JPS61215004A - 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 (Field of Industrial Application) The present invention relates to a method for manufacturing panels used for the outer walls of houses, etc.

(Prior Art) Conventionally, the outer walls of houses have generally been made by attaching wire mesh to wooden boards, finishing the top with mortar, and then finishing with lysine or stucco.

Recently, panels formed of ALC boards, siding boards, wood chip cement boards, plaster-aluminum boards, etc., as seen in Japanese Patent Publication No. 41-2'3360, have been developed.

(Problems to be Solved by the Invention) 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.

In addition, it is known that ceramic foam made by foaming silicic acid-containing raw materials can satisfy all of the above qualities and is optimal as an exterior wall material. It is only used as a small tile.

The inventors attempted to manufacture large-area panels made of ceramic foam by foaming a silicic acid-containing raw material, but experiments revealed that there were manufacturing difficulties. In other words, the cooling time after foaming is extremely long and manufacturing efficiency is poor, and if the cooling rate is increased, cracks occur during the process, making it impossible to obtain sufficient mechanical strength of the panel.
The problem is that the freeze fracture resistance, which is a characteristic of foam, decreases.

It is presumed that this crack is caused by internal stress caused by shrinkage of the foam during the cooling process.

In order to prevent the occurrence of cracks, if the cooling time is set at the expense of production efficiency, for example, about 20 hours, the manufacturing cost will naturally increase, and even then it will be difficult to completely overcome the occurrence of cracks.

(Means for Solving the Problems) The present invention attempts to solve the above-mentioned problems by the configuration described in the claims.

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, anti-flinder rock, and rhyolite. still,
Blast furnace slag or the like may also be used.

Softeners lower the melting point of silicic acid-containing raw materials such as volcanic ejecta, making them easier to soften. Ash, bicarbonate of soda, glass powder,
Glaze etc. are used.

In particular, soda carbonate and soda are preferred because they are inexpensive and have a high alkali metal content.

As the foaming agent, carbon powder, silicon carbide, etc. are used. In particular, in the case of silicon carbide, it does not decompose unless the temperature reaches around 2000°C when used alone, but in the presence of a molten silicic acid raw material, it decomposes at around 1000°C or lower, ensuring that the molten silicic acid-containing raw material is It is preferable because it can be foamed.

Further, in the method of the present invention, an appropriate amount of a viscosity modifier may be added for the purpose of adjusting the melt viscosity and secondarily the softening point.

As the viscosity modifier, CaO raw material, Al2O3 raw material, MgO raw material, B2O3 raw material, etc. are used. As CaO raw materials, limestone and slaked lime are used, and as A1□03 raw materials, clays that mainly contain a large amount of A1□03, such as hentonite, kaolin, hirume clay, and fly ash, are used, and MgO Magnesium carbonate or the like is used as the raw material, and borax, boric acid or the like is used as the B2O3 raw material.

Furthermore, in the present invention, pigments, bubble stabilizers, etc. may be added as appropriate.

The above raw materials are ground using a ball mill, roll mill, etc., and then uniformly mixed using a ball mill, pump blender, etc. The above raw material is ground to 100 mesoshu or less, preferably 300 mesoshu or less. In addition, there are already 100
The following powdered raw materials and liquid softeners can be simply mixed uniformly with other raw materials.

The foamable mixture thus obtained may be left in powder form, but in order to make it easier to handle or to place on a conveyor held, it may be made into small particles using a granulator or a vacuum extruder. It may be used to form an elongated strip shape.

The stainless steel wire used in the present invention may be either ferritic stainless steel or austenitic stainless steel. The linear expansion coefficient of stainless steel wire is approximately 10
10-6/℃ or higher (e.g. 10-12 x 10-6
/"c), and the linear expansion coefficient of the ceramic foam described below (approximately 7 x 10-6/℃ or less, for example 5 to 7 x 10
-6/'C). The stainless steel wires used in the present invention have a diameter of 4 ++ m or less and are arranged at intervals of 4 cm or more. They may be arranged in parallel at intervals of 4 cm or more in one direction, or may be arranged in parallel at intervals of 4 cm or more in a direction perpendicular to this direction. Alternatively, the parts where the wires intersect may be welded to form a net-like body, or a hexagonal wire mesh may be formed, with mutually parallel wires spaced at intervals of 4 cm or more. Stainless steel wire was selected as a material with heat resistance and a favorable coefficient of linear expansion relative to ceramic foam.

To manufacture a panel using the above foamable mixture and stainless steel wire, first, the foamable mixture is arranged to have a uniform thickness, stainless steel wires are placed on top of it at intervals of 4 cm or more, and then A foamable mixture is placed on top of it to a uniform thickness, heated to soften and melt the main raw materials, and then foamed by decomposition of the foaming agent. If necessary, molding such as roll pressing is performed. In addition, if necessary, glaze is applied and the panel is obtained by cooling.

(Function) In the present invention, stainless steel wires of a specific diameter are placed inside the foam at specific intervals and interposed in close contact with each other, thereby preventing the occurrence of cracks during cooling after foaming.

The crack-preventing effect of this stainless steel wire is estimated as follows. The coefficient of linear expansion of the stainless steel wire is larger than that of the ceramic foam, and the stainless steel wire tends to contract more than the ceramic foam during cooling.

This difference in the degree of shrinkage causes residual shrinkage force in the stainless steel wire. In other words, when the ceramic foam shrinks during cooling, distortion occurs inside the ceramic foam and induces cracks to form, but the residual shrinkage force of the stainless steel wire keeps the entire ceramic foam in a bound state. , prevents cracks from forming.

However, if the shrinkage force of the stainless steel wire is too large, in the long run, the stainless steel wire will continue to shrink even after cooling, causing it to separate from the interface of the ceramic foam.
Ceramic foam breaks into two layers. Therefore, in the present invention, the diameter of the stainless steel wire is set to 4 mm or less, and the distance between the stainless steel wires is set to 4 cm or more, so that the residual shrinkage force of the stainless steel wire is made smaller than the compressive strength of the ceramic foam. However, the ceramic foam will not split into two layers.

(Example) FIG. 1 shows an example of an apparatus for carrying out the method of the present invention. In the figure, 10 is a conveyor device, and this conveyor device 10 has a conveyor belt 12 made of a heat-resistant material such as stainless steel. This hair belt 12
is adapted to run under the guidance of rolls 11. When the conveyor heald 12 travels below, it is guided by guide rolls 13, and a release agent 14 is applied to the surface thereof. The mold release agent 14 is generally a suspension of alumina powder or zircon powder in water.

The conveyor heald 12 passes through the heating furnace 20 when traveling on the upper side. Inside the heating furnace 20, there are preheat zones 21 in order from the inlet 20a to the outlet 20b.
, a heating zone 22, and a cooling zone 23.

A burner 24 is arranged in the heating zone 22, and the burner 24 performs heating as described below. In addition, air is blown out near the outlet 20b of the cooling zone 23 to perform cooling, which will be described later. Further, a press roll 25 is arranged in a portion of the cooling zone 23 near the heating zone 22.

A first hopper 31 and a second hopper 32 for supplying the foamable mixture A are arranged above the conveyor belt 12 between its conveyance start end 12a and the population 20a of the heating furnace 20. Between these hoppers 31 and 32, stainless steel wires with a diameter of 1.6 mm are arranged orthogonally at intervals of 7 mm.
A feed roll 33 is arranged for feeding the net-like body B whose intersection points are welded.

A carry-out conveyor device 40 is located at a position slightly away from the conveyance end 12b of the conveyor belt 12, and between the conveyance start end 40a of the carry-out conveyor device 40 and the conveyance end 12b of the conveyor belt 12, there are A moving cutter 41 is arranged.

When the conveyor heald 12 runs on the upper side, the foamable mixture A is supplied from the first hopper 31 to a uniform thickness onto the upper surface of the conveyor belt 12, which has been previously coated with a mold release agent. Next, 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 to a uniform thickness.

The conveyor belt 12 sends the laminate having the foamable mixture A in the lower layer, the stainless steel mesh B in the middle, and the foamable mixture A in the upper layer to the heating furnace 2o. 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 with each other to become an integral body. A ceramic foam C is obtained. The stainless steel 3H-shaped body B is buried in the ceramic foam C.

The heating and foaming temperature varies depending on the type of foamable mixture A, but is usually 700 to 1100°C.

If the temperature exceeds 1100° C., a high-performance furnace will be required and damage to the Conhair Held 12 will occur.

In addition, when a trolley is used as a means for conveying the above-mentioned laminate to the heating furnace 20, it is also possible to set the foaming temperature to 1100°C or higher.

After the foaming is completed, the ceramic foam C, which is still deformable, is molded to a predetermined thickness by a pressing roll 25, and then enters a cooling zone 23 to be cooled. Presser roll 2
Forming 5 achieves uniform thickness, surface smoothness, and improved mechanical strength. As mentioned above, cooling is done by air cooling and cooling zone 23.
This is done by blowing air near the exit.

Even if this cooling is completed in a short time, the presence of the stainless steel mesh body B can prevent the ceramic foam C from cracking, as explained in the operation section. Specifically, it takes 30 minutes to 4 hours, preferably 1 to 3 hours, to cool down to 300°C, which allows for easy movement and processing, which significantly improves panel manufacturing efficiency. can be improved.

The stainless steel net-like ceramic foam C cooled as described above is cut into a predetermined length by a cutter 41 to obtain a panel 50 as a product. This panel 50 is carried out by the carry-out container device 40.

As shown in FIG. 2, the manufactured panel 50 has a stainless steel net B inside the ceramic foam C, and therefore has excellent impact resistance. It also has the characteristics of ceramic foam C, such as heat insulation, durability, heat resistance, and water resistance, and since there are no cracks, there is no reduction in the freeze fracture resistance of the ceramic foam.

The panel 50 manufactured by the method of the present invention is preferably used for the exterior wall of a house. In this case, as shown in FIGS. 3 and 4, the outer wall is constructed by connecting a plurality of panels 50.

In the case of FIG. 3, a groove 51 is formed on the side edge of the panel 50, and a washer 52 inserted into this a51 and a stud 53 arranged on the back side of the panel 50 are connected to each other.
The panels 50 are interconnected by tightening the ports 54 and nuts 55. After connection, panel 5
A gasket 56 is press-fitted between 0 and 0.

In the case of FIG. 4, in order to lock the washer 52, a notch 57 is formed in place of the groove 52, and after connection, a sealing material such as cement, mortar, putty, etc. is applied to the notch 57.
8. Fill and seal. In FIGS. 3 and 4 above, the stainless steel net B inside the panel 50 is connected to the washer 52.
In terms of strength, it is preferable to interpose the screw and the stud 53 for connection. Note that the surface of the panel 50 can be decorated by applying glaze or painting to increase the durability of the surface.

<Experimental example 1> Anti-flinder stone was crushed in a ball mill and milled to 300 meters per 189
0% powder. Also, the frog's eye clay was made into powder in the same way. And 70 parts of these anti-firestones (parts by weight, same below)
and 5 parts of Hirume clay were uniformly mixed in a ball mill with 10 parts of powdered slaked lime, 15 parts of soda ash, and 0.2 parts of silicon carbide to obtain a foamable mixture.

As a stainless steel mesh body, 5US with a diameter of 1.6+n is used.
A piece of 304 wire knitted vertically and horizontally at 7 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 0℃ for 2 hours, 3cm thick, 3m long, specific gravity 0
．． Eight panels were manufactured. The manufactured exterior wall panels were clean and free of cracks. Further, even when the obtained panel was used for a long period of time, the panel did not crack into layers due to shrinkage of the stainless steel mesh.

On the other hand, a foamable mixture with the same composition as above was heated and foamed without using a stainless steel net, and the dirt was slowly cooled in an insulated oven for more than 10 hours, but the ceramic foam did not crack. - I was unable to obtain a large panel as described above.

<Experimental Example 2> Seventy-five parts of shirasu and 10 parts of limestone were each powdered and thoroughly mixed with 15 parts of powdered soda ash and 0.3 parts of silicon carbide to obtain a foamable mixture. Using a granulator, this is made into a powder with a diameter of about 2
It was granulated into m1I+.

In addition, as a stainless steel mesh body, 5US with a diameter of 1.6 fins is used.
A piece of wire made of 304 was woven into a tortoise shell shape with an interval of 7 cm. Then, using the apparatus shown in Fig. 1, the stainless steel mesh body was placed in the foamable mixture, heated and foamed at 1010°C, cooled to 300°C in 2 hours, and made into a 4 cm thick, 90 cm medium, Length 2.5m
, a panel with a specific gravity of 0.5 was manufactured. The resulting Banel had no cracks and was beautiful. Further, even when the obtained panel was used for a long period of time, the panel did not crack into layers due to shrinkage of the stainless steel mesh.

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 the ceramic foam cracked. , it was not possible to obtain a large panel as described above.

(Effects of the Invention) As explained above, according to the present invention, stainless steel wires with a diameter of 41 mm or less are interposed in the foamable mixture at intervals of 4 cm or more to cause foaming, so that the foaming mixture can be cooled in a very short time. The ceramic foam will not crack even when used, and will not form layers even after long-term use, greatly improving production efficiency and providing panels with a large area at low cost.

Furthermore, since the manufactured panels are made of ceramic foam, they have excellent heat insulation, durability, heat resistance, and water resistance, and since they have stainless steel wire inside the ceramic foam, they have excellent impact resistance. It has been improved. Moreover, the freeze-fracture resistance of the ceramic foam panel, which is obtained without cracking, is not reduced.

Principle 1 - Figure 1 is a schematic diagram showing an example of an apparatus for carrying out the method of the present invention, and Figure 2 is a partially cutaway perspective view of an example of a panel obtained by the method of the present invention. , 3 and 4 are cross-sectional views showing an example in which the panel shown in FIG. 2 is applied to an outer wall.

A: Foamable mixture, B: Stainless steel mesh, C:
・Ceramic foam, 50...panels.

Claims (1)

[Claims] 1. 60 to 85 parts of silicic acid-containing raw material (parts by weight, same below),
A foamable mixture is prepared by uniformly mixing 40 to 15 parts of a softening agent and 0.1 to 0.4 parts of a foaming agent, and this foamable mixture is arranged to a substantially uniform thickness, and a layer of 4 mm or less in diameter is placed on top of the foamable mixture. stainless steel wires are placed at intervals of 4 cm or more, the foamable mixture is placed on top of the wires to a substantially uniform thickness, and the foamed mixture is heated and foamed to integrate them, and then cooled. How to manufacture panels.