the thickness adjusting sheet and applying vibration to the cement material through the thickness adjusting sheet, the cement material is held so that shearing force is not applied to the cement material as much as possible, and the cement material is pressed and consolidated by vibration. The water-containing cement board can improve the solid content connection so that the water-containing cement board does not break, and the surface of the water-containing cement board can be smoothed by vibration, and has a good texture with a uniform thickness It can be molded into. Therefore, even if it is a wet method with a good dispersion state of the solid content, an inorganic board having a good texture with a uniform thickness can be obtained without requiring a large-scale water treatment facility. Moreover, the sliding resistance generated by rubbing the thickness adjusting sheet and the cement material can be reduced, and the load on the forming sheet generated by providing the thickness adjusting sheet can be reduced. As a device to be advanced, a large-scale device is not necessary.
[0024]
In the invention according to claim 2 of the present invention, since the thickness adjusting sheet is formed of a breathable sheet, the sheet enters between the cement material and the thickness adjusting sheet when the thickness adjusting sheet is brought into contact with the cement material. Air can be released through the thickness adjustment sheet, and the surface of the water-containing cement board can keep the air traces from being recessed like a crater, so the appearance without air traces is good A simple inorganic plate can be obtained.
[0025]
In the invention according to claim 3 of the present invention, since water is supplied to the place where the cement material and the thickness adjusting sheet are in contact with each other, when the thickness adjusting sheet is brought into contact with the cement material, there is no gap between the cement material and the thickness adjusting sheet. It can be removed with water so that the air that intrudes into the cement material does not remain on the cement material, and the traces of air can be kept on the surface of the water-containing cement board so as not to be recessed like a crater, Therefore, it is possible to obtain an inorganic plate having a good appearance with no trace of air.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a production apparatus used in a reference example of the present invention.
FIG. 2 is a schematic view showing a part of a manufacturing apparatus used in an example of an embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Molding sheet 2 Thickness adjustment sheet 3 Cement material 4 Hydrous cement board 8 Supply box 24 Small rotation roll 25 Drive belt 26 Large rotation roll

Claims (3)

A thickness adjusting sheet that can be advanced in the same direction as the sheet is provided above the forming sheet that advances in one direction, and this thickness adjusting sheet is provided on the upper side of the forming sheet and is provided in a cylindrical supply box that opens at the upper and lower surfaces. It is introduced from the opening on the upper surface and is led out from the outlet formed in the surface facing the direction of travel of the molding sheet of the supply box, and is passed through the supply box so that the solid content concentration including the solid content including cement and water is Supply a cement material of 20 to 55% by weight to the supply box and supply it from the supply box onto the molded sheet, and supply a driving belt connecting the small rotation roll and the large rotation roll above the outlet of the supply box the outer surface of the drive belt and disposed on a portion of the defect portion deficient in the outer wall side of the box on the upper surface of the thickness adjusting sheet in a feeding box those Then, the cement material is brought into contact with the thickness adjusting sheet in the supply box, and the driving belt is advanced between the small rotating roll and the large rotating roll, thereby driving the thickness adjusting sheet and proceeding from the small rotating roll to the large rotating roll. The cement material is formed into a hydrous cement board by advancing in the same direction as the forming sheet and applying vibration to the cement material through the thickness adjusting sheet while sandwiching the cement material between the forming sheet and the thickness adjusting sheet. The manufacturing method of the inorganic board characterized.   The method for producing an inorganic board according to claim 1, wherein the thickness adjusting sheet is formed of a breathable sheet.   Water is supplied to the location where a cement material and a thickness adjustment sheet contact, The manufacturing method of the inorganic board of Claim 1 or 2 characterized by the above-mentioned.

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