JPH0667606B2 - Manufacturing method of concrete clad material for interior and exterior - Google Patents

Description

TECHNICAL FIELD The present invention relates to a concrete material for interior and exterior of a building and a method for producing the same.

[Prior Art and Background of the Invention]

Buildings using the ALC method are popular, but there are some limitations in using ALC products as interior and exterior materials.
ALC products are manufactured in factories by quality control by a method of curing an aerated concrete molded product in an autoclave, but although their quality is improving, they are originally in terms of water resistance and weather resistance. The main reasons are that ALC products are generally poor in design as they are and that there is a problem in exposing them as they are as interior and exterior materials.

However, ALC has excellent workability, is lightweight, and is inexpensive.
It has unique advantages for product features and construction of buildings such as buildings and general buildings. If it can be used as it is as a concrete material for interiors and exteriors, it has sufficient water resistance and durability If it can be used as a concrete material for interior / exterior with various surface strengths, there are advantages that cannot be achieved in this field.

The present invention has been made for the purpose of providing an ALC-based concrete material that can be effectively used as an interior / exterior material of a building while sufficiently exhibiting the features of ALC products.

[Structure of Invention]

According to the present invention, a thin layer of carbon fiber reinforced concrete, which is not yet solidified, is compacted on the surface of a cured concrete of a cellular concrete by using a roll, and the integrated product is subjected to autoclave curing. Method (referred to as method (1)), which is a concrete for interior and exterior that consists of press-molding a thin layer of carbon fiber reinforced concrete that does not solidify yet on the surface of a cured concrete of aerated concrete, and curing the integrated product in an autoclave. A method for producing a clad material (referred to as a method (2)), in press-molding a thin layer of carbon fiber reinforced concrete which is not yet solidified on the surface of a cured concrete of a cellular concrete, the carbon fiber reinforced concrete was placed in a mold. In addition, the aerated concrete hardened material was placed directly on top of the carbon fiber reinforced concrete in the formwork, which had not yet solidified. A method for producing a concrete clad material for interior and exterior (referred to as method (3)), which comprises press-molding a clad molded product by pressing, and curing the resulting molded product in an autoclave, and a method for producing a hardened carbon fiber reinforced concrete. Provided is a method for producing a concrete clad material for interior and exterior (referred to as method (4)), which comprises manufacturing a thin plate, placing aerated concrete on the back surface thereof, and curing the integrated product.

[Detailed Description of the Invention]

According to the manufacturing method of the present invention, the inside and outside of the ALC product, which has excellent workability, is lightweight and inexpensive, has sufficient water resistance and durability, and has sufficient surface strength and bonding strength. The concrete material for mounting can be mass-produced as a prefabricated product with good manufacturability. In any case, the product as the clad material has a thickness of 50 to 250 m.
It can be made with a wide range of m, and the in-plane area can be arbitrarily shaped into a standard product or a custom product in a panel or block shape.
At that time, most of the thickness is covered by ALC. Depending on the thickness of the ALC, the layer of carbon fiber reinforced concrete is 1/3 or less of the total thickness, preferably 1/4 or less, and more preferably 1/5 or less as thin as possible.

According to the method of the present invention, in any method, it is important to form carbon fiber reinforced concrete (hereinafter, also referred to as CFRC) into a thin plate shape. ), (2), and (3), roll molding or press molding is applied. In the method (4), a papermaking method similar to that applied to mass production of asbestos slate can be applied. That is, a slurry of concrete mix in which carbon fibers are dispersed (slurry containing a large amount of water) is prepared, and while stirring the slurry, a wire having a predetermined mesh is used to continuously produce a mix having a predetermined thickness.

In addition, ALC and C are used in any of the methods (1) to (4).
FRC sheets are cured by autoclave curing before or after clad.

As the cellular concrete used in the present invention, any conventional cellular concrete can be used, but ALC is particularly preferable. As the CFRC, ordinary carbon fiber reinforced concrete in which short fibers are uniformly dispersed is used, and it is economical to use pitch type carbon fibers in particular. In addition, various admixtures can be added to the CFRC if necessary. When clad, a CFRC thin plate may be clad on only one side of the wide side of the ALC, or a CFRC thin plate may be clad on both sides of the wide side of the ALC to form a sandwich-shaped clad product.
In the latter case, the material is particularly suitable for interior materials such as corridors and partition walls. The clad products of the present invention are made of concrete exterior and interior materials for buildings, as well as CFRC thin plates on the surface.
CFR serves to reinforce the strength of the C body on its surface, so CFR
It can also be used for flooring with the C side as the floor.

The contents of the present invention will be specifically described below with reference to the drawings.

FIG. 1 is a partially cutaway view showing a typical shape of a concrete clad material for interior and exterior according to the present invention, where 1 is a cellular concrete layer and 2 is a carbon fiber reinforced concrete layer. The cellular concrete layer 1 has a rectangular thick panel shape having a necessary thickness as a structural material, and a thin layer of the carbon fiber reinforced concrete layer 2 is joined so as to cover the entire area of the one wide surface side. . Hereinafter, the carbon fiber reinforced concrete layer 2 will be referred to as a CFRC layer, and the cellular concrete layer 1 will be referred to as an ALC layer. In the example of FIG. 1, the CFRC layer 2 is the ALC layer 1
The edge part 3 of the CFRC layer extends to part of the thickness of the ALC layer 1 on the side surface in the thickness direction of the ALC layer 1 while at the same time completely covering one wide surface side of the ALC layer 1. On the other hand, it is shaped like a thin CFRC box.
The outermost surface of the CFRC layer 2 is provided with vertical and horizontal linear shallow grooves 4 as a pattern.

Fig. 2 shows the longitudinal section of the clad material in Fig. 1, but there is no gap between the ALC layer 1 and the CFRC layer 2 on both the wide side and the side, and they are completely joined. . Lateral side
The edge portions 3 of the CFRC layer 2 come into contact with each other when the wall surfaces are formed adjacent to each other with this clad material, and thus the joint strength is weak as in conventional ALC products. With the clad material of the present invention, the solution is completely solved, and the joints at this portion can be reliably sealed. Depending on the mode of use, this edge 3 may not be necessary. However, even in this case, it is preferable that substantially the entire area of at least one wide surface side of the ALC layer 1 is covered with the CFRC layer 2. Although not shown in the figure, if the edge portion 3 of the CFRC layer 2 is embedded in the ALC layer in a wedge shape, the reliability of the bonding strength of both layers can be further improved.

FIG. 3 is an illustrative process diagram showing an embodiment (methods (1) and (2) above) of the method for producing a concrete clad interior / exterior material of the present invention. The method uses an ALC product (eg, a commercially available ALC product) as the raw material for the ALC layer. First, as shown in the figure, CFRC 9 is placed on the wide side of the ALC product 8 (step (e)). Next, in the method (1), the cast uncured CFRC 9 is rolled onto the surface of the ALC product 8 by the roll 10 to form a thin layer (step (f)). Moreover, in the method (2), the uncured CFRC9
Is pressed into a thin plate shape on the surface of the ALC product 8 (step (f) ′). In either case, a thin layer 9 of carbon fiber reinforced concrete that has not yet solidified is pressure-molded on the surface of the ALC product. Then, the obtained integrated product 12 is subjected to autoclave curing (step (g)).

According to this method, a thin layer of CFRC9 that has not yet solidified is firmly pressure-bonded to the ALC product by the roll 10 or the press plate 11 and a clad material having a strong bonding strength is obtained.
If a roll with a pattern or a press plate with a pattern is used as the roll 10 or the press plate 11 in the steps (f) and (f) ′, a clad material for interior and exterior having a pattern on the outermost surface can be obtained.

FIG. 4 is an illustrative process chart showing an embodiment of the method (3) according to the present invention. In this case, first, the formwork for thin plate manufacturing
CFRC14 is placed in 13 (process (h)). And formwork
The ALC product 8 is pressure-bonded to the uncured CFRC 14 existing inside 13 by using the press plate as a substitute (steps (i) and (j)). Then, after the mold release, the clad molded product 15 in which the ALC product 8 and the uncured CFRC portion are pressure-bonded to each other is subjected to autoclave curing (step (k)). Even with this method, the ALC product 8 and the uncured CFRC14 can be firmly pressure-bonded to each other, so that the strength of the joint surface of the clad product is high. If the formwork 13 to be used has a pattern, the outermost surface can be provided with the pattern.

FIG. 5 is an illustrative process diagram for explaining the production method (4) of the present invention. In this method, aerated concrete is cast on the back surface of a thin sheet of hardened carbon fiber reinforced concrete, and the integrated product is cured.
6 is manufactured by papermaking, roll molding, press molding, or the like, and is cured by autoclaving to obtain a cured thin plate (step (l)). Next, the ALC 18 is placed on the back surface of the cured CFRC thin plate 17 (step (m)). The formwork 19 is used. Then, the mold 19 is released from the mold, the integrally molded product
20 is steam-cured (step (n)) and then autoclave-cured (step (n) ′). AL also in this way
During the C curing process, ALC and cured CFRC are joined with sufficient adhesive strength. Also, the surface of the CFRC can be patterned during molding.

In this way, according to the method of the present invention, the concrete interior / exterior clad material can be produced economically with a simple and small man-hour, and the pattern can be freely added, and the joint strength between the two materials becomes very high. Further, the concrete clad material obtained by the present invention has sufficient characteristics such as the lightweight and inexpensive properties of cellular concrete, while having durability, water resistance, weather resistance and excellent surface strength. Therefore, sufficient quality as an exterior material for a building is maintained. In addition, conventional ALC can also be used for tile finishing, which has problems with its adhesive strength and water resistance, and when it is painted, it has a beautiful finish that cannot be obtained with conventional ALC. It is intended to provide the market with a new material having new characteristics as a lightweight interior / exterior material for automobiles.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing a typical shape of a concrete clad material for interior and exterior according to the present invention, FIG. 2 is a longitudinal sectional view of the clad material of FIG. 1, and FIG. FIG. 4 is a schematic process chart for explaining one manufacturing method of the concrete for cladding material, FIG. 4 is a schematic process diagram for explaining another manufacturing method, and FIG. 5 is another for explaining another manufacturing method. It is an illustration process figure. 1 ... Aerated concrete layer (ALC layer), 2 ... Carbon fiber reinforced concrete layer (CFRC layer), 3 ... Edge of CFRC layer 2, 4 ... Pattern.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Tatsuo Suenaga 2-191-1 Tobita-cho, Chofu-shi, Tokyo Kashima Construction Co., Ltd. Technical Research Institute (72) Inventor Hiroaki Nakagawa 2-1-11-1 Tobita, Chofu-shi, Tokyo Kashima Construction Co., Ltd., Technical Research Institute (72) Inventor, Kaichi Taniguchi, 2-1-1, Tobita, Chofu-shi, Tokyo Kashima Construction Co., Ltd., Technical Research Laboratory (56) Reference JP-A-52-41638 (JP, A) Kai 55-126582 (JP, A) JP 60-13159 (JP, A) JP 60-26748 (JP, A)

Claims (4)

[Claims] 1. A method for producing a concrete clad material for interior / exterior, which comprises compacting a thin layer of carbon fiber reinforced concrete which is not yet solidified on the surface of a cured concrete of a cellular concrete by using a roll and subjecting the integrated product to autoclave curing. . 2. A method for producing a concrete clad material for interior and exterior, which comprises press-molding a thin layer of carbon fiber reinforced concrete which is not yet solidified on the surface of a cured concrete of a cellular concrete by using a press plate and subjecting the integrated product to autoclave curing. . 3. When press-molding a thin layer of carbon fiber reinforced concrete which is not yet solidified on the surface of a cured concrete of aerated concrete, the carbon fiber reinforced concrete is placed in the mold and not yet solidified in the mold. A method for producing a concrete clad material for interior and exterior, which comprises press-molding a cellular concrete hardened product directly onto the top surface of carbon fiber reinforced concrete to form a crimp on the clad molded product and subjecting the resulting molded product to autoclave curing. 4. A method for producing a concrete clad material for interior / exterior, which comprises producing a thin plate of hardened carbon fiber reinforced concrete, placing a foamed concrete on the back surface thereof, and curing the integrated product.