JP6910777B2 - Manufacturing method of building materials - Google Patents

Description

The present invention relates to a method for producing a building material and a building material.

Ceramic siding boards, metal siding boards, ALC boards (Autoclaved Lightweight aerated Concrete), etc. are applied as building materials that make up the outer and inner walls of buildings. Among them, ceramic siding boards are building materials using inorganic materials such as wood cement board, wood wool cement board, pulp fiber mixed cement board, wood piece mixed cement calcium silicate board, and wood fiber mixed cement calcium silicate board. Excellent surface design.

Here, Patent Document 1 includes three layers, a surface layer, a core layer, and a back layer, each of which is composed of a hydraulic material, a silicic acid-containing substance, and a wood reinforcing material, and has an average specific gravity of 1.1. The above wood cement board is described.

According to the wood cement board described in Patent Document 1, since the surface has acute angles and deep irregularities, the effect of being excellent in formability is exhibited. Here, "formability" means the ability to satisfactorily form an uneven pattern such as an embossed pattern on the surface of the surface layer.

On the other hand, Patent Document 2 describes a lightweight thick cured product which is an extruded product whose weight has been reduced by using a lightweight aggregate.

JP-A-2009-242189 Japanese Unexamined Patent Publication No. 59-156705

According to the wood cement board described in Patent Document 1, although it has an advantage of excellent formability, the average specific gravity is 1.1 or more, and the workability and transportability at the time of construction of the wood cement board in recent years can be improved. Considering this, further weight reduction is required.

On the other hand, the lightweight thick cured product described in Patent Document 2 has an advantage that it can be produced with high productivity and at a low price, but a new production method that replaces the production method using a lightweight aggregate has been desired.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for producing a building material which is lightweight and has excellent formability, and a building material.

In order to achieve the above object, the method for producing a building material according to the first aspect of the present invention reacts the aluminum powder by curing a material for a core layer containing a hydraulic material, a silicic acid-containing substance, and an aluminum powder. For the first step of forming a foamable core layer mat by incompletely curing the hydraulic material and the silicic acid-containing material while forming bubbles, and for a surface layer containing the hydraulic material and the silicic acid-containing material. The second step of spraying the material to form the non-foaming surface mat, and the foaming core layer mat are loaded on the non-foaming surface mat, and the non-foaming surface mat and the foaming core are loaded. It includes a third step of forming a laminated mat having a layered mat, and a fourth step of pressing and curing the laminated mat.

According to the manufacturing method according to the first aspect of the present invention, it is possible to manufacture a building material which is lightweight by the foamable core layer mat and has excellent formability by the non-foamable surface layer mat.

In particular, when pressing a laminated mat, the foamable core layer mat is a mat that has not been completely cured by curing, whereas the non-foamable surface layer mat is a mat that has not been cured, so the core layer mat is more than the surface layer mat. Is hard and hard to crush. Therefore, the obtained building material can be used to produce a building material that is lighter than a normal building material such as a cement plate having the same thickness.

Further, since the foamable core layer mat is a mat in an incompletely cured state, a building material having excellent adhesion between each layer can be produced by pressing and curing after forming the laminated mat.

Furthermore, by spraying a surface layer material containing a hydraulic material and a silicic acid-containing material to form a non-foaming surface layer mat, a dense non-foaming surface layer mat having no bubbles as compared with a foam core layer mat can be obtained. Can be formed. Therefore, it is excellent in formability such that an uneven pattern can be satisfactorily formed on the surface by pressing.

The incomplete curing in the first step is a state in which the foamable core layer mat has been cured to a certain extent so that it can be transported on the non-foaming surface layer mat, and further curing is performed. Means.

As the hydraulic material, for example, cement, slag, gypsum and the like can be applied, and as the silicic acid-containing material, for example, fly ash, fly ash balloon, silica sand, diatomaceous earth, silica fume and the like can be applied.

As the curing, there are natural curing, steam curing, autoclave curing and the like, and only one of them may be performed, or two or more kinds may be performed.

Examples of the press include a roll press, a filter press, a stack press, and the like, and only one of them may be used, or two or more types may be used.

In addition, the second aspect of the method for producing a building material according to the present invention is to press the non-foaming surface layer mat in the second step.

Before loading the foamable core layer mat, the non-foamable surface layer mat is pressed in advance in the second step, the foamable core layer mat is loaded, and the press is performed again in the fourth step. Will only press the non-foaming surface mat twice. Therefore, the surface layer can be made more dense, and the manufacturing method is excellent in formability.

In the method for producing a building material according to the third aspect of the present invention, in the third step, a hydraulic material and a back layer material containing a silicic acid-containing material are sprayed on the foamable core layer mat. It further has a step of forming an effervescent backing mat.

By spraying a back layer material containing a hydraulic material and a silicic acid-containing material to form a non-foaming back layer mat, the back surface of the manufactured building material can be reinforced. For example, when two workers grip and transport the end of the building material in the longitudinal direction, there is a concern that tensile stress may occur near the center of the building material and cracks may occur. , Building materials are less likely to be damaged. The material for the back layer can include, for example, a reinforcing material such as pulp, wood powder, wood flakes, and synthetic fibers. If the reinforcing material is contained, the flexibility of the building material is improved and damage can be further suppressed, which is preferable. ..

Further, in the fourth aspect of the method for producing a building material according to the present invention, in the third step, the thickness of the foamable core layer mat is the thickest among the mats constituting the laminated mat.

By making the thickness of the foamable core layer mat the thickest among the mats constituting the laminated mat, it is possible to manufacture a building material having the thickest foamable core layer among the layers constituting the building material. The manufactured building material has excellent formability due to the effect of the non-foaming surface layer, and the foamable core layer having a large number of bubbles is the thickest among the layers constituting the building material, so that the weight is further reduced. Be done.

Further, in the method for producing a building material according to the fifth aspect of the present invention, in the third step, the thickness of the non-foaming back layer mat is equal to or larger than the thickness of the non-foaming surface layer mat.

By setting the thickness of the non-foaming back layer mat to be equal to or greater than the thickness of the non-foaming surface layer mat, it is possible to manufacture a building material in which the thickness of the non-foaming back layer is equal to or greater than the thickness of the non-foaming surface layer. Since the non-foaming back layer, which is less likely to cause cracks during transportation, has the same thickness as or thicker than the non-foaming surface layer, cracks are less likely to occur in the non-foaming back layer, and the effect of suppressing damage during transportation is achieved. Will increase further.

Further, in the method for producing a building material according to the sixth aspect of the present invention, the mass of the non-foaming surface layer mat: the mass of the foamable core layer mat: the mass of the non-foaming back layer mat is 10 to 20:45. ~ 70: 15 ~ 45 to manufacture building materials.

When the mass ratios of the non-foaming surface layer mat, the foamable core layer mat, and the non-foaming back layer mat are within the above numerical range, the building material is lightweight, has excellent formability, and has an excellent effect of suppressing damage during transportation. can get.

Further, in the method for producing a building material according to the seventh aspect of the present invention, in the second step, the surface layer material is sprayed on a template with an uneven pattern lined out.

By spraying the surface layer material on the template with the uneven pattern lined out, the uneven pattern can be satisfactorily formed on the surface of the non-foaming surface layer mat, so that a building material having excellent design can be manufactured. ..

Further, the building material according to the eighth aspect of the present invention is provided on the foamable core layer containing bubbles formed by the reaction of the hydraulic material, the silicic acid-containing material, and the aluminum powder, and the foamable core layer. In addition, it is provided with a hydraulic material and a non-foaming surface layer containing a silicic acid-containing substance.

According to the building material of the eighth aspect of the present invention, the weight of the building material is reduced by having a structure in which the non-foaming surface layer is loaded on the foamable core layer having bubbles formed by the reaction of the aluminum powder. Can be planned.

Further, since a non-foaming surface layer containing a hydraulic material such as cement, for example, a silicic acid-containing substance such as fly ash or silica sand is formed on the surface of the foamable core layer, it is compared with the foamable core layer. It is excellent in formability because it has a dense non-foaming surface layer without bubbles.

Further, in the building material according to the ninth aspect of the present invention, the foamable core layer is provided on a non-foamable back layer containing a hydraulic material and a silicic acid-containing substance.

Since the non-foaming back layer is formed on the back surface of the foamable core layer, the building material is reinforced and the effect of suppressing damage during transportation can be obtained. The non-foaming back layer can contain reinforcing materials such as pulp, wood powder, wood flakes, and synthetic fibers. If the reinforcing material is included, the flexibility of the building material is improved and damage can be further suppressed. preferable.

Further, in the building material according to the tenth aspect of the present invention, the foamable core layer is the thickest of the layers constituting the building material.

The effect of the tenth aspect is the same as the effect of the fourth aspect.

Further, in the building material according to the eleventh aspect of the present invention, the non-foaming back layer has a thickness larger than that of the non-foaming surface layer.

The effect of the eleventh aspect is the same as the effect of the fifth aspect.

Further, in the building material according to the twelfth aspect of the present invention, the mass of the non-foaming surface layer: the mass of the foamable core layer: the mass of the non-foaming back layer is 10 to 20: 45 to 70: 15 to. It's 45.

The effect of the twelfth aspect is the same as the effect of the sixth aspect.

Further, in the building material according to the thirteenth aspect of the present invention, an uneven pattern is formed on the surface of the non-foaming surface layer.

Unevenness can be easily formed by the non-foaming surface layer, and an appropriate unevenness pattern such as an embossed pattern can be applied to the unevenness pattern formed on the surface. The sex is enhanced.

According to the method for producing a building material and the building material of the present invention, a building material having a structure in which a non-foaming surface layer is loaded on an foamable core layer in which bubbles are formed is produced, thereby being lightweight and excellent in formability. Can be provided.

It is a vertical sectional view of Embodiment 1 of the building material of this invention. It is a vertical sectional view of Embodiment 2 of the building material of this invention.

Hereinafter, embodiments of the building material of the present invention and the method for manufacturing the same will be described with reference to the drawings.

(Embodiment 1 of building materials)
FIG. 1 is a vertical cross-sectional view of the first embodiment of the building material of the present invention. The building material 10 shown has a structure in which the non-foaming surface layer 2 is loaded on the foamable core layer 1.

The foamable core layer 1 is formed of a hydraulic material such as cement, slag, gypsum, etc., for example, a material containing at least a silicic acid-containing substance such as fly ash, fly ash balloon, silica sand, diatomaceous earth, silica fume, etc. The bubble 1a formed by the reaction is provided inside.

The non-foaming surface layer 2 is formed of a hydraulic material such as cement, for example, a silicic acid-containing material such as fly ash or silica sand, for example, a material containing wood flakes 2a. The wood flakes are formed by finely cutting wood into flakes, and have, for example, a particle size of about 2 to about 5 mm and a thickness of about 1 to about 2 mm. In addition, inorganic admixtures such as mica, pearlite, bentonite, wollastonite, pulp sludge ash, and biomass ash, and organic admixtures such as acrylic resin, animal and vegetable fats and oils, succinic acid resin, silicon resin, and silane resin. One or more of the above may be blended as needed.

An uneven pattern 2b is formed on the surface of the non-foaming surface layer 2 (the surface opposite to the foamable core layer 1).

The planar shape of the building material 10 is, for example, a rectangle, for example, a building material having a length of about 1.8 to about 3.0 m in the longitudinal direction and a length of about 0.5 m in the lateral direction, and has a thickness. t is in the range of about 14 to about 25 mm.

In the building material 10, the thickness of the non-foamable surface layer 2 is t1, and the thickness of the foamable core layer 1 is t2.

The thickness t2 of the foamable core layer 1 is thicker than the thickness t1 of the non-foamable surface layer 2.

In the building material 10, the ratio of the mass of the non-foaming surface layer 2 to the mass of the foamable core layer 1 is set to 10 to 45: 55 to 90.

First, the building material 10 is a very lightweight building material having a structure in which the non-foaming surface layer 2 is loaded on the foamable core layer 1 containing a large number of bubbles 1a.

Since the non-foaming surface layer 2 containing the hydraulic material, the silicic acid-containing material, and the wood flakes 2a is formed on the surface of the foamable core layer 1, the surface layer becomes a dense surface layer having no air bubbles. , Surface patterns such as uneven patterns can be formed well, and it is excellent in formability.

Further, in the building material 10, since the foamable core layer 1 having the bubbles 1a is the thickest among the two constituent layers, further weight reduction can be achieved.

(Embodiment 2 of building materials)
FIG. 2 is a vertical sectional view of a second embodiment of the building material of the present invention. The illustrated building material 10A is different from the building material 10 of FIG. 1 in that the foamable core layer 1A is loaded on the non-foamable back layer 3A. The building material 10A has a structure in which a non-foaming surface layer 2A and a non-foaming back layer 3A are loaded on both sides of the foamable core layer 1A.

The non-foaming back layer 3A is formed from a hydraulic material such as cement, for example, a silicic acid-containing material such as fly ash or silica sand, for example, a material containing wood flakes 3a. These wood flakes are formed by cutting wood into fine flakes, for example, having a particle size of about 2 to about 5 mm and a thickness of about 1 to about 2 mm. In addition, inorganic admixtures such as mica, pearlite, bentonite, wollastonite, pulp sludge ash, and biomass ash, and organic admixtures such as acrylic resin, animal and vegetable fats and oils, succinic acid resin, silicon resin, and silane resin. One or more of the above may be blended as needed.

The building material 10A has a thickness of t'and is in the range of about 14 to about 25 mm. The thickness of the non-foaming surface layer 2A is t1', the thickness of the foamable core layer 1A is t2', and the thickness of the non-foaming back layer 3A is t3'.

The thickness t2'of the foamable core layer 1A is thicker than the thickness t1'of the non-foaming surface layer 2A and the thickness t3'of the non-foaming back layer 3A, and the thickness t3'of the non-foaming back layer 3A is non-foaming. It has a thickness equal to or greater than the thickness t1'of the surface layer 2A.

In the building material 10A, the ratio of the mass of the non-foaming surface layer 2A: the mass of the foamable core layer 1A: the mass of the non-foaming back layer 3A is set to 10 to 20: 45 to 70: 15 to 45. ..

An upper solid portion 2c is provided on the front surface side of the side end portion of the building material 10A, and a lower solid portion 3c is provided on the back surface side of the side end portion in order to bond the building material to another adjacent building material. The upper solid portion 2c and the lower solid portion 3c are provided by pressing the building material 10A, curing it, and then cutting the portion to be cut at the side end portion.

In the building material 10A, the flexibility of the building material 10A is enhanced by forming the non-foaming back layer 3A on the back surface of the foamable core layer 1A. Generally, the building material is transported by, for example, a method in which two workers grip and transport the end portion in the longitudinal direction thereof, but this is because the building material 10A is made more flexible by the non-foaming back layer 3A. During transportation, tensile stress is generated near the center of the building material, cracks are generated, and damage can be suppressed.

Further, in the building material 10A, since the thickness t3'of the non-foaming back layer 3A, which is less likely to crack during transportation, has a thickness equal to or greater than the thickness t1'of the non-foaming surface layer 2A, the non-foaming back layer 3A Cracks are less likely to occur, and the effect of suppressing damage during transportation is even higher.

As described above, the non-foaming surface layer 2A contributes to the formability of the surface uneven pattern, and the non-foaming back layer 3A contributes to the flexibility of the building material 10 and the good transportability brought about by this flexibility.

Further, in the building material 10A, since the foamable core layer 1A having the bubbles 1a is the thickest among the three constituent layers, further weight reduction can be achieved.

(Manufacturing method of Embodiment 1 of building materials)
Next, a method of manufacturing the building material 10 will be described. First, by curing the water-hard material, the silicic acid-containing material, and the core layer material containing the aluminum powder, the aluminum powder is reacted to form bubbles, and the water-hard material and the silicic acid-containing material are combined. It is incompletely cured to form an effervescent core layer mat (first step).

The foamable core layer mat is a cured product, but is a mat in an incompletely cured state in which curing progresses if further curing is performed. Therefore, the foamable core layer mat can be brought into close contact with the non-foamable surface layer mat and the non-foamable back layer mat by further curing in a later step.

Examples of the curing include steam curing, autoclave curing and the like. The curing in this step is a curing in which the material for the core layer is incompletely cured, and one example is steam curing at 40 to 60 ° C. for 3 to 10 hours.

This step may be performed at the same time as the second step described later, or may be performed separately.

Next, a surface material containing a hydraulic material, a silicic acid-containing material, and wood flakes is sprayed on a template with a lined uneven pattern to form a non-foaming surface mat (second step). ..

Here, after spraying the surface layer material, it may or may not be press-processed, but by press-processing, the non-foaming surface layer mat becomes more dense and the surface of the non-foaming surface layer mat becomes more uneven. It can be shaped even better.

The second step of pressing is preferably performed on the entire non-foaming surface mat. The press pressure is not particularly limited, but one example is 0.5 to 2.0 MPa.

Next, the foamable core layer mat is loaded on the non-foamable surface layer mat formed in the second step to form a laminated mat composed of the non-foamable surface layer mat and the foamable core layer mat (). Third step).

Finally, the building material 10 shown in FIG. 1 is manufactured by pressing and curing the laminated mat (fourth step).

The pressing is performed on the entire laminated mat, and as an example, the pressing is performed at 0.5 to 1.0 MPa.

It is preferable that the press pressure in the fourth step is smaller than the press pressure in the second step. As a result, the bubbles of the foamable core layer mat are well retained, the non-foamable surface layer mat can be made more dense, and the building material 10 after curing has better adhesion between the layers.

Curing includes natural curing, steam curing, autoclave curing and the like. When autoclave curing is performed, the adhesion between the foamable core layer 1 and the non-foamable surface layer 2 is excellent. When autoclave curing is performed after steam curing, the adhesion between the foamable core layer 1 and the non-foamable surface layer 2 is further excellent.

(Manufacturing method of the second embodiment of building materials)
Next, a method for manufacturing the building material 10A will be described. Here, the first step and the second step are the same as the manufacturing method of the first embodiment.

Next, loading the foamable core layer mat on the non-foamable surface layer mat is the same as the manufacturing method of the first embodiment. However, in the production method of the second embodiment, a non-foaming back layer mat is further sprayed with a back layer material containing a hydraulic material, a silicic acid-containing substance, and wood flakes on the foam core layer mat. To form. As a result, a laminated mat composed of a non-foaming surface layer mat, a foamable core layer mat, and a non-foaming back layer mat is formed (third step).

Finally, the laminated mat is pressed and cured to produce the building material 10A shown in FIG. 2 (fourth step).

(Experiments and results that verified lightness and formability)
The present inventors have produced building materials for Samples 1 to 11 and verified the lightness and formability of each building material.

Table 1 below shows the materials for forming the surface layer, core layer, and back layer of each building material, the mass ratio of the surface layer, the core layer, and the back layer, and the presence or absence of pressing after spraying the surface layer material.

In the production of each building material, a surface layer mat was formed by spraying a surface layer material on a template in which a brick pattern having a depth of 4 mm and an inclination angle of 55 degrees was lined out. Next, the core layer mat was loaded on the surface layer mat. Next, the back layer material was sprayed on the core layer mat to form a back layer mat, stack-pressed at a pressure of 0.7 MPa, and steam-cured at a temperature of 60 ° C. for 10 hours while still in a pressed state. Then, it was cured in an autoclave at a pressure of 0.6 MPa and a temperature of 165 ° C. for 7 hours to obtain each building material having a thickness of 18 mm, which was applied to Samples 1 to 11. Some of the building materials of Samples 9 to 11 have no core layer and no surface layer and back layer, but the thickness of each sample is 18 mm, and the pressing conditions and curing conditions are the same.

Regarding the formation of the core layer, the water-hardening material, silicic acid-containing material, and core layer material containing aluminum powder are sufficiently kneaded with water having a temperature of 20 ° C as the lower limit (the amount of water is 60 to 70% of the solid amount). After stirring, the mixture was poured into a mold and heated and cured at about 40 to 60 ° C. to prevent water from evaporating to form a core layer mat. The obtained core layer mat was removed from the mold, moved onto the surface mat, and loaded.

In Table 1, Samples 1, 3 to 9 were prepared by spraying the surface layer material on the template, pressing the entire surface layer mat at a pressure of 1.5 MPa, and then loading the core layer mat. On the other hand, for Samples 2 and 10, after spraying the surface layer material on the template, the next step was performed without pressing. As the inorganic admixture, a crushed product of mica and wood cement board scrap is used at a mass ratio of 7: 5.

Below, Table 1 shows the verification results regarding the forming material of each building material, the mass ratio of each layer, as well as the lightness and formability.

[Table 1]

In Table 1, regarding the formability, the surface of each building material was visually observed, and the one in which the brick pattern of the template could be expressed was ○ (good), and the one in which the brick pattern could be expressed, but many burrows were seen. Those that can be displayed are marked with Δ (possible), and those for which the brick pattern cannot be expressed or those with large defects such as cracks in the sample body are marked with × (impossible).

From Table 1, in all of Samples 1 to 9, the specific gravity is as light as less than 1.0 in terms of lightness, and good results are obtained in terms of formability. In Sample 2, some burrows were found in a part of the surface layer, but the brick pattern could be expressed, so it was evaluated as ○ to △ (good to acceptable).

On the other hand, in Samples 10 and 11, the specific gravity of Sample 10 was larger than 1.0, and the lightness was not good. Sample 11 was not formable.

From the results of this experiment, in the building material consisting of the surface layer, the core layer in which bubbles are formed, and the back layer, the mass of the surface layer: the mass of the core layer: the mass of the back layer is in the range of 10 to 20: 45 to 70: 15 to 45. Was demonstrated to be preferable.

It was also demonstrated that a building material in which a surface layer material is sprayed on a template, the entire surface layer mat is pressed, and then a core layer mat is loaded is excellent in formability and is preferable.

The transportability of Samples 1 to 8 having a back layer was evaluated. Regarding transportability, the condition of each building material after grasping both ends in the longitudinal direction and lifting it 1 m above the ground and transporting it 10 m laterally is visually checked, and it is good if there is no change such as damage. Those with cracks or breakage were evaluated as impossible. As a result, good transportability was obtained in all of Samples 1 to 8.

Although the embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and there are design changes and the like within a range that does not deviate from the gist of the present invention. Also, they are included in the present invention.

1,1A ... foamable core layer, 1a ... air bubbles, 2,2A ... non-foaming surface layer, 2a ... wood flakes, 2b ... uneven pattern, 3A ... non-foaming back layer, 3a ... wood flakes, 10,10A ... building material

Claims (6)

A water-hard material, a silicic acid-containing material, and a core layer material containing aluminum powder are kneaded with water in an amount of 60 to 70% of the solid amount and cured to react the aluminum powder with air bubbles. The first step of forming an effervescent core layer mat by incompletely curing the water-hard material and the silicic acid-containing material.
A second step of spraying a surface material, including hydraulic materials, silicic acid-containing materials, and wood flakes, to form a non-foaming surface mat.
A third step of loading the foamable core layer mat on the non-foaming surface layer mat to form a laminated mat having the non-foaming surface layer mat and the foamable core layer mat.
The laminated mat is provided with a fourth step of pressing and curing.
The wood flakes have a particle size of 2 to 5 mm and a thickness of 1 to 2 mm.
The material for the core layer is a method for producing a building material containing 0 to 3% by mass of fibers. In the second step, the non-foaming surface mat is pressed.
The method for producing a building material according to claim 1, wherein the press pressure in the fourth step is made smaller than the press pressure in the second step. The method for producing a building material according to claim 1 or 2, wherein in the third step, the thickness of the foamable core layer mat is the thickest among the mats constituting the laminated mat. The method for producing a building material according to any one of claims 1 to 3, wherein the mass of the non-foaming surface layer mat: the building material having the mass of the foamable core layer mat of 10 to 45:55 to 90 is produced. .. The method for producing a building material according to any one of claims 1 to 4, wherein in the second step, the surface layer material is sprayed on a template whose uneven pattern is lined out. The method for producing a building material according to any one of claims 1 to 5, wherein the surface layer material contains 25% by mass of the hydraulic material.

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