JPH10244521A - Manufacture of alc plate with pattern, and template used therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a complicated uneven pattern by disposing heat resistant resin durable against iron or autoclave curing in a bottom of a form so that the pattern of a surface of the template for cast molding the resin is disposed upside, injection foam molding foamable mortal in the form, and autoclave curing it, thereby prolonging a form life. SOLUTION: A template 4 for forming an uneven pattern on a surface is disposed at a bottom of a form 1 made of a board 2 and a side part 3, i.e., on the board 2, its surface is coated with release agent 8, and then a reinforcing bar cage 9 embedded in ALC is set in the form 1. Then, foamable mortar 10 is injected, the part 3 is removed at the time of semicured state, and an upper part of a mortar molding 11 is horizontally cut by a piano wire 12. The molding 11 is charged in an autoclave 13 together with the board 2 and the above template 4, steam cured, and the cured ALC plate is released from the plate 4 on the board 2. As a result, the life of the template can be prolonged, and a complicated finely uneven pattern can be accurately formed on the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight aerated concrete manufactured by autoclaving, that is, AL.
The present invention relates to a method for producing C, and more particularly to a method for producing an ALC plate having an uneven pattern formed on its surface.

[0002]

2. Description of the Related Art AL widely used for building wall materials, etc.
In order to enhance the design of the C plate, an uneven pattern is formed on the surface. For example, JP-A-62-2270
No. 6 describes that a foamable concrete is poured into a mold in which an irregular pattern for transfer is formed of a ceramic material, and the entire mold is autoclaved to produce an ALC plate with an irregular pattern. I have.

[0003] The formwork used in the above method is:
An uneven pattern of ceramic material is integrally formed on the base.Specifically, a cement paste layer obtained by kneading alumina cement, pearlite, and water is applied to the surface of the base made of calcium silicate plate. Then, an uneven pattern portion is formed using a mold, an iron, or the like.

[0004]

However, the mold used in the above-mentioned method for manufacturing an ALC plate has the following problems. That is, if thermal expansion and contraction due to autoclave curing are repeatedly applied to the mold, cracks and the like are likely to be generated in the ceramics forming the concave and convex pattern portion, and thus there is a problem that the life of the mold is relatively short. In addition, since the base portion and the concavo-convex pattern portion are integrally formed, if the concavo-convex pattern portion is damaged, it is necessary to replace the entire formwork. Further, the ceramic material has a problem that it is difficult to form a complicated uneven pattern. Therefore, an object of the present invention is to provide a method of manufacturing a patterned ALC using a mold that does not cause these problems.

[0005]

According to a first aspect of the present invention, there is provided a method of manufacturing a patterned ALC plate, comprising forming a concave-convex pattern on the surface by casting iron or a heat-resistant resin resistant to autoclave curing. The template is placed on the bottom of the mold so that its pattern surface is on the top, foamable mortar is injected into the mold and foamed, and the mortar molded body is autoclaved together with the mold. It is characterized by the following.

As described above, when a template having an uneven pattern formed on the surface thereof by casting iron or a heat-resistant resin resistant to autoclave curing is used as a pattern forming portion,
Even if the mortar molded body is autoclaved and the thermal expansion and shrinkage of the mold are repeated, the life of the mold can be prolonged without cracks or the like occurring in the uneven pattern of the mold plate. Further, since the formation portion of the uneven pattern is separable from the mold body, if the mold plate is damaged, only the mold plate needs to be replaced. Further, since the mold is formed by casting of iron or a heat-resistant resin capable of withstanding autoclave curing, complicated fine irregularities and deeply carved patterns can be formed on the surface thereof with high precision.

The invention described in claim 2 is a preferred embodiment of the above method, wherein the linear expansion coefficient of the mold plate is substantially the same as or close to the linear expansion coefficient when the mortar molding is cured. It is a feature. With such a configuration, a large shearing force is not generated between the mortar molded body surface and the mold plate surface during curing in the autoclave curing, so that it is possible to suppress the occurrence of cracks and the like in the pattern forming portion of the mortar molded body. The invention according to claim 3 is a preferred embodiment of the above method, wherein a plurality of divided templates are arranged at the bottom of the mold. With this configuration, the template can be made more easily. Further, the invention according to claim 4 is a template used for the mold of the above method, wherein an irregular pattern is formed on the surface by casting and casting a heat-resistant resin that can withstand autoclave curing. Is what you do.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of a mold used in the method of the present invention. The mold 1 comprises a base 2 having a flat upper surface and side portions 3 arranged around the base 2.
Is arranged. In addition, the side part 3 which comprises one side of a longitudinal direction
Is set by sliding on the base 2 in accordance with the length of the ALC plate to be manufactured.

The template 4 is formed by connecting template pieces 5 obtained by dividing the entire pattern into a plurality of portions. FIG. 2 is a longitudinal cross-sectional view showing a connection portion of each template piece 5 in a partially enlarged manner. A connection pin 6 is provided on a side edge of one template piece 5 to be connected, and the other mold piece is connected. Pin holes 7 are provided in the side edges of the plate pieces 5 correspondingly, and the adjacent mold plate pieces 5 are connected to each other by inserting or fitting the connecting pins 6 into the pin holes 7. It should be noted that the directions perpendicular to the illustration may be similarly connected.

[0010] By forming the template 4 in a divided shape as described above, its manufacture is facilitated, and its weight is reduced and handling is facilitated. It is preferable that the width and length dimensions of these template pieces 5 be values obtained by dividing the module dimensions of the ALC board or one integral number thereof. Also, by connecting the template pieces 5 with the connecting pins 6 and the like, it becomes easier to separate the ALC plate from the template. However, it is of course possible to use an integrally formed template 4.

The base 2 and sides 3 of the formwork 1 can be made of commonly used materials, such as steel or cast iron.
The template 4 is made by casting iron or a heat-resistant resin resistant to autoclave curing. A template formed by casting iron, that is, a template made of cast iron, can be produced by, for example, casting molten iron into a sand mold having a pattern formed thereon. As the heat-resistant resin that can withstand the temperature of the autoclave curing (usually about 180 ° C.), for example, a thermosetting resin such as a phenol resin, or a material in which a reinforcing material such as glass fiber is mixed therein can be used. It can be made by compression molding the material with a press die having it.

Foamable mortar is usually prepared by adding water and aluminum powder as a foaming agent to raw materials such as cement, silica stone and gypsum, and then kneading the mortar. The body is 10 kg / cm ² , 1
In the autoclave curing performed in a steam atmosphere at about 80 ° C., when it is cured, it thermally expands with a linear expansion coefficient of about 5 to 9 × 10 ⁻⁹ (/ ° C.). Here, the coefficient of linear expansion refers to a rate of change in length due to a change in temperature of a material, and is expressed by (length after expansion−
It can be calculated by (length before expansion) / (length before expansion × difference in temperature change). The coefficient of linear expansion of the mortar molded article during curing can be changed by changing the mortar composition, and the value is measured by heating the ALC plate after autoclaving and measuring the temperature and the change in length due to thermal expansion. Required by

Since an irregular pattern is formed on the template 4, if the coefficient of linear expansion of the mortar molded body and the template 4 during curing in autoclave curing are significantly different, shear stress and the like generated between the two will increase. As a result, cracks and the like easily occur in the pattern portion of the mortar molded body. Therefore, it is preferable to use a material having a thermal expansion coefficient close to the thermal expansion coefficient of the mortar molded body as the template 4. Here, the coefficient of thermal expansion close to the coefficient of thermal expansion of the mortar molded body, when expressed by the coefficient of linear expansion, is 0.5 to 2.0 of the coefficient of linear expansion of the mortar molded body.
The linear expansion coefficient is in the range of about twice, preferably about 0.8 to 1.5 times. The linear expansion coefficient of cast iron is usually 10 × 10 ^{-6 to} 12
It is about ^10-6 (/ ° C), and this value is a linear expansion coefficient of 5 × ^{10-6 to} 9 × 10 at the time of curing the above-mentioned mortar molding.
Since it is close to the range of ^-6 (/ ° C.), the material of the template 4 is also preferable from this point. The linear expansion coefficient of the phenol resin is usually about 10 × 10 ^{−6 to} 20 × 10 ⁻⁶ (/ ° C.), and it can be used similarly.

Next, a method of manufacturing a patterned ALC plate using the above-described mold will be described with reference to the process chart of FIG. First, as shown in step (a), a mold 1 composed of a base 2 and side portions 3 is prepared, and a mold plate 4 having an uneven pattern formed on the surface thereof is placed on the bottom of the mold 1 so that the pattern surface faces upward. That is, it is arranged on the base 2. Next, as shown in step (b), a release agent 8 is applied to the surface of the template 4, and then, as shown in step (c), the reinforcing cage 9 to be embedded in the ALC is set in the mold 1.

Next, as shown in step (d), foamable mortar 10 is injected into the mold 1, and when it is in a semi-cured state, the side portions 3 are removed as in step (e). 1
1 is cut horizontally with a piano wire 12. Next, as shown in (f), the mortar molded body 11 is put into the autoclave 13 together with the base 2 (and the template 4 thereon) and steam-cured. Then, the ALC plate hardened by the steam curing is separated from the template 4 on the base 2, and the remaining template 4 is cleaned and returned to the step (a) again.

[0016]

EXAMPLE A patterned ALC plate was manufactured according to the process chart of FIG. First, the plane area is 1800 mm in width and 450 in length.
On a base 2 in a mold 1 having a width of 0 mm, a width of 300 mm, a length of 300 mm, a thickness of 25 mm and a linear expansion coefficient of 11 × 10
^-6 (/ ° C) cast iron template pieces 5 having an uneven pattern formed on their surfaces were connected to each other while being laid down in a width of 6 columns and a length of 15 rows (a total of 90 pieces). The uneven pattern has a depth of 16 mm and a width of 3
A groove of 0 mm is formed at a pitch of 30 mm in length and width. Next, the reinforcing steel cage 9 is set in the mold 1 and the coefficient of linear expansion during curing in autoclave curing is 7 × 10 ^−6.
(/ ° C.) foamable mortar 10 was injected into the mold 1.

When the mortar molded body 11 is in a semi-cured state, the side portions 3 are removed, the upper part of the mortar molded body 11 is cut with a piano wire, and then 10 kg / cm ² G, 18
Steam curing was performed in an autoclave at 0 ° C. AL obtained
A good uneven pattern without cracks was formed on the surface of the C plate. Autoclave curing of the same template 4 was repeated 1000 times, but no cracks or the like were generated.

[0018]

As described above, in the method for producing a patterned ALC plate of the present invention, a template having a concave and convex pattern formed on its surface by casting and molding iron or a heat-resistant resin resistant to autoclave curing is used as a pattern forming portion. Therefore, even if the mortar molded body is autoclaved and the thermal expansion and contraction are repeated for each of the mold frames, cracks and the like are not generated in the uneven pattern of the mold plate, and the life can be extended. In addition, since the formation portion of the uneven pattern is separable from the mold body, if the mold plate is damaged, only the mold plate can be replaced. Further, since the mold plate is formed by casting of iron or a heat-resistant resin that can withstand autoclaving, complicated and fine uneven patterns can be accurately formed on the surface thereof.

In the above, when the linear expansion coefficient of the mold plate is set to be substantially the same as or close to the linear expansion coefficient at the time of curing of the mortar molded body, when the mortar molded body is cured in the autoclave curing. In addition, it is possible to avoid generating a large shearing force between the surface of the mortar molded body and the surface of the template, thereby suppressing the occurrence of cracks or the like in the pattern formed on the mortar molded body. Further, in the above, the template can be divided into a plurality of template pieces so that the entire pattern is divided into a plurality of pieces, and it can be arranged at the bottom of the mold. Can be made more easily, the weight can be reduced, and the handling becomes easier.

[Brief description of the drawings]

FIG. 1 is a perspective view of a mold used in the method of the present invention.

FIG. 2 is a longitudinal sectional view showing a connection part of each template plate piece 5 of FIG. 1 in a partially enlarged manner.

FIG. 3 is a process chart showing a method for producing a patterned ALC plate of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Form frame 2 Base 3 Side part 4 Mold plate 5 Mold plate piece 6 Connecting pin 7 Pin hole 8 Release agent 9 Reinforcement cage 10 Foamable mortar 11 Mortar molded body 12 Piano wire 13 Autoclave

Claims (4)

[Claims] 1. A mold plate 4 having an uneven pattern formed on its surface by casting iron or a heat-resistant resin resistant to autoclave curing, is disposed on the bottom of the mold frame 1 so that the pattern surface faces upward. A patterned AL characterized in that a foamable mortar 10 is injected into a mold 1 and foam-molded, and the mortar molded body 11 is autoclaved together with the mold 1.
Manufacturing method of C plate. 2. The mortar molding 11 having a linear expansion coefficient of the mold plate 4
The method for producing a patterned ALC plate according to claim 1, which has a value that is substantially the same as or near the linear expansion coefficient at the time of curing. 3. A template 4 formed by a plurality of divided template pieces 5.
The method of manufacturing a patterned ALC plate according to claim 1 or 2, wherein the plurality of template pieces (5) are arranged at the bottom of the mold (1). 4. A template used in the method according to claim 1, wherein an irregular pattern is formed on a surface of the template by casting an iron or a heat-resistant resin resistant to autoclave curing.