JPH0739090B2 - Method for manufacturing inorganic panel - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an outer wall used for a building, a partition, other building materials such as partitions and shutters, outdoor facilities such as toilets and pool houses, and a non-combustible material used for prefabricated refrigerators and the like. The present invention relates to a method for manufacturing an inorganic panel having excellent heat insulating properties, and particularly to a manufacturing method capable of continuously producing an inorganic panel.

[0002]

2. Description of the Related Art Today, the spread of air-conditioning equipment in houses and buildings and the increase in size of freezers and refrigerating warehouses are not only lightweight and have excellent heat insulating properties, but also flammability, smoke emission, and harmful gas generation. There is a demand for the development of panels that are excellent in terms of disaster prevention and have no problems such as sex. In order to meet such a demand, conventionally, an inorganic panel obtained by adding an inorganic silicate-based inorganic binder to a granular inorganic foam and binding-molding the inorganic foam has been proposed. However, such an inorganic panel is satisfactory in that it is lightweight and has excellent heat insulating properties, but there is a problem that it is insufficient in terms of compressive strength, water resistance, and weather resistance. It was Therefore, as a means for solving such problems, a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the above-mentioned binder mainly composed of metal silicon powder are used, which is lightweight. We have developed and proposed a method for manufacturing inorganic panels that can improve the compressive strength and water resistance without compromising the productivity, and also shorten the time required for curing compared to conventional methods to improve productivity. (JP-A-62-7,681, JP-A-63-151,691 and JP-A-1-
180,331).

The inorganic panels obtained by these methods all have excellent performance and are superior in productivity as compared with the conventional methods, but they are inorganic foams as molding materials for the panel body. When a reaction mixture composed of a body, an alkali silicate solution and a curing agent mainly composed of metal silicon powder is prepared, the reaction mixture gradually starts its reaction,
It is difficult to control the reaction during the steps from the preparation of the reaction mixture to the reaction of the reaction mixture to form the panel body.
For example, if the process of filling the reaction mixture into the mold takes an unnecessarily long time, the reaction proceeds during this process, making it difficult to uniformly fill the reaction mixture. Since gas is violently generated with the reaction, the unreacted reaction mixture is blown off by the generated gas and the filling state of the reaction mixture filled in the mold is disturbed, which makes uniform molding difficult. In order to prevent this, it is necessary to cover the upper mold with a ventilation hole from above the mold and mold it, which necessitates a batch-type reaction, and also a large-scale fixing jig for degassing the upper mold. Is required, and there is a problem that heating cannot be performed sufficiently. When pressure and reaction are performed using a double conveyor,
There was a problem that gas could not be smoothly removed from the top surface, and continuous production was difficult.

[0004]

Therefore, the present inventors have proposed a reaction mixture containing a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the binder, which is mainly composed of metal silicon powder. In producing an inorganic panel consisting of a panel body formed by reacting, a metal plate attached to both front and back surfaces of the panel body, and a frame material attached to the peripheral edge surface of the panel body, if necessary, As a result of intensive research on a method capable of continuously and efficiently manufacturing the inorganic panel by solving the above-mentioned problems, one of the front and back metal plates and a frame material used as necessary are set. To form a panel frame for molding the reaction mixture, prepare a reaction mixture for each panel and fill the panel frame under pressure, preferably with a large number of vent holes on the upper surface side. By introducing into the reactor across the double belt conveyor for molding by reacting a reaction mixture found that allowing continuous production,
The method of the present invention has been completed.

Therefore, an object of the present invention is to react a reaction mixture containing a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the above-mentioned binder, which is mainly composed of metallic silicon powder, to form a molded product. And a metal plate that is attached to both front and back surfaces of this panel body,
It is an object of the present invention to provide a method capable of continuously manufacturing an inorganic panel including a frame material attached to a peripheral edge surface of a panel body with high dimensional accuracy if necessary.

[0006]

That is, according to the present invention, a reaction mixture containing a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the binder mainly containing metal silicon powder is reacted. When manufacturing an inorganic panel comprising a molded panel body, metal plates attached to both front and back surfaces of the panel body, and a frame material attached to the peripheral edge surface of the panel body, if necessary, A frame forming step of setting one of the metal plates and a frame material used if necessary to form a panel frame for molding the reaction mixture, and an adhesive application for applying a thermosetting adhesive to the inner surface of the panel frame The process, the reaction mixture filling process of adjusting the reaction mixture for each panel and filling the panel frame under pressure, and the belt located on the upper surface side has a large number of vent holes.
It is introduced into the reaction furnace while sandwiching the panel frame filled with the reaction mixture while being pressurized by the double belt conveyor, and the reaction is accelerated by heating to form a complete reaction product and at the same time the thermosetting adhesive The reaction step of adhering the panel body molded on the inner surface of the panel frame with the agent, then the grinding step of grinding the upper surface of the panel body molded in the panel frame, and the thermosetting adhesive applied on the inner surface side It is a method for producing an inorganic panel, which comprises a hot pressing step in which the other of the front and back metal plates is set on the upper surface side of the panel body, and the hot pressing is performed by hot pressing.

In the present invention, the granular inorganic foam to be used may be any conventionally known one, but is preferably obsidian, vermiculite, pearlite or pinelite, and these inorganic foams are preferred. As for the body, only one kind thereof can be used, or two or more kinds can be used as a mixture. Regarding the particle size and density of this inorganic foam, it depends on the type of product panel, intended use, etc.
Usually 0.5-10 mm particle size and usually 0.1-0.25
A density of g / cm ³ is used. In addition, when a particularly lightweight and excellent heat insulating material is required, the density is 0.1
It is preferable to use one having a content of ˜0.16 g / cm ³ .
Further, in order to adjust the density of the molded panel body to an appropriate value, preferably three or more kinds of inorganic foams having different particle diameters are prepared, and these are mixed at an appropriate ratio. It is desirable to use.

As the alkali silicate solution used as the binder in the method of the present invention, a sodium silicate aqueous solution or a potassium silicate aqueous solution is usually used, but it is preferably silica in view of solubility in water and raw material cost. It is a sodium acid aqueous solution. As this sodium silicate, SiO
The molar ratio of ₂ and Na ₂ O is usually in the range of 2.0 to 3.5, preferably 2.3 to 2.7,
The concentration of the aqueous solution is usually 35 to 42% by weight, preferably 40 to 42% by weight. The amount of the alkali silicate solution used is usually 30 to 120 parts by weight, preferably 50 to 100 parts by weight, based on 100 parts by weight of the inorganic foam, although it varies depending on the concentration. If the amount of the alkali silicate solution used is less than 30 parts by weight, the binding strength will be small and the strength will be deteriorated. If the amount used is more than 120 parts by weight, the binder will be excessive, and the binder will be added at the stage of heat generation / dehydration curing reaction. As a result,
The problem arises that it does not work effectively. The alkali silicate used in the present invention is not limited to the alkali silicate as a single substance, and may be a mixture of sodium metasilicate, sodium orthosilicate, sodium disilicate, sodium tetrasilicate, or the like. Good.

Further, examples of the binder curing agent used in the present invention include metal silicon, ferrosilicon which is an alloy of iron and silicon, a mixture of metal silicon and silicon dioxide, and the like.
Metallic silicon powder having the properties of metallic silicon is used alone or 2
Although it can be used as a mixture of one or more kinds, a phosphate is preferably used in combination as another component of the curing agent for the purpose of improving compression strength and water resistance. The phosphate used for this purpose may be any one as long as it reacts with alkali silicate during the curing reaction to form a binder substance which is poorly water-soluble and has excellent thermal stability, and preferably aluminum phosphate, magnesium phosphate, Metal phosphate such as iron phosphate and zinc phosphate,
There are metal salts of polyphosphoric acid, condensed metal phosphates in which a metal oxide and phosphorus pentoxide are bonded at a predetermined ratio, and the like, and more preferred are condensed metal phosphates represented by condensed aluminum phosphate. The amount of the metal silicate powder used varies depending on the type and concentration of the alkali silicate solution, but is usually 10 to 20 parts by weight, preferably 13 to 15 parts by weight, relative to 100 parts by weight of the alkali silicate. If the amount of the metallic silicon powder used is less than 10 parts by weight, the improvement of the compressive strength and water resistance will be insufficient, and if it is more than 20 parts by weight, the metallic silicon powder will oxidize and will not work effectively. Also, the amount of phosphate added to improve the compressive strength and water resistance is determined by the amount of alkali in the alkali silicate solution,
Although it depends on the type and concentration of the alkali silicate solution, it is usually 2 to 3 with respect to 100 parts by weight of this alkali silicate solution.
It is 0 part by weight, preferably 10 to 20 parts by weight. If the amount of phosphate used is less than 2 parts by weight, the effect of adding this phosphate will be ineffective, and if it is more than 30 parts by weight, the improvement effect on compressive strength and water resistance will not be improved.

In the method of the present invention, a reinforcing additive may be blended, if necessary, to improve the mechanical strength of the manufactured product, for example, the tensile strength, and it is used for this purpose. Examples of the reinforcing additive include mineral fibers such as steel fiber, glass fiber and rock wool, and the mixing ratio thereof can be appropriately selected depending on the use of the product inorganic panel and the like. The amount of the alkali silicate solution and the curing agent used in the case where the reinforcing additive is mixed is considered as a part of the inorganic foam, and the amount of the reinforcing additive varies depending on the type of the reinforcing additive. Requires a slight increase.

In the present invention, either a front or back metal plate and, if necessary, a metal plate for reacting a reaction mixture of the above-mentioned inorganic foam, an alkali silicate solution and a curing agent to form a panel body. A molding panel frame formed by setting a frame material to be used is used.
The metal plate used in the frame forming step is preferably the back surface metal plate of the product panel, because it may be scratched or slightly deformed in the subsequent manufacturing steps.

Here, the molding panel frame assembled in the frame forming step needs to be accurately dimensioned at least at the outer periphery thereof, and therefore, the frame materials constituting the panel frame are each subjected to a minus error. It is desirable to assemble the panel frame by using a frame assembling jig having a stopper for adjusting the outer circumference and using fixing means capable of absorbing a negative error such as a connecting metal fitting and a pop rivet.

Next, a thermosetting adhesive is applied to the inner surface of the molding panel frame thus formed. Examples of the thermosetting adhesive used in this adhesive application step include various polyurethane-based, urea-based, phenol-based, resorcinol-based, epoxy-based, polyester-based, polyimide-based, etc. Polyurethane type.

After the thermosetting adhesive is applied to the inner surface,
A reaction mixture containing an inorganic foam, an alkali silicate solution and a curing agent is filled in the molding panel frame. When filling the reaction mixture, it is necessary to prepare an amount of the reaction mixture for each panel and fill the panel under pressure, which may leave the reaction mixture for a long time after the reaction mixture is prepared. In addition, there is no problem that the reaction starts during the filling process of the reaction mixture to generate heat and curing starts, or that the once cured product is charged.

In the reaction mixture filling step, the inorganic foam, the binder and the curing agent are preferably added to the panel 1.
A raw material supply step of measuring the amount per sheet and supplying it to a mixer, a raw material mixing step of preparing a reaction mixture by mixing the raw materials with this mixer, and transferring the prepared reaction mixture into a molding panel frame, A filling step of evenly distributing the transferred reaction mixture in the panel frame and filling while pressurizing;
It is preferable to have a mixer washing step of washing the inside of the mixer with water at the timing of preparing each reaction mixture and forcibly drying with air. After preparing the reaction mixture per panel in this way, the inside of the mixer is washed with water. By doing so, the cured product that has been prepared before and remains in the mixer in the reaction mixture to be prepared next, and the curing reaction that has started or has already been completed is mixed, and the curing reaction of the reaction mixture is It does not adversely affect the quality and performance of the panel body that is manufactured unevenly.

After the reaction mixture is filled in the molding panel frame, the panel frame is sandwiched by a double belt conveyor composed of a breathable belt having a large number of ventilation holes on the upper surface side, and then the panel frame is placed in the reaction furnace. The reaction mixture introduced is reacted in this reaction furnace to be molded into a panel body, and at the same time, it is adhered to the inner surface of the panel frame by the thermosetting adhesive. Here, the breathable belt on the upper surface side of the double belt conveyor is
A resilient, porous rubber belt is preferred. When the diameter of the ventilation holes of the breathable belt is large, a fine cloth-like or mesh-like intervening material is interposed between the reaction mixture and the breathable belt of the double belt conveyor located on the upper surface side. It is desirable to let By using the reaction mixture and the breathable belt in this manner, the entire surface of the upper surface of the reaction mixture is evenly opened, whereby the gas generated by the reaction escapes straight upward when passing through the reaction mixture. It is possible to form a panel body with uniform quality and performance throughout. The fine mesh-like or mesh-like interposer used here preferably has a mesh roughness of 0.5 to 1.5 mm, which prevents scattering of powdery particles (unreacted mixture) when gas is generated by the reaction. Anything that can be prevented may be used. In addition, the reaction furnace used here is usually provided with a curing / drying region for curing and drying the molded panel body after the reaction in the latter half thereof.

When molding the panel body,
The reaction mixture is positively heated from outside by a suitable heating means in the reaction furnace to cure. Regarding the heating temperature for heating from the outside at this time, various conditions at the time of molding, for example, the outside air temperature, the composition of the reaction mixture or the type and size of the molding panel frame to be used, and the thermosetting adhesive to be used The temperature is usually 50 to 120 ° C., preferably 60 to 100 ° C., although it varies depending on the type and curing temperature thereof.
Is the range. And, as the heating means for heating the reaction mixture in the panel frame in the reaction furnace, for example, a hot air heater installed in a heating chamber and heated by hot air, or any conventionally known means such as high frequency heating or far infrared heating However, far infrared heating is preferable. When a lath net for improving the strength is put in the panel body of the product, the lath net can be energized for heating. The speed of the double belt conveyor that conveys the panel frame filled with the reaction mixture in the reaction furnace is determined in consideration of the length of the heating area in the reaction furnace and the required heating time.

The panel body molded in the molding panel frame passes through the inside of the reaction furnace and the curing and drying furnace, and then its upper surface is ground to be finished flat. Since the thickness dimension of the panel is determined in this grinding step, it is preferable to use a high-speed rotating drum type polishing machine capable of increasing the flatness of the belt on the lower surface and performing grinding while pressing from the upper portion. Further, a dust removing device or the like is used to blow off the shavings generated by the grinding work from the upper surface of the panel body and collect the dust with a suction duct.

After grinding the upper surface of the panel body molded in the molding panel frame in this manner, the upper surface side of the panel body is coated with a thermosetting adhesive on the inner surface side, either the other side. The metal plate of No. 1 is set, and it is attached under pressure and heating with a hot press. Conditions in this hot press process,
That is, the heating temperature, pressure, pressing time, etc. are appropriately selected according to the type of adhesive used.

In the method of the present invention, preferably, after the hot pressing step, the peripheral edge portion of the metal plate adhered to the panel body is screwed to the molding panel frame.
Therefore, by screwing the metal plate to the panel frame in this screwing process, the metal plates on both the front and back surfaces that cover the panel body and the frame material used as necessary are integrally joined by this screwing, and the strength of the entire panel is increased. In addition, it does not cause a problem such as peeling and dropping during a fire.

[0021]

According to the method of the present invention, one of the front and back metal plates and, if necessary, a frame material are set to form a panel frame for molding a reaction mixture, and a reaction mixture is prepared for each panel. Then, the panel frame is filled under pressure, sandwiched by a double belt conveyor having a large number of ventilation holes on the upper surface side, and introduced into the reaction furnace to cause the reaction mixture to react to form a reaction mixture. It is possible to mold a panel body with uniform quality and performance without being left for a long time after being prepared and before being sent to the reaction step, which enables continuous production.

[0022]

EXAMPLES The method of the present invention will be specifically described below based on Examples and Comparative Examples.

Example 1 As shown in FIG. 1, in a production line, a hopper 1 capable of accommodating three kinds of inorganic foams having different particle diameters, a binder tank 2 accommodating an alkali silicate aqueous solution, and a metallic silicon powder. A curing agent hopper 3 containing a curing agent for a binder as a main component is disposed, and the amount of the inorganic foam, the binder and the curing agent for one panel are respectively provided from the hopper 1, the binder tank 2 and the curing agent hopper 3. Are intermittently measured and supplied to the mixer 4, and mixed by the mixer 4 to prepare a reaction mixture for one panel.

In the vicinity of the production line, a metal plate 5a, which is attached to the back side of the panel body obtained by reacting and molding the reaction mixture, and a frame attached to the peripheral edge surface of the panel body. An adhesive application device 6 for applying a thermosetting adhesive to the inner surface of the molding panel frame 5 formed by fixing the material 5b with a screw or the like is provided. The panel frame 5 coated with the adhesive at 6 is transferred to the next reaction mixture filling device 7 at a predetermined time interval.

When the molding panel frame 5 after application of the adhesive is transferred to the reaction mixture filling device 7, the reaction mixture prepared at the timing is supplied into the panel frame 5 and is not shown in the drawing. The panel frame 5 is uniformly and airtightly filled with the reaction mixture supplied by the leveling device and the pressing device. Here, in the filling operation of the reaction mixture, for example, first, half of the filling amount of the reaction mixture is supplied into the panel frame 5, and the panel frame 5 is flattened and pressed by the leveling device and the pressing device. Is preferably filled in half, and then half of the remaining filling amount is similarly filled, so that the reaction mixture is more tightly filled in the panel frame 5.

The molding panel frame 5 thus filled with the reaction mixture is placed on the upper surface side of an interposer setting device 8a for setting the mesh interstices arranged at the inlet of the reaction curing furnace 8. The mesh-like interposition product is set in and is fed into the reaction curing furnace 8 in that state. In this reaction curing furnace 8, as shown in FIG. 2, a breathable belt 9a having a large number of ventilation holes 10 on the upper surface side is used. The panel frame 5 filled with the reaction mixture 11 is sandwiched between the constructed double belt conveyors 9 and the panel frame 5 filled with the breathable belt 9a and the reaction mixture 11 is inserted.
A mesh-like interposer 12 is interposed between and. After the reaction in the reaction curing furnace 8 is completed, the panel body that has been cured by heating for a predetermined time, dried, and molded is applied to the inner surface of the panel frame 5 at the same time by the thermosetting adhesive applied to the inner surface of the panel frame 5. To be glued.

The panel body molded in the molding panel frame 5 in this manner has its upper surface flatly ground by a grinding device 13 such as a high-speed rotary drum type polishing machine after the mesh-like inclusions are removed. It In this grinding device 13, the accuracy of the smoothness of the lower surface side belt is extremely high, and since the panel to be ground is pressed from above to perform polishing, the thickness accuracy is ± 0.2 mm or less. Further, the grinding device 13 is provided with a suction duct (not shown), and the shavings generated by the grinding work are collected so as not to remain on the upper surface of the panel body.

When the upper surface of the panel body is ground flat in this way, the molding panel frame 5 accommodating the panel body is sent to the next face material joining device 14. Then, in this manufacturing line, an adhesive application device 16 for applying a thermosetting adhesive to the metal plate 15 on the front surface side, and a metal whose inner surface is applied with the thermosetting adhesive by the adhesive application device 16 Board 1
Reversing device 1 for reversing 5 and sending it to face material joining device 14
7 and the metal plate 15 supplied from the reversing device 17 are coated on the upper surface of the panel frame 5 by the above-mentioned face material joining device 14.

In this way, the molding panel frame 5 covered with the metal plate 15 on the front side and having the panel body housed therein is
Next, it is sent to the hot press 18, where the metal plate 15 is attached to the upper surface of the panel body and the panel frame 5 under pressure and heating. After the hot pressing step, a screw fixing step (not shown) for screwing the peripheral edge of the front surface side metal plate 15 attached to the panel body to the panel frame 5 is provided.
Is fixed to the panel frame 5 with screws, which prevents peeling and dropping of the metal plate in the event of a fire, for example. Then, the product panel manufactured through this screwing process is put on the market after the product check.

The product panel passed the fireproof test of the outer wall for fireproof time according to the notification of the Ministry of Construction, and was excellent in its appearance, strength, weather resistance and the like. Incidentally, when the bending strength of the product panel is measured according to JIS A 1414, a simple bending strength of 2000 to 2400 kg is obtained, which is about three times the standard design strength.

[0031]

EFFECTS OF THE INVENTION According to the method of the present invention, a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the above-mentioned binder mainly composed of metal silicon powder are used, and they are lightweight. An inorganic panel excellent in compressive strength and water resistance can be efficiently and continuously produced without damage.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a production line of an inorganic panel according to an embodiment of the present invention.

FIG. 2 is a sectional view showing a double belt conveyor in the reaction curing furnace shown in FIG.

[Explanation of Codes] 1 Hopper 2 Binder tank 3 Hardener hopper 4 Mixer 5 Molding panel frame 5a Back side metal plate 5b Frame material 6 Adhesive coating device 7 Reaction mixture filling device 8 Reaction curing furnace 8a Interposition setting device 9 Double Belt Conveyor 9a Breathable Belt 10 Vents 11 Reaction Mixture 12 Reticulated Interposer 13 Grinding Device 14 Face Material Joining Device 15 Surface Metal Plate 16 Adhesive Coating Device 17 Inversion Device 18 Hot Press

Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area B29K 105: 04

Claims (5)

[Claims] 1. A panel body formed by reacting and molding a reaction mixture containing a granular inorganic foam, an alkali silicate solution used as a binder, and a curing agent for the binder, which is mainly composed of metal silicon powder, and a molded product. When manufacturing an inorganic panel consisting of metal plates attached to both the front and back sides of the panel body, and a frame material attached to the peripheral edge surfaces of the panel body, if necessary, either one of the front and back metal plates and if necessary used A frame forming step for forming a panel frame for molding the reaction mixture by setting a frame material for the reaction mixture, an adhesive applying step for applying a thermosetting adhesive to the inner surface of the panel frame, and a panel 1
The reaction mixture filling step of adjusting the reaction mixture for each sheet and filling the panel frame under pressure, and the belt located on the upper surface side
While pressurizing by a double belt conveyor having a large number of ventilation holes, it is introduced into the reaction furnace while sandwiching the panel frame filled with the above reaction mixture, and the reaction is accelerated by heating to form a complete reaction product. At the same time, a reaction step of adhering the panel body formed on the inner surface of the panel frame with the thermosetting adhesive, a grinding step of grinding the upper surface of the panel body formed in the panel frame, and a thermosetting type on the inner surface side. A method of manufacturing an inorganic panel, comprising: a hot pressing step of setting the other metal plate, which is coated with an adhesive, on the upper surface side of the panel body and applying the hot plate under pressure and heating. . 2. The reaction mixture filling step comprises a raw material supply step of measuring a quantity of a plurality of inorganic foams having different particle diameters, a binder and a curing agent per panel and supplying the raw material to a mixer, and a raw material supply step of the mixer. A raw material mixing step of mixing to prepare a reaction mixture, and a filling step of transferring the prepared reaction mixture into a molding panel frame, uniformly distributing the transferred reaction mixture into the panel frame, and filling while pressurizing 2. The method for producing an inorganic panel according to claim 1, further comprising a mixer washing step of washing the inside of the mixer with water and forcibly drying with air at a timing during the preparation of each reaction mixture. 3. The method for producing an inorganic panel according to claim 1, wherein the belt located on the upper surface side of the double belt conveyor in the reaction step is an elastic porous rubber belt. 4. A high-speed rotating drum type polishing machine equipped with a dust removing device for completely flattening one surface of a semi-finished panel product which continuously flows in a grinding step and polishing it to a constant thickness. Manufacturing method of inorganic panel. 5. The metal plate is screwed to the panel frame in a screwing step of screwing the peripheral edge of the metal plate attached to the panel body to the panel frame after the hot pressing step.
A method for producing the described inorganic panel.