JPH04179502A - Light-weight concrete flat tile and manufacture therefor - Google Patents

Abstract

PURPOSE:To maintain the strength, and obtain a light-weight concrete flat tile at low cost by laminating a fiber mixed layer formed with fiber-mixed mortar and a fiber non-mixed mortar layer. CONSTITUTION:A plurality of mold frames 11 are placed in the form of being in contact with other mold frames each other on a conveyor 12 and transported at a constant speed in the direction of arrow (a). At a predetermined position of the conveyor 12, a filling device 13 is located that is adapted to fill fiber mixed mortar into the mold 11, and on the downstream side of the filling device 13, a press roller 14 is arranged which rotates in the direction of arrow (b). On the downstream side of the press roller 14 and the position spaced at a predetermined distance, a mortar extruding device 15 is installed, and in succession to the extrusion molding device 15, a slipper 16 is placed. The slipper 16 is adapted to compress the mortar filled in the mold 11 and form the surface thereof, and serves to compress the mortar filled in the mold 11 and laminate a mortar layer 2 on a fiber mixed layer 1.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a lightweight concrete flat tile and a manufacturing method thereof.

<Conventional technology> Various concrete roof tiles have been used in the past. These concrete tiles are generally heavy (and have a big impact on the structure of the building.) Therefore, there is a demand for concrete tiles that are lighter in weight.

Generally, in order to reduce the weight of concrete structures, there are methods to use lightweight aggregates such as pumice, volcanic slag, and sintered fuel ash, or to reduce the thickness of the structure and increase the resulting strength. A method of compensating for the decrease by mixing resin or fiber has been implemented.

However, concrete roof tiles manufactured using lightweight aggregates have reduced bending strength, and in order to improve this bending strength, it is necessary to increase the thickness. For this reason, it is difficult to achieve significant weight reduction.

In order to solve this problem, a technique disclosed in Japanese Unexamined Patent Publication No. 61-91080 has been proposed. This technique applies approximately 0.05n to 0.1% of cement-light aggregate-water mixture.
A lightweight concrete roof tile is manufactured using a material mixed with silica fume having an average particle size of 5μ. According to this technique, it is possible to obtain tiles that are lighter than conventional concrete tiles and have the same bending strength.

Furthermore, as a method for manufacturing special concrete roof tiles, a technique disclosed in Japanese Patent Publication No. 2-11402 has been proposed. This technique is used, for example, to produce concrete roof tiles with a woodgrain pattern, in which the material is discharged onto pallets arranged in series and compressed by means of slippers, while simultaneously forming a plurality of grooves on the upper surface.

<Problems to be Solved by the Invention> When attempting to reduce the weight of concrete tiles using lightweight aggregate, it is necessary to use expensive materials as shown in JP-A No. 61-91080 in order to manufacture concrete tiles with high strength. It is necessary to use , which increases the cost.

Furthermore, if a concrete roof tile is manufactured using a material mixed with resin or fiber and using the technology disclosed in Japanese Patent Publication No. 2-11402, it is possible to reduce the weight without reducing the strength. However, the resin or fibers are mixed into the entire concrete roof tile, which increases the cost.

An object of the present invention is to provide a lightweight concrete flat tile that maintains the strength as a roof tile and is low in cost, as well as to provide a method for manufacturing the same.

<Means for Solving the Problems> In order to solve the above problems, the lightweight concrete flat tile according to the present invention has a fiber-mixed layer formed by mortar mixed with fibers and a mortar layer not mixed with fibers, which are laminated. That's what happens.

In addition, the manufacturing method for lightweight concrete flat tiles involves filling a formwork with mortar mixed with fibers and compressing it to form a fiber-mixed layer, and then filling the formwork with mortar and compressing it to form a fiber-mixed layer. It is characterized by laminating a mortar layer on the top.

<Function> According to the above-mentioned lightweight concrete tile (hereinafter simply referred to as "Tile J"), the strength of the tile can be maintained and the weight can be reduced, and the cost will not increase.

That is, the entire back surface of the roof tile is not supported by the field material, and bending force corresponding to external force acts on the roof tile. Therefore, by constructing a tile by laminating a fiber-mixed layer formed by mortar mixed with fibers and a mortar layer, when an external force is applied to the tile, the tensile force generated in response to this external force is absorbed by the fiber-mixed layer. The compressive force can be supported by the mortar layer. Therefore, even if the thickness is reduced, the strength of the roof tile can be maintained.

Therefore, the weight can be reduced and the cost will not increase.

Moreover, according to the above manufacturing method, tiles having uniform quality can be manufactured.

<Example> An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is an overall perspective view of the roof tile seen from the back, and FIG. 2 is a sectional view thereof.

In the figure, tile A is constructed by laminating a fiber-mixed layer 1 formed by mixing fibers into mortar and a mortar layer 2 without fibers.

Various patterns are formed on the exposed surface 3 of the tile A in accordance with the design of the building, and reinforcing ribs 5 are formed on the back surface 4. Further, an overlap part 6 and an underlap part 7 are formed on both sides of the tile A, respectively, to engage with other adjacent tiles. The shape of the tile A is the same as that used conventionally, and the overall thickness is thinner than that of the conventional tile.

The composition of the mortar layer 2 is not particularly limited, and general mortar can be used.

For example, it is preferable to use 30 to 40 parts by weight of water and 250 to 350 parts by weight of sand to 100 parts by weight of cement.

However, it is also possible to use lightweight aggregates outside the sand plain.

The fiber-mixed layer 1 is made of a material in which alkali-resistant fibers are mixed into mortar.

As for the composition of the mortar constituting the fiber-mixed layer 1, it is possible to use the same mortar as the mortar constituting the mortar layer 2. Then, the length of the fibers is adjusted to 3 cm to 6 cm, and the fibers are mixed into the mortar at a ratio of about 1% by weight and stirred to prepare the material for forming the fiber-mixed layer 1. .

As described above, the tensile strength of the fiber-mixed layer 1 can be increased by mixing relatively short fibers into the mortar and stirring them so that these fibers are entangled with each other.

As the fibers, alkali-resistant fibers such as glass fibers, acrylic fibers, and carbon fibers can be used.

In this embodiment, the ribs 5 of the tile A are formed by the fiber-mixed layer 1, and the other parts are formed by the mortar layer 2. This is because when a bending force is generated on the tile A due to an external force acting on the tile A, the largest tensile force acts on the rib 5, so this tensile force is borne by the fiber mixed layer 1. However, the forming portion of the fiber-mixed layer 1 is not limited to the above embodiment, and may be formed at the tip of the rib 5 depending on the size of the tile A, or may be formed at a predetermined thickness of the back surface of the tile A in the four examples. It goes without saying that it may be formed on the opposite side.

By configuring the roof tile A as described above, it is possible to reduce the weight while maintaining the strength as a concrete roof tile. Furthermore, since fibers are not mixed throughout the roof tile, the cost will not increase significantly.

Next, a method of manufacturing the above roof tile will be explained.

The method for manufacturing tile A according to the present invention is a method for rationally manufacturing tile A having the above-mentioned configuration, in which a mold having a shape corresponding to the shape of tile A is filled with fibers by a filling device. a step of filling mortar mixed with and compressing it with a press roller to form a fiber-mixed layer I;
The process consists of the steps of extruding mortar using an extrusion molding device and compressing it using a slipper into the mold on which the fiber-mixed layer 1 has been formed, thereby laminating the mortar layer 2 on the fiber-mixed layer 1.

Therefore, by arranging a large number of molds and transporting them at a constant speed, filling and compressing the fiber-containing mortar and extruding and compressing the mortar, tiles A with uniform quality can be created.
can be produced continuously.

An example of a manufacturing apparatus for carrying out the above manufacturing method will be explained with reference to the drawings.

FIG. 3 is an explanatory diagram of the manufacturing apparatus, and FIG. 4 is an explanatory diagram of the main parts.

The formwork 11 is molded to have a shape corresponding to the shape of the back surface 4 of the tile A, as shown in FIG. That is, grooves 11a are formed in the formwork 11 at positions corresponding to the ribs 5 of the tile A, and a flat surface 11b corresponding to the back surface 4 is formed. Furthermore, an overlap portion 6 is provided on the side surface of the formwork 11.
A groove 11c corresponding to the groove 11c is formed.

As shown in FIG. 4, a large number of molds 11 are placed on a conveyor 12 in contact with other molds, and are conveyed by the conveyor 12 at a constant speed in the direction of arrow a.

A filling device 13 for filling the formwork 11 with mortar mixed with fibers is arranged at a predetermined position of the conveyor 12, and a filling device 13 is placed downstream of the filling device 13 at a predetermined distance away from the mold in the direction indicated by the arrow. A press roller 14 that rotates is arranged.

The filling device 13 mixes mortar and fibers at a predetermined ratio and fills the mold 11 conveyed by the conveyor 12 with the pre-stirred fiber-mixed mortar.

The filling amount or filling thickness of the fiber-containing mortar in the formwork 11 differs depending on the specifications of the roof tile A to be manufactured. For this reason, it is preferable that the filling device 13 is configured so that the filling amount of the fiber-mixed mortar per unit time can be set appropriately.

Further, as in this embodiment, when filling only the grooves 11a formed in the formwork with fiber-mixed mortar, the filling device 13 has a nozzle 12 at a position corresponding to the groove 11a of the formwork 11 being conveyed.
It is preferable to provide a groove 11a so as to reliably fill the groove 11a with fiber-mixed mortar.

The press roller 14 is for compressing the fiber-mixed mortar filled in the formwork 11. For this reason, the formwork 11
It is constructed so that the entire surface can be pressed. Then, the fiber mixed mortar filled in the formwork 11 is transferred to the press roller 1
4, it is possible to form the fiber mixed layer l.

As in this embodiment, fiber-mixed mortar is applied to the grooves 11 of the formwork 11.
When filling the press roller 14 with the press roller 14, as shown in FIG. This allows the fiber-mixed mortar filled in the grooves 118 to be pressed. still,
It goes without saying that the shape of the press roller 14 should be appropriately set depending on the thickness of the fiber-mixed layer 1 to be formed on the tile A, the forming portion, etc.

A mortar extrusion molding device 15 is disposed downstream of the press roller 14 and separated by a predetermined distance, and a slipper 16 is disposed continuously with the extrusion molding device 15.

The extrusion molding device 15 has a similar structure to an extrusion molding device commonly used for manufacturing concrete roof tiles. That is, the extrusion molding device 15 stores mortar mixed and stirred in a predetermined ratio in advance, and the mold 11 is filled by extruding this mortar by the rollers 15a.

The slipper 16 is used to compress the mortar filled in the formwork 11 and to shape the surface.

Then pickpocket the mortar filled in the formwork 11.
6, it is possible to laminate the mortar layer 2 on the fiber mixed layer 1.

Further, by forming appropriate irregularities on the surface for forming the mortar surface of the slipper 16, it is possible to form a pattern corresponding to the irregularities on the surface 3 of the tile A.

As described above, the fiber mixed layer 1 and the mortar layer 2 are laminated on the continuous formwork 11 to form a long material for the tile A, and then a cutting device is installed downstream of the slipper 16. The tile A can be manufactured by cutting the raw material of the tile A according to the front and rear ends of the formwork 11 using the cutter 17 and curing it under predetermined conditions.

<Effects of the Invention> As explained in detail above, according to the lightweight concrete flat tile according to the present invention, by laminating a fiber-mixed layer formed by mixing fibers into mortar and a mortar layer without mixing fibers, , it is possible to maintain the strength as a roof tile. For this reason, the overall thickness of the tile can be reduced,
Therefore, the weight can be reduced and the cost will not increase.

Further, according to the method for manufacturing a lightweight concrete flat tile according to the present invention, a lightweight concrete flat tile having uniform quality can be manufactured.

[Brief explanation of the drawing]

Fig. 1 is an overall perspective view of the tile seen from the back side, Fig. 2 is a sectional view thereof, Fig. 3 is an explanatory view of the manufacturing equipment, and Fig. 4 is an explanatory view of the main parts. A is a roof tile, 1 is a fiber mixed layer, 2 is a mortar layer, 3 is a surface,
4 is the back surface, 5 is the lip, 6 is the overlapping part, 7 is the underlap part, 11 is the formwork, Ila is the groove, 13 is the filling device, 14 is the press roller, 15 is the extrusion molding device, 16 is the slip y/size , 17 is a cutting device. Patent applicant Asahi Kasei Industries Co., Ltd. Representative Patent attorney Shukichi Nakazumi

Claims (2)

[Claims] (1) A lightweight concrete flat tile made by laminating a fiber-mixed layer formed of fiber-mixed mortar and a fiber-free mortar layer. (2) Filling a mold with mortar mixed with fibers and compressing it to form a fiber-mixed layer, and then filling the mold with mortar and compressing it to stack a mortar layer on the fiber-mixed layer. A method for manufacturing lightweight concrete flat tiles featuring: