JPH1086117A - Manufacture of inorganic cement plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reduce variations in the size of an inorganic cement plate and further reduce the positional deviation of a recess and protrusion pattern to be imparted onto the surface of the inorganic cement plate. SOLUTION: An FRP molded plate 1 having a recess and protrusion pattern on its surface is disposed on the bottom of a formwork 3 surrounding the circumference of a shaping space, and an aqueous slurry 4 of an inorganic material, in which cement is used as a binder, is injected into this shaping space. The aqueous slurry is press-molded while removing excess water, and a green sheet 6 is produced on the FRP molded plate 1. In the manufacture of the inorganic cement plate, which is released from the formwork after curing the green sheet 6 under the condition that it is placed on the FRP molded plate 1, an ALC plate 2 is integrally joined to the rear face of the FRP molded plate 1.

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 an inorganic cement board, and more particularly, to forming a green sheet on an FRP mold plate having an uneven pattern on its surface, imparting the uneven pattern, and further curing the green sheet. The present invention relates to a method for producing an inorganic cement board.

[0002]

2. Description of the Related Art Conventionally, as one of the methods for manufacturing an inorganic cement board used for a ceramic tile or an exterior material, an uneven pattern is formed on the bottom of a formwork surrounding a shaping space. An FRP forming mold plate is disposed, and an aqueous slurry of an inorganic material using cement as a binder is poured into the shaping space, and press-formed while removing excess water to form the FRP.
There is a method in which a green sheet is prepared on an RP forming template, the green sheet is cured while being placed on the FRP forming template, and then the mold is released.

[0003]

In recent years, various types of appearance patterns have been used for ceramic-based inorganic cement boards, and the design required for them has been increasing. For example, an exterior material used for an outer wall surface of a building or the like is increasingly provided with a concavo-convex pattern having joints such as a brick tone or a tile tone. In the case of an exterior material having such a concavo-convex pattern, it is desirable in terms of appearance that the joint of the concavo-convex pattern does not shift between adjacent exterior materials when applied to a wall surface or the like. Therefore, it is desirable that the entire inorganic cement plate is accurately formed to a predetermined size in the manufacturing process of the inorganic cement plate and that the uneven pattern is accurately applied to the surface thereof without causing a deviation.

However, in the case of manufacturing an inorganic cement board by the above-mentioned method, the FRP mold plate is thermally deformed due to a temperature change, particularly a temperature rise in a curing process, and the size thereof is further increased. The green sheet cured in the state of being placed on the sheet also changes its dimensions and hardens. Therefore, there has been a problem that the inorganic cement plate is dimensionally changed and the uneven pattern provided on the surface is misaligned.

The present invention has been made in view of the above circumstances, and provides a method of manufacturing an inorganic cement board capable of reducing a dimensional change and a positional shift of an uneven pattern provided on a surface. It is.

[0006]

Means for Solving the Problems In order to solve the above-mentioned problems, a method of manufacturing an inorganic cement board according to the present invention provides a method of manufacturing an inorganic cement board, comprising:
A P-forming mold plate is arranged, an aqueous slurry of an inorganic material using cement as a binder is poured into the shaping space, and press-molding the slurry while removing excess water to form a green sheet on the FRP forming mold plate. In the method for producing an inorganic cement board, which is prepared and cured while the green sheet is placed on the FRP mold, the FRP is removed.
An ALC plate is joined to and integrated with the back surface of the molding die plate.

In this method of manufacturing an inorganic cement board, an ALC board is joined and integrated on the back surface of the FRP forming board, so that the ALC board functions to suppress thermal deformation of the FRP forming board. Therefore, when the green sheet produced on the FRP forming template is cured while being placed on the FRP forming template, the thermal deformation of the FRP forming template is suppressed and the thermal deformation of the FRP forming template is accompanied by the thermal deformation of the FRP forming template. As a result, the deformation of the green sheet which is deformed due to the deformation of the green sheet is suppressed, and as a result, the dimensional change of the inorganic cement plate, which is a cured body of the green sheet, and the deviation of the uneven pattern are reduced.

[0008] A method of manufacturing an inorganic cement board according to a second aspect is the method of manufacturing an inorganic cement board according to the first aspect, wherein a plurality of green sheets are stacked on the FRP forming template and cured. It is characterized by doing.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.

[0010] In the method for producing an inorganic cement board of the present invention, an FRP mold board having an uneven pattern on its surface is arranged at the bottom of a mold frame surrounding the shaping space, and cement is placed in the shaping space. Inject an aqueous slurry of an inorganic material as a binder, press-mold this while removing excess water to produce a green sheet on the FRP molding template,
The green sheet is cured while being placed on the FRP forming template, and then removed from the mold to produce an inorganic cement plate. An ALC plate is integrally joined to the back surface of the FRP forming template. It is something that has been.

[0011] The formwork has a shaping space that opens upward inside the formwork. The shape of the mold is not particularly limited,
It is formed according to the shape of the intended inorganic cement plate, and for example, when manufacturing an exterior material, etc., usually, the opening shape of the shaping space is a cylindrical shape or a bottomed box shape having a rectangular opening shape. The formed one is used.

The FRP mold plate is used by being arranged at the bottom of the shaping space inside the mold, and is formed into a shape that just fits in the bottom of the shaping space.
The matrix resin used for the FRP forming the FRP mold plate is not particularly limited, and a resin system generally used can be used. Preferably, a resin system having excellent durability is selected. This is preferable, and for example, a polyester resin can be used. Further, the reinforcing fiber used in the FRP is not particularly limited, for example, nylon fiber, polyester fiber,
Organic fibers such as pulp, glass fibers, inorganic fibers such as asbestos, and metal fibers can be used. The reinforcing fibers may be dispersed in the raw material mixture, or formed into a mesh and backed during resin molding. Further, the FRP may contain a filler or the like.

As the above-mentioned FRP mold plate, a plate in which an ALC plate is previously joined and integrated on the back surface is used. This A
The joining means of the LC plate is not particularly limited, and for example, can be bonded to the back surface of the FRP mold plate using an adhesive or the like. It is preferable that the ALC plate has a size substantially equal to that of the FRP mold plate so that the ALC plate can be stuck to the entire back surface thereof. You can also.

The inorganic material used in the method for producing the inorganic cement board is not particularly limited, and the composition of the inorganic cement board can be appropriately changed depending on the intended use. Is used in which an aggregate, a reinforcing fiber and the like are mixed with cement.
In this case, the cement used is not particularly limited, and generally used cements such as Portland cement and blast furnace cement can be used. The aggregate is not particularly limited and may be selected according to the intended use of the inorganic cement board. For example, generally used mineral aggregates, inorganic aggregates, and organic aggregates Aggregate can be used, and specifically, silica powder,
Examples include silica sand, silica, gravel, fly ash, perlite, vermiculite, glass balloons, shirasu balloons, and the like. Further, as the reinforcing fiber material, for example, generally used organic fibers, inorganic fibers, metal fibers, and the like can be used, and specific examples thereof include pulp, cotton, hemp, vinylon, and asbestos.

An aqueous slurry can be prepared by charging the above-mentioned inorganic material into water and mixing and dispersing the same. The solid content concentration of the aqueous slurry is not particularly limited, and can be appropriately adjusted to a concentration that facilitates handling.

In the method for manufacturing an inorganic cement board, an inorganic cement board is manufactured, for example, as shown in FIG. That is, first, as shown in FIG. 1 (a), an FRP molding template 1 in which an ALC plate 2 is integrally joined to a back surface with an uneven pattern facing upward is arranged at the bottom of a shaping space of a mold frame 3, and a mold is formed. An aqueous slurry 4 of an inorganic material is poured into the shaping space of the frame 3. The amount of the aqueous slurry 4 to be poured at this time is determined by the solid content concentration of the aqueous slurry 4 and the thickness of the target inorganic cement plate. Next, as shown in FIG.
The excess water is dewatered by a suction press 5 having a drainage hole 5a from above the aqueous slurry 4 in the shaping space, and compression-molded to a predetermined thickness while dewatering, thereby producing a green sheet 6.

Then, as shown in FIG. 1 (c), the green sheet 6 is taken out of the mold frame 3 while being placed on the FRP forming mold plate 1, and a plurality of these sheets are laminated. It is introduced and cured by heating. By curing a plurality of layers in this manner, the production efficiency is improved. In this curing step, the green sheet 6 is cured to have a solidified shape. At this time, the FRP mold plate 1 is in a state of being easily thermally deformed by heating, but the ALC plate 2 joined and integrated on the back surface suppresses this thermal deformation, so that the predetermined shape is maintained.
The deformation of the green sheet 6 and the uneven pattern imparted to the surface thereof, which are affected by the deformation of the P-molding plate 1, are also prevented, and the green sheet 6 is cured as an external dimension of a predetermined size and an uneven pattern aimed at. Can be done.

Further, in the method for producing the inorganic cement plate, ALC used as a reinforcing plate of the FRP forming template 1 is used.
The plate 2 is less likely to thermally expand than a metal plate such as an iron plate, and has an excellent effect of suppressing a dimensional change, and is relatively lightweight, so that it is easy to carry. Further A
Since the LC plate 2 has excellent heat insulating properties, FIG.
When the green sheet 4 is cured in a laminated state as in (c), the cured laminate of the inorganic cement plate can be gradually cooled as a whole when cooling after curing. The temperature distribution generated between the peripheral portion and the central portion of the inorganic cement plate with cooling can be small, which is effective in preventing cracks and the like.
In other words, the inorganic cement board with residual heat after curing is
This is because when the temperature is rapidly cooled or a temperature distribution is generated in the plate and the temperature difference is increased, cracks are easily generated.

In the method for manufacturing an inorganic cement board, a curing step in which the green sheet is placed on the FRP forming template as primary curing and then a secondary curing step of removing the green sheet from the FRP forming template is provided. It does not matter. That is, since the inorganic cement plate is easily deformed in the initial stage where the soft green sheet starts to harden, the shape at this stage is determined by primary curing to determine the shape of the inorganic cement plate to a predetermined shape. This is because curing can be further promoted under further severe conditions, such as steam curing or autoclave curing, in the next curing. In this case, the FRP that was not possible with the primary curing in the secondary curing
Curing at a high temperature equal to or higher than the heat resistance temperature of the molding plate becomes possible.

[0020]

The present invention will be described below in more detail with reference to Examples.

Example 1 A rectangular cylindrical form having an imprinting space with an opening size of 900 mm × 1800 mm inside, and an epoxy acrylate resin as a matrix resin (Rigolac G-20T, manufactured by Showa Polymer Co., Ltd.) ), And an FRP mold plate made of FRP containing reinforcing fibers and having an uneven pattern for transfer on the upper surface was prepared. An ALC plate (containing a mesh reinforcing material) was joined and integrated on the back surface of the FRP mold plate with an epoxy adhesive. Incidentally, the linear expansion coefficient of this FRP mold plate was 16.5 × 10 ^-6 in a state where the ALC plate was integrated. Then, after placing the above-described FRP molding template at the bottom of the shaping space of the above-mentioned mold with the uneven pattern facing upward, 30% by weight of cement, 40% by weight of silica stone, 10% by weight of pearlite, and 10% by weight of N-ukp pulp % Of an inorganic material (solid content concentration: 25% by weight) is poured into the shaping space of the above-described mold, and the excess water is dewatered by a suction press 5 from above, at a pressure of 40 MPa. Compression molding was performed to obtain a 15 mm thick green sheet. Further, the green sheet is taken out from the shaping space of the mold while being placed on the FRP mold plate, and a plurality of these sheets are laminated as primary curing in a curing room at 80 ° C. for 10 hours. did.
After curing, the inorganic cement boards which were hardened in a state of being laminated in a plurality were naturally cooled to room temperature and removed from the mold. At this time, the longitudinal dimension of the green sheet on the FRP forming template before the curing was measured, and the longitudinal dimension of the cured inorganic cement board in which the green sheet was cured was measured in the same manner. did. Before and after this curing, the dimensional change in the longitudinal direction of the inorganic cement plate was 2 mm, and the deviation of the joint grooves of the uneven pattern on the surface was 1 m at the maximum.
m. In addition, as a result of measuring the temperatures of the outer peripheral portion and the central portion of the inorganic cement plate in the cooling process after curing, the temperature difference was at most 20 ° C. Furthermore, 175 ° C-
An inorganic cement plate was further cured by autoclaving for 10 hours to accelerate the curing.

(Comparative Example 1) Except that the above-mentioned FRP mold plate was used alone without joining an ALC plate to the back surface thereof,
An inorganic cement board was obtained in the same manner as in the first embodiment. Incidentally, the linear expansion coefficient of this FRP mold plate alone is 50.2 × 1
It was 0 ^-6 . At this time, similarly to Example 1, the dimensional change of the inorganic cement plate was measured, and the temperature difference between the outer peripheral portion and the central portion of the inorganic cement plate during the cooling process after the primary curing was measured. In this case, the dimensional change of the inorganic cement plate was 5 mm before and after curing, and the maximum temperature difference between the outer peripheral portion and the central portion of the inorganic cement plate in the cooling process after curing was 50 ° C.

Discussion of the results When Example 1 and Comparative Example 1 were compared, in Example 1, the linear expansion coefficient of the FRP mold plate was reduced to 1/3 of that of Comparative Example 1, The dimensional change of the cement board and the displacement of the joint groove of the uneven pattern are also reduced. Therefore, in Example 1, the thermal deformation of the FRP forming template was suppressed in the primary curing process in which the green sheet having been formed and provided with the concavo-convex pattern was placed on the FRP forming template, thereby suppressing the thermal deformation of the inorganic cement. It can be said that the dimensional deformation of the plate was also reduced. Further, in Example 1, the temperature difference between the outer peripheral portion and the central portion of the inorganic cement plate in the cooling process after curing was smaller than that in Comparative Example 1, and the temperature distribution in the plate was improved. I have. This is AL
It is presumed that the laminate of the inorganic cement plate was gradually cooled as a whole due to the heat insulating property of the C plate, and that only the outer peripheral portion was prevented from being rapidly cooled.
As described above, since the temperature distribution in the board during the cooling process of the cured inorganic cement board is improved, cracks and the like generated by distortion caused by the temperature distribution in the board are prevented.

[0024]

As described above, as described above, the FRP of the present invention
According to the manufacturing method of the forming mold, it is possible to reduce the dimensional change of the inorganic cement board and the deviation of the uneven pattern.

[Brief description of the drawings]

FIGS. 1 (a), 1 (b), and 1 (c) are schematic explanatory views sequentially showing manufacturing steps of a method for manufacturing an inorganic cement board according to an embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 FRP forming template 2 ALC board 3 Mold 4 Aqueous slurry 5 Suction press 6 Green sheet

Claims (2)

[Claims] 1. An FRP forming template having an uneven pattern on its surface is arranged at the bottom of a mold frame surrounding the periphery of a shaping space, and an aqueous slurry of an inorganic material using cement as a binder is injected into the shaping space. This was press-molded while removing excess water to produce a green sheet on the FRP forming template, and the green sheet was cured with the green sheet placed on the FRP forming template. A method for manufacturing a cement board, wherein an ALC board is joined and integrated to the back surface of the FRP mold plate. 2. The method for producing an inorganic cement board according to claim 1, wherein a plurality of green sheets are stacked on the FRP forming template and cured.