JPH10230509A - Production of tiled building panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance the productivity of a tiled building panel. SOLUTION: A plate-shaped water-containing mat 15a is formed by dehydrating a molding material slurry based on cement and fibers by a casting method or a papermaking method and a tile sheet 18 is formed by bonding a plastic film 20 or pasteboard to the surfaces of a large number of preliminarily arranged tiles 19 to be superposed on the water-containing mat 15 so that the plastic film 20 or pasteboard becomes an upper side. In this state, the superposed one is pressed through an elastic sheet 22 by a press plate 17 while the water- containing mat 15a is dehydrated from the uneder surface thereof under reduced pressure by a vacuum dehydration box 14 to bond the tiles 19 to the water- containing mat 15a under pressure. At this time, the elastic sheet 22 expands into joint parts 23 by press pressure to seal the joint parts 23 and plays an important role in the molding of the molding material built up within the joint parts 23 from below.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a tiled building board for manufacturing a tiled building board having a tile attached to a surface.

[0002]

2. Description of the Related Art In a construction site, the work of attaching tiles one by one to the wall surface of a building at a building site takes a great deal of time and is inefficient, and in recent years, for example, Japanese Patent Publication No. Sho 62-1832.
No. 2, Japanese Patent Application Laid-Open No. 3-104605 and Japanese Patent Application Laid-Open No. 6-143215, when a cement-based building board is manufactured, a tiled building board with a tile attached to the surface is manufactured. There is something.

[0003] In Japanese Patent Publication No. 62-18322, a dry material containing cement or the like is sprayed in a mold, water is sprayed, and a process of pressing while vibrating is repeated to form a plate-like molded body. A joint frame is placed on the upper surface of the plate-like molded body, a tile is fitted into the joint frame, and the tile is pressed while applying vibration to the upper surface of the plate-like molded body, and the thickness of the tile is reduced. Is embedded in the plate-shaped molded body up to the middle portion of the substrate to be cured and cured.

However, in this manufacturing method, not only the formation of the plate-like molded body and the embedding of the tile cannot be performed simultaneously, but also the work of fitting the tile into the joint frame is extremely troublesome, and generally requires a large number of man-hours. The disadvantage is that the production efficiency is poor.

In Japanese Patent Application Laid-Open No. 3-104605, a tile is fitted in a tile frame in advance, a cement extruded mat is placed on the upper surface of the tile, and the tile and the cement extruded mat are pressed by pressing or the like. It is hardened and cured. This manufacturing method also has the disadvantage that the work of fitting the tiles into the tile frame is troublesome and the production efficiency is poor.

In order to solve such a drawback, Japanese Patent Application Laid-Open No. Hei 6-143215 discloses a tile sheet made by attaching a plastic film to the surface of a large number of tiles arranged in advance so that the plastic film is on the lower surface side. It is housed in a formwork, and concrete is poured from above to harden and remove the concrete.

[0007]

However, in this manufacturing method, since the tile sheet is laid under the concrete poured into the formwork, the noro component (moisture including cement) of the concrete flows from the joints between the tiles. It penetrates between the tile surface and the plastic film, and the tile surface is easily stained. As a countermeasure for this, in the manufacturing method of the above publication,
The joint between the tiles is filled with a rod-shaped filler, and the rod-shaped filler prevents intrusion of the noro component, but the work of filling the joint between the tiles with the rod-shaped filler is troublesome, and the tile It is difficult to completely seal the intervening joint portion with the rod-shaped filler, and the infiltration of the noro component cannot be completely prevented, and the tile surface may be stained.

[0008] The present invention has been made in view of such circumstances, and an object of the present invention is to improve the productivity of a tiled building board and to reliably prevent a tile surface from being stained. An object of the present invention is to provide a method for manufacturing a building board.

[0009]

In order to achieve the above object, a method for producing a tiled building board according to claim 1 of the present invention comprises a method of casting a slurry of a molding material containing cement and fibers as main components. Dehydration by a papermaking method to form a plate-like hydrated mat, a tile sheet made by attaching a plastic film or mount to the surface of a large number of pre-arranged tiles, the hydrated mat with the plastic film or mount facing up Stacked on top, furthermore, a thick elastic sheet is stacked on the tile sheet, and the tile is pressed onto the wet mat by pressing from above the elastic sheet while decompressing and dehydrating from the lower surface side of the hydrated mat. It cures and cures to produce tiled building boards.

In this manufacturing method, a tile sheet is stacked on a plate-shaped hydrated mat made by a casting method or a papermaking method, and a thick elastic sheet is laid on the tile sheet. When pressing the tile on the hydrated mat by pressing from above the elastic sheet while decompressing under reduced pressure, the part of the thick elastic sheet corresponding to the joint between the tiles swells downward into the joint due to the pressing pressure In addition to sealing the joint portion, a molding material that swells from the water-containing mat in the joint portion is formed into a concave shape at the bulging portion of the elastic sheet. Furthermore, the elastic sheet also plays a role of pressing the plastic film or the backing of the tile sheet against the surface of the tile by pressing pressure and bringing the two into close contact with each other. To prevent infiltration into the surface of the Further, at the time of pressing, since dehydration is performed from the lower surface side of the hydrous mat under reduced pressure, dehydration is efficiently performed from the lower surface side of the hydrous mat, which also helps to prevent moisture from entering the tile surface.

In this case, a resin mortar layer may be interposed between the hydrated mat and the tile. By doing so, an adhesion reinforcing layer made of resin mortar is formed at the bonding portion between the building board (inorganic board) and the tile, and the adhesive strength of the tile is increased.

It is preferable that the elastic sheet is made of inexpensive material such as synthetic rubber, natural rubber or foamed resin and has a thickness of 5 mm or more. If the thickness of the elastic sheet is too thin, the amount of the elastic sheet swelling into the joint due to press pressure decreases, and the sealing performance of the joint decreases, and the dent of the joint formed by the elastic sheet decreases. It is.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment in which the present invention is applied to a casting method will be described below with reference to FIGS. First, the configuration of the molding apparatus will be described with reference to FIGS. On the lower surface of the cavity 11 surrounded by the side frame 10, a movable bottom plate 12 is supported by a push-up cylinder 13 so as to be vertically movable, and a decompression dewatering box 14 is fixed on the movable bottom plate 12, and is formed on the decompression dehydration box 14. Material slurry 15 is injected. Vacuum dewatering box 14
A large number of small holes for water passage (not shown) are formed on the upper surface of the box. By reducing the pressure inside the vacuum dewatering box 14 with a vacuum pump or the like, the molding material slurry 15 is depressurized through the small holes for water passage. It is dehydrated, and the water-containing mat 15a is formed.
On the other hand, a pressurizing cylinder 16 of a press is installed downward above the cavity 11, and a press platen 17 is fixed to a lower end of the pressurizing cylinder 16.

A method for manufacturing a tiled building board using the molding apparatus configured as described above will be described. First, FIG.
As shown in (a), a predetermined amount of a molding material slurry 15 is injected into the cavity 11. This molding material slurry 15
Is composed of 40 to 60 parts by weight of cement and 5 to 10 parts by weight of wood pulp, and 10 to 15 parts by weight of lightweight aggregate of pearlite or shirasu, as well as inorganic powders 35 such as slag, coal ash and silica powder. ~ 40 parts by weight are mixed and dispersed in water,
The concentration was adjusted to 7 to 10 g / dl. When the molding material slurry 15 is injected into the cavity 11,
Vacuum pump (not shown) inside the vacuum dehydration box 14
Then, the molding material slurry 15 in the cavity 11 is decompressed and dewatered by the decompression dewatering box 14 to form a water-containing mat 15a as shown in FIG. The water sucked into the vacuum dehydration box 14 is
It is discharged by a drain pump (not shown) or the like.

Thereafter, as shown in FIG. 1 (c), a tile sheet 18 of the same size is placed on the wet mat 15a.
Stack up. The tile sheet 18 has a plastic film 20 on the surface of a large number of tiles 19 arranged in advance.
(See Fig. 3)
A plastic film 20 is placed on the hydrated mat 15a.
They are stacked with the (mount) facing upward.

As the tile 19, a ceramic tile, a natural stone tile, a ceramic tile, or the like, which is generally commercially available as an exterior wall tile, or a natural stone formed by cutting natural stone, is used. Further, in order to increase the adhesive strength of the tile 19, it is preferable to use a tile 19 having a sole 21 (convex portion) on the back surface as shown in FIG. In a tile with a target weight, as shown in FIG.
It is preferable that the shape of the side end surface of the tile 19 is formed so that the upper surface side (front surface side) of the joint portion 23 has a tapered shape expanding.

On the other hand, as described above, the hydrated mat 1
On the tile sheets 18 stacked on 5a, a thick elastic sheet 22 of the same size is stacked. The elastic sheet 22 is formed of synthetic rubber, natural rubber, or foamed resin, and has a thickness of 5 mm or more and 50 mm or less.

Thereafter, as shown in FIGS. 2 (a) and 3 (a), the pressurizing cylinder 16 of the press machine is lowered while depressurizing and dewatering from the lower surface side of the water-containing mat 15a by the depressurizing dewatering box 14. The board 17 is lowered, and the tile sheet 18 and the hydrated mat 15a are pressed via the elastic sheet 22. The water squeezed out of the water-containing mat 15a by this press is sucked into the reduced-pressure dewatering box 14, and as shown in FIGS. 2 (b) and 3 (b), the thickness of the water-containing mat 15a is reduced and the wall thickness is increased. Elastic sheet 2
2 corresponding to the joint 23 between the tiles 19
2a swells downward into the joint 23 due to the pressing pressure and seals the joint 23. In this process, the tile 19 is pushed into the water-containing mat 15a by the press pressure,
A molding material that swells from the water-containing mat 15a in the joint 23 is formed into a concave shape by the bulging portion 22a of the elastic sheet 22.

After the press is completed, the press platen 17 is raised to the upper standby position, and compressed air for vacuum breaking is supplied to the vacuum dehydrating box 14 to release the suction by the vacuum dehydrating box 14. As shown in ()), the lifting cylinder 13 is raised, the molded product is raised, and the mold is opened. Thereafter, the molded product is cured and cured to produce an inorganic plate 24 (that is, a tiled building plate) to which a tile 19 is attached as shown in FIG. In addition, since the plastic film 20 (backing paper) stuck on the surface of the tile 19 also functions as a protective sheet for preventing the surface of the tile 19 from being damaged, after the tiled building board is attached at the building site, Plastic film 20
You just have to remove the (mount).

According to the manufacturing method of the first embodiment described above, the tile 19 is previously
Since the tile sheet 18 attached to the (mount) is used, the labor of arranging the tiles 19 one by one in the cavity 11 can be omitted. In addition, the tile 19 is replaced with the wet mat 15a.
When pressing, the elastic sheet 22 is pressed in a state where the tile sheet 18 and the elastic sheet 22 are stacked on the water-containing mat 15a, so that the elastic sheet 22 swells into the joint part 23 by the pressing pressure and seals the joint part 23. The molding material that swells from the water-containing mat 15a in the joint portion 23 can be formed into a concave shape by the bulging portion 22a of the elastic sheet 22. Accordingly, the bulging portion 22a of the elastic sheet 22 functions as a joint frame (or a rod-shaped filler) for sealing and molding the joint portion 23, and a member corresponding to a conventional joint frame is not required, and the joint frame is not required. This eliminates the need for a troublesome work of fitting the tiles 19 into the device, thereby improving production efficiency.

Furthermore, the elastic sheet 22 is formed by pressing the plastic film 20 (mount) of the tile sheet 18 by pressing.
Also presses against the surface of the tile 19 to make the two close together, and in combination with the sealing effect of the joint 23 described above, it is possible to surely prevent the moisture of the water-containing mat 15a from entering the surface of the tile 19. This makes it possible to prevent the occurrence of defective products in which dirt adheres to the surface of the tile 19, thereby improving the product yield. At the time of pressing, the wet mat 15a
Since the dewatering is performed from the lower surface side of the tiles 19, the dewatering can be efficiently performed from the lower surface side of the water-containing mat 15a, which also helps to prevent moisture from entering the surface of the tile 19.

By the way, in the first embodiment, the thickness of the elastic sheet 22 is set to 5 to 50 mm, for the following reason. That is, if the thickness of the elastic sheet 22 is too thin, the amount of the elastic sheet 22 swelling into the joint 23 due to the pressing pressure decreases, the sealing property of the joint 23 decreases, and the elastic sheet 22 is formed. The dents in the joints 23 are reduced, and molding defects in the joints 23 occur. Therefore, in order to improve the sealing property and the moldability of the joint 23, the thickness of the elastic sheet 22 should be 5 mm.
It is preferable to make the above. However, when the thickness of the elastic sheet 22 is too large, the pressing pressure applied to the periphery of the joint 23 of the elastic sheet 22 is dispersed and the amount of the elastic sheet 22 swelling into the joint 23 tends to be reduced. . Therefore, in order to secure an appropriate bulging amount of the elastic sheet 22, the thickness of the elastic sheet 22 is preferably set to 50 mm or less.

In the first embodiment, FIG.
As shown in (a), since the sole 21 is formed on the back surface of the tile 19, the bonding strength between the tile 19 and the inorganic plate 24 can be improved by the anchor effect of the sole 21.
Furthermore, in the tile 19 shown in FIG. 4B, the joint material 23 is formed so as to have a tapered shape (an inverted wedge shape) in which the upper surface is expanded, so that the molding material filled in the joint material 23 is formed. Of the tile 19 and the inorganic plate 24 together with the anchor effect of the sole 21 can be increased.
And the joining strength can be further improved.

In the first embodiment described above, the hydrated mat 15a is formed by the casting method. However, in the second embodiment of the present invention shown in FIG. 5, the hydrated mat 15a is formed by the papermaking method.
b is formed and transported to the pressing step, where the tiles 19 are formed.
Is pressed onto the hydrated mat 15b. Here, when forming the water-containing mat 15b by a papermaking method, for example, using a fourdrinier papermaking apparatus, a molding material slurry is continuously supplied onto an endless filtration belt, and the upper surface of the filtration belt is used. The molding material slurry is dewatered to produce a hydrated mat, or the hydrated mat is wound up in a plurality of layers with a making roll to form a thick hydrated mat. As another papermaking method, the molding material slurry is stored in a storage tank, and a cylindrical rotating body with an endless filtration belt stretched is immersed in the molding material slurry in the storage tank and rotated.
By depressurizing the inside of the cylindrical rotating body, the molding material is adsorbed on the surface of the filtration belt in the molding material slurry, and the cake layer of the molding material is conveyed on the filtration belt while being dewatered under reduced pressure. There is also a method of compression molding into a shape.

Further, in the second embodiment, when the hydrated mat 15b is formed, a resin mortar material is sprayed on the surface of the hydrated mat 15b to form the resin mortar layer 30. The hydrated mat 15b is cut in accordance with the size of the building board, and after stacking the tile sheet 18 and the thick elastic sheet 22 on the resin mortar layer 35, the hydrated mat 15b is moved to the pressing position by the water-permeable conveyor belt 31. Conveyed. In this press position, a decompression dewatering box 32 is installed below the conveyor belt 31, and a pressurizing cylinder 33 of a press machine is installed above the conveyor belt 31.
The press plate 34 is fixed to the lower end of the pressurizing cylinder 33.

Then, the tile sheet 18 and the elastic sheet 2
When the water-containing mat 15b in which the sheets 2 are stacked is conveyed to the pressing position, the conveyor belt 31 stops, and the pressure cylinder 33 of the press machine is lowered while depressurizing and dewatering from the lower surface side of the water-containing mat 15b by the decompression dewatering box 14. The press plate 34 is lowered to press the tile sheet 18 and the hydrated mat 15b via the elastic sheet 22 in the same manner as in the first embodiment described above, and the tiles 19 are turned into a resin mortar layer on the surface of the hydrated mat 15b. Crimping to 30. At this time, the elastic sheet 22 swells into the joint 23 by the pressing pressure as in the first embodiment, and the joint 23
And the resin mortar rising from below in the joint portion 23.
It also plays a role of forming a concave shape at the bulging portion.

After the press is completed, the press platen 34 is raised to the upper standby position, and compressed air for vacuum breaking is supplied to the decompression and dehydration box 32 to release the suction by the decompression and dehydration box 32. By rotating, the molded product is transferred to a curing curing process.

In the second embodiment described above,
The same effects as in the first embodiment can be obtained. In addition, in the second embodiment, since the resin mortar layer 30 is interposed between the tile 19 and the water-containing mat 15b, the adhesion between the building board (inorganic board) and the tile 19 is strengthened by the resin mortar. The layer is formed, and the adhesive strength of the tile 19 can be further increased.

However, according to the present invention, even when the hydrated mat is formed by the papermaking method as in the second embodiment, the tile sheet is directly stacked on the hydrated mat without forming the resin mortar layer. Alternatively, when the water-containing mat is formed by the casting method as in the first embodiment, a resin mortar material may be sprayed on the upper surface of the water-containing mat to form a resin mortar layer.

[0030]

As is apparent from the above description, according to the method for manufacturing a tiled building board of claim 1 of the present invention, tiles are placed on a plate-like hydrated mat made by a casting method or a papermaking method. With the sheet and the thick elastic sheet stacked on top of each other, the tiles are pressed onto the wet mat by pressing from above the elastic sheet while decompressing and dehydrating from the lower side of the wet mat, so that tiled building boards can be efficiently used In addition to the production, the dirt on the tile surface can be reliably prevented, the product yield can be improved, and the production cost can be reduced as a whole.

Furthermore, in claim 2, a resin mortar layer is interposed between the hydrated mat and the tile.
Adhesive strength between building boards and tiles can be increased, and product quality can be improved.

According to a third aspect of the present invention, the elastic sheet is formed of an inexpensive material such as synthetic rubber, natural rubber or foamed resin.
Since the thickness is set to 5 mm or more, it is possible to sufficiently secure the sealing property and the formability of the joint at the time of pressing.

[Brief description of the drawings]

1A and 1B show a manufacturing process of a tiled building board according to a first embodiment of the present invention, in which FIG. 1A shows a slurry injection process, FIG. 1B shows a slurry dewatering process,
(C) is a figure which shows the setting process of a tile sheet and an elastic sheet.

FIGS. 2A and 2B show a continuation of the manufacturing process of FIG. 1, wherein FIG. 2A shows a state at the start of pressing, FIG. 2B shows a state at the end of pressing, and FIG. It is.

FIG. 3 (a) is a diagram showing the state at the start of pressing in detail,
(B) is a figure which shows the state at the time of press completion in detail.

FIG. 4 (a) is a cross-sectional view of a tiled building board having a normal joint, and FIG. 4 (b) is a cross-sectional view of a tiled building board having an inverted wedge joint.

FIG. 5 is a view showing a pressing step of pressing a tile to a water-containing mat in a second embodiment of the present invention.

[Explanation of symbols]

11: cavity, 13: push-up cylinder, 14: vacuum dehydration box, 15: molding material slurry, 15a, 15b
... Hydrous mat, 16 ... Pressure cylinder, 17 ... Press board,
18 ... tile sheet, 19 ... tile, 20 ... plastic film, 21 ... soles, 22 ... elastic sheet, 22a ...
Swelling part, 23 ... joint part, 24 ... inorganic board (building board), 3
0: resin mortar layer, 31: conveyor belt, 32: decompression dewatering box, 33: pressurized cylinder, 34: press board.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 13/08 102 E04F 13/08 102U

Claims (3)

[Claims] 1. A molding material slurry containing cement and fibers as main components is dehydrated by a casting method or a papermaking method to form a plate-shaped hydrated mat, and a plastic film or a plastic film is formed on the surface of a plurality of tiles arranged in advance. A tile sheet made by attaching a mount is stacked on the hydrated mat with the plastic film or the mount facing upward, a thick elastic sheet is further stacked on the tile sheet, and dewatered under reduced pressure from the lower side of the hydrated mat. A method of manufacturing a tiled building board, wherein the tile is pressed onto the hydrated mat by pressing from above the elastic sheet while curing and curing the tile. 2. The method for manufacturing a tiled building board according to claim 1, wherein a resin mortar layer is interposed between the hydrated mat and the tile. 3. The method according to claim 1, wherein the elastic sheet is formed of synthetic rubber, natural rubber, or foamed resin, and has a thickness of 5 mm or more.