JPH0584721A - Alc panel and its manufacture - Google Patents

Abstract

PURPOSE:To make the deformation of a panel smaller and prevent a cavity around a reinforcing bar from being exposed on the surface by a method wherein, when an ALC panel including reinforcing bars is fabricated, a form comprising side boards which are upwardly expanded and opened and a detachable bottom board is used so that, after raw material has been cured, the bottom board is changed to a transfer means to send the panel to a cutting process. CONSTITUTION:A form comprises side boards 10, 11 which are outwardly inclined at an angle theta of 1-20 degrees and a detachable bottom board 12. Reinforcing bars 8 comprising main bars 6 and auxilary bars 7 are set in the form and water slurry including aluminum powder, as a foaming agent, is fed into the form to effect foaming and curing. Next, the board 12 is converted to a transfer means and then the boards 10, 11 are removed and the product thus formed is sent to a cutting process to cut it into panel shape, which are cured by steam under high temperature and pressure. In the ALC panel 5, differences in bulk specific gavity of each part of the panel can be made 0.04 or less. Further, a cavity 24 around the reinforcing bars 8 extends in a direction of a short side of the panel 5 and hence the cavity is not exposed on the surface. And moreover, when the panel is sent to the cutting process, stress exerted on the cured matter can be made smaller.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to an ALC panel and a method for manufacturing the panel.

[0002]

2. Description of the Related Art Conventionally, as a typical method for manufacturing an ALC panel, an ALC raw material containing aluminum powder is punched into a rectangular form frame in which mat-shaped reinforcing bars consisting of main bars and auxiliary bars are set upright. A cured product is obtained by setting and foaming and curing, and the cured product is cut in the orientation direction of the mat-shaped reinforcing bar to produce a plurality of panel-shaped molded products, and the molded products are steamed under high temperature and high pressure. A method of curing to make a panel (vertical setting method) and a method in which the mat-like reinforcing bars are laid horizontally and the ALC raw material is placed in the same manner as above, foamed and cured to obtain a cured product. After that, there is a method of making a panel by the same operation as described above (horizontal setting method).

[0003]

However, when an ALC panel, in particular, an ALC panel having a width in the shortest side direction of about 1 m or more is manufactured by the conventional method, the following problems occur. That is, in the vertical setting method, the absolute dry bulk specific gravity difference ρ of ALC at any two positions in the ALC panel is different by 0.04 or more, and as a result, a compression strength difference is generated depending on the part of the ALC panel, and the panel is distorted. There is a problem that it will occur.

ALC obtained by the horizontal set method
In the panel, the absolute dryness difference is small, but the voids generated around the reinforcing bars extend in the thickness direction of the panel, and as a result, the voids are likely to be exposed on the panel surface, impairing the appearance of the panel, and However, there is a problem in that rainwater easily enters the voids, resulting in a decrease in the strength of the panel.

An object of the present invention is to provide an ALC panel and a method for manufacturing the ALC panel which can solve the above problems.

[0006]

According to the invention of claim 1, the insulation of ALC at any two positions in a lightweight cellular concrete (ALC) panel with reinforcing bars, which is obtained by using aluminum powder as a foam. Dryness specific gravity difference ρ0 is 0.0
4 or less, the ALC panel is in a range satisfying the formula 2, and the void portion formed around the reinforcing bar extends in a direction orthogonal to the thickness direction of the panel;

[0007]

[Equation 2]

However, in Expression 2, W is 30 to 250
The panel width (cm) in the direction orthogonal to the thickness direction of the panel in the range of cm is shown. Here, the absolute dry bulk specific gravity difference ρ0 means a value measured by the test method described in JIS A5416.

According to the third aspect of the present invention, in the above-described method for manufacturing an ALC panel, (a) a mold including side plates that widen upward as the form frame and a bottom plate separable from the side plates. While using a frame, (b) when the cured product is placed on the transportation means and transferred to the cutting step,
After raising the mold and / or lowering the bottom plate thereof, the bottom plate is replaced with the conveying means, and a cured product is placed on the conveying means and conveyed.

The invention of claim 5 is the ALC described above.
In the method of manufacturing a panel, (a) a mold comprising a side plate that widens upward as the mold and a bottom plate that is separable from the side plate is used, and (b)
When the cured product was placed on the transport means and transported to the cutting step, the cured product was directly held by the gripping means, or the bottom plate was separated from the mold to hold the cured product on the side plate. A means is adopted in which the gripping means is indirectly gripped by the gripping means to place the gripping means on the transporting means.

[0011]

In the invention of claim 1, since the absolute dry bulk specific gravity difference ρ0 of ALC at any two positions in the ALC panel is less than a certain value, the variation of the compression strength depending on the parts of the ALC panel is less than a certain value. Is suppressed, and as a result, distortion in the ALC panel is suppressed. Further, since the void portion generated around the reinforcing bar extends in the specific direction of the panel described above, there is no possibility that the void portion is exposed to the panel surface side.

In the inventions of claims 3 and 5,
Since the side plate of the mold used for casting the ALC raw material is expanded as it goes upward, the external pressure applied to the bubbles of the cured product during the foaming / curing process of the ALC raw material is almost the same at any position. As a result, the size and shape of the bubbles in the finally obtained cured product are homogenized, and an ALC having a small absolute dry bulk specific gravity difference between arbitrary sites is obtained.

Further, in a preferred embodiment of the invention of claim 3, when the cured product is placed on the conveying means and conveyed to the cutting step, the mold is raised or the bottom plate thereof is lowered. After that, or after lowering the bottom plate while raising the mold, the bottom plate is replaced with the transporting means, and the cured product is placed on the transporting means, so that the moving range of the cured product is minimized. It will be possible. Therefore, the cured product can be supported with less stress.

A typical embodiment of the present invention will be described below with reference to the drawings.

[0015]

Example 1 First, as shown in FIG. 1, an ALC raw material was placed in the placing step A, and the obtained cured product 1 was conveyed to the cutting step C by the conveying means 2 in the conveying step B. , A method for obtaining the desired ALC panel 5 by cutting the panel-shaped molded product 3 obtained in this step into steam in the autoclave 4 of the curing step D under high temperature and high pressure in that step To do.

61 parts by weight of silica stone as a siliceous raw material, 15 parts by weight of quicklime as a calcareous raw material, 20 parts by weight of cement,
A small amount of aluminum powder was added as a foaming agent to a water slurry in which 70 parts by weight of water was mixed with 100 parts by weight of the main raw material composed of 4 parts by weight of gypsum, and this ALC raw material was
A mat-shaped reinforcing bar 8 including a main bar 6 and a secondary bar 7 shown in FIG.
It was placed on the mold 9 in which was set. The water slurry was vibrated during casting.

As shown in FIG. 3, the mold 9 expands upward and has two long side plates (vertical height 3 m, length 3 m) 10 facing each other, and orthogonal to the side plates. Short side plate (vertical height 3 m, length 1.5
m) 11 and a bottom plate (about 3 m in the long side direction × about 1.5 m in the short side direction) 12 provided on the end face side that is separable from these side plates. The long side plate 10 and the short side plate 11 were each inclined outward from the vertical plane at an angle θ of 2 degrees.

After the raw material was cast in the mold 9, the raw material was left as it was in the mold for several hours to be foamed and cured to obtain a cured product 1. Prior to transferring the cured product 1 to the cutting step C by the transfer means 2 shown in FIG. 1, the cylinder 14 of the first jack 13 installed below the bottom plate 12 is extended as shown in FIG. After raising the mold 9, the cylinder 16 of the second jack 15 installed on the long side plate 10 is extended to move the long side plate 10 to the cylinder 16 thereof.
Supported.

Then, the cylinder 14 of the first jack 13 is contracted to lower the bottom plate 12. At this time, as shown in FIG. 4, the cured product 1 in the mold 9 was supported by the inclined surfaces of the long side plate 10 and the short side plate 11. The bottom plate 12
The bottom plate 12 is placed on the wheels 17 arranged below the mold 9 at appropriate intervals and driven by a motor 18 to discharge the bottom plate 12 from below the side plates 10 and 11 to the outside of the mold 9. It was Then, after that, as shown in FIG. 5, the conveying means 2 including a frame 19 and a plurality of flat bars 20 arranged in the traveling direction of the wheels 17 is placed on the wheels 17 and is placed from the outside of the frame 9. It was moved in below the long and short side plates 10, 11.

In this way, after the bottom plate 12 and the conveying means 2 are replaced below the side plates 10 and 11,
The side plate 1 is made by contracting the cylinder 16 of the second jack 15.
0 and 11 and the cured product 1 are placed on the conveying means 2 and the side plate 1
0 and 11 and the hardened | cured material 1 were isolate | separated. Separated cured product 1
1 was placed on the conveying means 2 and conveyed to the cutting step C, as shown in FIG. Thereafter, the cured product 1 was cut in the same manner as the conventional technique to obtain a panel-shaped molded product 3. At this time, the cutting wastes 21, 22 and 23 at the both ends and the upper end on the long side and the short side obtained by cutting the cured product 1 were discarded.

Finally, the panel-shaped molded product 3 while being placed on the carrier means 2 is carried into the autoclave 4 shown in FIG. 1 and steam-cured under high temperature and high pressure, so that the long side length 30
ALC with 0 cm x short side length 150 cm x thickness 10 cm
Fifteen panels 5 were obtained.

As shown in FIG. 6, the ALC panel 5 is embedded with a mat-shaped reinforcing bar 8 composed of a main bar 6 and a secondary bar 7, and the ALC panel 5 is surrounded by the main bar 6.
Direction orthogonal to the thickness direction of the short side direction (X direction)
The void portion 24 was extended toward. A position of about 15 cm from one long side toward the other long side and a position of about 15 cm from the other long side toward the one side in the central portion of the panel 5 in the long side direction (Y direction). Blocks G and H each having 10 cubic cm at the center were cut out, and a block K similar to the above was cut out at an almost intermediate position between both blocks.

When the absolute dry bulk specific gravity of the blocks G, H and K was measured, they were 0.542 and 0.5.
It was 02, 0.530 (maximum minimum absolute dry bulk specific gravity difference ρ0 = 0.040). When the compressive strengths σ of these blocks G, H and K were measured by JISA5416, they were 63.0 Kgf / square cm and 54.4 Kgf / square c.
m, 59.1 Kgf / square cm. Then, the difference σ0 between the maximum value σ1 and the minimum value σs of the compression strength was calculated.

Further, the diameters of about 300 bubbles in each of the X-direction cross section and the Y-direction cross section of the blocks G, H, and K were analyzed and measured by an image processing device (manufactured by JEOL Ltd.), and shown in Table 1. The average bubble diameter in the X and Y directions and the ratio of the two were obtained.

[0025]

[Table 1]

According to Table 1, the bubble diameters in the X, Y directions at the upper, middle, and lower positions are substantially the same, that is, the bubbles have a substantially spherical shape, and the upper, middle, and lower positions are the same. The bubble diameters in the X direction and in the Y direction at the position were almost the same. This is AL
It is implied that the size of the bubbles in any part of the C panel is about the same.

Next, the side plates 10 and 11 of the form 9 shown in FIG.
The same experiment as above was repeated several times by keeping the inclination angle θ of 2 degrees and changing the depth.
Various ALs having a width W in the X direction of 60 cm and 100 cm
C panel 5 was manufactured. Then, similarly to the above, the absolute dry bulk specific gravity ρ1 of the block G, the absolute dry bulk specific gravity ρ3 of the block H, and the absolute dry bulk specific gravity ρ2 of the block K were measured. The difference between the maximum value ρl and the minimum value ρs of the three values (ρl-ρs)
= Ρ0 was calculated. The results are shown in Table 2 together with the measurement results of the absolute dry bulk specific gravity when the panel width W (cm) is 150 cm, and the maximum minimum absolute dry bulk specific gravity difference ρ
A relational straight line between 0 and the panel width W (cm) in the X direction is shown as a relational straight line I in FIG.

[0028]

[Table 2]

Equation 3 was obtained from this relational straight line I.

[0030]

[Equation 3]

[0031]

[Comparative Example 1] For comparison, the side plate 1 according to Example 1 was used.
0, 11 vertical, 3 types of panels (W = 60, 10
An experiment was performed to obtain 0, 150 cm), and blocks g, h, and k (not shown) similar to those in Example 1 were obtained. Absolute dry bulk specific gravity difference ρ0 and compression strength σ0 of these blocks g, h, k
Was measured and the results shown in Table 3 were obtained.

[0032]

[Table 3]

Further, Table 1 showing the average diameter of bubbles in Example 1 is also shown in Comparative Example. The relationship between the panel width W (cm) shown in Table 3 and the maximum / minimum absolute dry bulk specific gravity difference ρ0 is shown by the relationship line II in FIG. 7.

Equation 4 was obtained from this straight line.

[0035]

[Equation 4]

As is clear from Example 1 and Comparative Example 1 of the present invention, (1) the present invention has a smaller absolute dryness specific gravity difference ρ0, (2) the present invention has a difference in compressive strength σ0, that is, compressive strength. It can be said that (3) the difference in bubble diameter is smaller in the present invention, that is, the size and shape of the bubble are uniform.

[0037]

[Embodiment 2] Next, the inclination angles θ of both side plates of the mold used in Embodiment 1 are increased to 15 degrees, and
ALC with different panel width W by variously changing the height of casting
Panel 5 was obtained. And the panel width W and the absolute dry bulk specific gravity difference ρ
The relationship with 0 was grasped and shown in Table 4, and this table was plotted to obtain the relationship line III in FIG. 7. Then, Equation 5 was obtained from this straight line.

[0038]

[Table 4]

[0039]

[Equation 5]

Table 4 also shows the relationship between the panel width W and the compressive strength σ. According to this embodiment, the panel width W is 200
It can be seen that even in cm, the absolute dry bulk specific gravity difference ρ0 is smaller than 0.04.

[0041]

[Embodiment 3] Next, the inclination angles θ of both side plates of the mold used in Embodiment 1 are increased to 20 degrees, and
Panel width W = 60, 100, by changing the height of casting
ALC panels of 150, 200, 250 and 300 cm were obtained. Then, the relationship between the panel width W and the absolute dry bulk specific gravity difference ρ0 was grasped and shown in Table 5, and this table was plotted to obtain the relationship straight line IV in FIG. 7.

[0042]

[Table 5]

Equation 6 was obtained from this line IV.

[0044]

[Equation 6]

Table 5 also shows the relationship between the panel width W and the compressive strength σ. According to this embodiment, the panel width W is 250.
It can be seen that even in cm, the absolute dry bulk specific gravity difference ρ0 is smaller than 0.04.

[0046]

[Comparative Example 2] The tilt angle θ of Example 3 was further increased to 30
Although the same effect as in Example 3 was obtained, the amount of shavings was large and accounted for 30% or more of the product, resulting in a significant decrease in yield. Comprehensively considering this Comparative Example and Example 3, in the range where the absolute dry bulk specific gravity difference is 0.04 or less,
It can be said that the inclination angle θ of the side plate is preferably not less than 2 degrees and not more than 15 degrees. When this is shown by a straight line showing the relationship between the panel width W and the absolute dry bulk specific gravity difference, the absolute dry bulk specific gravity difference ρ0 is (1/3
It can be said that it is better to be (750) · W or less and (1/5740) · W or more.

[0047]

Example 4 In the same experiment as in Example 1, the ALC raw material was placed in the mold 9 and the side plates 10 and 11 and the bottom plate 12 were separated from each other, as shown in FIG. Side plate 1
The side plates were held at 0 and 11, and the side plates were held by the holding means 25. Then, the gripping means 25 was raised and moved laterally by the crane 26 to place the cured product 1 and the side plates 10 and 11 on the conveying means 2 which is connected to the cutting step C (see FIG. 1). Then, the side plates 10 and 11 were separated from the cured product 1, and thereafter, a panel-shaped molded product was obtained from the cured product 1 in the same manner as in Example 1. The panel-shaped molded product thus obtained was steam-cured under high temperature and high pressure to obtain an ALC panel of the present invention. When the absolute dry bulk density difference ρ0 of this panel is measured, it is 0.0
It was 34. However, in this embodiment,
The hardness of the cured product had to be slightly higher than in the above case, and the decrease in productivity was inevitable.

The present invention is not limited to the above-mentioned embodiments, but can be carried out by changing to the following modes, for example, as long as the fundamental technical idea of the present invention is followed and the effects of the invention are not significantly impaired. ..

(1) In the embodiment of the fourth embodiment, when the gripping means 25 grips the hardened material, when the hardened material 1 has an appropriate hardness, the hardened material 1 is moved to the side plates 10, 11.
After separating, the hardened material can be directly gripped by the gripping means 25. In this embodiment, the contact portion of the gripping means 25 with the cured product 1 needs to have a structure that does not cause the destruction of the cured product 1, for example, a structure similar to the side plate 10 or the like.

(2) Only the short side plates of the formwork can be made vertical, and the angles of both the long side plates can be different from each other. (3) The angle of the long side plate was tested in the range of 2 to 15 degrees in the embodiment, but the effect of the present invention is not significantly impaired even if it is carried out in the range of 1 to 20 degrees beyond the above range. (4) As a method of setting the reinforcing bar to the mold, so-called reinforcement, in which the water slurry of the main raw material is placed in the mold and after the foaming of the water slurry is started, the reinforcing bar is set in the mold Post-muscle set method can be adopted. In the method of the present invention, the post-reinforcing bar setting method is rather preferable. because,
Since the mold spreads upward, the speed at which the water slurry expands in the mold during foaming after being cast into the mold is faster than when using a conventional mold. Therefore, when the viscosity is low, the water slurry rises to a predetermined height in the mold, and the reinforcing bar is ALC
Because it can be embedded in the water slurry, the voids formed around the reinforcing bars become smaller.

(5) As a method of separating the bottom plate and the side plate, a method of fixing the side plate and raising or lowering the bottom plate, or a method of relatively moving them and then fixing them may be adopted. (6) If it is possible to set a so-called main reinforcing bar as a reinforcing bar in the horizontal direction in the formwork,
Reinforcing bars corresponding to so-called accessory muscles can be omitted.

(7) The side plate does not have to be a flat surface, but may be slightly curved or the inclination angle may change in the middle. (8) The absolute dry bulk specific gravity of the ALC panel according to the present invention (the absolute dry bulk specific gravity calculated excluding the reinforcing bars) is 0.35 to 1.
20, preferably 0.40 to 0.80.
AL that was finally obtained when the absolute dry bulk density was less than 0.35
The low strength of C panels makes them unsuitable for building material applications where ALC panels are typically used. If the absolute dry bulk specific gravity exceeds 1.2, the size of bubbles in the upper and lower positions of the cured ALC raw material cast in the mold remarkably differs, and as a result, the ALC panel of the present invention cannot be obtained.

(9) The panel width W of the present invention is set to 30 to 250 cm for its purpose of use, that is, for practical use of building materials, but the panel width W has a remarkable effect as compared with the prior art.
Is 80 to 200 cm. If the productivity and the quality are sacrificed, the conventional technique is uncertain if it is less than 80 cm, but it cannot be prevented. If it exceeds 200 cm, it is necessary to reduce the width of the short side of the mold, which lowers the productivity.

(10) In the method of the present invention, when the inclination angle of the side plate is constant, the smaller the width of the bottom plate in the short side direction and the lower the height of the side plate are, the smaller the absolute dry bulk specific gravity tends to be. Therefore, the size of the formwork is determined in consideration of this tendency. In the present invention, it is preferable to use a mold having a bottom plate having a short side width of 150 to 250 cm in order to keep the productivity of the ALC panel above a predetermined level. In this case, the inclination angle θ of the long side plate and the mold are used. The vertical height h of is set to a range that satisfies the expression 7. However, the inclination angle θ is the same as the range of the present invention.

[0055]

[Equation 7]

[0056]

As described above in detail, the present invention exhibits the following effects. (1) The absolute dry bulk specific gravity difference ρ between two arbitrary portions of the ALC panel is a predetermined value, 0.0 even if the panel width W changes.
Since it is maintained at 4 or less, the distortion of the panel is suppressed and the quality of the ALC panel is maintained in good condition.

(2) Since the void formed around the reinforcing bar extends in the short side direction of the panel, the void is AL
There is no possibility of being exposed on the surface side of the C panel, and as a result,
Unlike the prior art, the appearance of the panel is not spoiled and rainwater does not enter the voids. Therefore, A
There is no fear of deterioration of the physical properties of the LC panel.

(3) When the cured product is conveyed to the cutting step by the conveying means, the stress applied to the cured product is small, and therefore AL
It is possible to suppress deterioration of physical properties of the C panel.

[Brief description of drawings]

FIG. 1 is a process diagram showing an outline of the invention of claim 2;

FIG. 2 is a partially cutaway side view of the formwork.

FIG. 3 is a partially cutaway perspective view of a formwork.

FIG. 4 is a vertical cross-sectional view showing a state where the formwork is raised.

FIG. 5 is a vertical cross-sectional view of a transportation unit.

FIG. 6 is a partially cutaway perspective view of an ALC panel.

FIG. 7 is a diagram showing the relationship between the ALC panel width W and the absolute dry bulk specific gravity difference ρ0.

FIG. 8 is a side cross-sectional view showing a conveying unit.

[Explanation of symbols]

 A Placing process B Conveying process C Cutting process D Curing process 1 Cured product 2 Conveying means 3 Panel-shaped molded product 5 ALC panel 8 Reinforcing bar 9 Form frame 10 Long side plate 11 Short side plate 12 Bottom plate 24 Void 25 Grasping means

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hiroshi Kobayashi 2035 Shimoi, Shimoi-cho, Owariasahi-shi, Aichi Onoda ALC Co., Ltd.

Claims (5)

[Claims] 1. Light-weight cellular concrete (AL) containing reinforcing bars, obtained by using aluminum powder as a foam.
C) When the absolute dry bulk specific gravity difference ρ0 of ALC at any two points in the panel is within 0.04 or less and the voids formed around the reinforcing bars are in the thickness direction of the panel. AL extending in a direction orthogonal to
C panel; However, in the above formula, W represents a panel width (cm) in a direction orthogonal to the thickness direction of the panel in the range of 30 to 250 cm. 2. The ALC panel according to claim 1, wherein the absolute dry bulk specific gravity is in the range of 0.35 to 1.20. 3. A hardened product with reinforcing streaks is obtained by pouring a water slurry, which is a main raw material composed of a siliceous raw material, a calcareous raw material, and cement, into a mold and foaming and hardening in the presence of aluminum powder. To obtain a panel-shaped molded product by transporting the cured product to a cutting step by a transporting device and cutting it in the vertical direction, and to obtain an ALC panel by steam curing the panel-shaped molded product under high temperature and high pressure. In the method for manufacturing an ALC panel comprising: (a) a mold comprising a side plate expanding as it goes upward and a bottom plate separable from the side plate, and
(B) When the cured product is placed on the conveying means and conveyed to the cutting step, after raising the mold or lowering its bottom plate, or lowering the bottom plate while raising the mold. After that, the bottom plate is replaced with the conveying means,
An AL characterized in that a cured product is placed on the conveying means.
C panel manufacturing method. 4. The A according to claim 3, wherein the side plate expands outward from the mold within a range of 1 to 20 degrees.
Method for manufacturing LC panel. 5. A cured product with reinforcing streaks is obtained by pouring a water slurry, which is a main raw material composed of a siliceous raw material, a calcareous raw material, and cement, into a mold and foaming and curing in the presence of aluminum powder. To obtain a panel-shaped molded product by transporting the cured product to a cutting step by a transporting device and cutting it in the vertical direction, and to obtain an ALC panel by steam curing the panel-shaped molded product under high temperature and high pressure. In the method for manufacturing an ALC panel comprising: (a) a mold comprising a side plate expanding as it goes upward and a bottom plate separable from the side plate, and
(B) When the cured product is placed on the transport means and transported to the cutting step, the cured product is directly gripped by the gripping means, or the bottom plate is separated from the mold to separate the cured product from the side plate. A method for manufacturing an ALC panel, characterized in that the holding means is indirectly held by the holding means and placed on the carrying means.