JP6910778B2 - Manufacturing method of building materials - Google Patents

Description

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

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.

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 considering the workability and transportability at the time of construction of the wood cement board in recent years, , Further weight reduction is required.

On the other hand, the lightweight and thick cured product described in Patent Document 2 has an advantage that it can be produced at a low price with good productivity, but there is a concern that it may be damaged due to bending during transportation.

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

In order to achieve the above object, the building material according to the first aspect of the present invention is provided on a non-foaming back layer containing a hydraulic material, a silicic acid-containing material, and wood flakes, and a non-foaming back layer. , A hydraulic core layer containing bubbles formed by the reaction of hydraulic material, silicic acid-containing material, and aluminum powder, and a hydraulic material, silicic acid-containing material, and wood provided on the foamable core layer. It is provided with a non-foaming surface layer containing flakes.

According to the building material of the first aspect of the present invention, it has a structure in which a non-foaming surface layer and a non-foaming back layer are laminated on both sides of a foamable core layer having bubbles formed by the reaction of aluminum powder. As a result, the weight of the building material can be reduced.

Further, on the surface of the foamable core layer, 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, and wood flakes formed by finely cutting wood into flakes is formed. As a result, there is a dense non-foaming surface layer without bubbles as compared with the foamable core layer, so that the formability is excellent. Here, "formability" means the ability to satisfactorily form an uneven pattern such as an embossed pattern on the surface of the surface layer.

In addition, since a non-foaming back layer containing wood flakes is formed on the back surface of the foaming core layer, the flexibility of the building material is increased, and for example, two workers grip the end portion of the building material in the longitudinal direction. It is possible to prevent the building material from being damaged due to the occurrence of tensile stress near the center of the building material during transportation.

The flexibility of this building material is provided mainly by the inclusion of wood flakes in the non-foaming back layer, which reinforces the non-foaming back layer and increases the flexibility of the non-foaming back layer.

In addition, in order to bond the building material to another adjacent building material, protrusions called actual parts may be provided on the front surface side of the side end portion and the back surface side of the side end portion of the building material. Since the front surface side and the back surface side are dense non-foaming layers, it is possible to form a real portion having sufficient strength.

Further, as a second aspect of the building material according to the present invention, a form in which the foamable core layer is thicker than the non-foaming surface layer and the non-foaming back layer can be mentioned.

The effect of the non-foaming surface layer is excellent in formability, the effect of the non-foaming back layer is excellent in transportability, and the foamable core layer having a large number of bubbles is the thickest among the layers constituting the building material. , Further weight reduction is achieved.

Further, as a third aspect of the building material according to the present invention, there may be mentioned a form in which the non-foaming back layer has a thickness equal to or larger than that 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, as a fourth aspect of the building material according to 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 45. Can be mentioned.

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

Further, in the fifth aspect of the building material according to the present invention, a form in which an uneven pattern is formed on the surface of the non-foaming surface layer can be mentioned.

The non-foaming surface layer makes it easy to form irregularities. An appropriate uneven pattern such as an embossed pattern can be applied to the uneven pattern formed on the surface, but the design of the building material is enhanced by having the uneven pattern on the surface.

A sixth aspect of the present invention is a method for producing a building material, in which the aluminum powder is obtained by curing a material for a core layer containing a hydraulic material, a silicic acid-containing substance, and an aluminum powder. The first step of reacting to form bubbles and incompletely curing the hydraulic material and the silicic acid-containing material to form an effervescent core layer mat, the hydraulic material, the silicic acid-containing material, and wood flakes. The second step of forming the non-foaming surface layer mat by spraying the surface layer material containing, the third step of loading the foamable core layer mat on the non-foaming surface layer mat, the foamable core A non-foaming back layer mat is formed by spraying a hydraulic material, a silicic acid-containing substance, and a back layer material containing wood flakes on the layer mat, and the non-foaming surface layer mat and the foamable core layer are formed. It includes a fourth step of forming a laminated mat composed of a mat and the non-foaming back layer mat, and a fifth step of pressing the laminated mat and curing it to produce a building material.

The incomplete curing in the first step is a state in which the curing has progressed to a certain extent so that it can be transported on the non-foaming surface layer mat, but the curing progresses if further curing is performed.

The curing includes natural curing, steam curing, autoclave curing, and the like, and only one of them may be performed, or two or more types 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.

According to the manufacturing method according to the sixth aspect of the present invention, a lightweight building material can be manufactured.

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-foaming surface layer mat and the non-foaming back layer mat are mats that have not been cured. The foamable core layer mat is harder than the non-foamable surface layer mat and the non-foamable back layer mat, and is less likely to be crushed. Therefore, in the obtained building material, the foamable core layer tends to be thicker than the non-foamable surface layer and the non-foamable back layer. Since the foamable core layer having a large number of bubbles tends to be thick, it is possible to manufacture 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.

Further, by spraying a surface layer material containing a water-hardening material, a silicic acid-containing substance, and wood flakes on the surface of the foamable core layer mat to form a non-foamable surface layer mat, it is compared with the foamable core layer mat. Therefore, a dense non-foaming surface mat without bubbles can be formed. Therefore, it is excellent in formability such that an uneven pattern can be satisfactorily formed on the surface by pressing. In the manufacturing method according to the sixth aspect, the building material obtained by pressing and curing is turned upside down, and the cured product of the surface layer mat is used as the surface layer. Therefore, the above-mentioned "surface of the foamable core layer mat" is used. , Means the lower surface of the foam core layer mat.

Further, the building material manufactured by spraying a hydraulic material, a silicic acid-containing substance, and a back layer material containing wood flakes on the back surface of the foamable core layer mat to form a non-foamable back layer mat. Flexibility can be imparted, and since the building material has flexibility, it is possible to suppress problems such as damage to the building material during transportation. In the manufacturing method according to the sixth aspect, the above-mentioned "back surface of the foamable core layer mat" means the upper side surface of the foamable core layer mat.

Further, the method for producing a building material according to the seventh aspect 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, press the non-foamable surface layer mat in advance in the second step, load the foamable core layer mat and the non-foamable back layer mat, and press again in the fifth step. Therefore, in the obtained building material, only the non-foaming surface mat is pressed twice. Therefore, the non-foaming surface layer can be made more dense, and the manufacturing method is excellent in formability.

When the press pressure in the second step and the press pressure in the fifth step are adjusted so that the press pressure in the fifth step is smaller than the press pressure in the second step, bubbles in the foam core layer mat are generated. The non-foaming surface layer mat can be made more dense while being held well, which is a manufacturing method excellent in formability and weight reduction. Further, in this case, in the building material after curing, the adhesion between the layers is even better, which is an excellent manufacturing method.

Further, the method for producing a building material according to the eighth aspect of the present invention is to produce a building material in which the thickness of the foamable core layer mat is thicker than the thickness of the non-foaming surface layer mat and the non-foaming back layer mat. Is.

The effect of the manufacturing method of the eighth aspect is the same as the effect of the building material of the second aspect.

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

The effect of the manufacturing method of the ninth aspect is the same as the effect of the building material of the third aspect.

Further, in the method for producing a building material according to the tenth 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: Manufactures building materials that are 15-45.

The effect of the manufacturing method of the tenth aspect is the same as the effect of the building material of the fourth aspect.

Further, in the method for producing a building material according to the eleventh 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. ..

According to the building material of the present invention and the method for producing the same, the building material has a structure in which both sides of the foamable core layer in which bubbles are formed are laminated with a non-foaming surface layer containing wood flakes and a non-foaming back layer. It is possible to provide a building material that is lightweight, has excellent formability, and is suppressed from being damaged during transportation.

It is a vertical sectional view of the embodiment 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.

(About the embodiment of the building material and its manufacturing method)
FIG. 1 is a vertical cross-sectional view of an embodiment of the building material of the present invention. The building material 10 shown in the figure has a structure in which a non-foaming surface layer 2 and a non-foaming back layer 3 are loaded on both sides of the foamable core layer 1.

The foamable core layer 1 is formed from a hydraulic material such as cement, slag, and gypsum, and a material containing at least a silicic acid-containing substance such as fly ash, fly ash balloon, diatomaceous earth, and silica fume, and is formed by reaction with aluminum powder or the like. The formed bubbles 1a are provided inside.

The non-foaming surface layer 2 and the non-foaming back layer 3 are formed of a material containing a hydraulic material such as cement, a silicic acid-containing substance such as fly ash or silica sand, and wood flakes 2a and 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.

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-foaming surface layer 2 is t1, the thickness of the foamable core layer 1 is t2, and the thickness of the non-foaming back layer 3 is t3.

The thickness t2 of the foamable core layer 1 is thicker than the thickness t1 of the non-foaming surface layer 2 and the thickness t3 of the non-foaming back layer 3, and the thickness t3 of the non-foaming back layer 3 is the thickness of the non-foaming surface layer 2. It has the same or thicker thickness as t1.

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 to the mass of the non-foaming back layer 3 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 10 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 10 and curing it, and then cutting the portion to be cut at the side end portion.

The building material 10 based on the above configuration is extremely lightweight because it has a structure in which the non-foaming surface layer 2 and the non-foaming back layer 3 are laminated on both sides of the foamable core layer 1 containing a large number of bubbles 1a. It is a building material that has been converted.

Further, 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, it becomes a dense surface layer without bubbles. , Surface patterns such as uneven patterns can be formed well, and it is excellent in formability.

Further, since the non-foamable back layer 3 including the wood flakes 3a is formed on the back surface of the foamable core layer 1, the flexibility of the building material 10 is enhanced. 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 10 is made more flexible by the non-foaming back layer 3. 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 10, since the thickness t3 of the non-foaming back layer 3 which is unlikely to cause cracks during transportation has a thickness equal to or more than the thickness t1 of the non-foaming surface layer 2, cracks occur in the non-foaming back layer 3. It is less likely to occur, and the effect of suppressing damage during transportation is even higher.

As described above, although the non-foaming surface layer 2 and the non-foaming back layer 3 are both formed of the same material, the non-foaming surface layer 2 contributes to the formability of the surface uneven pattern and is a non-foaming back layer. 3 contributes to the flexibility of the building material 10 and the good transportability provided by this flexibility.

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

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

Next, the foamable core layer mat formed in the first step is loaded on the non-foaming surface layer mat formed in the second step (third step).

Next, a non-foaming back layer mat is formed by spraying a back layer material containing a hydraulic material, a silicic acid-containing substance, and wood flakes on the foam core layer mat. 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 (fourth step).

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

The press working by the fifth step is performed on the entire laminated mat. As an example, it may be performed at 0.5 to 1.0 MPa.

It is preferable that the press pressure during the press working in the fifth step is smaller than the press pressure during the press working 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-foaming surface layer 2 and the adhesion between the foamable core layer 1 and the non-foaming back layer 3 are excellent. When autoclave curing is performed after steam curing, the adhesion between the foamable core layer 1 and the non-foaming surface layer 2 and the adhesion between the foamable core layer 1 and the non-foaming back layer 3 are further excellent.

(Experiments and results that verified lightness, formability, and transportability)
The present inventors have produced building materials for Samples 1 to 11 and verified the lightness, formability, and transportability 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 8 and 11. Some of the building materials of Samples 9 and 10 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 8 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, 9 to 11, the surface layer material was sprayed on the template, and then the core layer mat was loaded 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 lightness, formability, and transportability.

[Table 1]

In Table 1, regarding the formability, the surface of each building material is visually observed, and the one in which the brick pattern of the template can be expressed is ○ (good), and the one in which the brick pattern can be expressed, but burrows can be seen. Those with a △ (possible) are marked with Δ (possible), and those with a large defect such as a crack in the sample body or those for which the brick pattern cannot be expressed are marked with × (impossible). Regarding transportability, the condition of each building material after grasping both ends in the longitudinal direction of each building material and transporting it 10 m in the lateral direction with the building material lifted 1 m above the ground is visually checked, and there is no change such as damage. ○ (good), and those with cracks or breakage were marked as × (impossible).

From Table 1, in all of Samples 1 to 8, the specific gravity is as light as less than 1.0 in terms of lightness, and good results are obtained in terms of both formability and transportability. 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, with respect to Samples 9 to 11, Sample 9 had a specific gravity of more than 1.0 and was not light in weight. In addition, sample 10 was not formable and transportable. Sample 11 was not transportable.

From the results of this experiment, in a building material consisting of a surface layer containing wood flakes, a core layer in which bubbles are formed, and a back layer containing wood flakes, the mass of the surface layer: the mass of the core layer: the mass of the back layer is 10 to 20:45. It was demonstrated that a range of ~ 70: 15 ~ 45 is preferred.

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.

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

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.
The third step of loading the foamable core layer mat on the non-foamable surface layer mat,
A non-foaming back layer mat is formed by spraying a back layer material containing a hydraulic material, a silicic acid-containing substance, and wood flakes on the foamable core layer mat, and the non-foaming surface layer mat and the above. A fourth step of forming a laminated mat composed of a foamable core layer mat and the non-foamable back layer mat.
A fifth step, in which the laminated mat is pressed and cured to produce a building material, is provided.
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 fifth 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 a building material in which the thickness of the foamable core layer mat is thicker than the thickness of the non-foaming surface layer mat and the non-foaming back layer mat is produced. The method for producing a building material according to any one of claims 1 to 3, wherein a building material having a thickness equal to or greater than the thickness of the non-foaming surface layer mat is produced. 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 to 70:15 to 45. The method for manufacturing a building material according to any one of 4 to 4. The method for producing a building material according to any one of claims 1 to 5, wherein the back layer material and the surface layer material contain 25% by mass of the hydraulic material.

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