JPH10146811A - Manufacture of ceramics exterior wall material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the permeability of the water content in the structure of a lower layer and realize the improvement of its dehydration efficiency by a structure wherein an upper layer and the lower layer, to which particles respectively having specified particle diameters are blended, are integrally laminated. SOLUTION: The diameter of the blended particle in a stock tank 2B serving as a lower layer is set to be 1.5-4.0mm. The diameter of the blended particle in a stock tank 2A serving as an upper layer is set to be smaller than 1.5mm so as to conceal the surface unevenness due to the particles added to the ceramics material employed in the lower layer in order to realize the smooth surface of a product. In addition, at the dehydration by sucking or pressing of this material, the stock of an outer surface tends to enter between the structures of the lower layer, resulting in better the adhesion between the lower layer and the upper layer. Due to the structure as mentioned above, the dehydrating properties of the lower layer is improved by covering the surface conditions caused by the particles having larger particle diameter added for the improvement of its dehydrating properties, resulting in allowing to manufacture a plank material having a dense structure and excellent strength as a whole.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a ceramic outer wall material, and more particularly to a method for forming a ceramic-based water-added material into a layer and dewatering it by a round-mesh paper-making method, a flow-on molding method, and a single-layer plate making method. The present invention relates to an improvement in a method of manufacturing a plate-like body through steps.

[0002]

2. Description of the Related Art As a method for producing a ceramic outer wall material such as a fiber reinforced cement board, there are known a round net forming method, a flow-on molding method and a one-layer plate manufacturing method.

[0003] In the round net making method, a rotating net mesh cylinder is immersed in an aqueous solution of cement, and a cement seed film is made with a felt belt which oscillates in contact with the cylinder, and this is wound up on a making drum and laminated. This is a method in which a plate-shaped body is manufactured by incising and flattening when the thickness of the plate reaches the thickness, and dehydrating by pressing.

In the flow-on molding method, a cement slurry is supplied in a layer form on a belt provided with a dewatering device, suctioned until a predetermined water content is achieved, dehydrated and formed into a layer, wound up on a making drum and laminated. This is a method in which a plate-shaped body is manufactured by incising and flattening when the thickness of the plate reaches the thickness, and dehydrating by pressing.

[0005] The one-layer plate making method is a method in which a cement slurry is supplied in a thick layer on a belt provided with a dewatering device, sucked and dewatered until a predetermined moisture content is obtained, adjusted to a desired plate thickness, and the plate is made as it is. is there.

[0006] In these methods for producing ceramic outer wall materials, a dehydration step after stratification is important in order to make the plate-like body dense and improve the strength.

[0007]

In the dewatering step, a suction box is arranged on the back of the dewatering belt and suction dehydration is performed from the formed plate through a water-permeable belt. There are times when you do.

In any case, in order to efficiently dewater the product, it is necessary that the structure of the molded plate is easy to pass water.
In order to make the structure easily water-permeable, it is conceivable to disperse an additive having a large particle size in the compounding material, so that the structure is coarsened.

However, in this case, although the dewatering efficiency is improved, the addition of the large particles exposes the particles to the surface of the product, resulting in unevenness, and there is a problem that the appearance of the product deteriorates. Also, in the case of press dewatering, products with a high water content immediately after molding, such as the flow-on molding method or the single-layer molding method, may cause water to squirt from the product side if a strong pressure is applied in a short time, There was a defect that voids and cracks were formed in the cement structure at the jetting site, resulting in defective products.

[0010]

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and has a particle size of 1.
On the upper surface of the lower layer containing 5 to 4.0 mm particles, 1.5
It is characterized in that a surface layer containing particles smaller than mm is laminated and integrated.

That is, in the above invention, the lower layer and the upper layer are composed of ceramic raw materials, and concretely, a cement material or the like is used. Further, in the above, the particles blended in the lower layer are for improving the water permeability of the water contained in the tissue of the lower layer, and the particles make up a water supply, and the water is removed during suction dehydration or press dehydration. This is to make it easy to escape.

The reason why the particle diameter is set to 1.5 to 4.0 mm is as follows.
If it is smaller than 5 mm, no adequate water supply can be performed, and no improvement in dewatering properties can be seen.If it is larger than 4.0 mm, although it is advantageous in terms of dewatering properties, it is possible to hide the irregularities of the added particles even when laminating the upper layer described later. It is not possible.

In the above, the particles are not particularly limited, but are crushed products themselves, crushed products of cement / concrete products, for example, inorganic materials such as crushed ALC products, crushed natural rock materials, crushed glass materials, and plastic particles. Organic matter may be used.

The upper layer is for covering the surface irregularities due to particles added to the lower ceramic material and smoothing the product surface. The reason that the particle diameter is smaller than 1.5 mm is that if the particle diameter is 1.5 mm or more, the surface of the surface layer will have irregularities due to particles, which is not appropriate in appearance.

The material of the surface layer easily enters into the space between the lower layers at the time of suction dehydration or press dehydration, thereby improving the adhesion between the lower layer and the upper layer. The surface state of the particles having a large particle diameter added for improving the dehydration property is covered with the upper layer, and thus a plate material having a fine structure and excellent strength as a whole can be produced.

[0016]

Next, an embodiment of the present invention will be described. The following materials were prepared as basic materials as ceramic materials.

42.5 parts by weight of cement 42.5 parts by weight of silica sand 10.0 parts by weight of perlite 5 parts by weight of reinforcing fiber 5 parts by weight [Example 1] Based on the above basic composition, the particle size is 0.1 mm to 1.5 mm.
The upper layer cement material A to which 5 to 20 parts by weight of the natural stone pulverized material is added is supplied to the raw material tank 2A of the round-mesh cylinder type papermaking apparatus 1 shown in FIG. The obtained seed film 5 was laminated on a winding drum 6 until the thickness became 3 mm.

Next, a particle size of 1.5 mm to 3 m
m of silica sand is added to the raw material tank 2B of the round-mesh cylinder-type papermaking apparatus 1 and 5 to 20 parts by weight of silica sand are added to the raw material tank 2B. The seed film 5 was rolled up and wound on the upper cement layer of the winding drum 6 to obtain a laminated body having a total thickness of 13 mm.

This was cut open, flattened, and pressed with a press at a pressure of 60 kg / cm ² to obtain a plate having a thickness of 12 mm. [Example 2] Based on the above basic composition, the particle size is 0.1 mm to 1.5 mm.
The cement material A for the upper layer, which is obtained by adding 5 to 20 parts by weight of the pulverized material of natural stone, is placed on the stratified belt 4A of the flow-on winding forming apparatus 8 shown in FIG. And supply 7 in the suction box
After the suction dehydration, the layer 5 is wound on a winding drum 6, and then the lower layer cement material B obtained by adding 5 to 20 parts by weight of silica sand having a particle size of 1.5 mm to 3 mm to the above basic composition is added to the second flow. Supply 5mm thick than box 5B,
This layer is superimposed on the winding drum 6 and the layer thickness of the entire winding
A 13 mm laminate was obtained.

This was cut open, flattened, and compressed and dewatered by a press at a pressure of 60 kg / cm ² to obtain a plate having a thickness of 12 mm. [Example 3] A first flow box of a stratification apparatus 9 shown in Fig. 3 in which a cement material B for a lower layer obtained by adding 5 to 20 parts by weight of a pulverized natural stone having a particle size of 1.5 mm to 4 mm to the above-mentioned basic composition is added. 5C is supplied to the permeable belt 4B so as to have a thickness of 20 mm, and then 5 to 20 parts by weight of silica sand having a particle diameter of 0.1 mm to 1.5 mm is externally added from the second flow box 5D to this layer. Material A is supplied to a layer thickness of 5 mm to form a layer having a total thickness of 25 mm, and is dehydrated by suction boxes 7... 7 provided on the lower surface of the permeable belt 4B.
kg / cm ² d compression dehydration press was performed to obtain a 12 mm-thick plate. [Comparative Example 1] A plate having the same thickness and the same size as in Example 1 was produced except that a cement material having a basic composition and no externally added particles in Example 1 was used as a raw material. [Comparative Example 2] A plate having the same thickness and the same size as in Example 2 was produced except that a cement material having a basic composition in Example 2 to which no externally added particles were added was used as a raw material. [Comparative Example 3] A plate having the same thickness and the same size as in Example 3 was produced except that a cement material having a basic composition in which no externally added particles were added in Example 3 was used as a raw material.

The water content of the product immediately after the plate making in each of the examples and the comparative example when the plate was made under the same conditions was measured.
The average of ３3 was 40%, and that of Comparative Example was 50%. By the way, when the maximum plate making speed required for setting the water content to 50% was tested, the conveyor speed in the comparative example was 10 m / min, whereas the speed in the example was increased to 15 m / min. did it.

In the press dewatering of Examples 1, 2, and 3, there was no jet of dewatered water from the side of the plate. On the other hand, in Comparative Examples 1, 2, and 3, water exudation from the side of the plate was observed in all the test examples, and several cases in which water erupted from the side were observed. The cracks shown were seen.

[0023]

As described above, according to the method of the present invention, the addition of large particles improves the dehydration efficiency of the water contained in the cement structure. As a result, when the same suction pressure or press pressure is used, the water content is increased. This has the effect of improving production efficiency, for example, by reducing the rate by about 20%, while reducing the required processing time for the same water content by about 30%.

In addition, since a layer to which large-diameter particles are not added is laminated on the product surface, the surface condition is good, and since this layer is thinner than the main body layer, it affects the dewatering efficiency. It has various effects, such as no presence.

[Brief description of the drawings]

FIG. 1 is a side view showing a first embodiment of the present invention.

FIG. 2 is a side view showing a second embodiment of the present invention.

FIG. 3 is a side view showing a third embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Round net cylinder type papermaking apparatus 2A ... Raw material tank 2B ... Raw material tank 3A ... Round net cylinder 3B ... Round net cylinder 4 ... Felt belt 4A ... Layered belt of flow-on winding molding apparatus 4B ... Breathable belt 5 ... Seed membrane 5A: First flow box 5B: Second flow box 5C: First flow box 5D: Second flow box 6: Winding drum 7: Suction box 8: Flow-on winding molding device 9: Layering device

Claims (1)

[Claims] A ceramic outer wall material characterized in that a surface layer containing particles having a particle size of less than 1.5 mm is laminated and integrated on the upper surface of a lower layer containing particles having a particle size of 1.5 to 4.0 mm. Production method.