JPH04296511A - Method of manufacturing inorganic molding and manufacturing apparatus therefor - Google Patents

Abstract

PURPOSE:To obtain a useful water glass inorganic molding as a building material by filling a curable inorganic molding raw material into a mold frame having an opening in its upper surface, and after press forming it via a press mechanism situated on the upper side of the mold, removing the circumferential mold frame. CONSTITUTION:A curable inorganic molding material of water glass, colloidal silica, and the like is filled into a mold frame having an opening in its upper surface, and press molding is effected for it via a press mechanism positioned on the upper side of the mold frame. Following this, after removing the circumferential mold frame, a molding is taken outside via a mechanism reciprocating along the bottom surface of the mold frame. An apparatus for molding the inorganic material is composed of a horizontal table 1 vertically provided on a base, a bottom part mold frame 12 fittingly mounted on the horizontal table 1, mold frame materials 3, 4, and the like. The bottom part mold frame 2 is moved upward by an elevating mechanism 5 of a hydraulic cylinder or the like provided on the fundamental table 1. The mold frame materials 3, 4 are moved horizontally to the position indicated by dotted lined via the reciprocal mechanism 6, 6 of a hydraulic cylinder or the like, and thus become releasable, furthermore, the mold frame material 3 comes upward to a predetermined height via another elevating mechanism 7.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and apparatus for producing inorganic molded bodies.

0002

[Prior Art] Conventionally, an inorganic aggregate made of calcined vermiculite and/or calcined shirasu (shirasu balloon) is mixed with water glass containing a hardening agent as a bonding material and then pressure-molded.
Inorganic lightweight building materials are produced by curing, and in recent years, the moisture content of the joined body is reduced as much as possible, pressure molding is performed in powder form, and this is heated and cured to shorten the time. A method for obtaining a product in a short period of time has been developed (Japanese Unexamined Patent Publication No. 1-317148).

0003

[Problems to be Solved by the Invention] When water glass and a water glass hardening agent are mixed with the inorganic aggregate to reduce the water content as much as possible, when the water content of the mixture becomes 50% by weight or less, The whole becomes a fluid powder with good dispersibility, so in actual manufacturing, it is packed into a mold and pressurized from above by a press mechanism to compact it and then release the pressure. The mold is then disassembled to remove the product. Since this work is a so-called table test manufacturing method in which each piece is completed by hand, it has the disadvantage of being inefficient and having low productivity.

0004

[Means for Solving the Problems] In contrast, the present invention provides assembly of the above-mentioned formwork, supply of a curable inorganic molding raw material, pressurization,
The disassembly of the mold and the removal of the product are performed by a device that operates in a series of sequences, allowing for continuous production.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the apparatus according to the present invention will be described with reference to the drawings. In FIG. 1, 1 is a horizontal stand set up on a base, and 2 is a bottom mold fitted and placed on this horizontal stand. The frames 3 and 4 and the two formwork members (not shown) located in the front and forward directions in the figure are a set of four formwork members that form a peripheral formwork along the four sides of the bottom formwork. The bottom formwork 2 is movable upward via a lifting mechanism 5 such as a hydraulic cylinder provided on the base 1, and the formwork members 3 and 4 are movable upward via a reciprocating mechanism 6 such as a hydraulic cylinder. , can be opened by moving left and right to the position indicated by the chain line in the figure, and one of them 3 can be raised to a predetermined height via a separate elevating mechanism 7 and can be further moved to the right in the figure. .

Next, reference numeral 8 denotes a press mechanism located above the bottom formwork 2, which is lowered by hydraulic pressure. In the figure, reference numeral 9 denotes a raw material hopper, which is normally retracted from the horizontal table 1, but when inputting raw materials, it moves forward onto the horizontal table 1 and discharges the raw material inside onto the bottom formwork 2 in a fixed quantity. It has become. The operation of each of these parts is
These operations are automatically performed in conjunction with each other via a separately provided control mechanism.

[0007] The operating sequence of the above device will be explained with reference to the drawings. (1) Surrounding the bottom formwork 2 placed on the horizontal table 1, formwork members 3 and 4 and two formwork members (not shown) at the front and rear in the figure are positioned to form the required formwork. After forming the
The raw material hopper 9 is advanced over the mold to drop the curable inorganic molding raw material into the mold (FIG. 1). Note that a mechanism for uniformly dispersing the raw material within the mold after being dropped or a mechanism for removing an excessive amount of raw material along the upper surface of the surrounding mold after overfilling the raw material may be added.

(2) After retracting the raw material hopper, the press mechanism 8 is lowered to pressure-form the raw material in the mold (FIG. 2). Note that this pressure forming may be performed by raising the entire mold toward the press mechanism 2 (here, a method of lowering the press mechanism 8 will be described).

(3) While raising the press mechanism 8,
The formwork members 3 and 4 are moved left and right in the figure, respectively, and the formwork members (not shown) located in contact with the molded body a at the front and back in the figure are respectively moved back and forth in the figure to open the surrounding formwork. (Figure 3).

(4) Push up the bottom mold 2 to raise the molded product a, raise one of the mold members 3 to the height of the molded product a, and then move this mold member 3 horizontally to the right. The molded body a is then pushed out onto a belt conveyor 10 provided in advance (FIG. 4). In the example shown in the figure, the formwork members forming the surrounding formwork are formed of four members that can move forward and backward, as shown in Fig. 5(A). The members are a set of two U-shaped planar parts shown in (B), those shown in (C), or (D).
One set may be movable and the other set may be fixed.

Next, FIG. 6 shows an example of an apparatus for manufacturing a plate-shaped inorganic molded body to which another plate material such as a natural stone plate is further bonded. In this embodiment, the other formwork member 4 is made to be able to be lowered, and this formwork member 4 is lowered in advance, and a natural stone board b having an adhesive layer on the upper surface is continuously made with another device. is conveyed onto the bottom formwork 2 via the roller conveyor 11, and then the formwork member 4 is raised to the state shown in FIG. By going through this process, a molded body with natural stone slabs can be made.

The above is an example of the manufacturing apparatus according to claim 2. For example, in the above apparatus, at least one of the plurality of mold members is reciprocated on the bottom mold as in the above apparatus. At least the formwork member facing this formwork member is made movable, and at least the formwork member facing this formwork member is made lowerable via an elevating mechanism, and after the curable inorganic molding material is pressure-molded, the formwork member made capable of being lowered is lowered. The manufacturing apparatus of claim 3 example) The same effect can be achieved.

[0013] Furthermore, in the above device, the formwork member is composed of one or more formwork members, and at least the formwork member located in one direction on the bottom formwork can be lowered via an elevating mechanism; The formwork is made to be able to be raised via an elevating mechanism, and after the curable inorganic forming raw material is pressure-molded, the above-mentioned formwork members are lowered and/or the bottom formwork is raised. Even if the inorganic molded body is configured to be taken out by advancing a reciprocating mechanism along the bottom surface of the mold and pushing the inorganic molded body onto a conveyor outside the mold (an example of the manufacturing apparatus of claim 4), it is the same. effect can be achieved.

[0014] Examples of the curable inorganic forming raw material used in the present invention include water glass, colloidal silica, and cement. As a matter of course,
These inorganic molding raw materials include aggregates, curing agents,
Various additives such as colorants can be mixed.

In the present invention, in any case, it is desirable to use a material with a low water content in the total composition and a material with a relatively fast curing speed as the above-mentioned inorganic molding material. When such an inorganic molding material is used, productivity and workability can be improved. In this case, it is desirable that the water content in the entire composition be 50% by weight or less.

The most preferred curable inorganic forming raw material in the present invention is a water glass-based powder containing an inorganic aggregate and a water glass hardening agent and having a water content of 50% by weight or less. Examples of inorganic aggregates include shirasu balloons, calcined vermiculite, kaolin, mica, talc, and silica. From the viewpoint of obtaining lightweight molded products, it is preferable to use lightweight aggregates such as whitebait balloons and calcined vermiculite.

[0017] As a Shirasu balloon, the average particle size is 20
~600 μm are used, but preferred shirasu balloons have a content of components with a particle size of 63 μm or less (hereinafter also referred to as component A) of 15 to 55% by weight, preferably 20 to 55% by weight.
It is a mixture of coarse shirasu balloons and fine shirasu balloons in which the content of components exceeding 50% by weight and particle size of 63 μm (hereinafter also referred to as component B) is 45 to 85% by weight, preferably 50 to 80% by weight.

The water glass used in the present invention refers to an aqueous solution of an alkali metal silicate such as sodium silicate, potassium silicate, or lithium silicate.
These products are commercially available as No. 1 standard products, JIS No. 2 standard products, JIS No. 3 standard products, etc.

Water glass hardening agents include conventionally known ones, such as inorganic acids and their salts such as phosphoric acid and boric acid, silica fluorides such as sodium silicofluoride, zinc oxide, magnesium oxide, calcium carbonate, and calcium sulfate. Examples include metal oxides and salts such as, acetate esters, etc.

[0020] When obtaining a molded product using shirasu balloons as an inorganic aggregate, the proportion of water glass used is 30 to 150 parts by weight in terms of solid content (alkali metal silicate) per 100 parts by weight of shirasu balloons. , preferably 40-13
It is 0 parts by weight. The hardening agent for water glass is 10 to 40 parts by weight, preferably 1 part by weight, per 100 parts by weight of the Shirasu balloon.
It is 5 to 30 parts by weight.

[0021] In the present invention, the pressure during molding is more than 5 kg/cm2G and 20 kg/cm2G.
It is preferable to specify it in a range of less than 5.5 to 19 kg/cm2G, preferably in a range of 5.5 to 19 kg/cm2G. Pressure molding pressure is 5kg/
Molded products molded at pressures below cm2G do not have strong adhesion between particles, tend to break at the edges, lack dimensional stability, and are far from perfect in terms of cracks. . In addition, the bending strength is low, and the strength is not sufficiently satisfactory as a building material. On the other hand, in the case of a molded body molded at a pressure of 20 kg/cm2G or more, the silane balloon itself is completely destroyed, and the resulting molded body has variations in thickness. The advantages of low thermal conductivity and non-water absorption properties are lost.

In the present invention, a polymer binder can be used in combination to increase the mechanical strength of the molded article. As this polymer binder, a water-soluble polymer or polymer latex can be used. As the water-soluble polymer, in addition to water-soluble urea/formamide resin and guanamine resin, polyvinyl alcohol, methylcellulose, polyvinylpyrrolidone, etc. are used. As the polymer latex, styrene/butadiene latex, acrylic latex, vinylidene chloride latex, vinyl chloride latex, vinyl acetate latex, etc. are used. The proportion of the polymer binder to be used is preferably 0.5 parts by weight or more, preferably 1 to 10 parts by weight, in terms of solid content, per 100 parts by weight of the shirasu balloon. If the proportion of the polymer binder used increases, the nonflammability of the building material will be impaired, so from the viewpoint of obtaining a noncombustible building material, the proportion of the polymer binder used is preferably 5 parts by weight or less.

[0023] In the present invention, the molding raw material is used in the form of fluid granules, with its moisture content maintained at 20 to 50% by weight, preferably 25 to 40% by weight. Such a granular mixture can be easily put into a mold and pressure-molded.

[0024] When obtaining a building material according to the present invention, it is preferable to fill a mold with the granular mixture, take out the molded product from the mold after pressure molding, and cure the pressed molded product at room temperature or under heating. In this pressure molding, the molded product can be cured in the mold, but since the pressure molded product is a solid material and is easy to handle, the molded product is removed from the mold and cured. It is preferable to cure by holding at room temperature or under heating. When curing the molded body under heat,
The heating temperature is 30° C. or higher, preferably 80° C. or lower, and the curing time is usually 1 to 3 hours.

The heat-cured molded body can be used as a product as it is, but in order to further advance the curing reaction and improve the mechanical strength, it is heated at room temperature or around room temperature for 3 to 1 hours.
It is preferable to hold and use it for about 0 days, preferably about 5 to 8 days. The shape of the molded object is in addition to a plate-like object, a block object,
It can have any shape such as a columnar body or a cylindrical body.

[0026]

Effects of the Invention As explained above, the present invention is capable of continuously molding a water glass-based inorganic material by press-molding a powdery raw material consisting mainly of shirasu balloons and mixed with water glass and a water glass hardening agent. This molded product is suitable for building materials such as interior materials, ceiling materials, lining materials, etc., and the product dimensions are always constant, making it easy to cut edges, cut, etc. in conventional gypsum boards, etc. Since no secondary processing is required, there is no waste of material and manufacturing costs can be reduced.

Example 1 Water glass (J
IS3 product) 100 parts by weight, water glass hardening agent (condensed aluminum phosphate) 7.3 parts by weight, whitebait powder (white clay) 7
．． 2 parts by weight, 4.6 parts by weight of mica, 4.6 parts by weight of kaolin, 1 part by weight of vinylon fiber (length 6 mm, diameter 15 μm), styrene-butadiene latex (solid content 40% by weight)
) After producing a mixture consisting of 3 parts by weight, the mixture is transferred to a powder metering device. On the other hand, a plurality of mold members are formed by hydraulic cylinders on the upper surface of a molding machine having a press function. Next, a powder measuring device is moved above the mold formed on the upper surface of the molding machine, and the mixture is dropped. Thereafter, a vertically movable press mechanism located above the molding machine is lowered, and pressure molding is performed under a pressure of approximately 6 kg/cm2G. Next, after the press mechanism is raised, the plurality of mold members are separated, and the bottom mold is raised from the bottom of the molding machine, which has a vertically movable portion in advance. Accordingly, one of the mold members is raised, and then the molded body is moved onto the transfer means by horizontal movement of the raised mold member. After that, it is transferred to a curing furnace and a curing room, and a water glass-based inorganic lightweight board is manufactured.

Example 2 A part of the mold member is formed on the upper surface of the molding machine in advance,
A natural stone slab with an adhesive layer on one side is then inserted by a conveying device. The natural stone slab is then completely fixed as the remaining formwork components are assembled. Thereafter, the above mixture is filled as shown in Example 1, and a water glass-based inorganic lightweight decorative board is manufactured according to Example 1.

[Brief explanation of the drawing]

FIG. 1 shows a state diagram of the apparatus when a raw material hopper 9 is advanced onto the mold and a curable inorganic molding raw material is dropped into the mold.

FIG. 2 shows a state diagram of the apparatus when the raw material hopper is retreated and then the press mechanism 8 is lowered to pressure-form the raw material in the mold.

[Fig. 3] In Fig. 3, the press mechanism 8 is raised and the mold members 3 and 4 are moved to the left and right in the figure, respectively, and a molded object a is formed.
This is a state diagram of the apparatus in which the surrounding formwork is opened by moving the formwork members located in contact with each other forward and backward in the figure, respectively.

4] In FIG. 4, the bottom mold 2 is pushed up to raise the molded product a, one mold member 3 is raised to the height of the molded product a, and this mold member 3 is further moved to the right. A state diagram of the apparatus in which the molded body a is pushed out onto a belt conveyor 10 provided in advance by horizontal movement is shown.

FIG. 5 is an explanatory diagram showing examples of formwork members forming the surrounding formwork.

FIG. 6 is an explanatory front view showing another example of FIG. 1; 1... Horizontal table 2... Bottom formwork 3, 4... Formwork members 5, 7... Lifting mechanism 6... Reciprocating mechanism 8... Press mechanism 9... Raw material hopper 10 ...Belt conveyor 11...Roller conveyor a...Molded body b...Natural stone plate

Claims (4)

[Claims] Claim 1: A curable inorganic molding raw material is filled into a mold with an open top and pressure-molded using a press mechanism placed above the mold, the surrounding mold is removed, and then the mold is A method for producing an inorganic molded body, comprising taking out the molded body outward through a mechanism capable of reciprocating along the bottom surface of a frame. 2. A formwork filled with a curable inorganic forming raw material is composed of a bottom formwork that can be raised via a lifting mechanism, and a surrounding formwork assembled from a plurality of formwork members,
At least one of the mold members is movable along the bottom surface of the mold via a reciprocating mechanism, and a curable inorganic molding material filled in the mold is pressure-molded above the bottom mold. furthermore, one of the reciprocally movable mold members is raised via a lifting mechanism, and the molded product on the raised bottom mold is pushed onto a conveyor previously provided on the outside. An apparatus for manufacturing an inorganic molded body, which is configured to: 3. The formwork filled with the curable inorganic forming raw material is composed of a bottom formwork and a closed formwork assembled from a plurality of formwork members, and above the bottom formwork there is a A press mechanism is provided for pressure-molding the curable inorganic molding material filled in the mold, and at least one of the mold members is provided.
One of the formwork members can be moved along the bottom surface of the formwork via a reciprocating mechanism, and the other formwork member can be lowered via the elevating mechanism. An apparatus for manufacturing an inorganic molded body, which is configured to push a molded body on a bottom mold onto a conveyor provided in advance on the outside by a mold member movable along the bottom mold. 4. A formwork filled with a curable inorganic molding material is composed of a bottom formwork and a surrounding formwork, and above the bottom formwork is a curable inorganic molding material filled into the formwork. It is equipped with a press mechanism for heat-forming the raw material, and is equipped with a mechanism that can reciprocate along the bottom of the mold on the outside of the surrounding mold, and furthermore, it is equipped with a press mechanism that can reciprocate along the bottom of the mold, and furthermore, the bottom mold and the surrounding mold are vertically moved relative to each other. Production of an inorganic molded body that is movable and configured such that, after the relative movement, the molded body on the bottom mold is pushed onto a conveyor previously provided on the outside through the reciprocating mechanism. Device.