JPS61106470A - Manufacture of panel - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing panels used for exterior walls of houses, etc.

(Prior art) Conventionally, the exterior walls of houses were generally made by attaching wire mesh on top of wooden boards, and then finishing the top with mortar (1, 1, 1, 2) and then finishing with risin or staff. ,
ALC as seen in Special Publication No. 42-23360
Panels formed from boards, siding boards, wood chips, cement boards, stone frames, full boards, etc. have been developed.

(The problem that the invention is trying to solve) However,
None of the above-mentioned exterior wall materials satisfies all of the requirements of heat insulation, durability, freeze-fracture resistance, heat resistance, and water resistance. Furthermore, it is known that ceramic foam made by foaming a silicic acid-containing raw material has all of the above characteristics and is ideal as an exterior wall material, but until now it has only been used as small tiles. be.

The present inventor came up with the idea of manufacturing a large-area panel made of ceramic foam by foaming a silicic acid-containing raw material, but as a result of experiments, it was found that there were difficulties in manufacturing. That is, cracks are likely to occur during the cooling process after foaming. This crack is presumed to be caused by internal stress caused by shrinkage of the foam during the cooling process.
After foaming, it is necessary to slowly cool the foam for a very long time (for example, about 20 hours) while keeping it warm, which significantly reduces production efficiency and increases manufacturing costs. Even so, it is impossible to reliably prevent the occurrence of cracks.(Means for Solving the Problem) The present invention has been made to solve the above problem, and its gist. is 60 to 85 parts of silicic acid-containing raw material (parts by weight,
(same below), 40 to 15 parts of softening agent, 0.1 to 0.0 parts of blowing agent.
Mix 4 parts uniformly to make a foamable mixture of 1 yen. Arrange this foamable mixture to a substantially uniform thickness, place a stainless steel net on top of it, and then place the foamable mixture on top of it. The method of manufacturing a panel is characterized in that the panels are arranged to have a substantially uniform thickness, heated and foamed to be integrated, and then cooled.

(Function) In the method of the present invention, by interposing the stainless steel mesh body tightly inside the foam, it is possible to prevent the occurrence of cracks during cooling after foaming.

(Example) Hereinafter, the panel manufacturing method of the present invention will be explained in detail.

Foamable mixture, product> A foamable mixture is prepared by uniformly mixing 6 to 85 parts (by weight, the same applies hereinafter) of a silicic acid-containing raw material, 40 to 15 parts of a softening agent, and 0.1 to 0.4 parts of a foaming agent. Manufacture. The reason why the blending ratio of raw materials is numerically limited as described above is that materials within this range result in a good foam.

As the silicic acid-containing raw material, volcanic products such as volcanic rock and volcanic ash are used, such as shirasu, obsidian, nacre, white clay, bentonite, andesite, basalt, volcanic rock, and rhyolite. Note that slag from a blast furnace or the like may also be used.

The softening agent lowers the melting point of the silicic acid-containing raw material such as the above-mentioned volcanic ejecta to make it easier to soften, and includes materials containing a large amount of alkali metal oxides, such as water glass, solid sodium silicate, soda carbonate, and sodium bicarbonate.

Glass powder, Kira clay, glaze, etc. are used. Furthermore, soda carbonate is preferred because it is inexpensive and has a high content of alkali metals.

As the foaming agent, carbon powder, silicon carbide, etc. are used. In particular, in the case of silicon carbide, it does not decompose unless it is heated to about 2.00°C when used alone, but in the presence of molten silicic acid raw material, it decomposes at a temperature of around 1000°C or lower, and it is melted. This is preferable because the silicic acid-containing raw material can be foamed reliably.

Furthermore, in the method of the present invention, an appropriate amount of a viscosity modifier may be added for the purpose of adjusting the softening point or adjusting the melt viscosity. Viscosity 31iI? As the i material, CaO raw material, Al2O, raw material, h, t go raw material, B, O, raw material, etc. are used.

Limestone and slaked lime are used as CaO raw materials.

AIzO, raw materials include bentonite, kaolin, leeches melon, etc.\120. A viscosity class containing a large amount of is used. Magnesium carbonate or the like is used as the MgO raw material. Borax, boric acid, etc. are used as B, O, and raw materials.

Furthermore, in the method of the present invention, pigments and the like may be added as appropriate.

The above raw materials are ground using a ball mill or the like, and then mixed uniformly using a ball mill, ribbon blender, or the like.

The above raw material is ground to 100 meshes or less, preferably 300 meshes or less. In addition, depending on the raw material, 1
There are powders with a size of 0.00 mesh or less, and there are also fluids such as softeners, but these do not need to be pulverized and can simply be mixed uniformly with the raw materials in the pond.

A foamable mixture is obtained as described above. The above-mentioned foamable mixture may be left in powder form, but in order to make it easier to place it on a conveyor belt as described below, it may be made into small particles using a granulator or into an elongated shape using a vacuum extruder. It's okay.

Stainless steel '9A! El-shaped body> The stainless steel mesh body used in the present invention may be either ferritic stainless steel or austenitic stainless steel. The stainless steel mesh body has a linear expansion of 4j bY: P
(ir':') l 11 X ] +1
- 'can/'am' (l -L(1+1 ei
f' I n = I nX I +1- "cm,'
rm'(:', ) is the linear expansion coefficient of one ceramic foam (approximately 7 x 1 + 1- = 7th f
:l#' C or more 1. For example, 5=7 :The I-R shape M1 is made of a parallel mesh that is contrary to the M1 shape, and it should be M1. As a material 11 with a preferable coefficient of The mixture is placed in a nearly uniform J7 shape, a stainless steel mesh is placed on top of it, and a foamable) R compound is placed on top of it to have a nearly uniform thickness, and this is heated and foamed to integrate. After that, it is cooled to obtain a panel. In order to explain in more detail the foaming, cooling, and accompanying steps of the method of the present invention, they will be explained based on a specific device.6 Figure 1 shows an example of the device for carrying out the method of the present invention. . In the figure, 1 ( ) is a conveyor device, and this conveyor device 1 ( ) has a conveyor belt 12 made of a heat-resistant metal such as stainless steel.

This conveyor belt 12 is configured to run within and beyond the roll 11. When the conveyor belt 12 runs on the lower side, it is guided by an idle roll 13, and a mold release material 14 is applied to the surface thereof. As the mold release material 14, a material made by suspending alumina powder or zircon powder in water is generally used.

The conveyor belt 12 passes through the heating furnace 20 when traveling on the upper side. Inside the heating furnace 20, preheating zones 21 are arranged in order from the large hole 20a toward the outlet 20b.
．． Heating zone 22. A cooling zone 23 is configured.

A burner 24 is arranged in the heating zone 22, and the burner 24 performs heating as described below.

Further, near the outlet 20b of the cooling zone 23, air is blown out to perform cooling, which will be described later. Further, a presser roll 25 is arranged in the cooling zone 23 at a portion closer to the heating zone 22 .

Above the conveyor belt 12, a PjSl hopper 31° and a second hopper 32 for supplying the foamable mixture A are arranged at a position between the conveyance start end 12a and the entrance 20a of the heating furnace 20. These hoppers 31.32
A feed roll 33 for feeding the stainless steel mesh body B is disposed at the opening.

A predetermined number 11 from the conveyance path '412b of the funbear belt 12!
@ An unloading conveyor device 40 is arranged at a remote position, and between the conveying start end/((la) of this unloading conveyor device 40 and the conveying end 12b of the conveyor belt 12,
A cutter 41 that moves up and down is arranged.

In the above configuration, when the conveyor belt 12 runs on the upper side, the conveyor belt 12 coated with a mold release material in advance.
-The foamable mixture A is supplied from the first hopper 31 to a uniform thickness. Then, on top of this foamable mixture A, a stainless steel mesh body B guided by a feed roll 33 is continuously supplied. Furthermore, the same foamable mixture A as described above is supplied from the second hopper 32 onto the stainless steel net B in a uniform thickness.

The conveyor belt 12 has foamable mixture A in the lower layer.

The laminate having the stainless steel mesh B in the middle and the foamable mixture A in the upper layer is sent to a heating furnace 20. This laminate is first preheated in a preheating zone 21 and then heated in a heating zone 22, and as a result, the foamable mixture A disposed above and below the stainless steel net B foams and fuses together.
- Ceramic foam C made into It is obtained. The stainless steel mesh body B is buried in the ceramic foam C. The heating and foaming temperature mentioned above varies depending on the type of foamable mixture A, but is usually 700°C to 110°C.
'C is preferably 850°C to 1000°C. 1
This is because if the temperature exceeds 100°C, the conveyor belt 12 will be damaged. Note that when a trolley is used as a means for transporting the laminate to the heating furnace 20, the foaming temperature may be set to 1100°C or higher (11≧).

After the above foaming, the ceramic foam C is cooled with a cooling saw/2: (
and cooled. Note that the ceramic foam (L) is molded to a predetermined thickness by a pressing roll 25 while still being deformable.
Blow air);

[If cooling is carried out in a short time, cracks can be prevented from occurring in the ceramic foam C due to the presence of stainless steel or pleated Ink 13.The principle of this crack prevention 11 will be explained below. ((1)
The coefficient of linear expansion is higher than that of ceramic foam C. At the time of cooling (cold), the stainless steel net B
tensile stress occurs. In other words, during cooling, the internal stress caused by the contraction of the ceramic foam C can be received by the stainless steel net B in tension, and as a result, cracks in the ceramic or foam C can be prevented. It is assumed that To be more specific, it is cold up to 311fl'C.
The time for this is 30 minutes to 4 hours, preferably 1 hour to 3 hours.
Even after cooling in such a short period of time, no cracks occur and production efficiency can be improved.

The ceramic foam C containing the stainless steel net B that has been cooled as described above is cut into a predetermined length by a cutter 41 to obtain a panel 50 as a product.

This panel 5 ( ) is carried out by a carrying out conveyor device 40 .

As shown in FIG. 2, the manufactured panel 50 has a stainless steel mesh body B inside the ceramic foam C, and therefore has excellent impact resistance.

In addition, the W8 thermal property is a characteristic of ceramic foam C.

It also has durability, freeze-fracture resistance, heat resistance, and water resistance.

Application Example of Panel> The panel 50 manufactured by the method of the present invention is used, for example, on the outer wall of a house. In this case, as shown in Figure tJS3 and Figure 4, a plurality of panels 50 are connected to form an outer wall with an even larger area. In the case of FIG. 3, a groove 51 of shape IIf'ζ is formed on the side edge of the panel 50, and a washer 52 is inserted into this groove 51, and a stand (stud) is placed on the back side of the panel 5 (). 5:) are tightened with bolts 5 and 55 (by doing so, the panels 50 are connected to each other. After the connection, a rubber slit 56 is press-fitted between the panels 50. .vS4, in order to lock the washer 52, the notch 5 is used instead of the groove described above.
7 is formed, and after connection, this notch 57 is filled with a sealing material 58 such as cement, mortar, putty, etc. to seal it.

In FIGS. 3 and 4, it is preferable in terms of strength that the stainless steel net B inside the panel 5 be interposed between the washer 52 and the stand S3.

In addition, when the said panel 50 is used for an external wall, the surface can be made more beautiful by applying glaze or painting to the surface.

<Experimental example 1> Anti-fire stone was crushed with a ball mill and passed through 300 meshes 90
% powder. In addition, the frog's eye clay was made into powder in the same way. Then, 70 parts of these anti-firestone and 5 parts of frog's eye clay were mixed with 10 parts of slaked lime, which had been powdered in advance, and 1 part of soda ash.
5 parts and 0.2 parts of silicon carbide were uniformly mixed in a ball mill to obtain a foamable mixture.

In addition, as a stainless steel mesh body, 5U of 1.5mmφ
A piece of S304 wire knitted vertically and horizontally at 3 cm intervals was prepared.

Then, using the apparatus shown in FIG. 1, the net-like body was placed in the foamable mixture □ and heated and foamed at 930'C.
Cooled to 300°C in 2 hours, thickness 3cIm1 width 90
A panel of c+a, length 3I and specific gravity 0.8 was produced. The manufactured exterior wall panels were clean and free of cracks.

On the other hand, a foamable mixture with the same composition as above was heated and foamed without using a stainless steel net, and then slowly cooled in a heat retention oven for more than 10 hours, but the ceramic foam cracked. , it was not possible to manufacture large-sized panels such as those described above.

Experiment 2> 75 parts of radish and 10 parts of limestone were each pulverized, and thoroughly mixed with 15 parts of powdered soda ash, silicon carbide f), and 311Fr in a colander to obtain a foamable mixture. This was made into granules with a diameter of about 21 mm using a granulator.

In addition, as a stainless steel mesh body, 1.5 mmφ S
A tortoiseshell-shaped wire knitted from US, +31'l wire was prepared.

Then, using the apparatus shown in FIG.
The mixture was heated and foamed at t' and cooled to 300'C for 2 hours to produce a panel with a thickness of 90 cm (1 IC ring), a length of 2.5 mm, and a specific gravity of 0.5. The manufactured panels were beautiful with no cracks.

On the other hand, a foamable mixture with the same composition as above was heated and foamed without using a stainless steel net, and then slowly cooled in an insulating furnace for more than 10 hours, but cracks appeared in the ceramic foam. , it was not possible to manufacture large-sized panels such as those described above.

1) Bow Milk As explained above, according to the method of the present invention, the foamable mixture is foamed by interposing the stainless steel mesh, so even if it is cooled in a short cooling time after foaming, the ceramic foam remains unchanged. Cracks do not occur, production efficiency can be improved, and panels with a large area can be provided at low cost. Since the manufactured panels are made of ceramic foam, they have insulation properties, durability, freeze-fracture resistance, heat resistance, and water resistance. Furthermore, since this panel has a stainless steel mesh inside the ceramic foam C, it has excellent impact resistance.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing an example of an apparatus for carrying out the method of the present invention, FIG. 2 is a partially cutaway perspective view of a panel manufactured by the method of the present invention, and FIGS. 3 and 4 are diagrams showing the panel. FIG. 3 is a cross-sectional view showing an example of application to an outer wall.

Claims (1)

[Claims] (1) 60 to 85 parts of silicic acid-containing raw material (parts by weight, same below)
, 40 to 15 parts of a softening agent, and 0.1 to 0.4 parts of a foaming agent are uniformly mixed to make a foamable mixture, and this foamable mixture is arranged to a substantially uniform thickness, and a stainless steel plate is placed on top of the foamable mixture. 1. A method for manufacturing a panel, which comprises placing a net-like body on top of the net-like body, further disposing the above-mentioned foamable mixture on the net-like body to have a substantially uniform thickness, heating and foaming the mixture to integrate it, and then cooling it.