JP3698426B2 - Lightweight aggregate manufacturing apparatus, lightweight aggregate manufacturing method, and lightweight aggregate - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a lightweight aggregate manufacturing apparatus, a lightweight aggregate manufacturing method, and a lightweight aggregate.
[0002]
[Prior art]
  Conventionally, when manufacturing building materials such as concrete with cement as the main component, gravel is blended in addition to the cement, but light weight aggregates have conventionally been used as an alternative to gravel to reduce the weight of concrete. It is used. Conventional lightweight aggregates include fired foams such as glass balloons and shirasu balloons having many fine bubbles obtained by pulverizing, granulating, and firing shale.
  In coal-fired power plants, a large amount of fly ash (coal ash) is generated as waste material, and most of it is landfilled. Fly ash is a porous inorganic material containing a large amount of silica components, and when it is mixed with other raw materials, it binds firmly to the same raw material. Therefore, effective use such as mixing the fly ash with cement raw materials and concrete is also performed. ing.
[0003]
[Problems to be solved by the invention]
  In the conventional technology described above, firing is necessary to produce a lightweight aggregate, and there is a problem that the production cost is high.
  In addition, it is conceivable to mix a material with a relatively low specific gravity such as wood powder to make a lightweight aggregate, but there is also a desire to effectively use a waste material with a relatively large specific gravity such as fly ash as a lightweight aggregate. there were.
  The present invention has been made in view of the above problems, and it is not necessary to use a material having a small specific gravity, and a lightweight aggregate production apparatus, a lightweight aggregate production method, and a mass production of lightweight aggregates at low cost. The purpose is to provide lightweight aggregate.
[0004]
[Means for Solving the Problems]
  In order to achieve the above object, the invention according to claim 1Material heating means for heating and softening a predetermined material containing a thermoplastic resin;A configuration comprising an extruding means that presses a predetermined softened material into a cylindrical shape and extrudes it, and a forming means that cuts the extruded cylindrical material and closes the opening of the end of the material. It is as. That is, the predetermined softened material is extruded into a cylindrical shape and cut so that the opening at the end is closed. Since the molded lightweight aggregate has a hollow shape, it is not necessary to use a material having a small specific gravity.
Of course, if a material with a small specific gravity is used, a very lightweight lightweight aggregate can be manufactured.
In addition, when manufacturing lightweight aggregates, firing is not necessary, and it is only necessary to extrude and mold the material. Therefore, lightweight aggregates can be manufactured continuously with inexpensive equipment, and lightweight bones can be manufactured at low cost. It becomes possible to mass-produce materials.
Furthermore, it can be softened so that it can be extruded by heating the material with the material heating means. Moreover, it can be solidified by cooling.
[0005]
  Here, the extruding means is not particularly limited as long as it can extrude a predetermined cylindrical material so that it can be cut and formed by the forming means.
  Further, when closing the opening at the end of the cylindrical material, the opening at both ends of the material may be closed, or only one of the openings may be closed. Even if it is a lightweight aggregate that is closed only on one side of the opening, fluid such as concrete that is to be mixed when the other opening is closed is difficult to enter the hollow part of the same lightweight aggregate, It is possible to reduce the weight of the molded body from the fluid.
  Furthermore, cutting the cylindrical material and forming so as to close the opening of the end portion may be performed at the same time, and either one may be performed first and the other may be performed later. Also good.
[0006]
  Various configurations are possible for the forming means. As an example thereof, the invention according to claim 2 is characterized in that the molding means has a molding die in which a recess facing the tip of the cylindrical material extruded by the extrusion means is formed. The opening of the tip is closed by inserting and crushing the tip of the tip into the recess of the mold. That is, the front end portion of the extruded cylindrical material is inserted into a recess formed at an opposing position in the mold and is crushed to close the opening.
  Various shapes can be considered for the concave portion of the mold. For example, if the recess is formed in a substantially hemispherical shape with the opening facing the tip of the cylindrical material, the recess becomes thinner toward the back side, and the tip of the same material is crushed to make sure that the opening Can be closed. Moreover, since the front-end | tip part of the same material is crushed and formed in a substantially semicircular shape, the appearance of the lightweight aggregate can be improved.
[0007]
  Various configurations for cutting the rear end of the cylindrical material are also conceivable. As an example,UpThe forming means has a configuration in which the cylindrical material extruded by the extruding means is cut by crushing in the cross-sectional direction to close the opening of the rear end portion of the material.Good. That is, the extruded cylindrical material is crushed and cut in the cross-sectional direction, and the opening at the rear end is closed.
According to the said invention, a cylindrical raw material can be cut | disconnected with a simple structure, and the opening of the rear-end part of a lightweight aggregate can be plugged up.
  In addition, by closing both the openings at both ends of the cylindrical material, a light-blocked cavity is formed in the lightweight aggregate, and the fluid such as concrete to be mixed is lightweight. It is possible to reduce the weight of the molded body of the fluid more reliably without entering the hollow portion of the aggregate.
[0008]
  As an example of a configuration that cuts by crushing a cylindrical material in the cross-sectional direction,UpThe forming means has a pressing part formed in a rounded shape at the tip, and the cylindrical material is crushed in the cross-sectional direction by pressing the tip of the pressing part against the cylindrical material. AsGood.
That is, at the time of cutting, the material is cut by crushing by pressing the tip of the pressing part against the resin layer. Accordingly, the cylindrical material is pressed against the tip of the pressing part, and is crushed and cut. By forming roundness at the front end of the pressing part, the material is crushed and cut, and the opening at the rear end part is closed.
According to the said invention, the simple structure which cut | disconnects a cylindrical-shaped raw material and plugs the opening of the rear-end part of a lightweight aggregate can be provided.
[0009]
  In order to continuously manufacture a large amount of lightweight aggregate, it is preferable that a softened material can be extruded from a plurality of locations and continuously formed. As an example,UpThe extrusion means extrudes the material from a plurality of extrusion ports into a cylindrical shape, and a plurality of the molds are provided and a plurality of the recesses corresponding to each of the plurality of extrusion ports are formed. As a configuration in which any one of the plurality of molds is opposed to the plurality of extrusion ports in order.Good.
  That is, the softened material is extruded in a cylindrical shape from a plurality of extrusion ports, and the tip portion is crushed by any of the plurality of molds to close the opening. Here, since a some shaping | molding die is opposed to several extrusion ports in order, a lightweight aggregate can be manufactured in large quantities continuously.
According to the said invention, it becomes possible to manufacture a light aggregate in large quantities continuously.
  Moreover, you may attach the said pressing part to a shaping | molding die. Then, it becomes possible to cut the cylindrical material by moving the mold, so that the structure can be simplified.
[0010]
  Various things can be considered as the predetermined material. As an example,UpThe specified material is composed of a meltable resin and a fine porous inorganic material.Good. That is, since a predetermined material contains a meltable resin, extrusion molding can be performed. Here, since the fine inorganic material is porous, it is firmly bonded to the meltable resin, and the lightweight aggregate becomes hard. Therefore, it is possible to produce a hard lightweight aggregate that can be used as a mixed material for concrete and building materials by effectively using the porous inorganic material.
  In addition, the said raw material may be comprised only from the said porous inorganic material and meltable resin, and may be comprised by adding 3rd materials other than the porous inorganic material and meltable resin. .
  Moreover, the porous inorganic material should just be a porous inorganic material made into the fine particle, and even if it is a powder form, it is contained in the fine particle said to this invention.
[0011]
  Here, various porous inorganic materials are conceivable, and the above-described fly ash may be used, or stone powder crushed from rock may be used. Further, since the hollow portion is formed even if the specific gravity of the porous inorganic material is relatively large, the manufactured lightweight aggregate can reduce the weight of a molded body such as concrete to be mixed.
  Although it is preferable to use a porous inorganic material as a raw material, it is preferable in that the lightweight aggregate can be hardened. Alternatively, an organic material such as wood powder may be used.
[0012]
  Various types of resin can be used..
[0013]
  further,UpAs a configuration provided with cooling means for cooling the molded materialGood.
That is, the molded material can be solidified by cooling. Moreover, it can prevent that the shape | molded raw material adhere | attaches mutually.
According to the said invention, the manufacturing efficiency of a lightweight aggregate can be improved further.
  Here, various structures can be considered for the cooling means. For example, cold water may be put in a predetermined cooling tank, and the molded material may be dropped into the cooling tank. Then, if a raw material is collect | recovered from the inside of the cooling tank, the lightweight aggregate formed by solidification can be obtained. Further, a dropping path part having a predetermined dropping path may be provided, and the material released from the mold may be cooled while being dropped by the dropping path part. Then, the formed material is cooled by air by dropping the dropping path and solidified.
  In addition, the structure which includes a thermoplastic resin in a predetermined material is only an example, and a thermosetting resin such as a phenol resin, a urea resin, a melamine resin, an unsaturated polyester resin, or an epoxy resin can be used.
[0014]
  By the way, the method of manufacturing a lightweight aggregate as described above is not necessarily limited to a substantial device,Claim 3Like the invention according toPredetermined material containing thermoplastic resin Same as the material heating process to heat and softenLight weight comprising: an extrusion process for pressing a predetermined softened material into a cylindrical shape and extruding it, and a molding process for cutting the extruded cylindrical material and closing the opening at the end of the material It is also effective as an aggregate manufacturing method.
[0015]
  Moreover, since a hollow part is formed by being manufactured by the manufacturing method mentioned above, and a lightweight lightweight aggregate can be provided,Claim 4Like the invention according toHeating and softening a predetermined material containing a thermoplastic resin,It is also effective as a lightweight aggregate produced by pressurizing and extruding a predetermined softened material into a tubular shape, cutting the extruded tubular material and closing the opening at the end of the material. .
  Of course,Claim 2Needless to say, it is possible to make the apparatus configuration described in (1) correspond to a lightweight aggregate manufacturing method and a lightweight aggregate.
[0016]
【The invention's effect】
  As described above, claim 1,Claims 3 and 4According to the invention, it is not necessary to use a material having a small specific gravity, and it is possible to mass-produce a lightweight aggregate at a low cost.Further, since the material can be heated and softened so that it can be extruded, the convenience can be improved.
[0017]
  According to the invention of claim 2, the opening at the tip of the lightweight aggregate can be closed with a simple configuration..
[0018]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, embodiments of the present invention will be described in the following order.
(1) About lightweight aggregate:
(2) Configuration of lightweight aggregate manufacturing device:
(3) Operation of lightweight aggregate manufacturing device:
(4) Summary:
[0019]
(1) About lightweight aggregate:
  Initially, the outline which manufactures a lightweight aggregate using the lightweight aggregate manufacturing apparatus concerning one Embodiment of this invention, and mixes with a building material is demonstrated.
  FIG. 1 is a schematic flowchart showing a process of manufacturing a lightweight aggregate and manufacturing a building material using the lightweight aggregate. In the present embodiment, a lightweight aggregate having a hollow portion is manufactured using fly ash A1 discharged from a coal-fired power plant and thermoplastic resin (meltable resin) A3 as predetermined materials.
  Fly ash A1 is a blackish ash produced when coal is fired, and is a finely divided (including powdered) porous inorganic material containing silica. The fly ash A1 may have various particle diameters, and may be any particle diameter that allows the fly ash A1 to be bonded together by the thermoplastic resin A3.
[0020]
  Various resins can be adopted as the thermoplastic resin A3, and for example, polypropylene, polyethylene, polystyrene, polymethyl methacrylate, vinyl chloride, nylon, polycarbonate, polyacetal, polybutylene terephthalate, polyethylene terephthalate, etc. can be used. . Of course, a plurality of these resins may be used in combination.
Further, when it is put into the lightweight aggregate manufacturing apparatus A4, it may be put as a solid raw material or may be put in a molten state.
[0021]
  A lightweight aggregate can be produced by using only one of the above-mentioned resins as the thermoplastic resin A3, and any one of the resins described above can be selected as the main component of the thermoplastic resin A3. What modified the resin selected using (predetermined acid) is good also as a subcomponent of thermoplastic resin A3. Of course, the acid that modifies the thermoplastic resin is not limited to maleic acid, and a modification of a resin different from the main component may be used as a subcomponent of the thermoplastic resin A3. Furthermore, since a resin obtained by modifying a thermoplastic resin with an acid is also usually a thermoplastic resin, only the modified resin may be used as the thermoplastic resin A3.
  In order to produce the modified resin, for example, addition polymerization may be performed by adding maleic acid to the raw material before the addition polymerization. Then, a carboxyl group which is one of hydrophilic groups is added to the polymer after addition polymerization. Therefore, the modified resin contained in the thermoplastic resin A3 tends to have an affinity with a hydroxyl group or the like.
[0022]
  The blending ratio of the fly ash A1 and the thermoplastic resin A3 can be appropriately determined according to the use of the lightweight aggregate. Generally, the higher the weight ratio of fly ash, the harder the hard stuff, and the higher the weight ratio of thermoplastic resin, the softer the ash. As the weight ratio of both, a preferable ratio can be appropriately selected according to the properties required for the lightweight aggregate.
  In order to make the lightweight aggregate like an inorganic material with low thermal expansion and flame resistance, the fly ash may be mixed with the fly ash and an equal weight or less thermoplastic resin. Even if the fly ash has a weight less than that of the thermoplastic resin, the fly ash particles are substantially spherical, so that a so-called bearing effect occurs in which the particles roll like a bearing when they come into contact with each other. Therefore, fly ash and molten thermoplastic resin can be easily mixed by the bearing effect to perform extrusion molding, injection molding, or the like, and a hard lightweight aggregate can be obtained.
[0023]
  Instead of fly ash A1, a fine and porous quartz-based mineral A2 may be used. The quartz-based mineral A2 is a mineral mainly composed of quartz, and is used after being pulverized to a particle size according to the application to be a stone powder. When lightweight aggregates were molded using various siliceous minerals, quartz schist and hard quartz rocks collected from Mt. Danto in Shitara-cho, Kitashiraku-gun, Aichi Prefecture were suitable for molding. The quartz schist and hard quartz rock are SiO₂ Is a mineral mainly containing quartz containing 80 to 85% by weight and containing some soda feldspar. Moreover, when the stone powder which grind | pulverized these rocks for mixing with a thermoplastic resin was observed with the microscope, it was confirmed that many fine pores exist. Therefore, the crushed quartz schist and hard siliceous rock are fine porous inorganic materials.
[0024]
  The blending ratio of the siliceous mineral A2 and the thermoplastic resin A3 can also be appropriately determined according to the use of the lightweight aggregate. The higher the weight ratio of the siliceous mineral, the harder the weight ratio of the thermoplastic resin. The more it becomes, the softer it becomes.
  In order to make a lightweight aggregate flame retardant with a small thermal expansion like an inorganic material, the siliceous mineral may be mixed with the siliceous mineral and an equal weight or less thermoplastic resin. Even if the weight of the thermoplastic resin is less than or equal to the weight of the quartz-based mineral, it becomes clayy and has good fluidity during melt mixing. Therefore, it can be easily mixed and extruded, and a hard lightweight aggregate can be obtained.
[0025]
  When a material composed of fly ash A1 and thermoplastic resin A3 is charged into the lightweight aggregate manufacturing apparatus A4, the apparatus A4 heats and softens the material, and pressurizes the softened material into a cylindrical shape. Extruded, the extruded cylindrical material is cut and the opening at the end of the material is closed. Since the material includes a thermoplastic resin, the thermoplastic resin is melted by heating, the material is softened, and can be extruded. Here, since both ends of the cylindrical material are crushed and the opening is closed, a light-weight aggregate A5 having a substantially capsule shape or a substantially ball shape (a substantially spherical shape having a cavity blocked from the outside) is manufactured. Is done.
[0026]
  The lightweight aggregate A5 is blended with building materials. The building material has cement as a main component, and a lightweight aggregate can be obtained by using lightweight aggregate as an alternative to gravel. The raw materials for building materials are put into the stirring vessel A6 and stirred, and mainly the cement raw material powder A7 and water A8 are put in addition to the lightweight aggregate A5. Of course, gravel may be included. These raw materials are stirred in the stirring vessel A6 and become a fluid building material raw material. When this fluid building material raw material is poured into a female mold of a building material having a predetermined shape, it is cured with the passage of time to become a building material A9, which is used in various buildings.
  If fly ash is used as the predetermined material, an effect of imparting a glossy feeling to the surface of the lightweight aggregate can be obtained. Therefore, the manufactured lightweight aggregate may be used for applications that require a decorative effect. .
[0027]
(2) Configuration of lightweight aggregate manufacturing device:
  Next, the external side view of one embodiment of the lightweight aggregate manufacturing apparatus is shown in FIG. Moreover, the external appearance top view of the said lightweight aggregate manufacturing apparatus is shown in FIG. In the figure, a lightweight aggregate manufacturing apparatus 10 constituting the above-described lightweight aggregate manufacturing apparatus A4 is roughly composed of a material supply apparatus 11, a material transport apparatus 12, a material heating apparatus 13, a lightweight aggregate forming apparatus 20, and a sorting transport apparatus 14. A control panel 15 is provided.
[0028]
  The material supply device 11 has a hopper device 11a which is formed in a hollow, substantially cylindrical shape and has an opening 11a1 on the upper surface. The material supply device 11 is pulverized into a finely divided porous inorganic material such as fly ash A1 and a fragment shape. A predetermined material made of the thermoplastic resin A3 is introduced from the opening 11a1 and accommodated in the hopper device 11a. Inside the hopper device 11a, a stirring blade 11a2 and a stirring blade connection disk 11a3 to which the stirring blade 11a2 is connected are arranged. The stirring blade connection disk 11a3 is connected to the stirring blade via a belt 11a4. It is connected to the drive motor 11a5. The drive of the motor 11a5 is transmitted to the disk 11a3 via the belt 11a4, and thereby the disk 11a3 and the stirring blade 11a2 are rotationally driven. Thereby, the raw material accommodated in the hopper device 11a is mixed while being stirred in a granular form. The mixed raw material is supplied from the mixed material supply port 11a6 to the raw material transport device 12 which is a device for the next process.
[0029]
  The material conveying device 12 is connected to the mixed material supply port 11a6 of the material supply device at the mixed material inflow port 12a, and receives the mixed material supplied from the mixed material supply port 11a6 at the mixed material supply port 12a. Here, a screw shaft 12c is disposed inside the substantially cylindrical hollow tube 12b, and a screw having a plurality of flights of helical threads formed along the axial direction is disposed on the screw shaft 12c. ing.
[0030]
  At this time, the raw material supplied at the mixed material inlet 12a is accommodated in a space formed by the hollow tube 12b, the screw shaft 12c, and the screw thread. The screw shaft 12c is connected to a screw shaft drive motor 12e via a gear portion 12d. When the motor 12e is driven to rotate the screw shaft 12c, the material accommodated in the space formed by the hollow tube 12b, the screw shaft 12c, and the thread is a predetermined shape formed by the rotating operation. Based on the extrusion speed, the mixed material is extruded from the mixed material inlet 12a toward the fluid outlet 12f while being mixed.
[0031]
  The material supplied from the mixed material inlet 12a is heated by the material heating device 13 provided in the material conveying device 12, and the thermoplastic resin is melted to soften the material. Therefore, the material extruded by the rotational movement of the screw shaft 12c is extruded to the fluid outlet 12f in a softened state. The material heating device 13 generally includes a plurality of heater portions 13a and a plurality of blower portions 13b corresponding to the heater portions 13a. The heater part 13a has a heating element, and the material in the hollow pipe 12b is heated by blowing air heated to a high temperature by the heating element to the hollow pipe 12b by the blower part 13b. That is, the material heating device 13 constitutes a material heating means that heats and softens the material.
[0032]
  Here, the heater part should just be raised to the temperature which fuses a thermoplastic resin, and should just determine the heating capability of a heater according to the kind of thermoplastic resin. If the heating of the heater is set so that the temperature of the raw material is higher than the melting point of the thermoplastic resin and lower than the melting point of the porous inorganic material, the porous inorganic material can be melted and mixed without being melted. .
  In addition, what is necessary is just to determine the capability in which the raw material conveying apparatus 12 conveys a raw material according to properties, such as a viscosity of the softened raw material.
[0033]
  The softened material is pushed into the lightweight aggregate forming apparatus 20 from the fluid outlet 12f. Then, it is extruded in a cylindrical shape, cut and molded so as to be twisted by a die face cutter, and cooled in a cooling bath 30. Here, the cylindrical material is solidified in such a state that the end portion is crushed and the opening is closed. Details of the lightweight aggregate forming apparatus 20 will be described later.
  The cooling tank 30 is filled with cold water cooled by a cooling mechanism (not shown), and the material after molding falling from the lightweight aggregate molding apparatus 20 is solidified with cold water. That is, the cooling tank 30 and the cooling mechanism constitute cooling means for cooling the molded material. By immediately solidifying the molded material, it is possible to prevent the molded materials from adhering to each other.
[0034]
  The solidified lightweight aggregate flows into the sorting and conveying device 14 from the lightweight aggregate inflow port 14a. The sorting / conveying device 14 has a sorting / conveying network, a conveying net vibration motor, and a lightweight aggregate container in which a large number of substantially circular small holes having a predetermined diameter are formed. The lightweight aggregates are sequentially put into the sorting and transporting network, and the size is sorted by the small holes of the sorting and transporting network by vibrating the sorting and transporting net by the transporting net vibration motor. Then, the lightweight aggregate remaining on the sorting and conveying network moves toward the lightweight aggregate collecting unit on the sorting and conveying network and is accommodated in the lightweight aggregate accommodating portion by a cyclone (not shown). In addition, the lightweight aggregate that has fallen from the sorting conveyance network is collected and reused.
[0035]
  The control panel 15 is provided with a plurality of operation buttons and an operation display for monitoring the setting of operation conditions and the operation state of the lightweight aggregate manufacturing apparatus 10 on the front surface. An operator of the apparatus 10 performs various operations using the control panel 15.
[0036]
  FIG. 4 is a vertical cross-sectional view of a main part of the lightweight aggregate forming apparatus 20. The lightweight aggregate forming apparatus 20 is attached to a cylindrical metal outer cylinder portion 21 centering on the direction of extrusion of the softened material, and an end portion of the outer cylinder portion 21 on the material outlet side (right side in the figure). A metal die 22, a metal mold 23 disposed opposite to the material outlet, a metal die face cutter 24, and the like are provided. Hereinafter, the arrangement of each member will be described based on the vertical and horizontal relationships with reference to FIG.
  A material inlet 21 a is provided on the left side of the outer cylinder portion 21, and the softened material flows into the material inlet 21 a from the material conveying device 12.
[0037]
  The die portion 22 is attached to the outer cylinder portion 21 so as to be inserted into a disc 22a in which a plurality of substantially circular extrusion ports 22a1 are concentrically formed and the respective extrusion ports 22a1 of the disc. The shaft center member 22b has a substantially circular cross section. The disc 22a is attached to the outer cylinder part so as to close the left opening of the outer cylinder part 21.
  5 is a side view showing the die portion 22 as viewed from the right side of FIG. In the present embodiment, a total of eight extrusion ports 22a1 are formed on the disk 22a. And since the axial center material 22b exists in the approximate center part of each extrusion port 22a1, the raw material of the softened state extruded from the extrusion port 22a1 is made into a cylindrical shape.
[0038]
  Here, since the softened material is pressed into the outer cylinder portion 21 while being pressurized by the material conveying device 12, the lightweight aggregate forming device 20 simultaneously converts the pressurized material into a cylindrical shape from the plurality of extrusion ports 22a1. Push out. That is, the material conveying device 12, the outer cylinder part 21, and the die part 22 constitute an extruding unit that pressurizes a predetermined softened material and extrudes it into a cylindrical shape.
  In addition, the magnitude | size of the extrusion port 22a1 and the diameter of the shaft center material 22b can be made into various magnitude | sizes and diameters according to the use of the lightweight aggregate to manufacture.
[0039]
  The molding die 23 is formed with a plurality of recesses 23a that correspond to the plurality of extrusion ports 22a1 and that are opposed to the tip of the cylindrical material extruded from the extrusion port 22a1. The concave portion 23a has a diameter substantially the same as the diameter of the extrusion port 22a1, and is formed in a substantially hemispherical shape with the opening facing the tip of a cylindrical material extruded from the extrusion port 22a1. Accordingly, the concave portion 23a becomes thinner toward the back side, and the cylindrical material extruded from the extrusion port 22a1 is inserted into the concave portion 23a, and is surely crushed to close the opening. Become.
  Of course, the shape of the recess 23a is not limited to a hemispherical shape, and various shapes such as a conical shape and a flat hemispherical shape are conceivable.
  The molding die 23 and the extrusion port 22a1 can have various intervals according to the use of the lightweight aggregate to be manufactured.
  A plurality (three) of the molds 23 of the present embodiment are provided. These molding dies 23 are attached and fixed to a Y-shaped member 23b that can rotate about a predetermined rotation axis, and move in accordance with the rotation of the Y-shaped member 23b to sequentially face the extrusion ports 22a1. It is supposed to be arranged in. In addition, although the shape | molded raw material will be in the state inserted in the recessed part 23a of a shaping | molding die, it will release by the compressed air supply apparatus mentioned later.
[0040]
  FIG. 6 is a side view seen from the right side of FIG.
  Each mold 23 is rotatably attached to a columnar rotating shaft member 25a penetrating the center portion. A spur gear 25b is externally fitted and fixed to each rotary shaft 25a, and a die face cutter portion 24 is attached and fixed through the mold 23.
Accordingly, the die face cutter unit 24 rotates integrally with the spur gear 25b. All of the three spur gears 25b mesh with one large spur gear 25c. In the figure, the central axes of the spur gears 25b1 to 3 (positions of the rotating shaft member 25a) are positions where the straight lines connecting the rotating shaft 25d of the large spur gear 25c are 120 degrees with each other. Each rotating shaft member 25a is rotatably attached to three end portions of a Y-shaped member 25e that can rotate around a rotating shaft 25d of the large spur gear 25c. The Y-shaped member 23b to which the molding die 23 is attached is attached so as to be rotatable with respect to the rotary shaft 25d.
[0041]
  A servo motor 25f capable of rotationally driving the large spur gear 25c or the Y-shaped member 25e is mounted on the rotary shaft 25d. Here, the rotational force from the servomotor 25f is transmitted while being switched to either the large spur gear 25c or the Y-shaped member 25e by the rotational force transmission switching mechanism 25g. Then, according to a predetermined sequence, the rotational force switching control is performed on the rotational force transmission switching mechanism 25g, and the rotation / stop control is performed on the servo motor 25f.
[0042]
  For example, when the rotational force of the servo motor 25f is transmitted to the Y-shaped member 25e with respect to the rotational force switching transmission mechanism 25g, the servo motor 25f is driven, so that any one of the plurality of molding dies 23 is sequentially arranged. Can be opposed to the extrusion port 22a1. At this time, the Y-shaped member 23b to which the molding die 23 is attached also rotates in synchronization with each other so that each of the concave portions 23a of the molding die is opposed to the extrusion port 22a1.
  Further, when the same rotational force is transmitted to the large spur gear 25c, each spur gear 25b is rotated by driving the servo motor 25f, and each molding die 23 is rotated at a position opposite to the plurality of extrusion ports 22a1. be able to. In the figure, the large spur gear 25c rotates clockwise, and the die face cutter unit 24 rotates clockwise together with the spur gear 25b.
  Of course, it goes without saying that the mechanism for rotating and moving the molding die and the die face cutter unit is not limited to the one described above.
[0043]
  The die face cutter unit 24 is attached to and fixed to the rotary shaft member 25a on the surface (left side in FIG. 4) where the recess 23a is formed in each mold 23, and rotates integrally with the rotary shaft member 25a. Or move together with the mold 23. Each die face cutter unit 24 includes a cutter table 24a serving as a mounting portion to the rotary shaft member 25a and a plurality (four in this embodiment) of cutters 24b that are mounted and fixed to the cutter table 24a. ing.
  Here, each cutter 24b slides on the surface of the disk 22a (the right side in FIG. 4), and cuts the cylindrical material extruded from the extrusion port 22a1 by rotating.
[0044]
  FIG. 7 is an external perspective view of the cutter 24b. The cutter 24b is composed of a table mounting portion 24b1 and a pressing portion 24b2. Bolt holes 24b3 and 24b3 are formed in the table mounting portion 24b1, and the cutter 24b can be screwed to the cutter table 24a with bolts (not shown).
  The pressing part 24b2 is formed with an inclination that descends from the rear side in the traveling direction toward the front side with reference to FIG. 7, and a cutting edge that cuts the cylindrical material extruded from the extrusion port 22a1 is formed at the tip 24b4. The tip 24b4 of the pressing part is not a sharp cutting edge, and is formed in a rounded shape. Therefore, the cylindrical material can be cut while being crushed in the cross-sectional direction by pressing the tip 24b4 of the pressing part against the cylindrical material. As a result, the opening of the rear end portion of the cylindrical material extruded from the extrusion port 22a1 is blocked.
  In addition, as long as a cutter can crush and cut | disconnect a cylindrical raw material to a cross-sectional direction, the thing of various shapes can be employ | adopted. For example, even with an obtuse angled cutter, it is possible to crush and cut a cylindrical material in the cross-sectional direction to close the opening at the rear end of the material.
[0045]
(3) Operation of lightweight aggregate manufacturing device:
  Hereinafter, operation | movement of this lightweight aggregate manufacturing apparatus 10 is demonstrated. Note that one of the plurality of molding dies 23 (molding die at the uppermost position in FIG. 6) is disposed with each of the plurality of recesses 23a facing each extrusion port 22a1. .
  When a material composed of a fine porous inorganic material and a granular thermoplastic resin is put into the material supply device 11, the material conveying device 12 conveys the material in the direction of the lightweight aggregate forming device 20 while mixing the materials. At this time, since the material heating device 13 heats the material, the thermoplastic resin is melted and the material is softened. Since the material conveying device 12 presses the softened material into the outer cylinder portion 21 of the lightweight aggregate forming device while pressing, the pressurized soft material M1 is pushed out from each extrusion port 22a1 as shown in FIG. It is. Here, since the shaft center material 22b is inserted into the extrusion port 22a1, the softened material M1 is extruded into a cylindrical shape like macaroni, and an opening is formed at the tip M1a (right side of the drawing) of the material M1. Is formed.
[0046]
  When the material M1 is further pushed out, as shown in FIG. 9, the tip portion M1a of the cylindrical material advances toward the recessed portion 23a formed at the position facing the extrusion port 22a1 in the molding die 23, and the recessed portion Enter 23a. Then, the front end M1a is crushed by the pressing force of the material M1 itself, and the opening is closed. Moreover, since the recessed part 23a is so thin that it becomes the back | inner side on the basis of the advancing direction of the raw material M1, it can crush the front-end | tip part M1a of a raw material reliably with a simple structure, and can close an opening. In addition, since the front-end | tip part M1a of the same material is crushed and formed in the substantially semicircle shape, it can make the appearance of a lightweight aggregate favorable.
[0047]
  Next, as shown in FIG. 10, by transmitting the drive of the servo motor 25f to the large spur gear 25c, the die face cutter unit 24 is rotated, and the tip of the pressing part 24b2 of the cutter 24b is pressed against the cylindrical material M1. As a result, the cylindrical material M1 is crushed in the cross-sectional direction. Here, since the tip of the pressing part 24b2 is formed in a rounded shape, the extruded cylindrical material M1 is crushed in the cross-sectional direction and cut. Then, as shown in FIG. 11, the rear end portion M1b of the extruded cylindrical material is crushed and the opening is closed.
Therefore, it is possible to close the opening of the rear end portion of the lightweight aggregate by cutting the cylindrical material while using a simple configuration in which a cutter having a rounded blade edge is used.
  As a result, the molded material M2 is formed with a hollow portion M2a that is a cavity blocked from the outside, and is formed into a substantially capsule shape or a substantially ball shape.
  As described above, the mold 23, the die face cutter unit 24, the members that rotate the die face cutter unit 24, and the mechanisms 25a to 25g cut the extruded cylindrical material and open the end of the material. Forming means for forming so as to close the cover.
[0048]
  Thereafter, the drive of the servo motor 25f is transmitted to the Y-shaped member 25e to move the mold 23 and the die face cutter part 24, and another mold 23 together with the die face cutter part 24 is opposed to the extrusion port 22a1. In FIG. 6, the lower left mold 23 is brought to the position facing the extrusion port 22a1. At this time, as shown in FIG. 12, the material M2 partially inserted into the recess 23a of the molding die receives the compressed air from the compressed air supply device, and leaves the recess 23a of the molding die.
And it falls in the cooling tank 30, becomes the lightweight aggregate M3 by being cooled and solidifying.
Then, the manufactured lightweight aggregate M3 is collected from the cooling tank 30.
[0049]
  Here, since the molded lightweight aggregate M3 is formed with a hollow portion M2a which is a cavity cut off from the outside, it is not necessary to use a material having a small specific gravity. That is, it is possible to produce a hard lightweight aggregate by effectively using a porous inorganic material such as fly ash, which is a waste material, or a fine-grained quartz-based mineral. Of course, if a material with a small specific gravity such as wood powder is used, a very lightweight lightweight aggregate can be provided. Moreover, the baking process which manufactures baking foams, such as a glass balloon and a glass balloon, is unnecessary, and what is necessary is just to extrude and shape | mold a raw material like a normal resin product. Therefore, it is possible to continuously manufacture lightweight aggregates with inexpensive equipment, and it is possible to mass-produce lightweight aggregates at low cost. Further, since a factory that manufactures resin products does not require expensive capital investment, it is possible to easily manufacture lightweight aggregates.
[0050]
  In addition, by using a thermoplastic resin as one of the materials, mass production of lightweight aggregate can be performed by a simple process of heating and melting and mixing with a porous inorganic material to soften the material and cooling to solidify. it can.
  Furthermore, a large amount of lightweight aggregate can be produced continuously by making a plurality of molds face the plurality of extrusion ports in order.
  In addition, the weight ratio of the porous inorganic material in the material can be set to be equal to or more than the weight of the thermoplastic resin. In this case, a very hard and lightweight lightweight aggregate like an inorganic material is used as a normal resin product. On the other hand, it can be produced by extrusion molding or the like.
[0051]
(4) Summary:
  The lightweight aggregate manufactured as described above can form a hollow body that is shielded from the outside air, so that the molded body of fluid such as concrete can be reliably reduced in weight. Even if the opening at one end is not blocked, it can be used as a lightweight aggregate. That is, even if a fluid such as concrete to be mixed with the lightweight aggregate tries to enter the hollow portion from the opening in the lightweight aggregate, the other end portion is closed, so the air present in the hollow portion is exposed to the outside. It remains without escaping, and the molded product from the fluid can be reduced in weight.
[0052]
  For this reason, for example, if a cutter with a sharp edge is used, the opening at the rear end of the cylindrical material will not be blocked with reference to the extrusion direction. Even if it shape | molds in the shape where only one was plugged, it can be used as a lightweight aggregate.
  In addition, when using a cutter with a blunt edge, if the mold having a recess facing the tip of the cylindrical material is not used, the opening of the tip of the cylindrical material is not blocked. In this case, the same can be said.
[0053]
  Furthermore, you may provide the press part heating means which heats the notch part of a cutter. For example, when a heater is embedded in the cutter table 24a and the heater is energized, the press-cut portion of the cutter can be heated. Then, it can cut | disconnect by softening the raw material containing a thermoplastic resin in the vicinity of a pressing part, and crushing easily, and can improve the manufacturing efficiency of a lightweight aggregate.
  Also, a mold temperature control means for controlling the temperature of the mold may be provided to perform control to make it easy to release the cylindrical material whose tip is crushed by the recess. For example, when a thermocouple and a temperature sensor are embedded in the mold, and control is performed to pass current to the thermocouple so that the temperature of the mold detected by the temperature sensor is within a predetermined range, The temperature of the mold can be controlled. Then, the manufacturing efficiency of a lightweight aggregate can further be improved.
[0054]
  As described above, according to the present invention, a lightweight aggregate manufacturing apparatus and a lightweight aggregate manufacturing method capable of mass-producing lightweight aggregates at low cost without using a material having a small specific gravity due to various aspects. Can be provided. Moreover, the useful lightweight aggregate by which the hollow part was formed and reduced in weight by manufacturing with the manufacturing method mentioned above can also be provided.
[Brief description of the drawings]
FIG. 1 is a schematic flowchart showing a process of manufacturing a lightweight aggregate and further manufacturing a building material.
FIG. 2 is an external side view of a lightweight aggregate manufacturing apparatus.
FIG. 3 is an external top view of the lightweight aggregate manufacturing apparatus.
FIG. 4 is a vertical sectional view of a main part of the lightweight aggregate forming apparatus.
5 is a side view showing the die portion as seen from the right side of FIG. 4;
6 is a side view showing the mold, various members, and mechanisms 25a to 25g as viewed from the right side of FIG.
FIG. 7 is an external perspective view of a cutter.
FIG. 8 is a cross-sectional view of a main part showing a state where a cylindrical material is extruded.
FIG. 9 is a cross-sectional view of a main part showing a state in which an opening at a tip end portion in a cylindrical material is closed.
FIG. 10 is a cross-sectional view of a main part showing a state in which a pressing part of a cutter cuts a cylindrical material in a cross-sectional direction.
FIG. 11 is a cross-sectional view of the main part showing a state in which the opening at the rear end of the cylindrical material is closed.
FIG. 12 is a side view of a principal part showing a partial cross-sectional view of a molded material being cooled to form a lightweight aggregate.
[Explanation of symbols]
10, A4 ... Lightweight aggregate manufacturing equipment
11 ... Material supply device
12 ... Material conveying device
13 ... Material heating device
14 ... Sorting and conveying device
15 ... Control panel
20 ... Lightweight aggregate molding device
21 ... Outer cylinder
21a ... Material inlet
22 ... Die part
22a ... disc
22a1 ... extrusion port
22b ... shaft core material
23 ... Mold
23a ... recess
23b ... Y-shaped member
24 ... Die face cutter
24a ... Cutter table
24b ... Cutter
30 ... Cooling tank
A1 ... Fly Ash
A2 ... Quartz mineral
A3 ... Thermoplastic resin
A4 ... Lightweight aggregate manufacturing equipment
A5, M3 ... Lightweight aggregate
M1 ... material
M1a ... the tip of the material
M1b: Rear end of material
M2 ... Molded material
M2a ... hollow part

Claims (4)

A material heating means for heating and softening a predetermined material containing a thermoplastic resin;
An extruding means for extruding the softened predetermined material into a cylindrical shape by pressing,
A lightweight aggregate manufacturing apparatus comprising: a molding unit configured to cut the extruded cylindrical material and close an opening of an end portion of the material.   The molding means has a molding die formed with a recess facing the tip of the cylindrical material extruded by the extrusion means, and the tip of the cylindrical material is inserted into the recess of the molding die. The lightweight aggregate manufacturing apparatus according to claim 1, wherein the opening at the tip is closed by pressing and crushing. A material heating process in which a predetermined material containing a thermoplastic resin is heated and softened;
An extrusion process in which the softened predetermined material is pressed into a cylindrical shape and extruded;
A lightweight aggregate manufacturing method, comprising: a molding step of cutting the extruded cylindrical material and closing an opening at an end of the material. Heating and softening a predetermined material containing thermoplastic resin, pressurizing and extruding the softened predetermined material into a cylindrical shape, cutting the extruded cylindrical material and closing the opening at the end of the same material A lightweight aggregate characterized by being molded and manufactured as described above.

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