JPH0383873A - Light-weight aerated concrete panel having open cell and its production - Google Patents

Abstract

PURPOSE:To readily obtain light-weight aerated concrete(ALC) having excellent sound absorbing qualities by casting a slurry of raw material of aerated concrete to cavities for molding panels mutually independent by using partition plates and coagulating. CONSTITUTION:Partition plates 6 are arranged in a mold 5 to form cavities 7 for molding plural mutually independent panels. Reinforcing rods 10 are set in the cavities 7. Then a slurry 16 of concrete raw material blended with thermally meltable fibers 15 is cast into the cavities 7, aerated and coagulated to give plural uncured panels 17 having the embedded reinforcing rods 10. Then the panel 17 is cured at the >= melt temperature of the fibers 15. ALC panels having fine cells connected by very small hollows are obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a lightweight cellular concrete (hereinafter referred to as ALC) panel having open cells and a method for manufacturing the same.

[Prior Art] Since approximately 70% of the volume of an ALC panel is composed of fine closed cells, it is widely used as a building material with excellent heat resistance. Additionally, although lightweight materials generally allow sound to pass through easily, ALC panels are made of closed cells, as mentioned above, despite their light weight, and as a result, the incident sound is reflected at a certain rate on the surface. It also has excellent sound insulation properties because it is difficult to pass through to the sides.

[Problem to be solved by the invention] However, while the ALC panel with a closed cell bottom as described above has a strong property of reflecting incident sound, it also absorbs sound by guiding the sound into the thickness of the panel and converting it into energy. Because of the weak sound absorbing properties of ALC panels, rooms made of ALC panels sometimes experience louder echoes and longer reverberation times.

An object of the present invention is to solve the above problems and provide a new ALC panel with excellent sound absorption properties and a new manufacturing method that can easily produce the ALC panel.

[Means for Solving the Problems] In order to achieve the above object, the ALC panel having open cells according to claim 1 is constructed such that fine cells are continuous through fine cavities.

The method for manufacturing an ALC panel having open cells according to claim 2 further includes the steps of arranging a partition plate in a mold to form a plurality of mutually independent panel molding cavities; a step of setting reinforcing bars on the
a step of forming a plurality of uncured panels in which the reinforcing bars are embedded by injecting concrete raw material slurry mixed with heat-fusible fibers into each of the panel forming cavities and foaming and solidifying the same, and the uncured panels; and a step of curing at a temperature higher than the melting temperature of the heat-fusible fiber.

[Function] According to the ALC panel having open cells according to claim 1, the incident sound enters the air bubbles inside the panel through various routes from the air bubbles on the surface of the panel through the cavity. Energy is converted in the bubbles and cavities and its level decreases.

Further, according to the method for manufacturing an ALC panel having open cells according to claim 2, reinforcing bars are set in a plurality of mutually independent panel molding cavities formed using partition plates, and heat-melt fibers are By injecting, foaming and solidifying concrete raw material slurry mixed with concrete, multiple uncured panels can be formed independently from each other, thereby eliminating the need for the conventional panel cutting process. This has an important meaning in the present invention. This is because it is very difficult to cut ALC in which heat-fusible fibers are dispersed smoothly with a cutting wire. Further, by curing the uncured panel at a temperature higher than the melting temperature of the heat-fusible fibers, the uncured panel is completely cured, and the heat-fusible fibers are melted to form a continuous cavity.

[Examples] Examples of the present invention will be described below with reference to the drawings.

As shown in FIGS. 3 and 4, the ALC panel 1 of the present invention is similar to the conventional ALC panel in that it has numerous fine air bubbles 3 in the ALC base material 2, but these It is completely different in that the air bubbles 3 are connected by countless fine cavities 4.

The continuity of the bubbles 3 means that all the bubbles 3 are not necessarily connected to the cavities 4.
However, by randomly connecting many air bubbles 3 through cavities 4, from many air bubbles 3 on the front surface of the panel to many air bubbles 3 on the back of the panel, It is sufficient if they are continuous while taking various routes.

The proportion of the air bubbles 3 in the volume of the ALC panel 1 is not particularly limited, but is generally 50 to 80%. The diameter of the bubble 3 is also not particularly limited, but is generally 0.5 to 5 mm.
It is. Further, the diameter of the cavity 4 is not particularly limited, but in relation to the diameter of the bubble 3, it is generally 100 to 200.
It is 0 μm.

According to the ALC panel I configured as described above, the incident sound enters the air bubbles 3 inside the panel through various routes from the air bubbles 3 on the surface of the panel through the cavity 4. Energy is converted within the bubbles 3 and cavities 4, and its level is reduced. Therefore, this ALC panel 1 has excellent sound absorption properties and also exhibits a certain level of sound insulation performance, so that a room configured with this ALC panel 1 can have comfortable reverberation, reverberation time, and sound insulation performance.

Next, a method for manufacturing the ALC panel 1 will be explained step by step.

(1) First, as shown in FIG.
A process of arranging a plurality of mutually independent panel molding cavities 7.

The material of the partition plate 6 may be any material as long as it does not allow the concrete raw material slurry 16 to pass through in a later step and can withstand the pressure thereof. In this embodiment, in order to prevent the concrete raw material slurry 16 from floating up due to buoyancy during injection, a steel partition plate 6 having a higher specific gravity than the slurry is used, and the partition plate 6 is attached to the formwork 1 with a stopper (not shown). I made it stop.

Any support means for the partition plate 6 may be used as long as it can support the partition plate 6 so that it does not move during pouring of the concrete raw material slurry.

In this embodiment, a frame-shaped support bar 8 is provided above the formwork 5.
A means was taken to fix the upper end of the partition plate 6 to a support rod 9 attached to the support bar 8 in a hanging state.

The number of partition plates 6 depends on the formwork 5 and panel molding cavity 7.
It depends on the size of, and is not particularly limited. Also,
It goes without saying that the size of the panel molding cavity 7 can be changed as appropriate depending on the dimensions of the ALC panel 1.

Note that a known mold release agent is applied to the inner surface of the formwork 5 and the surface of the partition plate 6.

(2) Next, as shown in FIG. 1, a step of setting reinforcing bars 10 in each panel molding cavity 7.

The reinforcing bars 10 are of a known type, in which two frames 11 made by welding a main bar and a sub bar vertically and horizontally are arranged at a predetermined interval, spacers 12 are placed between both frames 11, and then welded. By doing so, it is formed into a cage shape.

Further, the means for supporting the reinforcing bars 10 is also a known one, in which a frame-shaped support bar 13 is passed above the formwork 5, and a support rod 14 attached to the support bar 13 in a hanging state is attached to the spacer. 12 so that it can be attached and detached.

(3) Next, as shown in FIG. A process of forming a plurality of uncured panels 17 with embedded

As the heat-melting fiber 15, various fibers can be used as long as they melt depending on the temperature during curing, such as chemical fibers such as polyvinyl acetate, copolyamide polyamide, copolymer polyethylene, copolymer polypropylene, etc. Glass fiber etc. can be illustrated. However, its melting temperature is 100 to 180, which is the normal autoclave curing temperature.
Preferably, the temperature is lower than ℃.

The heat-fusible fiber 15 replaces the cavity 4 after melting, and therefore its diameter is not particularly limited, but is generally about 100 to 2000 μm. The length of the heat-fusible fiber 15 is also not particularly limited, but is generally 2 to 50 mm.
It is about mm. Further, the mixing ratio of the heat-fusible fibers 15 is preferably such that when the concrete raw material slurry 16 is foamed and expanded, the heat-fusible fibers 15 are dispersed at intervals of about 1 to 10 mm.

The concrete raw material slurry 6 is a known material whose main raw materials are silica stone, quicklime, cement, aluminum powder as a foaming agent, etc., and the above-mentioned heat-fusible fibers 15 are mixed therein and dispersed in the road. .

The concrete raw material slurry 16 injected into the panel molding cavity 7 expands to envelop the reinforcing bars 10 while generating countless air bubbles 3 while left standing for 2 to 3 hours, and eventually solidifies and becomes semi-hardened. condition, uncured panel 1
form 7. At this time, as shown in FIG.
The particles are skewered and pierced through in the shape of dumplings, and are randomly distributed throughout the body.

As described above, in this embodiment, a plurality of uncured panels 17 can be molded independently from each other by a plurality of mutually independent panel molding cavities 7 formed using the partition plates 6. This eliminates the need for the process of cutting a block of green cake into multiple panels using a cutting wire or the like, which was done in the conventional ALC panel manufacturing method. This has an important meaning in the present invention. because,
ALC in which numerous thermofusible fibers 15 are dispersed as described above.
This is because it is very difficult to cut smoothly with a cutting wire. The present inventor devised a step of arranging the partition plate 6 as a method of avoiding this cutting step.

(4) Subsequently, the plurality of uncured panels 17 are removed from the formwork and partition plate 6, placed in a known autoclave (not shown), and cured under high temperature, high pressure steam (for example, 180° C., 10 atm). Allow to completely harden.

At this time, the heat-fusible fibers 15 melt due to the curing temperature, and are replaced by continuous cavities 4 as shown in FIG. Therefore, an ALC panel 1 having open cells as shown in FIG. 3 can be obtained.

According to the method for manufacturing an ALC panel configured as described above, open cells consisting of air bubbles 3 and cavities 4 can be easily formed by melting the thermofusible fibers 15, etc., and the partition plate 6 etc. Since the difficult panel cutting process can be omitted, the ALC panel 1 can be easily manufactured.

It should be noted that the present invention is not limited to the configuration of the above-mentioned embodiments, and can be modified and embodied as desired without departing from the spirit of the invention.

[Effect of the invention] As detailed above, the AL having open cells according to claim 1
According to the C panel, excellent sound absorption properties can be obtained due to the open cells consisting of fine air bubbles and cavities. The ALC panel described above can be easily manufactured because it facilitates the formation of the ALC panel and can also omit a difficult panel-shaped cutting process.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional perspective view showing the state in which the partition plate and reinforcing bars are set in the formwork and concrete raw material slurry is injected in the formwork in this example; Fig. 2 is a partially enlarged sectional view of the obtained uncured panel; FIG. 3 is a perspective view showing a part of the manufactured ALC panel, and FIG. 4 is a partially enlarged sectional view of the ALC panel. 1... ALC panel, 3... Air bubble, 4... Cavity,
5... Formwork, 6... Partition plate, 7... Panel molding cavity,
10... Reinforcement bar, 15... Thermofusible fiber, 16...
・Concrete raw material slurry 17...uncured panel.

Claims (1)

[Claims] 1. A lightweight cellular concrete panel having open cells, characterized in that fine cells (3) are connected by fine cavities (4). 2. A step of arranging a partition plate (6) in the formwork (5) to form a plurality of mutually independent panel molding cavities (7), and providing reinforcing bars in each of the panel molding cavities (7). The reinforcing bars ( 10), and a step of curing the uncured panels (17) at a temperature higher than the melting temperature of the heat-fusible fibers (15). A method for manufacturing lightweight aerated concrete panels.