JPH08224715A - Non-combustible board and its manufacture - Google Patents

Abstract

PURPOSE: To obtain a non-combustible board with a deep uneven pattern on the surface and a high bending strength. CONSTITUTION: A slurry-like material M1 consisting a short reinforcing fiber 5 and water blended with cement and an extender is supplied to a gas-permeable conveyor belt 11 with an upward gradient part 15 from above, and an air is evacuated using a negative pressure chamber 27 located at the lower surface of the gradient part 15. The lower layer of the material M1 is carried with the conveyor belt 11, while the upper layer flows clown 1:y gravity. Thus a difference in the velocity between the upper and the lower layer generates, so that most of the fiber is oriented in a longitudinal direction. Especially, the part near the belt 11 of the lower fiber layer is sucked by the vacuum toward the belt 11 side, while the remote part is oriented in an arrow B direction by the velocity difference. Thus a reinforcing fiber 5 is alined in the longitudinal direction, so that a base material produced has a high tensile strength on the lower surface. This base material is reversed and is deposited under pressure on an uncured facing material charged in a die frame with an uneven die face, and is allowed to become hardened integrally with the facing material. Thus the board manufactured has a deep uneven surface and a high tensile strength on the rear.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention is mainly applied to outer walls of houses,
The present invention relates to a nonflammable plate having an uneven pattern, which is used for an inner wall, a ceiling and the like.

[0002]

2. Description of the Related Art Cement plates, calcium silicate plates, etc., are examples of the above-mentioned noncombustible plates. Cement plates are raw materials prepared by mixing cement, fillers, short fibers for reinforcement, etc. with water in a slurry form. The silicate calcium plate is also a plate made of a raw material obtained by mixing calcium silicate and the like with an extender, short fibers for reinforcement and the like in a slurry form into a plate and solidifying.

The surfaces of these plates are provided with various patterns of unevenness and are colored with a paint for sale. The concavo-convex pattern was made by pressing in the semi-solidified state and had a depth of 2 to 3 mm, but if the depth is increased and the corners are sharpened, a luxurious feeling can be obtained. Since the number of types of patterns increases when the depth is variously changed, recently, the depth of the uneven portion is 4 to 6 mm.
There is a growing tendency to increase the quality and increase the quality.

However, it is difficult to press a semi-solidified product to form deep irregularities, and the sharpness of the corners of the pattern disappears, and the deeper the recesses, the smaller the minimum thickness of the plate. When the plate is lifted at both ends in the longitudinal direction during construction, the center part may bend and break due to its own weight, and increasing the thickness to increase the strength increases the weight. , Becomes inconvenient to handle.

Further, using the above-mentioned raw materials, reinforcing fibers are aligned in the longitudinal direction and thinly formed into a semi-solidified thin plate,
A laminated plate is also known in which this is wound around a roll a plurality of times, cut out, pressed and solidified. The laminated plate has large bending strength because the reinforcing fibers are aligned in the longitudinal direction, but a gap is liable to remain between the layers. It may be lengthened and the plate may be chipped due to delamination.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to increase the depth of irregularities without increasing the thickness or weight of a plate to increase the quality and prevent a decrease in strength.

[0007]

The constitution of the plate which has solved the above-mentioned problems is, as described in claim 1, a slurry-like raw material obtained by mixing a curable non-combustible material, water, reinforcing fibers and the like. In the form of a plate, and in a long noncombustible plate solidified by forming a concavo-convex pattern on the surface of the plate, the fibers that are oriented in the longitudinal direction of the plate are made into paper and the strength in the longitudinal direction is increased. On a substrate formed with 10% or more greater than the strength in the width direction,
It is characterized in that a surface material in which a raw material substantially the same as the raw material is molded to form an uneven pattern is integrally polymerized.

In one of the methods for manufacturing the plate, as described in claim 2, the breathable belt is run endlessly through the ascending slope portion, and a negative pressure is applied to the lower surface of the ascending slope portion. The curable non-combustible material, water, slurry-like raw material mixed with fibers for reinforcement, etc. are supplied to the ascending slope portion, and the raw material is conveyed upward while flowing down the raw material on the belt to convey the above-mentioned fibers. A mold surface for forming a semi-solidified base material having a substantially equal thickness in the state of being aligned in the longitudinal direction by 10% or more on the back surface side with respect to the front surface side, and forming the surface of the plate separately from the base material. In the mold of the surface material provided on the bottom, mold the substantially same raw material as the base material, the surface side of the base material is polymerized and adhered to the upper surface of the unsolidified surface material in the mold frame, It is characterized by solidifying together.

In another manufacturing method, as described in claim 3, in claim 2, after the base material is polymerized on the upper surface of the surface material, the back surface of the base material is interposed with a water-absorbing dehydrator and a porous plate. It is characterized by applying pressure.

Still another manufacturing method is, as described in claim 4, according to claim 2 or 3, wherein the surface side of the base material is brought into close contact with the upper surface of the uncured surface material in the mold of the surface material. It is characterized in that the form of the base material and the surface material is turned upside down while maintaining the close contact state, the surface material is placed on the base material, and the surface material is pressed through the form frame.

As another aspect of the present invention, as described in claim 5, in claim 2 or 3, the surface side of the base material is brought into close contact with the upper surface of the uncured surface material in the form of the surface material. It is characterized in that the form of the base material and the surface material is turned upside down while maintaining the close contact state, the surface material is placed on the base material, and vacuum is drawn from the back surface side of the substrate to dehydrate.

[0012]

DETAILED DESCRIPTION OF THE INVENTION Embodiments will be described below with reference to the drawings. 1 is a front view of a non-combustible wall plate 1 having a masonry pattern according to the present invention, FIG. 2 is an end view, and FIG. 3 is 3-3 of FIG.
A cross section is shown in an enlarged manner, 2 is a front surface, 3 is a back surface, and the dimensions are, for example, a width W of 45 cm, a thickness T of 14 mm, and a length L of 3.
The depth of the groove 4 as a joint pattern provided on the surface 2 is, for example, 5 mm. The wall plate 1 is made by mixing a cement with an extender, and further, as a reinforcing material, a slurry-like mixture of 5 to 20% by weight of fibers 5 having a length of 10 mm and having a length of 10 mm as a main material. A cement plate that has been solidified and has a width several times the width W continuously made in the longitudinal direction by a device described later, cut to a predetermined length L, and then cut off both ears. It is made by vertically dividing the width W.

On the back surface 3 side, most of the fibers 5 are aligned in the longitudinal direction of the wall plate 1 as shown by 5a in FIG. Many are oriented in the longitudinal direction. By making 10% or more of the entire reinforcing fibers 5 so as to face the longitudinal direction, the strength in the longitudinal direction can be increased by 10% or more as compared with the width direction. With this configuration, as shown in FIG. 4, with the load F, the wall plate 1 makes the back surface 3 face down, and the virtual line 1a.
Even if it is bent as shown by, the fiber 5a on the back surface 3 side acts as a tension member to generate tensile strength and is difficult to break.

Next, FIG. 5 shows an apparatus 10 for manufacturing a base material on the back side of a wall board, in which, for example, cement, a filler, a short fiber mainly composed of pulp as a reinforcing material, water and the like are mixed. When the slurry-like raw material M ₁ is supplied, the apparatus 10
The above-mentioned arrangement of the fibers 5 is obtained by the paper-making operation described later. The same base material can be obtained when calcium silicate is used as the main raw material. Reference numeral 11 in the figure is a belt having air permeability, which moves in the direction of arrow A through the upwardly inclined portion 15 and the horizontal portion 16 by the rollers 12, 13, 14 and an appropriate guide member, and the unloaded side 1
7 is guided by the guide roller 18 and returns.

The upper surface of the ascending slope portion 15 is covered with a cover 19, and a supply port 20 for the raw material M ₁ is provided continuously above the cover 19.
A recirculation device 21 is continuously provided at the lower end, and is communicated with the supply port 20 via a delivery device 22 and a circulation flow path 23. Further, on the upper surface of the horizontal portion 16, there is provided a leveling device 24 in which a belt 26 is stretched over three rollers 25 and is driven at substantially the same speed as the belt 11. Negative pressure chambers 27 and 28 are provided on the lower surface of the ascending slope portion 15 and the lower surface of the horizontal portion 16 and are evacuated by a vacuum pump. Of these, the negative pressure chamber 27 is particularly important.

[0016] allowed to run the belt 11 in the arrow A direction, when supplying the material M ₁ from the supply port 20, the feedstock M ₁ is transported in the arrow A direction by the frictional force while receiving a downward suction force from the negative pressure chamber 27 At the same time, due to gravity, the action of flowing down in the direction of arrow B occurs, the lower layer portion is conveyed upward due to the speed difference in both directions,
The upper layer portion flows down, returns from the circulation channel 23 to the supply port 20, and is mixed with new raw material.

At this time, the lower layer portion of the raw material M ₁ is the negative pressure chamber 2
Since the negative pressure of 7 is strongly received, 1 of the fibers 5 in the lower layer portion
As for the book, a portion near the belt 11 is sucked to the belt 11 side together with water and moves integrally with the material M _{1 in the} belt 11 and the vicinity thereof, and a portion far from the belt 11 is in the direction of arrow B of the material M _1. Since the fibers 5 move in accordance with the movement, the fibers 5 are oriented in the direction of movement of the belt 11 as indicated by 5a in FIG. 3, and the fibers in the vicinity of the belt 11 are subjected to a strong papermaking action, as shown in FIG. Aligned and stronger.
The upper surface of the fiber 5 also papermaking is acted the ratio facing the falling direction as the belt 11 side not large, because the ones facing the multidirectional many, not equipped with the fiber, the surface material described later M ₂
And has the advantage of being easy to polymerize.

Next, the raw material M ₁ is supplied to the horizontal portion 16 and the leveling device 2
Although the upper surface is rubbed by the belt 26 with the roll 25 of No. 4 and the upper surface is rubbed by the belt 26, small unevenness remains on the surface. Then, the papermaking action under the negative pressure and the squeezing action of the roll 25 semi-dehydrate it to a state in which it does not flow, and it is transported to a substantially constant thickness and cut into a constant length, and the base material 34 described later is used. Becomes

On the other hand, a mold 30 shown in FIG. 6 is prepared for the raw material M _{2 of the} surface material to be the surface portion of the wall plate 1.
The bottom surface 31 of 0 is a mold surface on which a ridge 32 for forming the groove 4 and other uneven patterns are appropriately provided.
A slurry-like raw material M ₂ made of substantially the same material as that of the base material 34 is flowed down and scattered into the mold 0, and is molded. As a result, a surface material M ₂ having a deep concave-convex pattern and sharp corners is obtained, although the fibers of the raw material M ₂ are not uniform.

The raw material M ₁ carried out from the base material manufacturing apparatus 10 is cut into a certain length while being conveyed by the conveyor 33 shown in FIG. In the lifting device 35, a lattice body 37 for preventing air flow is fixed to the opening of a downward facing shallow box-shaped lifting adsorber 36, and a wire net and felt that act as a perforated plate on the lattice body 37. The dehydrator 38 is stretched, the lifting adsorber 36 is connected to the vacuum source by the hose 39, and is fixed to the robot arm 40. When the lifting device 35 is brought into contact with the surface of the base material 34 and vacuumed, the base material 34 is adsorbed while absorbing water. Therefore, the device 35 is moved by the robot arm 40 to separate the base material 34 from the conveyor 33. Can be moved to a position.

FIG. 8 shows a reversing device 41. The reversing device 41 receives the substrate 34 hung by the hoisting device 35, adsorbs the back surface 34a thereof, and then inverts it so that the front surface side faces down. This is for pressing the surface side onto the raw material M ₂ of the surface material in the mold 30 of FIG. In FIG. 8, a dehydrating body 38 composed of a wire net 43 and a felt 44 is supported by a lattice body 45 that does not hinder the flow of air at the opening of the upward shallow box-shaped reverse adsorption device 42.
Connected to the vacuum source at 6. The bottom portion of the suction device 42 has a robot arm 48 via a plurality of reinforcing ribs 47.
It is connected to the.

As shown in FIG. 8, the reversing device 41 is moved below the lifting device 35, and one of the devices 35 and 41 is moved up and down so that the suction device 42 of the reversing device 41 is placed on the back surface of the substrate 34. The upper adsorbing device 36 is brought into close contact with the upper adsorbing device 36 and the upper adsorbing device 36 is returned to the atmospheric pressure.
After adsorbing the base material 34 on the substrate 34, the reversing device 41 is rotated in the direction of arrow A to be reversed, and as shown in FIG. 9, the uncured surface material M ₂ filled in the mold 30 is placed. The base material 34 is polymerized to release the negative pressure, and the base material 34 is placed on the surface material M ₂ .

In FIG. 9, the mold 30 is stopped when it is conveyed by the conveyor 50 and comes to the abutment 51, and by the above-mentioned operation, the base material 34 is superposed on the surface material M ₂ and the reversing device 41.
After being removed, it is conveyed, and after waiting for curing, it is molded to form the wall plate 1.

In the above operation, the base material 34 was adsorbed and inverted on the surface material M ₂ and polymerized, but it may be polymerized by another method. Further, the polymerized wallboards may be stacked and pressed, and after curing, the form may be separated to form a wallboard having a sharp pattern.

After the base material 34 is placed on the surface material M _{2 in} the process shown in FIG. 9, the base material 34 is pressed through the dehydrating body 38 to improve the adhesion between the surface material M ₂ and the base material 34. At the same time, it is possible to pressurize the surface material M ₂ in the mold 30 to form an accurate uneven pattern, and to extrude the water to solidify.

Next, in the embodiment shown in FIGS. 10 to 13, after the base material 34 is overlaid on the raw material M ₂ of the surface material, the dehydration is positively performed to further accelerate the solidification of the surface material M ₂ and the base material 34. It is something that is done on a regular basis. The thicknesses of the surface material M ₂ and the base material 34 are shown in an enlarged scale as compared with those in FIG. 9.

From the state shown in FIG. 9, the reversing adsorber 42 is pulled up, and the surface material M ₂ and the base material 34 are placed on the formwork 30 and placed on the conveyor 52 shown in FIG.
In the reversing mechanism 53, a rotating ring 54 is rotatably supported by a support roller 53a, and conveyors 55 and 56 are installed up and down.
2 through the rotating ring 54, conveyors 55, 56
It is sent in between, half-turned in the direction of arrow B, the base material 34 is put down, sent out on the conveyor 57, and further sent to the dehydrator 58 in FIG.

The dehydrator 58 has a porous conveyor 5 at the bottom.
9, a vacuum chamber 60, a vacuum duct 61, a support grid 62 for supporting the conveyor 59, and a pressure plate 63 on the upper part.
When the pressure plate 63 is pressed in the direction of arrow C, the base material 34 and the surface material M ₂ are pressed through the mold 30 to squeeze out water, and the suction action of the vacuum chamber 60 further promotes dehydration. And cure faster.

Then, as shown in FIG. 13, a conveyor 64
Then, the wall plate 1 in which the surface material M ₂ is adhered onto the base material 34 is obtained by taking out the mold 30 and removing the mold 30.

In the dehydrator 58, dewatering may be performed only by vacuuming, or water may be squeezed by only pressing the pressure plate 63. In any case, the water flows downward and is discharged, so that the water can be easily dehydrated.

The wall plate 1 produced by the above operation has a high ratio of the reinforcing fibers 5 oriented in the longitudinal direction of the base material 34, so that the tensile strength in the longitudinal direction is greater than that in the width direction and the longitudinal direction is curved. The strength against bending that causes a tensile force in the longitudinal direction on the back surface side is large because the reinforcing fibers 5 are aligned in the longitudinal direction in large quantities on the back surface side as indicated by 5a. Further, since the front surface of the base material 34 and the surface material M ₂ do not have fibers aligned with each other, they are easily polymerized and are molded in the mold frame 30 in an uncured state.
The surface shape is obtained by accurately transferring the mold surface, and finally, a wall plate having high strength and a desired deep concave-convex shape on the surface can be obtained.

[0032]

As described above, according to the first aspect of the invention, since the surface material has the uneven pattern formed by molding the slurry-like raw material into the mold, the depth of the unevenness is large. Since the plate surface is formed and the ratio of the reinforcing fibers in the base material oriented in the longitudinal direction is increased, the strength in the longitudinal direction of the seat plate is increased by 10% or more than that in the width direction. Even if used, it is possible to improve the ratio of strength in the longitudinal direction as compared with the reinforcing fibers having no directionality,
Longitudinal bending has the advantage of being able to substantially increase its strength, since it is the most susceptible bending caused by pressures or impacts applied to the surface when handling the plate or when attached to a building.

Next, according to the second aspect of the present invention, the reinforcing fibers of the base material can be oriented in the longitudinal direction only by using the conveyor belt having the upwardly inclined portion and the negative pressure chamber, In particular, it is easy to manufacture a strong base material in which a large number of reinforcing fibers on the back surface side are aligned in the longitudinal direction, and on the other hand, since the front surface part is formed by a separate mold, it has an advantage that an accurate pattern can be easily formed.
Since the base material is lifted using two sets of adsorption devices, inverted and placed on the surface material, there is an advantage that a large-sized plate can be easily manufactured.

According to the third aspect of the invention, since the unsolidified surface material is pressed through the base material in the mold, accurate irregularities are formed and the surface material can be adhered to the base material without any gap. Therefore, the water in the base material and the surface material is dehydrated through the dehydration body, and the solidification and drying of the plate are promoted.

According to the fourth aspect of the present invention, the base material is brought into close contact with the upper surface of the uncured surface material, and these are inverted to apply pressure with the surface material facing upward, and the back side of the base material is evacuated. ,
In addition to the embossing action, the close contact action, and the water squeezing action, a water absorbing action occurs, solidification is promoted, and work efficiency is improved.

According to the fifth aspect of the present invention, the uncured surface material is overlaid on the base material and a vacuum is drawn from the bottom. Therefore, water flows downward and is easily separated from the raw material, and the dehydration efficiency is improved. There is.

[Brief description of drawings]

FIG. 1 is a plan view of a plate embodying the present invention.

FIG. 2 Same as above, side view

FIG. 3 is an enlarged sectional view of the same as above.

FIG. 4 is an explanatory view of the operation of the embodiment.

FIG. 5 is a front view of a substrate manufacturing apparatus.

FIG. 6 is a cross-sectional view of a surface material formwork.

FIG. 7 is a front view of a substrate lifting device.

FIG. 8 is a front view of the reversing device when receiving the same as above.

FIG. 9 is a front view of the same device when it is placed.

FIG. 10 is a front view of a reversing mechanism used in another manufacturing method.

FIG. 11 is a front view of the inverted state.

FIG. 12 is a front view of the dehydrator.

[Fig. 13] Front view of the product taken out

[Explanation of symbols]

 1 plate 2 front surface 3 back surface 4 groove 5 fiber 10 base material manufacturing device 11 belt 24 leveling device 27, 28 negative pressure chamber 30 formwork 34 base material 35 lifting device 36 moving adsorber 41 reversing device 42 reversing adsorber 53 reversing mechanism 58 dehydrator

Claims (5)

[Claims] 1. A long sheet obtained by forming a slurry-like raw material obtained by mixing a curable non-combustible material, water, reinforcing fibers, etc. into a plate and solidifying it by forming an uneven pattern on the surface thereof. In the non-combustible plate of the shaku, the fibers are manufactured by increasing the number of those oriented in the longitudinal direction of the plate,
A surface material having an uneven pattern formed by molding the same raw material as the raw material into a base material having a strength in the longitudinal direction 10% or more greater than a strength in the width direction is integrally polymerized. And non-combustible plate. 2. A breathable belt is run endlessly through an ascending slope portion, and a negative pressure is applied to the lower surface of the ascending slope portion so that curable non-combustible material, water, reinforcing fibers, etc. A state in which the mixed slurry-like raw material is supplied to an ascending slope portion and is conveyed upward while flowing down on the belt, and the fibers are aligned in the longitudinal direction by 10% or more on the back surface side with respect to the front surface side. Then, a semi-dehydrated base material having a substantially equal thickness is formed into a paper, and in addition to the base material, a mold of a surface material having a mold surface for forming the surface of the plate at the bottom is provided in the same shape as the base material. A method for producing a non-combustible plate, characterized in that a raw material is put in a mold, and a surface side of the base material is polymerized and adhered to an upper surface of an unsolidified surface material in the mold to be solidified integrally. 3. The non-combustible plate according to claim 2, wherein after the base material is polymerized on the upper surface of the surface material, the back surface of the base material is pressed through a water-absorbing dehydrator and a porous plate. Method. 4. The surface side of the base material according to claim 2 or 3, wherein the front surface side of the base material is brought into close contact with the upper surface of the uncured surface material in the form of the surface material, and while maintaining the close contact state, the base material and the surface material are A method for producing a non-combustible plate, which comprises inverting a mold upside down, placing a surface material on a base material, and pressing the surface material through the mold. 5. The substrate according to claim 2, wherein the surface side of the base material is brought into close contact with the upper surface of the uncured surface material in the form of the surface material, and the adhered state is maintained. A method for producing a non-combustible plate, which comprises inverting a formwork upside down, placing a surface material on a base material, and vacuuming from the back surface side of the substrate to dehydrate.