JP4070855B2 - Method for producing lightweight lightweight concrete panel with pattern - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a patterned lightweight cellular concrete panel having an uneven pattern on the surface.
[0002]
[Prior art]
The lightweight cellular concrete panel is excellent in economic efficiency, light weight, fireproof heat insulation, and workability, but has a problem that the surface has poor design.
In order to overcome this problem, a method has been proposed in which a lightweight cellular concrete panel is pressed against a surface of a decorative mold having an uneven pattern at the stage of a semi-cured mortar panel to form a pattern (Japanese Patent Publication No. 3-27368). No. 5, 34,121, and JP-A-9-1557056).
[0003]
However, in the above method, the semi-cured mortar panel is often at a relatively high temperature of about 60 ° C., and the temperature difference from the surrounding tends to be large. In such a case, as shown in FIG. 2 , there is a problem that the decorative mold 1 having the uneven pattern is warped. This is because the part of the decorative mold that is in contact with the semi-cured mortar panel 2 is hot, whereas the back of the decorative mold is almost equal to room temperature and has a temperature gradient inside the decorative mold. It is. When a temperature gradient is generated inside the decorative mold, the high temperature side expands due to the temperature, and the entire decorative mold warps in a convex shape on the high temperature side. If the makeup mold is warped, it is difficult to accurately copy the irregularities on the surface of the makeup mold, and further, a mold release failure at the time of demolding is likely to occur due to the warpage of the makeup mold.
[0004]
In order to prevent this, there is a method of making the makeup mold made of thick steel and fixing it on a firm surface plate. In this way, a lot of labor is required to replace the makeup mold, and many varieties are used. In production, the efficiency is greatly reduced.
Moreover, although the uneven | corrugated pattern is required for the surface of a decorative mold, in order to make the decorative mold | die which has an uneven | corrugated pattern metal, much labor is required. For this reason, only the uneven pattern on the surface is made of a material that is relatively easy to form an uneven pattern such as urethane rubber, plastic, etc., and there are cases where the steel mold is lined on the back of the decorative mold. Since it occurs, it is necessary to fix it to the above-mentioned firm surface plate.
[0005]
[Problems to be solved by the invention]
SUMMARY OF THE INVENTION An object of the present invention is to provide a method for producing a patterned lightweight aerated concrete panel that can easily replace a makeup mold and can produce a wide variety of products with high productivity without causing warping of the makeup mold during molding. There is.
[0006]
[Means for Solving the Problems]
That is, the present invention relates to a lightweight lightweight concrete with a pattern that forms a pattern by pressing a decorative mold having a pattern on a semi-cured cellular mortar panel obtained from a cellular mortar slurry obtained by mixing a foaming agent into a mortar slurry. In the panel manufacturing method, ALC on the back side of the decorative mold plate having a pattern made of hard urethane rubber on a semi-cured mortar panel obtained from a foam mortar slurry in which a foaming agent is mixed in a mortar slurry, A method for producing a lightweight lightweight concrete panel with a pattern, characterized by pressing a decorative surface-decorating plate made by integrating a base having a thickness of 20 to 200 mm made of any of tobermorite artificial wood .
[0007]
Hereinafter, the present invention will be described in more detail.
The semi-cured mortar panel used in the present invention is obtained, for example, by cutting a semi-cured foam mortar block using the following raw materials into a panel shape.
Examples of the method of cutting the semi-cured foam mortar block into a panel shape include a method used when cutting a normal lightweight foam mortar. For example, a method of cutting a semi-cured light-weight foam mortar block with a wire material such as a piano wire arranged in tension, or a method of cutting with a plurality of strained wiring materials to obtain a plurality of panel-shaped semi-cured products Etc.
[0008]
The raw material for the cellular mortar block is not particularly limited as long as it is generally used as lightweight cellular concrete. For example, mortar slurry using silica, cement, quicklime, water as a raw material, adding gypsum, crushed litter, etc. as necessary, and further mixing bubbles can be used. As a method of mixing bubbles into the bubble mortar block, a method of mixing a bubble agent into the mortar slurry is used .
[0009]
When the foam mortar slurry obtained in this way is poured into a mold with reinforcing bars in advance, cured, and has a hardness suitable for cutting, it can be removed from the mold to obtain a mortar block with semi-cured bubbles. it can. In the present invention, as shown in FIG. 1 , the decorative mold for imparting a concavo-convex pattern needs to have the base 5 integrated with the decorative mold plate 4 on which the concavo-convex pattern is formed. Since the base of the back surface has heat insulation properties, the heat from the semi-cured mortar panel 2 does not reach the back surface, and no thermal gradient is generated between the front surface and the back surface. Therefore, generation | occurrence | production of the curvature of a makeup | decoration type | mold caused by a thermal gradient can be prevented.
[0010]
In addition, the substrate must have a thickness that can withstand bending stress due to temperature during molding. Since the decorative plate on the surface has a thermal expansion property, a bending stress that tends to become convex toward the surface is generated. Furthermore, even if the substrate itself has a heat insulating property, the thermal conductivity does not become zero, so a thermal gradient is generated in the vicinity of the boundary with the decorative mold plate, and even in this region, a convex bending toward the surface Stress is generated. Therefore, in order to prevent the warping of the decorative mold during molding, which is the object of the present invention, the base must have a thickness that hardly distorts even by the resultant force of the bending stress.
[0011]
In the present invention, the base of the back surface of the decorative mold preferably has a thermal conductivity of 400 to 700 J / mh ° C. and a thickness of 20 to 200 mm.
In the above range of thermal conductivity, the semi-cured mortar panel is in contact with the decorative mold for a very short time of about 10 seconds, so the heat transferred from the semi-cured mortar panel to the decorative mold is Before being transmitted to the back surface of the substrate having heat insulation properties, heat is radiated to the periphery after the semi-cured mortar panel is pressed and before the next semi-cured mortar panel is arranged.
[0012]
When the thermal conductivity is less than 400 J / mh ° C., heat insulation is given priority, so that the strength of the substrate itself is lowered, and it cannot withstand bending stress due to the temperature during molding. Further, if the thermal conductivity exceeds 700 J / mh ° C., the heat of the semi-cured mortar panel is easily transferred to the back surface of the decorative mold. Is likely to occur. The thermal conductivity of the substrate is more preferably 450 to 650 J / mh ° C. in order to prevent the temperature gradient between the front surface and the back surface while maintaining the strength of the substrate itself.
[0013]
Furthermore, as for the thickness of the base | substrate which has heat insulation, 20-200 mm is preferable. When the thickness of the substrate is less than 20 mm, a thermal gradient is generated between the front surface and the back surface, and the substrate is easily distorted due to bending stress due to the temperature at the time of molding, and warpage occurs. On the other hand, if the thickness of the substrate exceeds 200 mm, a great deal of labor is required to replace the decorative mold, resulting in a decrease in productivity. In order to easily replace the decorative mold and prevent the decorative mold from warping, it is more preferable that there is 25 to 100 mm.
[0014]
The material of the decorative mold plate having the uneven pattern on the surface of the decorative mold in the present invention is not particularly limited as long as it has a strength capable of transferring the pattern to a semi-cured mortar panel. Rubber, hard plastic, foamed polystyrene, steel, stainless steel, aluminum, titanium and the like can be used. Considering the accuracy and durability of the pattern, hard urethane rubber, hard plastic, and metal are particularly preferable. Further, as the decorative uneven pattern, for example, stone tone, brick tone, tile tone and the like are used.
[0015]
Specific examples of the base material integrated on the back surface of the decorative plate in the present invention described above include inorganic heat insulating building materials such as ALC, zonotlite artificial wood, and tobermorite artificial wood. Since these materials are inorganic, they have a smaller coefficient of thermal expansion than organic heat insulating materials, and can maintain compressive strength and bending strength even if they have a certain degree of heat insulation.
[0016]
The base and the decorative sheet on the surface need to be integrated. If the decorative template is made of a material such as urethane rubber or plastic and is poured into the master mold to copy the surface irregularities, press the base material from the back before the decorative template material is cured. There is a way to make a contact. In this case, it is more effective if a process such as cutting is performed on the base surface on the side in contact with the decorative mold in advance.
[0017]
If the decorative plate on the surface is metallic, it is integrated with an adhesive or the like. In this case, if the adhesive surfaces are cut and the decorative mold is made as thin as possible, it is easy to integrate and difficult to separate.
[0018]
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLES Hereinafter, although the manufacturing method of the lightweight lightweight concrete panel with a pattern of this invention is demonstrated by an Example, this invention is not limited to these Examples.
[0019]
[Example 1]
30mm thick tobermorite artificial wood (manufactured by Ube Industries, Woody Serum EX, thermal conductivity 540J /) on the back of a sandstone-like hard urethane rubber decorative mold with a maximum pattern depth of 10mm and a minimum mold thickness of 10mm mh [deg.] C.) was prepared by bonding and integrating the urethane rubber before curing the urethane rubber.
[0020]
Lightweight cellular concrete mortar containing 53 parts by weight silica, 7.5 parts by weight quicklime, 37 parts by weight cement, 2.5 parts by weight dry gypsum, 68 parts by weight water and 0.06 parts by weight aluminum powder based on these solids 100 The slurry was poured into a mold, and after curing, a semi-cured foam mortar block was obtained. This bubble mortar block was cut to obtain a semi-cured mortar panel test piece of 50 × 610 × 2000 mm. The obtained semi-cured mortar panel specimen was placed in a 90 × 610 × 2000 mm steel mold with the decorative mold placed thereon, and pressed at a pressure of 1.5 kg / cm 2 for 10 mm. The temperature of the semi-cured mortar panel specimen during pressing was 62 ° C. and the room temperature was 24 ° C.
[0021]
Immediately after pressing the above operation every 5 minutes 50 times, a 2000 mm long decorative mold was placed on the surface plate and the warpage was measured, but no warpage occurred, and the decorative mold was easily replaced with a weight of 43 kg. I was able to.
[0022]
[Example 2]
Adhere 100 mm thick ALC (heat conductivity 540 J / mh ° C) to the back of a sandstone-like hard urethane rubber decorative mold with a maximum pattern depth of 10 mm and a minimum mold thickness of 10 mm before curing the urethane rubber. An integrated makeup mold of 610 × 2000 mm was prepared.
[0023]
A 50 × 610 × 2000 mm semi-cured mortar panel specimen prepared in the same manner as in Example 1 was placed in a 160 × 610 × 2000 mm steel mold on which the decorative mold was placed, and 1.5 kg / cm 2. Was pressed at a pressure of 10 mm. The temperature of the test specimen during pressing was 55 ° C. and the room temperature was 21 ° C.
Immediately after the above operation was pressed 50 times every 5 minutes, the back surface temperature of the decorative mold was 23 ° C., almost the same as room temperature, and the warpage was measured with a 2000 mm long decorative mold on the surface plate. Occurrence was not observed.
[0024]
[Comparative Example 1]
A sandstone-like hard urethane rubber decorative mold having a maximum pattern depth of 10 mm and a minimum mold thickness of 40 mm was prepared.
A 50 × 610 × 2000 semi-cured mortar panel specimen prepared in the same manner as in Example 1 was laid with a sandstone-like hard urethane rubber decorative mold having a maximum pattern depth of 10 mm and a minimum mold thickness of 10 mm. It installed in the steel formwork of 610x2000mm, and pressed 10mm. The temperature of the semi-cured mortar panel specimen during pressing was 60 ° C., and the room temperature was 20 ° C.
[0025]
When pressing 50 times every 5 minutes, the back surface temperature of the decorative mold was 47 ° C, and when a 2000 mm long decorative mold was placed on the surface plate and the warpage was measured, the central part of the 2000 mm long was up to 9 mm toward the pattern surface. Warped convexly.
[0026]
[Comparative Example 2]
A decorative mold of 610 × 2000 mm was prepared by adhering a 30 mm thick steel plate to the back of a sandstone-like hard urethane rubber decorative mold having a maximum pattern depth of 10 mm and a minimum mold thickness of 10 mm.
A 50 × 610 × 2000 semi-cured mortar panel specimen prepared in the same manner as in Example 1 was laid with a sandstone-like hard urethane rubber decorative mold having a maximum pattern depth of 10 mm and a minimum mold thickness of 10 mm. It installed in the steel formwork of 610x2000mm, and pressed 10mm. The temperature of the semi-cured mortar panel specimen during pressing was 59 ° C. and the room temperature was 18 ° C.
[0027]
When pressing 50 times every 5 minutes, the back surface temperature of the decorative mold became 40 ° C, and when the warpage was measured by placing the decorative mold on the surface plate, the central part of 2000 mm long warped convexly up to 2 mm toward the pattern surface. It was. In addition, a crane was required to replace the decorative mold with a total weight of 320 kg.
[0028]
【The invention's effect】
The method for producing a lightweight lightweight concrete panel with a pattern according to the present invention does not warp the decorative mold during molding, allows easy replacement of the decorative mold, and allows a variety of products to be manufactured with high productivity.
[Brief description of the drawings]
FIG. 1 is a sectional view schematically showing a state in which a decorative mold is not warped by heat of a semi-cured mortar panel according to a manufacturing method of the present invention. Cross-sectional view from the direction perpendicular to the longitudinal direction, showing the state in which the decorative mold is warped by the heat of the semi-cured mortar panel by the method.
1 Makeup type 2 Semi-cured mortar panel 3 Surface plate 4 Makeup type plate 5 Base

Claims (1)

In the method for producing a lightweight lightweight concrete panel with a pattern in which a pattern is formed by pressing a decorative mold having a pattern on a semi-cured foam mortar panel obtained from a foam mortar slurry obtained by mixing a foaming agent into a mortar slurry . Any of ALC, zonotlite-type artificial wood, and tobermorite-type artificial wood on the back side of the decorative mold plate having a pattern made of hard urethane rubber on a semi-cured mortar panel obtained from a foam mortar slurry in which a foaming agent is mixed with a mortar slurry A process for producing a lightweight lightweight concrete panel with a pattern, comprising pressing a decorative surface-decorating mold plate integrated with a base having a thickness of 20 to 200 mm .

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