JPH08231284A - Production of alc panel - Google Patents

Abstract

PURPOSE: To produce an ALC panel while suppressing the discoloration due to carbonation by forming a protective layer on the face of an ALC base material in contact with the external air. CONSTITUTION: A protective layer forming stage is interposed between the base material cutting stage and base material curing stage in the ALC production process. A protective layer 15 not affected by the external air and interrupting contact with the external air is formed at least on both outer side faces 14 with a parallel positional relation to the cut face formed when the base material is cut in the base material cutting stage among the faces 13 of an ALC base material 11 in contact with the external air.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an ALC panel, and more particularly, to a method of effectively preventing carbonization of the surface of an ALC base material obtained in the manufacturing process by contact with outside air. The present invention relates to a method for manufacturing an ALC panel capable of manufacturing a panel.

[0002]

2. Description of the Related Art ALC panels are not only robust but also lightweight and have excellent heat insulation and fire resistance. Therefore, floor panels, partition wall panels, and outer walls of steel structures, such as houses, factories and warehouses, are particularly popular. Widely used as a panel.

The ALC panel used for the above-mentioned applications is manufactured by approximately the following steps. That is,
Using silica sand, cement, lime, etc. as main raw materials, adding chemicals and aluminum powder as a foaming agent to these, stirring and mixing these with water to make a slurry-like mother liquor, and then a substantially rectangular parallelepiped shape with an open top In the mold exhibiting a reinforcing material such as a reinforcing bar is set in a vertical direction in a plurality of rows in advance, and a mother liquor pouring step of pouring to a predetermined depth in anticipation of foaming the slurry mother liquor into the mold and increasing the amount, Then, the mother liquor in the form of slurry is foamed by a chemical reaction in a greenhouse and the AL
C base material foaming step of molding a C base material, a hardening step of curing until a hardness of a molded body obtained through the base material foaming step becomes cuttable, and an ALC mother obtained through the hardening step Base material cutting process that cuts the material in the vertical direction at equal intervals so that the reinforcing material is embedded, base material curing process that cures the cut ALC base material in the high temperature and pressure autoclave for a predetermined time, and the final product It is manufactured by going through the finishing process and finishing.

[0004]

By the way, a lightweight and robust ALC panel can be manufactured by a conventional manufacturing method.

However, in the conventional ALC panel manufacturing process, the ALC base material after being foamed in the greenhouse is appropriately subjected to the base material cutting step immediately after the hardening step and the mold removal. It is cut into various thicknesses, and then the base material curing step is performed. Therefore, A
On the surface of the LC base material that comes into contact with the outside air, the calcium hydroxide contained in the raw material is carbonated by carbon dioxide in the air.

On the other hand, the original color tone exhibited by the ALC panel after being commercialized depends on the tobermorite produced by the reaction between the calcium hydroxide and the silica sand during the curing step in the autoclave. However, the above-mentioned calcium hydroxide contained in the raw material is carbonated as described above and changes into calcium carbonate, so that the side of the silica sand loses its reaction target and cannot produce tobermorite. For this reason, silica sand remains as unreacted material
As a result of remaining in the LC panel composition, the material tone of the silica sand itself appears on the surface of the ALC panel as it is. Therefore, each ALC panel has a mixture of a material color tone such as silica sand and a color tone depending on the generation of tobermorite depending on the presence or absence of contact with the outside air. That is, some ALC panels are manufactured to have different color tones from other standard specification type ALC panels.

Therefore, when it is used for the outer wall of a general building, even if a discolored ALC panel is mixed,
Although there is no problem because finally the coating process is applied to match the color tone, in buildings such as warehouses and factories, there are many cases where the above coating process is not performed due to cost etc. Therefore, there is a disadvantage that a wall surface having an ununiform color tone is formed.

The present invention has been made in view of the above problems in the prior art. In the process of manufacturing an ALC panel, the outside air contact surface of the ALC base material is not affected by the outside air or the outside air is exposed to the outside air. By forming a protective layer that stops touching, discoloration due to carbonation can be suppressed AL
It is an object of the present invention to provide a method for manufacturing a C panel.

[0009]

The present invention is intended to achieve the above object. Among them, the structural feature of the invention of claim 1 is that a slurry mother liquor consisting of predetermined components is poured into a mold body. Mother liquor pouring step, parent material foaming step in which the poured slurry mother liquor is foam-molded as an ALC matrix by a chemical reaction, and hardening is performed until the molded body obtained after foam molding has a hardness that can be cut. A base material cutting step of vertically cutting the molded body after curing in the lateral direction and the length direction, and a base material for curing the ALC base material after the base material cutting step for a predetermined time in an autoclave A which is performed after at least the curing process
In the method for manufacturing an LC panel, a protective layer forming step is interposed between the base material cutting step and the base material curing step to cut at least the base material cutting surface of the outside air contact surface of the ALC base material. The purpose is to form a protective layer on both outer side surfaces that are in a positional relationship parallel to the cut surface formed by cutting in the process, without being affected by the contact with the outside air or cutting off the outside air contact.

Further, the protective layer is formed by a slurry layer formed by adhering an ALC base material slurry having the same color tone as that of an ALC panel as a product as in the invention according to claim 2 or. A coating layer formed by coating a coating material exhibiting the same color tone as that of the ALC panel as a product as in the invention of claim 5, or a shielding formed by covering a shielding cover as in the invention of claim 4. It can be formed by layers.

[0011]

Therefore, according to the invention of claim 1, the AL
Among the outside air contact surfaces of the C base material, at least both outer side surfaces that are in a positional relationship parallel to the cut surface cut and formed in the base material cutting step can be formed with a protective layer that interrupts the outside air contact. It is possible to suppress carbonation of these outer surfaces and effectively prevent discoloration.

According to the second aspect of the present invention, the protective layer is formed by adhering an ALC base material slurry which exhibits the same color tone as that of the ALC panel as a product and which has been sufficiently hydrated and is not easily carbonated. Since it is formed of the slurry layer, even if the wall surface is formed by mixing it with an ordinary ALC panel, the appearance can be finished without a feeling of strangeness.

Further, according to the invention of claim 3, since the protective layer is formed of a coating layer formed by coating a coating material having the same color tone as that of the ALC panel as a product, Even if the wall surface is formed by mixing with the ALC panel of No. 1, it is possible to finish without any discomfort in appearance.

Further, according to the invention of claim 4, since the protective layer is formed by the shielding layer covering the shielding cover, the covering surface of the ALC base material is carbonated. Can be effectively suppressed, and the occurrence of discoloration can be suppressed.

[0015]

Embodiments of the present invention will be described below. A
A general manufacturing method of an LC panel is a mother liquor pouring step of pouring a slurry mother liquor composed of predetermined components into a mold body, and the poured slurry mother liquor is chemically reacted to form an ALC base material 11 as shown in FIG. A base material foaming step of foam-molding, a hardening step of curing the molded body obtained after foam-molding to a hardness at which it can be cut,
A base material cutting step of forming the base material 12 to be cut by vertically cutting the LC base material 11 along its length as shown in FIG. 2, and cutting the base material 11 through the base material cutting step. Base 12
It is performed by at least passing through a base material curing step of curing the ALC base material 11 after forming the base material in an autoclave for a predetermined time and a finishing step of finishing the ALC panel P as a final product as shown in FIG. ing.

In addition, in the method of manufacturing an ALC panel according to the present invention, the protective layer forming step is interposed between the base material cutting step and the base material curing step, so that the outer periphery of the ALC base material 11 itself. Air contact surface 13 located on the surface
Therefore, the protective layer 15 is formed to prevent contact with the outside air.

That is, the protective layer 15 is formed of the ALC base material 11 before the transition to the base material cutting step after the hardening step as shown in FIG. 1 and the ALC base material as shown in FIG.
It is formed on the ALC base material 11 before the transition to the next base material curing step after the base material cutting step of cutting the base material 11 into each of the cut substrates 12.

Moreover, the protective layer 15 has the outside air contact surface 1
Among the three, at least formed on both outer side surfaces 14, 14 of the ALC base material 11 in a positional relationship parallel to the cutting surface 12a of the base material 12 to be cut formed in the base material cutting step, If necessary, it can be formed also on each outside air contact surface 13 located on the other outer peripheral surface.

In this case, the protective layer 15 has the same color tone as that of the product ALC panel P as described in claim 2, for example, product waste of the ALC panel P processed into a slurry by a ball mill or the like. Formed by a slurry layer 16 formed by adhering a slurry or an ALC base material slurry such as a waist slurry obtained by processing scraps of the ALC base material 1 that has been aged until just before shifting to the base material curing step into a slurry state. can do.

The protective layer 15 can also be formed by a coating layer 17 formed by coating a coating material having the same color tone as that of the ALC panel P as a product. As the coating material, for example, acrylic resin-based white paint or a kneaded product of white cement and water can be preferably used.

Further, the protective layer 15 may be formed as a shielding layer 18 formed by covering a shielding cover as described in claim 4. Shielding layer 18 in this case
A stainless steel plate, which is a non-ferrous metal material, can be preferably used as well as a wet towel. In this case, when the shielding layer 18 is formed by covering a stainless steel plate, the ALC base material 11 is removed after a base material curing step of curing the ALC base material 11 in an autoclave for a predetermined time to cover the wet towel. If it is formed by installing, it will be removed immediately before shifting to the base material curing step.

Since the present invention is configured as described above, in the manufacturing process of the ALC panel P, the cutting of the outside air contact surface 13 of the ALC base material 11 which is cut and formed at least in the base material cutting step. On both outer side surfaces 14 that are in a positional relationship parallel to the surface 12a, the protective layer 1 that prevents contact with the outside air
5 can be formed, and therefore, by blocking the contact with the carbon dioxide component, it is possible to suppress carbonation of these outer side surfaces 14, 14.

Therefore, the components necessary for producing tobermorite such as calcium hydroxide remain on the outside air contact surface 13 of the ALC base material 11 without being carbonated by carbon dioxide. As a result, the AL
The C base material 11 undergoes the base material curing step,
As for the outside air contact surface 13, a required chemical reaction such as generation of tobermorite by reacting calcium hydroxide or the like with silica sand or the like can be rapidly progressed, so that it is manufactured through the next process finishing step. Each ALC
It is possible to manufacture the panel P while maintaining the uniform quality without discoloration due to carbonation.

In this case, as in the invention described in claim 2,
When the protective layer 15 is formed by the slurry layer 16 formed by adhering the ALC base material slurry having the same color tone as the ALC panel P as a product, the wall surface is formed by mixing with the normal ALC panel P. However, it is possible to finish it without any discomfort in appearance.

That is, the slurry layer 16 formed of the product waste slurry or the waist slurry of the ALC panel P has almost the same quality as the reaction product existing when the ALC base material 11 is cured in the base material curing step. It will contain the reactants. Therefore, the slurry layer 16 as the protective layer 15
Holds the same components as the composition of the ALC base material 11 during curing of the ALC base material 11, and as a result, can have the same color tone as that of a normal ALC panel P.

When the protective layer 15 is formed of a coating layer 17 formed by coating a coating material having the same color tone as that of the ALC panel P as a product, as in the third aspect of the invention. In addition, even if a wall surface is formed by mixing it with a normal ALC panel P, it can be finished without a feeling of discomfort in appearance.

Further, when the protective layer 15 is formed of the shielding layer 18 covering the shielding cover as in the invention described in claim 4, the covering surface of the ALC base material 11 is oxidized. It is possible to effectively suppress the occurrence of discoloration, and it is possible to suppress the occurrence of discoloration.

[0028]

[Table 1]

Table 1 above shows a treated type ALC panel (FIGS. 1 and 2) to which the method of the present invention is applied, which is manufactured by forming the protective layer 15 on the outside air contact surface 13 of the ALC base material 11.
In the outermost part), ALC panel of standard specifications (formed by the blank 12 to be cut having a cutting surface 12a that does not contact the outside air) provided as a product, and an ALC base material Outside air contact surface 1 at 11
3 shows the results of measuring the brightness and color tone of a non-processed ALC panel manufactured without forming the protective layer 15 on 3 using a colorimeter.

The "brightness (L)" column in the table is a numerical value indicating the degree of brightness. The larger the value, the higher the degree of brightness. Further, the "redness (a)" column is a numerical value indicating the degree of redness, and the larger the numerical value, the more redness. Further, the "yellowness (b)" column shows that the yellowness increases as the numerical value increases.

In Table 1 above, the reference example is the measured value of a standard ALC panel (product), and the comparative example is the one prepared without the protective layer 15 on the outside air contact surface 13 of the ALC base material 11. The measured values for the treated ALC panel are shown respectively. Further, in Table 1 above, Example 1 shows the measured values when the protective layer 15 is formed of the slurry layer 16 made of the product waste slurry, and Example 2 is the protective layer 15 formed of the slurry layer 16 made of the waist slurry. The measured value for the case of
5 shows the measured value in the case of forming the coating layer 17 formed by applying the white paint, and Example 4 shows the case of forming the protective layer 15 by the coating layer 17 formed by applying the white cement kneaded material. In Example 5, the measured value was used as the shielding layer 1 in which the protective layer 15 was covered with a shielding cover made of a stainless steel plate.
The measured values for the case of forming No. 8 are shown below.

As a result, in the case of the comparative example, the "brightness (L)" is considerably lower than that of the standard example, and both "redness (a)" and "yellowness (b)" are present. Was significantly higher than the standard example, and it was confirmed that the color changed. That is, in the case of the comparative example, the outside air contact surface is carbonated.

On the other hand, in each of Examples 1 to 5, the "brightness (L)", "redness (a)", and "yellowness (b)" were comparable to the standard examples, and the outside air contact surface It was confirmed that there was no discoloration. That is, Examples 1 to 5
Regarding No. 3, it is shown that carbonation can be suppressed by forming the protective layer 15 on the outside air contact surface 13.

[0034]

As described above, according to the first aspect of the present invention, among the outside air contact surfaces of the ALC base material, at least the cut surface cut and formed in the base material cutting step is used. A protective layer can be formed on both outer surfaces that are in parallel to each other so as to prevent contact with the outside air. Therefore, it is possible to suppress carbonation on these outer surfaces and effectively prevent discoloration. You can Therefore, by using the product of the present invention, it is possible to form a harmonious wall surface of the same color tone without performing a complicated coating application work for adjusting the color tone.

Further, according to the invention of claim 2, since the protective layer is formed by a slurry layer formed by adhering an ALC base material slurry having the same color tone as that of the ALC panel as a product, Even if the wall surface is formed by mixing with the ALC panel of No. 1, it is possible to finish without any discomfort in appearance.

Further, according to the invention of claim 3, since the protective layer is formed by a coating layer formed by coating a coating material having the same color tone as that of the ALC panel as a product, Even if the wall surface is formed by mixing with the ALC panel of No. 1, it is possible to finish without any discomfort in appearance.

Further, according to the invention of claim 4, since the protective layer is formed by the shielding layer covering the shielding cover, the covering surface of the ALC base material is carbonated. Can be effectively suppressed, and the occurrence of discoloration can be suppressed.

[Brief description of drawings]

FIG. 1 is an overall perspective view showing an example in which a protective layer forming step in the method of the present invention is interposed before a base material cutting step.

FIG. 2 is an overall perspective view showing an example in which a protective layer forming step in the method of the present invention is interposed after a base material cutting step.

FIG. 3 is a perspective view showing the appearance of an ALC panel manufactured by the method of the present invention.

[Explanation of symbols]

 Reference Signs List 11 ALC base material 12 cut substrate 12a cut surface 13 outside air contact surface 14 outer side surface 15 protective layer 16 slurry layer 17 coating layer 18 shielding layer P ALC panel

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Tetsuro Shimizu Inventor, 1150 Hazawa-machi, Kanagawa-ku, Yokohama, Kanagawa Prefecture Central Research Laboratory, Asahi Glass Co., Ltd. Within the corporation

Claims (4)

[Claims] 1. A mother liquor pouring step of pouring a slurry mother liquor composed of predetermined components into a mold body, a base material foaming step of foaming and molding the poured slurry mother liquor as an ALC base material by a chemical reaction, and foam molding. A hardening step of curing the molded body obtained later until it becomes a hardness that can be cut, a base material cutting step of vertically cutting the molded body after curing in the lateral direction and the longitudinal direction, and the base material ALC performed at least through a base material curing step of curing the ALC base material that has undergone the cutting step in an autoclave for a predetermined time
In the panel manufacturing method, a protective layer forming step is interposed between the base material cutting step and the base material curing step, so that the outside air contact surface of the ALC base material is
An ALC panel characterized by forming a protective layer that is not affected by the outside air contact or is cut off from the outside air at least on both outer side surfaces that are in a positional relationship parallel to the cut surface cut and formed in the base material cutting step. Manufacturing method. 2. The protective layer is formed by a slurry layer formed by adhering an ALC base material slurry which exhibits the same color tone as that of an ALC panel as a product and which has undergone a sufficient hydration reaction and is resistant to carbonation. The ALC according to claim 1.
Panel manufacturing method. 3. The method for manufacturing an ALC panel according to claim 1, wherein the protective layer is formed by a coating layer formed by coating a coating material having the same color tone as that of the ALC panel as a product. . 4. The method of manufacturing an ALC panel according to claim 1, wherein the protective layer is formed of a shielding layer which covers a shielding cover.