JPH08187712A - Manufacture of hollow gypsum cured material - Google Patents

Abstract

PURPOSE: To provide a method for manufacturing a gypsum building material in which the efficiency of manufacturing steps can be enhanced by obtaining a space for wirings in the material and reducing the weight of the material. CONSTITUTION: A gypsum building material made of a hollow gypsum cured material having a space therein is manufactured by the steps of supplying a gypsum slurry containing a hemihydrated gypsum, a fibrous substance and an admixture agent to a conveyor belt 2 having an uneven part on the surface, regulating it in a predetermined thickness, manufacturing the cured material 5 having the uneven part therein, and then feeding the slurry having the same physical properties as those of the gypsum slurry between the adjacent protrusions of the material 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to weight reduction of a gypsum building material, and provides a method for manufacturing a hollow gypsum hardened product in a continuous process for reducing the weight of the gypsum building material.

[0002]

2. Description of the Related Art Gypsum building materials have been widely used as partitioning materials for buildings and houses, pipe spaces, fireproof partition walls such as elevator shafts, etc. as building materials excellent in fire resistance, sound insulation and non-stretchability. . Further, in recent years, high-rise buildings and condominiums have been actively constructed, and there is a strong tendency toward high-rise intelligent construction. Therefore, demand for sound insulation, fire protection, and disaster prevention gypsum building materials is increasing. Further, in the construction industry as well, there is generally a shortage of craftsmen such as carpenters and plasterers, and due to the good workability of gypsum building materials, the demand for them has increased in recent years.

As shown in FIG. 4, such a gypsum building material is manufactured by using a reinforcing material such as hemihydrate gypsum, water, glass fiber, etc. as a main material, and adding a setting regulator, a foaming agent, etc., if necessary.
Each material was weighed with a weighing device (not shown) so as to have a predetermined composition, and the gypsum paste was kneaded with the mixer 1 on the surface paper 3 on the lower surface fed on the pallet table 11. It is supplied and pressed by a pair of molding rolls 4 provided between the pallet table 11 and the molding conveyor belt 6 and molded into a predetermined thickness. At this time, the surface paper 3 on the upper surface side is supplied to the molding roll 4 on the upper surface side, and the surface paper 3 is brought into close contact when pressed. The molded uncured gypsum board 5 moves to the molding conveyor belt 6, is cured on the conveyor belt 6, and is cut into a predetermined size by a cutter provided at the end of the conveyor belt 6, and is then dried. It was dried as a product. As a manufacturing method that does not require paper for strength reinforcement on both sides, in JP-B-57-49004, a gypsum board without paper on both sides is manufactured by a papermaking method from a slurry in which hemihydrate gypsum and fibers are dispersed in water. A method of doing so is disclosed.

[0004]

In recent years, further improvement in sound insulation performance, fire resistance, and workability has been demanded, and a plaster building material for interior having a thickness of 10 mm or more and 100 mm or less is required. ing. In the case of manufacturing a product with a thick building material in this way, not only does the weight increase and the construction performance deteriorates as a result, but in the drying step during manufacturing, the drying temperature is a low temperature below the dehydration temperature of gypsum. Therefore, it takes a long time to uniformly dry the inside, resulting in a decrease in manufacturing efficiency.
Furthermore, the wiring of communication lines accompanying intelligentization in the office and multimedia in the future, and the electrical wiring work accompanying the increase in the number of installation locations such as outlets due to the spread of electrical appliances in the home are increasing. There was a need for additional work to install ducts, etc., and there was a request to supply a partition wall, etc., which enables easy wiring work for electric and communication lines in the wall. Also, in condominiums and houses, indoor airtightness has improved due to the widespread use of aluminum sashes, and along with this, the occurrence of mold, especially on the north side wall due to condensation, has become a problem. It is possible to prevent the generation of mold to some extent by sticking the etc., but it has not yet been completely prevented. In order to solve this problem, the present applicants provide a method for producing a hollow light-weight gypsum hardened body in Japanese Patent Application No. 6-092902, entitled "Hollow gypsum hardened body". According to the present application, in a gypsum hardened body having a paper-like layer on both sides, a hollow lightweight gypsum hardened body in which a hollow portion of an arbitrary shape made of paper quality or the like is provided inside and a manufacturing method thereof are described. In the production of hardened gypsum, there is a problem that the process of supplying a core made of paper or the like is added during the manufacturing process, and the process becomes a little complicated, but a hollow lightweight gypsum hardened product is provided. Although it was a useful invention that was made possible, the present applicants have conducted further research and, as a result of earnestly researching a method for continuously and efficiently manufacturing a gypsum hardened product, have developed the following manufacturing method. Came to do.

[0005]

A method for producing a hollow gypsum hardened body of the present invention comprises a hemihydrate gypsum, a fibrous substance and water on a conveyor belt, if necessary, with a thickener, a foaming agent and a coagulating agent. In a method for producing a gypsum hardened product, which comprises a prescribed amount of one or more kinds of admixtures such as a regulator and the like, which is kneaded with a mixer to continuously produce a hardened gypsum, a conveyor belt having irregularities on the surface. After supplying the gypsum slurry to the above and adjusting the thickness to a predetermined value, the gypsum slurry is supplied to the end of the convex surface of the obtained gypsum hardened body having an uneven surface to integrate the hollow portion inside. The present invention is characterized by producing a gypsum hardened product having it, and is described as follows according to steps.

One of admixtures for hemihydrate gypsum, fibrous substance, and water, such as a thickener, a foaming agent, and a coagulation modifier, if necessary.
A prescribed amount of at least one type is mixed and kneaded with a mixer to produce a gypsum slurry.

An endless conveyor belt is provided with irregularities on its upper surface, and the conveyor belt is stretched by a tail and a head pulley.

A first step of supplying the gypsum slurry to the conveyor belt and adjusting it to a predetermined thickness by a thickness adjusting machine such as a roller or a weir. At this time, paper quality may be supplied to the surface and pressed by a roller or the like to adjust the thickness.

After being hardened to a predetermined hardness, the gypsum slurry is transferred onto a flat conveyor belt of the next stage and kneaded by a mixer provided separately, and is a space composed of convex portions and convex portions on the inner surface side. The second step of supplying the resin to the end portion of the, and connecting the convex portions to the convex portions with a gypsum slurry to form a hollow gypsum hardened body that penetrates. At this time, if paper quality is previously supplied to the surface of the flat conveyor belt, a hollow gypsum hardened product having paper quality parts on both sides can be manufactured.

The obtained hollow gypsum cured product is cut into a predetermined size as usual, and then dried at 50 ° C. or higher and 120 ° C. in a dryer.
A hollow gypsum building material can be manufactured by drying at the temperature below.

As a second method, hemihydrate gypsum, a fibrous substance, and water, if necessary, one or more admixture materials such as a thickener, a foaming agent, and a coagulation modifier are provided on a conveyor belt. Is mixed in a predetermined amount, and the gypsum slurry kneaded with a mixer is supplied, and in the method for producing a gypsum hardened product which continuously produces a gypsum hardened product, the gypsum slurry is supplied on a conveyor belt having irregularities on the surface to a predetermined amount. The thickness of the gypsum is adjusted, and at least one of the surfaces is manufactured to have a gypsum hardened body, and then a flat plate-shaped gypsum hardened body to be separately manufactured is joined, or two gypsum hardened bodies having the uneven surface are joined. A hollow gypsum hardened body can be manufactured by joining the convex parts of the gypsum hardened body to each other.

[0012]

[Function] The shape of the unevenness of the surface of the conveyor belt used in the above-described manufacturing process needs to be a shape that allows easy peeling of the conveyor belt and the gypsum hardened product in the manufacturing process. It is preferable that the width A of the root on the conveyor belt side and the width B of the end portion are larger or equal to B than B, because the detachment is easy and the shape of the recess on the belt side is flat. Alternatively, it may have a curved shape retracted to the conveyor belt side, and any shape is not particularly limited as long as it can be easily detached.

The width of the concave portion and the convex portion and the height of the convex portion are preferably 10 mm when the width of the concave portion is 10 to 200 mm.
If it is less than 200mm, the duct width cannot be secured.
If the above is the case, it is necessary to increase the plate thickness on the strength, the efficiency of the drying process is reduced, and the weight reduction effect is reduced, which is uneconomical. The width of the convex portion is 5 to 50 mm and the height is 10 to 10
A value of 0 mm is preferable, and if the width of the recess is smaller than this, it is inconvenient in the manufacturing process, and if it is 50 mm or more, the drying efficiency is reduced and the weight reduction effect is also reduced, which is uneconomical. If the height is less than 10 mm, it will be difficult to secure the gap between the ducts, and the weight reduction effect will be small.
If it is above, it may be difficult to secure the strength of the plate, which is not preferable. The plate thickness on the surface is required to be about 5 to 30 mm in order to secure the strength, but it cannot be unconditionally determined because of the relationship with the reinforcing material used. The irregularities provided on the conveyor belt may be endless irregularities in the traveling direction as shown in FIG. 2 or may be provided transversely to the traveling direction. It is necessary to provide unevenness so that it is provided.

The gypsum slurry used in the second step is a mixture of the hemihydrate gypsum and the fibrous substance with a foaming agent and a coagulation modifier, if necessary, and the adhesiveness with the hardened gypsum produced in the first step. A water-soluble adhesive may be appropriately added to improve the properties, and a synthetic resin such as a resin may be appropriately added thereto.

The gypsum slurry is poured into a conveyor belt having irregularities on the surface, the level is adjusted to a predetermined thickness by a level adjuster, and then the separately kneaded high-density gypsum slurry is supplied, and a gypsum hardened body having a plurality of layers is also prepared. It can be manufactured.

The properties of the gypsum slurry of the present invention are generally such that the cured gypsum has a specific gravity of about 0.4 to 0.7 when cured in order to reduce the weight of the cured gypsum and improve heat insulation efficiency and the like. Mixing a foaming agent to make a foamed gypsum slurry,
High-density gypsum with a specific gravity of 0.7 to 1.0 may be used if necessary. The fibrous substance used at this time is usually glass fiber, but in addition to this, carbon fiber, natural fiber, synthetic fiber, slag fiber, asbestos and the like can be used.

In the method for producing a cured product of the present invention, a cured product having unevenness on the surface is independently produced, an adhesive such as a double-sided tape is attached to the surface of the convex portion of the cured product, and the product is shipped and applied at a construction site. Depending on the situation, it may be used as a hollow partition wall that is laminated with a flat gypsum board supplied separately. When used for the inner wall of the building body, the convex surface of the cured body may be directly attached to the inner wall of the building body. In any case, not only a space for wiring can be secured, but also dew condensation on the inner wall is prevented, which is an effective means for suppressing generation of mold and the like.

[0018]

【Example】

Example 1 FIG. 1 is a conceptual diagram showing a manufacturing process of an example of the present invention.

According to FIG. 1, 1 is a mixer for kneading hemihydrate gypsum, glass fibers and a coagulation modifier, 2 is a conveyor belt having irregularities on the surface, 3 is paper for surface layer, and 4 is a conveyor belt 2. This is a roller for adjusting the thickness of the uncured gypsum 5 supplied above. Hemihydrate gypsum, glass fiber, and coagulation adjusting agent are each weighed with a weighing device (not shown) so as to have the composition shown in Table 1. First, 0.015 of anionic surfactant (Vinsol 80 manufactured by Yamamune Chemical Co., Ltd.) was added to 80 parts by weight of kneading water.
After adding 0.1 part by weight of polyvinyl alcohol and polyvinyl alcohol, high speed stirring at 6000 rpm was performed with a mixer to foam, and 100 parts by weight of hemihydrate gypsum and 1.5 parts of glass fiber were added.
Parts by weight, 0.0 citrate as a set retarder
5 parts by weight were added and kneaded to produce a foamed gypsum slurry. This gypsum slurry is a conveyor belt 2 having a width of 590 mm and 7 rows of convex portions having a width of 40 mm and a height of 30 mm.
It is supplied on top to form the uncured gypsum layer 5. The surface layer paper 3 having a thickness of 0.5 mm (280 g / m ² ) is supplied to the surface of the uncured gypsum layer 5 and at the same time, the thickness adjusting roller 4 is adjusted to a height of 60 mm from the concave surface of the conveyor belt 2.
The thickness of the uncured gypsum layer 5 on the conveyor belt 2 is adjusted by pressing with, and at the same time the surface paper 3 is uncured gypsum layer 5
Adhere to the surface of. After hydration of the uncured gypsum layer 5 reaches a predetermined strength, the uncured gypsum layer 5 is moved to the next conveyor belt 6. The hardened gypsum layer 5 on the conveyor belt 6 has irregularities on the inner surface as shown in FIG. 2, and the gypsum slurry is supplied to the concave portions formed between the adjacent convex portions of the irregular surface. Then, the gypsum hardened body having a hollow portion is manufactured by connecting the convex portions to each other. Therefore, first, the surface layer paper 3 is supplied to the surface of the conveyor belt 6, and the hardened gypsum layer 5 is moved on the surface layer paper 3 to provide each concave portion formed between adjacent convex portions and convex portions. The gypsum slurry having the above composition kneaded by the mixer 7 is supplied to the supply port 8 via the transport pump 9, and the gypsum slurry is cured on the conveyor belt 6 until a predetermined strength is reached, and then the cutter is used. It was cut and dried in a dryer at a temperature of 80 to 90 ° C. for the time shown in Table 1, the weight was measured, and the dry state was measured. As a result, 16 hours of drying produced a gypsum hardened product having a space inside. It turned out to be possible.

Example 2 Using the same apparatus as in Example 1, 100 g by weight of gypsum slurry, 0.8 part by weight of glass fiber, and 75 parts of water were used.
By weight, in addition to this, 0.03 parts by weight of a setting retarder is added to produce a hollow gypsum hardened body having the same shape as in Example 1, and the same as 80
It was found that it was possible to reduce the drying time by 65 to 70% as compared with the conventional dense gypsum hardened product, by drying at a temperature of ~ 90 ° C for the time shown in Table 1 and judging from the weight.

Example 3 Using the same composition and the same equipment as in Example 1, the steps after the conveyor belt 6 were omitted, and a hardened gypsum body having irregularities inside was produced, and the conventional method shown in FIG. 4 was used. Separately, a gypsum board without surface paper is manufactured on the upper surface side, and when the gypsum board is uncured, the gypsum hardened body having irregularities is placed inside the gypsum board,
Both were pressed and bonded, and two days later, the bending strength was measured by a one-divisional-one-point loading method with a span of 100 mm. As a result, as shown in Table 1, the same results as in Example 1 were shown. The same effect can be obtained by pouring the gypsum slurry between the gypsum hardened body having irregularities inside and the gypsum board to bond them together. Example 4 The composition of the gypsum slurry was the same as in Example 1, and the shape of the conveyor belt 2 was gypsum hardening having irregularities as a structure in which seven rows of convex portions having a width of 35 mm and a height of 15 mm were provided on a conveyor belt having a width of 600 mm. A gypsum hardened body having a space inside is similarly produced by manufacturing a body and bonding the gypsum hardened bodies having irregularities after drying using a commercially available double-sided tape. It was found to have excellent performance as a building material made of a cured product.

[0022]

[Table 1]

[0023]

EFFECTS OF THE INVENTION By producing a gypsum building material using the method for producing a cured gypsum of the present invention, it is possible to significantly reduce the drying time of the product, and continuously on a conveyor belt, It is also possible to efficiently manufacture a hollow gypsum hardened product, which has a space for cable wiring etc. inside and is a lightweight or dense gypsum hardened product made of a hollow gypsum hardened product with excellent heat insulation and sound insulation. It has become possible to manufacture building materials for construction.

[Brief description of drawings]

FIG. 1 is a flow chart showing an example of a manufacturing process of a hollow gypsum cured product of the present invention.

FIG. 2 is a cross-sectional view taken along line AA showing the relationship between a conveyor belt having irregularities on the surface and a cured gypsum body.

FIG. 3 is a BB cross-sectional view showing a hollow gypsum hardened body on a conveyor belt.

FIG. 4 is a flowchart showing a manufacturing process of a conventional gypsum hardened body.

[Explanation of symbols]

 1. Mixer 2. Conveyor belt with uneven surface 3. Surface paper 4. Molding roller 5. Gypsum layer (gypsum hardened body) 6. Flat conveyor belt

Front Page Continuation (72) Inventor Fumio Matsumoto 1-297 Kitabukuro-cho, Omiya City, Saitama Prefecture Mitsubishi Materials Corporation Cement Research Center

Claims (5)

[Claims] 1. A hemihydrate gypsum, a fibrous substance, and water are mixed on a conveyor belt with a predetermined amount of one or more of a thickener, a foaming agent, and a coagulation modifier, if necessary. In the method for producing a gypsum hardened product which continuously produces a gypsum hardened product by supplying a kneaded gypsum slurry, the gypsum slurry is supplied on a conveyor belt having irregularities on the surface and adjusted to a predetermined thickness, and then obtained. Separately, between the end of the convex surface and the end of the convex surface of the gypsum hardened body having an uneven surface on at least one surface, at least hemihydrate gypsum, fibrous substance, and water among the above materials are separately provided. A method for producing a hardened gypsum body, which comprises producing a hardened gypsum body having a hollow portion inside by supplying and integrating a mixed and kneaded gypsum slurry. 2. A hemihydrate gypsum, a fibrous substance, and water, if necessary, at least one of a thickener, a foaming agent, and a setting regulator.
Gypsum slurry, which is prepared by kneading a mixture in which a proportion of at least one kind is kneaded with a mixer, is supplied onto a conveyor belt having unevenness on the surface, and the surface is adjusted to have a predetermined thickness, and unevenness is formed on the inner surface. Before the step of producing a certain gypsum hardened body, at the end of the convex portion of the gypsum hardened body having irregularities on the inner surface produced in the step, hemihydrate gypsum, fibrous substance, and water as necessary. 2. The hollow process according to claim 1, further comprising a step of supplying a slurry prepared by kneading at least one of a thickener, a foaming agent and a coagulation modifier with a mixer and connecting the convex portions. A method for producing a cured gypsum. 3. On a conveyor belt, hemihydrate gypsum, a fibrous substance, and water are mixed with a predetermined amount of one or more of a thickener, a foaming agent, and a coagulation modifier, if necessary, and then mixed with a mixer. In the method for producing a gypsum hardened product in which a kneaded slurry is supplied to continuously produce a gypsum hardened product, the gypsum slurry is supplied on a conveyor belt having irregularities on the surface to adjust the thickness to a predetermined value, and either A method for producing a cured gypsum body, which comprises producing a cured gypsum body having irregularities on one surface. 4. A hollow gypsum hardened product according to claim 1, characterized in that a flat plate made of the gypsum hardened product is adhered to the end of the convex part of the gypsum hardened product according to claim 3 having irregularities on the surface. Method 5. The convex part of the gypsum hardened product according to claim 3 having irregularities on the surface and the convex part of the gypsum hardened product according to claim 3, which is separately manufactured, are joined together. 4. The method for producing a hollow gypsum cured product according to 4.