JPH1170531A - Wall panel and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the generation of defective appearance and to minimize the effect by the generation of gas or the like by providing an absorbing material on the rear face of an outer wall material formed from an inorg. material prepared by mixing a reactive inorg. powder, an alkali metal silicate and water by integral molding. SOLUTION: An outer wall material 1 is produced from an inorg. foamable material formed by mixing a reactive inorg. powder, an alkali metal silicate, water and a foaming agent. This inorg. foamable material is used to be integrally molded to form a wall panel. In this manufacturing method, at first, the raw materials are mixed by a mixer to form the inorg. foamable material. When a decorative surface is formed on an upper side, paper is preliminarily put in a mold as an absorbing material 2. When the decorative surface is formed on a lower side, the absorbing material 2 is added to the lid later placed on the inorg. foamable material. The absorbing material 2 is not limited to paper and a moisture absorbing material such as cloth or a polymeric absorbent may be used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a lightweight and durable wall panel and a method for manufacturing the same.

[0002]

2. Description of the Related Art The following are examples of lightweight and durable wall panels. That is, this wall panel uses an inorganic foaming material generated by mixing a reactive inorganic powder, an alkali metal silicate, water and a foaming agent. Since the inorganic foamable material has thermosetting properties, the inorganic foamable material is processed by integral molding to produce the outer wall material of the wall panel. Such an outer wall material is disclosed in JP-A-59-116163.

[0003] According to the outer wall material of the wall panel, since a large number of air bubbles are formed inside by foaming of the foaming agent, the weight of the outer wall material can be reduced. In addition, since the reactive inorganic powder is used as a base, the durability of the outer wall material can be improved.

[0004]

However, the above-described wall panel has the following problems. That is, the outer wall material of the wall panel is produced by integral molding. However, after the integral molding, unreacted components may remain inside the outer wall material. In such a case, the unreacted components are dissolved by the moisture contained in the outer wall material, and spots due to the dissolved components and recrystallization of the dissolved components occur on the surface of the outer wall material. As a result, there is a problem that appearance defects of the outer wall material occur.

[0005] The amount of the foaming agent is determined by the amount of the foaming agent,
It is easily influenced by temperature and the like, and the generated gas pressure may exceed the assumed pressure. For this reason, it is necessary to make the strength of the mold defining the shape of the outer wall material excessively strong.

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above-mentioned problems, to prevent the occurrence of poor appearance, and to obtain a stable molded article of an inorganic material while minimizing the influence of the generation of gas and the like. It is an object of the present invention to provide a wall panel and a method of manufacturing the same.

[0007]

In order to achieve the object, according to the first aspect of the present invention, an inorganic material formed by mixing a reactive inorganic powder, an alkali metal silicate and water is formed by integral molding. It is characterized by a wall panel including an outer wall material and an absorbing material provided on the back surface of the outer wall material.

[0008] In the first aspect of the present invention, the absorbing material absorbs moisture and gas in the inorganic material to reduce the increase in pressure. For this reason, it is possible to prevent appearance defects and to minimize the influence of gas generation, thereby obtaining a stable molded product of an inorganic material.

[0009] According to a second aspect of the invention, the reactive inorganic powder is a SiO ₂ -Al ₂ O ₃ -based powder, SiO ₂ -
Al ₂ O ₃ system powder is 100 parts by weight, the alkali metal silicate is 0.2 to 450 parts by weight, the water is characterized by the wall panel of claim 1 wherein is incorporated in from 35 to 1500 parts by weight.

According to the third aspect of the present invention, since the absorbing material for absorbing moisture in the inorganic material is provided on the back surface of the outer wall material, even if unreacted components are present inside the outer wall material, the unreacted components are not removed. The water in which the reaction components are dissolved is absorbed by the absorbent.

According to a fourth aspect of the present invention, in the wall panel according to any one of the first to third aspects, the absorbing material comprises a foam sheet for absorbing a pressure in a molding die. It is characterized by.

[0012] According to the fourth aspect of the present invention, the foam sheet is compressed to absorb the pressure in the molding die.

According to the fifth aspect of the present invention,
The wall according to any one of claims 1 to 4, wherein the absorbing material is made of an inorganic foamed hardened material having open cells that absorb excess gas generated from the foaming agent and that are connected to the outside and discharged. Features a panel.

According to the fifth aspect of the present invention, the open cells of the inorganic foamed cured product absorb excess gas generated from the blowing agent and discharge the excess gas to the outside. For this reason, there is no possibility that the generated gas pressure exceeds the assumed pressure, and it is not necessary to make the strength of the molding die excessively strong.

According to a sixth aspect of the present invention, in the wall panel according to any one of the first to fourth aspects of the present invention, the absorber has a substantially elongated shape and is arranged in a plurality. It is characterized by.

According to the sixth aspect of the present invention, a plurality of substantially elongated absorbers are arranged in the hardened inorganic material even after the mold is released. For this reason, the back surface side of the inorganic material constituting the outer wall material is sandwiched by the absorber to form a rib and to be reinforced.

According to the seventh aspect of the present invention,
The absorbent is placed in a molding die, and the inorganic material produced by mixing the reactive inorganic powder, the alkali metal silicate and water is poured into the molding die, and the inorganic material in the molding die is mixed with the inorganic material.
The method is characterized by a method of manufacturing a wall panel that is adjusted to a temperature of 0 ° C. or less.

[0018] According to the present invention, the absorbent is disposed in a molding die, and the inorganic material formed by mixing the reactive inorganic powder, the alkali metal silicate and the water is molded. By pouring into a mold for molding and adjusting the temperature of the inorganic material in the mold for molding to a temperature of 40 ° C. or less, foaming occurs appropriately, moisture and gas are absorbed, and the wall panel is formed relatively easily. Is done.

According to another aspect of the present invention, there is provided a molding die for substantially closing a gas generated from a foaming agent mixed in the inorganic curable material, wherein the inorganic curing material is provided in the molding die. In the method for producing a wall panel for producing an inorganic foam by heating and foaming a curable material, a partial pressure of a gas generated from the foaming agent on the theoretical calculation, and steam at a temperature reached by heating the inorganic curable material It features a method of manufacturing a wall panel that includes the step of back-calculating the amount of blowing agent such that the sum of the pressure does not exceed the design pressure of the mold.

According to the present invention, the amount of the foaming agent to be mixed in advance is determined by the step of back-calculating the amount of the foaming agent so as not to exceed the design pressure of the mold. Since the inorganic curable material and the foaming agent are charged into the mold, when the inorganic curable material is heated and foamed, the amounts of gas and water vapor generated by foaming can be assumed substantially uniquely.

Therefore, for example, by appropriately adjusting the amount of water to be absorbed by the absorbing material, it is possible to prevent the appearance defect from occurring, and to minimize the influence of the generation of gas and the like, thereby stably forming the inorganic material. Goods can be obtained.

[0022]

Next, an embodiment of the present invention will be described.
This will be described with reference to the drawings.

[Embodiment 1] Embodiment 1 of the present invention
1 is shown in FIG. This wall panel includes an outer wall material 1 and an absorber 2.

The outer wall material 1 is made of an inorganic foaming material formed by mixing a reactive inorganic powder, an alkali metal silicate, water and a foaming agent.

As the reactive inorganic powder of the inorganic foamable material, for example, cements, fluorides, acidic metal oxides,
There are divalent or higher-valent metal salts of higher fatty acids, divalent or higher-valent metal salts of water-soluble polymers having a carboxyl group, divalent metal sulfates, and divalent metal sulfites. In particular, as the reactive inorganic _powder, SiO 2 -Al ₂ O ₃ system powder are preferred.

As the SiO ₂ —Al ₂ O ₃ powder,
SiO ₂ 10 to 90% by weight, Al ₂ O ₃ 90 to 10% by weight
Those having the following composition are preferred. This SiO ₂ -Al ₂ O
_{The 3} type powder is composed of SiO ₂ and Al ₂ O ₃ by synthesis.
Although 0% by weight is obtained, generally readily available ones contain about 5% impurities. Such materials include, for example, fly ash, corundum, ash of an electrostatic precipitator generated during the production of mullite, metakaolin, pulverized and fired bauxite, and the like. It is not something to be done.

The alkali metal silicate as the inorganic foamable material is represented by the following general formula.

M ₂ O.nSiO _{2 In} the formula, M represents at least one selected from the group consisting of Li, K and Na, and n represents a positive rational number. Among them, those having n of 0.05 to 8 are preferable. When n is less than 0.05, the strength of the obtained inorganic foamed cured product decreases, and when n exceeds 8, the viscosity of the alkali metal silicate aqueous solution increases, and the mixing with the reactive inorganic powder becomes difficult. It becomes difficult. More preferably, n is 0.5 to
2.5.

The addition amount of the alkali metal silicate is preferably 0.2 to 450 parts by weight based on 100 parts by weight of the reactive inorganic powder. If the amount is less than 0.2 part by weight, the amount of the alkali required for the reaction is too small, resulting in poor curing.
If the amount is more than 10 parts by weight, a problem occurs in the water resistance of the obtained inorganic foamed cured product. More preferably, it is 10 to 350 parts by weight, and still more preferably 20 to 250 parts by weight.

Preferably, the alkali metal silicate is added as an aqueous solution. The concentration of the aqueous alkali metal silicate solution is preferably from 10 to 60% by weight. When the content is less than 10% by weight, the reactivity with the reactive inorganic powder is reduced, and when it exceeds 60% by weight, a solid content is easily generated. Alkali metal silicate aqueous solution, alkali metal silicate,
It can be prepared by dissolving in water under pressure and heating, and pressurizing the aqueous solution of alkali metal hydroxide with SiO ₂ component such as silica sand and silica powder so that n becomes a predetermined amount. Can be prepared by dissolving under heating.

The water of the inorganic foaming material may be added as an aqueous alkali metal silicate solution, may be added independently, or may be used in combination.
The addition amount of water is preferably 35 to 1500 parts by weight based on 100 parts by weight of the reactive inorganic powder. If the amount is less than 35 parts by weight, the obtained inorganic foamable material will not be sufficiently cured, and mixing will be difficult. If it exceeds 1500 parts by weight, the strength of the obtained inorganic foamed cured product will decrease. More preferably 45 to 1000 parts by weight, even more preferably 50 to 1000 parts by weight.
５００500 parts by weight.

As the foaming agent for the inorganic foamable material, for example, Mg, Ca, Cr, Mn, Fe, Co, Ni, C
Metal foaming agents such as u, Zn, Al, Ga, Sn, Si, and ferrosilicon, and peroxides such as hydrogen peroxide, sodium peroxide, potassium peroxide, sodium perborate, and the like. Among these, aluminum foaming agents and hydrogen peroxide are preferred from the viewpoints of cost, safety, availability, ease of mixing, and the like. Further, from the viewpoint of easy control of the foaming speed, Si,
Ferrosilicon is preferred.

When a metal foaming agent is used as the foaming agent, it is preferable to disperse and mix in an appropriate amount of water. Further, a thickener, an emulsifier and the like may be mixed for dispersion stabilization. The amount of the foaming agent to be added can be appropriately determined according to the density of the target inorganic foamed cured product. Further, if necessary, a surfactant may be added to make the air bubbles fine.

Further, a filler, a reinforcing fiber, a foaming aid and the like may be added as required. In this case, it is preferable to add the reactive inorganic powder before mixing with a mixer or the like.

As the filler to be added, for example, silica sand,
Examples include porous powders such as silica powder, fly ash, slag, silica fume, mica, talc, wollastonite, calcium carbonate, aerosil, silica gel, zeolite, activated carbon, and alumina gel.

The reinforcing fibers to be added include, for example, vinylon, polypropylene, aramid, acryl, rayon, carbon, glass, potassium titanate, alumina,
Examples include steel and slag wool.

Examples of the foaming assistant to be added include porous powders such as silica gel, zeolite, activated carbon and alumina gel; metal stearate such as zinc stearate, calcium stearate and aluminum stearate; sodium oleate and olein Metal oleate such as potassium silicate; metal palmitate such as sodium palmitate and potassium palmitate; surfactants such as sodium laurylbenzenesulfonate and sodium lauryl sulfate;

Using such a raw material, an inorganic foamable material is produced. Further, the inorganic foamable material is integrally molded to form a wall panel. FIG. 2 shows an example of this manufacturing method. In this manufacturing method, the raw materials are mixed by the mixer 101 to generate the inorganic foamable material A. On the other hand, when the decorative surface is on the upper side, paper is previously placed in the mold 102 as the absorbing material 2. When the decorative surface is on the lower side, the absorbent 2 is added to a lid to be placed later on the inorganic foamable material A. The absorbent 2 is not limited to paper, but may be any material that absorbs moisture, such as cloth or a polymer absorbent.

Thereafter, the inorganic foamable material is poured into the mold 102 (FIG. 2A).

When the absorbent is added to the lid, the order of the casting and the addition may be reversed (the casting and then the addition). At this time, the temperature of the inorganic foamable material A is adjusted by cooling as necessary so that the temperature of the paste-like inorganic foamable material A is 40 ° C. or lower. This is because, when the temperature of the inorganic foamable material A exceeds this temperature, foaming occurs quickly even if silicon powder is used as the foaming material. After pouring the inorganic foamable material A into the mold 102, vibration is applied for leveling and defoaming as necessary.

After pouring the inorganic foaming material A, the lid 1
03, the inside of the mold 102 is sealed (FIG. 2 (b)), and the inorganic foamable material A is heated to 40 ° C. or higher ((c) in FIG. 2).

The material before casting is preferably at 20 ° C.
In the following, since the composition temperature at the time of adding the foaming agent to the mixture of the SiO ₂ —Al ₂ O ₃ -based inorganic powder and the alkali metal silicate is maintained at a low temperature, the foaming start time is delayed. Can be done. For this reason, the substrate mold 10
The bubble shape can be maintained in a predetermined shape without foaming until the filling into 2, and a desired appearance quality can be obtained.

Therefore, since foaming hardly occurs, it is more advantageous that the non-foamed material can be prepared and stored in a large amount before the curing reaction of the material occurs. The heating is preferably performed at a temperature of 60 ° C. or more.
After filling, the temperature of the composition is raised to a temperature at which foaming is possible, and foaming is completed in a short time. Therefore, handling in the process is simplified, and the productivity of the inorganic foamed cured product can be improved.

When the temperature of the inorganic foamable material A is set to the above-mentioned temperature, a curing reaction occurs together with the foaming reaction, and a desired outer wall material 1 as an inorganic foamed cured product is obtained. After demolding ((d) in FIG. 2), it is cooled and dried by after-curing ((e) in FIG. 2) to obtain a wall panel of a building. The absorber 2 is attached to the back surface of the outer wall material 1.

The above is the configuration of the wall panel. When the outer wall material 1 of the wall panel is formed by integral molding, unreacted components may remain inside the outer wall material 1. In such a case, the unreacted components are dissolved by the water contained in the outer wall material. At this time, as shown in FIG. 3, moisture existing near the back of the outer wall material 1, that is, moisture in which unreacted components are dissolved is first absorbed by the absorbent 2. In FIG. 3, reference numeral 1 </ b> A is a bubble formed in the outer wall material 1.

The water absorbed at the beginning absorbs the water in the central portion of the outer wall material 1 and the surface 1B of the outer wall material 1.
Moisture in the vicinity also moves toward the back surface. That is, the moisture in the outer wall material 1 moves toward the back surface by the absorbing material 2.

As described above, according to the first embodiment, it is possible to prevent the appearance defect from occurring on the surface 1B.

Further, since the absorbing material 2 is stuck to the back side of the outer wall material 1, the appearance can be prevented with a simple structure and at a low production cost.

Further, since it is only necessary to put the absorber 2 on the mold 102 to attach the absorber 2, the special device is not required, and the appearance defect can be prevented.

[Modification] A modification of the first embodiment differs from the first embodiment in the method of attaching the absorber 2. That is, in the second embodiment, after the outer wall material 1 is formed by integral molding, the absorbing material 2 is attached.

Also in this case, the unreacted components can be absorbed by the absorbing material 2 to prevent appearance defects.

[0052]

Embodiment 2 In Embodiment 2, an inorganic material produced by mixing an aluminosilicate-based reactive inorganic powder, an alkali metal silicate and water is injected into a mold 102 as shown in FIG. . A predetermined decoration 102a is applied to the inner bottom surface of the molding die 102 so that a mold surface treatment in which a pattern such as decoration is transferred to the surface 11a of the outer wall material 11 as a product shown in FIG. It is configured to have a substantially U shape.

A lid 103 is placed on the upper surface of the mold 102. The lid 103 has a foam sheet 1 as an absorbent material on an inner upper surface facing the outer wall material 11 back surface 11b.
04 is attached. This form sheet 104
It has a substantially flat plate shape attached to a substantially central position of the inner upper surface 103a, and has a strength of starting deformation of about 0.1 kg.
A polyethylene foam material of about f / cm ^{2 to} 1.0 kgf / cm ² is used.

[Example 1] Specifically, in the case of a wall panel having a width of 900 mm and a thickness of 18 mm, a foam sheet 104 having a width of 600 mm and a thickness of 6 mm is used. The pulverized metakaolin of the reactive powder is 100 parts by weight of metakaolin and triethanolamine: ethanol = 25: 75 (weight ratio).
Of a mixed solution of 0.5 kwh / k
g of mechanical energy to give 100 parts by weight. Other formulations used the following.

Aqueous solution of alkali metal silicate: 1.4 165 parts by weight of special potassium silicate Filler: 100 parts by weight of wollastonite 100 parts by weight of magnetic separation silica Reinforcing fiber: 2 parts by weight of vinylon Blowing agent: 0.08 parts by weight of metal silicon fine powder Viscosity adjuster: water 10 parts by weight The above-mentioned mixture is kneaded at 20 ° C. or less using the mixer 101 for 5 minutes, and the kneaded mixture 10 is placed in the stainless steel mold 102 having an inner diameter of 280 * 280 * 30 mm.
5 (FIG. 7A).

Next, at this time, when the specific gravity of the compound 105 is 2.0 to 1.0, the charging amount of the blowing agent is 5
In the case of increasing the percentage (44% → 46.2%), the volume after foaming becomes 88% → 92.4%. Furthermore, assuming that the foaming temperature has increased, a foam volume increase of 10% is expected, and 9%.
It is considered that the foam of the kneaded material 105 occupies a volume of 2.4% to 97.02%. Therefore, the foam sheet 104 as the cushioning material is also considered to be a gas, and the volume of the gas is changed from 56% to 62.82%. This is about 1.1
It corresponds to 22 times.

After the casting of the kneaded material 105, the lid 103
The upper edge opening 102b of the mold 102 is closed while being pressed from above with a constant pressure of 0.5 kgf / cm ² (FIG. 7B).

At this time, the gas in the foam sheet 104 attached to the back side of the lid 103 is released from the upper edge opening 10.
It is discharged to the outside of the mold from a gap between the upper end surface of the cover 2b and the outer peripheral edge 103b on the lower surface of the lid 103. For this reason, the foam sheet 104 is compressed to about 75% (12% of the total volume →
3%).

In general, the gas in the kneaded material 105 hardly comes out to the outside. However, in the second embodiment, since the gas in the foam sheet 104 is discharged, the amount of foaming agent is slightly increased, or the temperature is relatively high, and the foaming amount is assumed. Even if the foaming amount is larger than that of the foam sheet 1,
The surplus generated gas is absorbed by the foam sheet 104 and exhausted to the outside. For this reason,
A predetermined concave portion 11a is formed on the back surface side while being kept at an appropriate pressure, and there is no fear that the thickness h1 of the completed outer wall material 11 as a molded product after removal from the mold is increased (FIG. 7 (3)).

Accordingly, as shown by the solid line in FIG. 4, even if the foaming amount is slightly different every time due to the temperature rise for a predetermined short time due to the heat of reaction, the generation of gas or the like occurs. Thus, a molded article of a stable inorganic material can be obtained while minimizing the influence of the above.

The other constructions and operations are substantially the same as those of the first embodiment, so that the description will be omitted.

[Embodiment 2] Embodiment 2 shown in FIGS. 8 and 9
In the case of a wall panel having a width of 900 mm and a thickness of 18 mm, a plurality of foam sheets 204 as a plurality of absorbents having a width of 50 mm and a thickness of 6 mm are arranged inside the lid 203 at predetermined intervals. It is affixed side by side on the upper surface 203a.

For this reason, the outer wall material 21 after removal from the mold has a structure shown in FIG.
As shown in the figure, a plurality of recesses 21c,
Are sandwiched between the ribs 21c are formed substantially parallel.

As described above, the rib portions 21d formed on the back surface 21b of the outer wall member 21 can improve the strength such as torsion resistance as shown in FIG. For example, in the case of a wall panel having a width of 900 mm and a thickness of 18 mm, the concave portion 2 having a substantially long shape having a width of 50 mm and a thickness of 6 mm is used.
By forming six 1c and 21c, it is possible to suppress the strength reduction to about 80% at the maximum bending stress. In FIG. 14, the overload resistance ratio is shown as compared with the case where the rib portion 21d is not formed.

Example 3 In Example 3 shown in FIGS. 11 to 13, the foam sheet 104 was used as the absorbing material.
And an inorganic foam hardened body 304 is interposed between the upper surface 103a and the inner surface 103a of the lid 103.

The cured inorganic foam 304 has a plurality of open cells which absorb excess gas generated from the foaming agent and communicate with the outside to be discharged.

In Example 3, the inorganic foamed cured product 3
04 is formed into a thickness of 6 mm * width of 100 mm * length of 280 mm, and the foam sheet 104 is placed at a substantially central position of the inorganic foamed cured product 304 at a thickness of 6 mm * width of 90 m
It is formed to have an m * length of 280 mm and attached.

This inorganic foamed cured product 304 is composed of the following compounds.

Fly ash (average particle size: 10 μm or less) 75 parts classified according to JIS6201 75 parts Alumina cement 9 parts Mica 18.5 parts Talc 27.5 parts Vinylon fiber (fiber length 3 mm) 0.65 parts Sodium oleate 1 0.3 parts CaO (200 mesh pass) 6.5 parts Special sodium hydroxide (molar ratio 1.5, water content 59%) was mixed with the above mixture by dry mixing for about 3 minutes.
Add 5 parts of water and mix for 1 minute. Hydrogen peroxide solution (35%)
After adding 15 parts and mixing for 30 seconds, the mixture is poured into the mold 102 (FIG. 13A).

Then, after closing with the lid 303, it is cured by heating (FIG. 13 (2)), and then removed from the mold and dried (FIG. 13 (3)).

At this time, the specific gravity of the blend 105 was 2.0
From 1.0 to 1.0, the volume after foaming becomes 70% to 73.5% when the input amount of the foaming agent is increased by 5% (35% to 36.5%). Furthermore, assuming that the foaming temperature is increased, a foam volume increase of 10% is expected, and 73.5%
→ It is considered that the foam of the kneaded material 105 occupies 77.175% of the volume. Therefore, the foam sheet 104 as the cushioning material is also considered to be a gas, and the volume of the gas is
55% → 60.425%. This is about 1.099
Equivalent to double.

As described above, the gas in the foam sheet 104 attached to the back surface of the lid 103 is caused by the upper end surface of the upper edge opening 102b and the outer peripheral edge 103 of the lower surface of the lid 103.
b, the foam sheet 104 is compressed to about 27.125% (2% of the total volume).
(0% → 14.575%).

For this reason, it is possible to slightly increase the amount of
Alternatively, even when the temperature becomes relatively high and the foaming amount becomes larger than the assumed foaming amount, so-called pressure buffering is performed by compressing the foam sheet 104 and excess generated gas is discharged from the foam sheet 104. And it is absorbed and exhausted by the inorganic foam cured body 304. Therefore, the mold 102
Is maintained at an appropriate pressure, a predetermined concave portion 31c is formed on the back surface side, and there is no possibility that the thickness h2 of the completed outer wall material 31 as a molded product after release is increased (FIG. 13).
(3)).

There is no danger that the generated gas pressure will exceed the expected pressure, and it is not necessary to make the strength of the molding die 102 and the lid 303 excessively strong. An outer wall material 31 that constitutes a certain wall panel can be obtained.

Further, the foam sheet 104 is compressed to become hollow, and can maintain the strength per weight, particularly the maximum bending stress. FIG. 14 shows the overload resistance ratio as compared with a material that is not hollowed. Further, with the same lightening amount, a larger maximum bending stress can be obtained as compared with the case where the rib portion 21d is formed on the back surface 21b shown in the second embodiment.

[0076]

Third Embodiment FIGS. 15 to 22 show a method of manufacturing an inorganic foamed cured product according to a third embodiment of the present invention. The same or equivalent parts as those in the first and second embodiments will be described with the same reference numerals.

In the third embodiment, the mold 1 for substantially sealing the gas generated from the foaming agent mixed in the inorganic curable material is used.
02 and a lid 103, and the inorganic curable material is heated and foamed in the mold 102 to produce an inorganic foam.

In this production method, the sum of the theoretically calculated partial pressure of the gas generated from the foaming agent and the steam pressure at the temperature reached by heating the inorganic curable material is used for molding. A step is provided for back-calculating the amount of blowing agent so as not to exceed the design pressure of the mold 102. When aluminum is used as the foaming agent, the following chemical formula 1
The foaming reaction proceeds according to the reaction of

[0079]

Embedded image When silicon is used as the foaming agent, the foaming reaction proceeds according to the reaction of the following chemical formula 2.

[0080]

Embedded image When aqueous hydrogen peroxide is used as the foaming agent, the foaming reaction proceeds according to the reaction of the following chemical formula 3.

[0081]

Embedded image It is assumed that the following conditions are satisfied as the premise of the calculation.

1. All blowing agents react.

2. A foaming reaction occurs uniformly in the mold 102.

3. Hydrogen gas and water vapor having a partial pressure corresponding to the temperature are present in the bubbles.

4. The volume Vm (cubic cm) of the space in the mold 102 at the time of casting is equal to the sum of all the volumes of the foamed cells (Equation 1).

[0086]

(Equation 1) 5. The number of blending parts of the foaming material is negligibly small compared to the number of blending parts of all the blends (Equation 2).

[0087]

(Equation 2) As the calculation procedure: Set the specific gravity and water content of the target foam, and
The inner volume of the mold 102 and the specific gravity of the casting material slurry (mixture) at the time of non-foaming are obtained.

2. From the material composition and the set value of the above 1, mold 1
Calculate the amount of casting to 02 (Equation 3).

[0089]

(Equation 3) FIG. 17 summarizes the symbols and units used.

3. Using the design pressure of the mold 102 and the value of the material temperature during foaming, the blending amount of the foaming agent is determined from the calculated value obtained in the above (2) (Equation 4).

[0091]

(Equation 4) The water vapor pressure can be obtained from a vapor pressure table once the material temperature is determined. The material temperature can be set at the time of foaming when heat generation and heat absorption are not involved, but at the time of foaming,
In the case where heat generation and heat absorption are involved, it is necessary to determine by a preliminary experiment.

From the equation of state, the partial pressure of water vapor is

(Equation 5) By substituting a value that can be substituted into the above formula 5, the following formula 6 is obtained.

[0093]

(Equation 6) By transforming Equation 6, Equation 7 is obtained, which determines the number of parts of the foaming agent.

[0094]

(Equation 7) Also, by using this theoretical formula, the casting pressure, the generated pressure fluctuation when the foaming temperature varies, is estimated, conversely,
It can be used to design molds and devices.

[0095]

Next, a specific calculation example will be described. Using the values shown in FIG. 17 to FIG. 19, the calculated casting amount and the silicon powder amount corresponding to the design pressure shown in FIG. 20 are shown. Also, 65
FIG. 21 shows the amount of silicon for each design pressure at ° C.

As a verification of the theoretical value, FIG. 22 shows a comparison between the measured value and the theoretical value by reacting according to the actual composition shown in FIG. The calculated pressure is close to the measured pressure, and it is understood that the calculated pressure is effective for determining the blending amount of the blowing agent.

[0097]

As described above, according to the first aspect of the present invention, the absorbing material absorbs moisture and gas in the inorganic material to reduce an increase in pressure. For this reason, it is possible to prevent appearance defects and to minimize the influence of gas generation, thereby obtaining a stable molded product of an inorganic material.

[0098] Further, by way of claim 2, wherein the reactive inorganic powder is a SiO ₂ -Al ₂ O ₃ -based powder, SiO ₂
-Al ₂ O ₃ system powder is 100 parts by weight, the alkali metal silicate is 0.2 to 450 parts by weight, the water is characterized by the wall panel of claim 1 wherein is incorporated in from 35 to 1500 parts by weight.

According to the third aspect of the present invention, since the absorbent for absorbing moisture in the inorganic material is provided on the back surface of the outer wall material, even if unreacted components are present inside the outer wall material, The water in which the unreacted components are dissolved is absorbed by the absorbent. Therefore, occurrence of poor appearance due to unreacted components can be prevented.

Further, according to the fourth aspect, the foam sheet is compressed to absorb the pressure in the molding die.

In the fifth aspect,
The open cells of the inorganic foamed cured product absorb the surplus gas generated from the foaming agent and discharge the surplus gas to the outside. For this reason, there is no possibility that the generated gas pressure exceeds the assumed pressure, and it is not necessary to make the strength of the molding die excessively strong.

Further, in the sixth aspect, even after the mold is released, a plurality of the substantially elongated absorbers are arranged in the hardened inorganic material. For this reason, the back surface side of the inorganic material constituting the outer wall material is reinforced by the absorbing material.

And, according to the seventh aspect,
The absorbent material is placed in a molding die, and the inorganic material produced by mixing the reactive inorganic powder, the alkali metal silicate and water is poured into the molding die, and the inorganic material in the molding die is removed.
By adjusting the temperature to 0 ° C. or lower, foaming occurs appropriately, moisture and gas are absorbed, and the wall panel is formed relatively easily.

According to the eighth aspect of the present invention, the amount of the foaming agent to be mixed is determined in advance by the step of back-calculating the amount of the foaming agent so as not to exceed the design pressure of the mold. Since the inorganic curable material and the foaming agent are introduced into the inside, the amounts of gas and water vapor generated by foaming when the inorganic curable material is heated and foamed can be substantially uniquely assumed.

Therefore, for example, by appropriately adjusting the amount of water to be absorbed by the absorbing material, it is possible to prevent the appearance defect from occurring, and to minimize the influence of the generation of gas and the like, and to form a stable inorganic material. Goods can be obtained,
Practically useful effects such as

[Brief description of the drawings]

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

FIG. 2 is a diagram illustrating a process for generating an outer wall material.

FIG. 3 is a cross-sectional view for explaining how water is absorbed by an absorbent.

FIG. 4 shows a second embodiment of the present invention, and is a graph showing a change in temperature with respect to elapsed time, comparing a case where heat of reaction exists and a case where heat of reaction does not exist.

FIG. 5 is a perspective view illustrating the configuration of a mold according to Example 1 of Embodiment 2.

FIG. 6 is a front view of an outer wall material obtained by the mold according to the first embodiment.

FIG. 7 is a diagram illustrating a process for generating the outer wall material according to the first embodiment.

FIG. 8 is a perspective view illustrating a configuration of a mold according to a second embodiment of the second embodiment.

FIG. 9 is a front view of an outer wall material obtained by the mold according to the second embodiment.

FIG. 10 is a table showing the bending stress of the outer wall material obtained by the mold of Example 2.

FIG. 11 is a perspective view illustrating a configuration of a mold according to a third embodiment of the second embodiment.

FIG. 12 is a front view of an outer wall material obtained by the mold according to the third embodiment.

FIG. 13 is a diagram illustrating a process for generating the outer wall material according to the third embodiment.

FIG. 14 is a table showing the bending stress of the outer wall material obtained by the mold of Example 3.

FIG. 15 is a schematic diagram illustrating a configuration of a mold according to a third embodiment.

FIG. 16 is a graph comparing the composition ratio of Embodiment 3 and the mixing ratio in slurry.

FIG. 17 is a table summarizing constants and the like used for calculation in the third embodiment.

FIG. 18 is a table illustrating the material composition of an example of the third embodiment.

FIG. 19 is a table of setting values used in the embodiment.

FIG. 20 is a table showing the amount of silicon powder for each foaming temperature obtained in an example.

FIG. 21 is a table showing the relationship between the design pressure and silicon of the example.

FIG. 22 is a table for verifying the accuracy of a theoretical value from an actually measured value obtained in the example.

[Explanation of symbols]

 1, 11, 21, 31 Exterior wall material 2 Absorbent material 102 type 103, 203, 303 Lid 104, 204 Foam sheet (absorbent material) 304 Inorganic foam hardened material (absorbent material)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI // B29L 31:10

Claims (8)

[Claims] 1. An outer wall material formed by integrally molding an inorganic material formed by mixing a reactive inorganic powder, an alkali metal silicate and water, and an absorber provided on the back surface of the outer wall material. Wall panels. 2. The method according to claim 1, wherein the reactive inorganic powder is SiO ₂ —Al ₂ O.
A ₃ system powder, SiO ₂ -Al ₂ O ₃ system powder is 100 parts by weight, the alkali metal silicate is 0.2 to 450 parts by weight, that the water is incorporated into 35-1500 parts by weight The wall panel according to claim 1, characterized in that: 3. The wall panel according to claim 1, wherein the absorbing material absorbs moisture in the inorganic material. 4. The wall panel according to claim 1, wherein the absorbent comprises a foam sheet that absorbs pressure in a molding die. 5. The absorbent material according to claim 1, wherein the absorbing material is made of an inorganic foamed hardened material having open cells which absorb excess gas generated from the foaming agent and communicate with the outside to be discharged. A wall panel according to any one of the preceding claims. 6. The wall panel according to claim 1, wherein a plurality of the absorbent members have a substantially elongated shape and are arranged in parallel. 7. An absorbent material is placed in a molding die, and an inorganic material produced by mixing the reactive inorganic powder, the alkali metal silicate and water is poured into the molding die, and the inside of the molding die is A method for producing a wall panel, comprising adjusting an inorganic material to a temperature of 40 ° C. or lower. 8. A mold for substantially sealing a gas generated from a foaming agent mixed in the inorganic curable material, wherein the inorganic curable material is heated and foamed in the mold to produce an inorganic foam. In the method for manufacturing a wall panel, the sum of the theoretical partial pressure of the gas generated from the blowing agent and the steam pressure at a temperature at which the inorganic curable material is heated by heating is a design pressure of a molding die. Back-calculating the amount of the foaming agent so as not to exceed the above-mentioned value.