JPS6198531A - Glazed cement-foam system panel and manufacture thereof - 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 APPLICATION The present invention relates to glazed cement-foam panels and methods of making the same. Specifically, the present invention relates to a panel having a relatively thin glazed cement-based surface layer as one surface layer, an inorganic foam layer as an intermediate layer, and a cement-based unfired layer as a back layer, and a method for manufacturing the same. 12. The panel according to the present invention is lightweight and has sufficient panel strength. It also has an excellent surface appearance and durability.

The panel is heat-insulating, sound-insulating, and fire-resistant, and is particularly useful as, for example, large panels for construction.

Prior Art As illustrated in Fig. 3, the surface of cement 1 - hardened body 2 (hereinafter simply referred to as "cement-based hardened body"), which is the main component, is glazed and hydrated after firing to restore strength. Glazed cement-based materials 1' (hereinafter simply referred to as "glazed cement products") are known.

The glazed cement product has durability and aesthetics almost equal to those of ceramic tiles, and is suitable as a building material because it can be made into a dog-like shape compared to conventional ceramic tiles. To provide the glaze layer 3 on the surface of the hardened cement body, there are methods such as thermal spraying, vapor deposition, and firing, but the firing method is generally used from the viewpoint of cost and surface quality. When trying to obtain a glaze layer on a large surface by firing, the following happens:
& A problem arose. However, methods of applying glaze by thermal spraying or vapor deposition have insufficient effects, especially for large-sized panels.
This is difficult to implement in cases such as flannel, etc. Furthermore, the method of adhering a foam molded product after producing a glazed cement product is generally impractical because the adhesion is poor. If an expensive organic strong adhesive is used in this case, there will be problems with heat resistance, weather resistance, etc., and it will be impractical.

Problems to be solved In conventional technology, the entire glazed cement product was fired.
Energy costs will increase. Moreover.

In order to provide the required strength when used as a cement-based panel, a certain degree of wall thickness is required.

In that case, a large amount of evaporated components such as moisture, organic matter, and inorganic matter are generated from inside during firing, and pinholes, baldness, and cracks occur in the glaze layer, which is undesirable from the aesthetic point of view. Glazed cement products themselves tend to crack or burst during firing.In order to eliminate these drawbacks, the wall thickness of glazed cement products should be made as thin as possible, and internal reinforcement such as reinforcing bars should be used. A method of burying the material and firing it has also been attempted. In order to give thin panels strength during use, it is necessary to bury a large amount of reinforcing material, which increases the cost.Also, there is a difference in the expansion and contraction rates of cement-based materials and reinforcing materials during firing. Nyoshiranok often occurred. These drawbacks are all due to the fact that the entire glazed ceramic product to be obtained is fired.

Furthermore, in order to achieve effects such as weight reduction, heat insulation, and sound insulation, foam moldings may be bonded to glazed cement products using inorganic or organic adhesives.

As mentioned above, it is not practical. Furthermore, in this case, the entire foam except the adhesive surface is exposed.

There is a problem of low practical strength.

Means for Solving the Problem The present inventor has proposed the following: equivalence of firing conditions during production of glazed cement products and foam products; 1. Adhesion due to molten vitrification during foam production; The present invention was completed by focusing on the compatibility between cement mortar and cement mortar, and combining these characteristics.

In accordance with the present invention, a relatively thin inorganic cement-based surface layer 2 is glazed and fired on one surface portion as illustrated in FIG.
4. An inorganic foam intermediate layer baked and integrated with the back surface of the cement-based baked surface layer 2 by a fusible (for example, glass) adhesive. and an inorganic cement-based non-fired back layer 5 which is bonded to the porous rough surface of the back surface of the foam layer 4 with inorganic cement. A glazed cementitious panel 1a is provided.

As illustrated in FIG. It may have a side layer 6 (preferably). In this case, the upper surface of the surface layer 2 is glazed, and the side layer 6 may be glazed or unglazed. 'i.e., similar to panel 1a above, but with the cementitious surface layer 2 having at least two side layers 6 extending downwardly from its edges, at least the upper surface of the surface layer A glazed cementitious panel lb is provided in which the foam intermediate layer 4 and the cementitious back layer 5 are glazed 3 and surrounded by at least two of the side layers 6.

The glazed cement-based panel of the present invention can be manufactured, for example, by the following method. That is, a relatively thin inorganic cement system is preliminarily hydrated and hardened. A glaze 3 is applied to the surface of the molded plate 20, an inorganic foam and a raw material are filled on the back side of the molded plate surface layer 2, and both are fired to achieve glaze and foaming, and to connect them as necessary. hydrating the cement board), applying an inorganic cement-based aqueous admixture onto the rough porous back side of the fired foam intermediate layer 4 (then hydrating the cement board with the back layer 5 or the front layer 2 and the back layer 5); hydration hardening of the inorganic cement-based layer)? :Characterized. A glazed inorganic cement surface layer 2, an inorganic foam intermediate layer 4 having a fusible (glassy) adhesive on the back surface of the surface layer, and an inorganic cement adhesive on the porous rough surface on the back surface of the intermediate layer. A method is provided for making a glazed cement-based panel consisting essentially of an inorganic cement-based unfired backing layer 5 having the following properties. In addition, it is also a preferable embodiment that the back surface of the front/face layer 2 of each of the panels described above is made into a rough surface such as an uneven surface.

In the above-mentioned glazed cement-based panel and its manufacturing method, the foam intermediate layer 4 may be (a) foamed and fused to the back surface of the surface layer 2 during firing and melting of the glaze.

Alternatively, (C:I) an appropriate amount of fusing material such as glass powder or frit may be applied to the back surface of the surface layer 2, and an inorganic foam plate of suitable size may be packed therein and these may be fused. In the present invention, the firing temperature at which the inorganic cement-based surface layer 2 is rehydrated and its strength is sufficiently recovered after firing is 1000°C or less, preferably about 950°C or less. Therefore, in the above embodiment (b), the melting and foaming temperature of the raw material for inorganic foam is 1
It is particularly useful when using foams that have a temperature of 000°C or higher. Note that also in the case of the above embodiment (a), 9 surface layer 2
A fusing material may be applied between the back side of the foam and the foam stock to strengthen the bond between the two.

The inorganic cement material used in the present invention is a hydraulic inorganic cement material and an essential component of water.

Aggregates and additives are usually optional. The cementitious material can advantageously contain non-combustible fibers and/or metal fibers or wires as reinforcement. As the raw material for the inorganic foam, known materials can be used, and it is also possible to contain a small amount of reinforcing material.

Two preferred embodiments of the present invention will be described below with reference to FIG. FIG. 1 is a sectional view of an embodiment of a glazed cement panel according to the present invention.

A glaze layer 3 is provided on the surface of the molded body 2 which is mainly composed of cement and has a reinforcing material inside.
On the back side, an inorganic foam layer 42 and a mortar or concrete layer 5 are sequentially laminated. This glazed cement panel can be manufactured as follows. Ordinary portland cement.

The essential ingredients are cement such as early strength cement and alumina cement, and water, and if necessary, one or more additives such as river sand, silica sand, andesite, aggregates such as crushed ceramics, water reducing materials, plasticizers, etc. are kneaded. The mortar raw material is molded into a molded body 2 by a molding method such as extrusion molding, press molding, cast molding, direct spray molding, spray suction molding, etc., and a reinforcing material is embedded inside. Here, as a reinforcing material.

Fibers such as asbestos, metal fibers, inorganic fibers, and wires such as metal wires can be used. Since the material is fired, a heat-resistant reinforcing material such as stainless steel or inorganic fiber is preferable. As a method for embedding the reinforcing material in the thin-walled molded body, if the reinforcing material is fiber, it may be mixed into one mortar raw material at the same time. If it is a wire rod, it can be embedded by wiring it in a mold and placing it, or by co-extrusion molding. The surface of the thin-walled molded body is glazed with a glaze raw material whose main ingredients are glass powder and 7-litre. After placing the inorganic foam raw material on the back side, it is baked at 600°C to 950°C for about 10 minutes to 6 hours.
9. A cement fired body is obtained which has a glaze layer on its surface and an integrally formed inorganic foam layer on its back side. here,
As a raw material for inorganic foam.

Use materials such as nacre, obsidian, and whitebait that foam and self-fuse when heated, or materials that foam internally when heated, such as a mixture of glass powder and dolomite or a mixture of cement and aluminum powder. I can do it. During the above firing, preliminary heating may be performed before or after glazing. Next.

Before, during, or after curing of the fired cement body, conventional mortar or concrete can be laminated on the back side of the inorganic foam layer to obtain the desired glazed cement panel. In this case, by embedding reinforcing material in the mortar or concrete layer, the glazed cement panel can be made to have even higher strength. The mortar layer and concrete layer are not fired.

There is no need to pay much attention to the material of the reinforcing material or the amount added. Any method such as underwater curing, steam curing, or humid air curing can be used for curing the fired body, but steam curing is preferable from the viewpoint of early increase in strength.

According to another preferred embodiment, a side surface layer 6 as shown in FIG. An example is an embodiment in which the fired foam, the intermediate layer 4, and the inorganic cement-based unfired back layer 5 are housed in a container-like space. In this case, the intermediate layer 4 and the back layer 5 also adhere well to the side surfaces 6 of the surface layer 2. Furthermore, it is advantageous if the cementitious material of the inorganic cementitious back layer 5 contains an expansive cement admixture. That is, inorganic cement mortars generally tend to shrink to a greater or lesser extent during their hydration hardening. Therefore, in the present invention, the cement material for the back layer applied to the container-like space of the surface layer contains at least a non-shrinkage amount of an expandable cement admixture in order to prevent shrinkage during the hydration hardening process. It is desirable to do so.

This strengthens the adhesion. Note that the term "expandable admixture" refers to a material that has the property of forming a hardening structure different from that of cement and expanding after cement mortar has hardened to some extent. Typically.

SuruC8 containing calcium, sulfo, and aluminate components
A (trade name, Denki Kagaku Kogyo Co., Ltd.) and Asano Dipcal (
Examples include (trade name 1 Nippon Cement Co., Ltd.) and Expan (trade name, Onoda Cement Co., Ltd.) containing a calcium oxide component. The amount of the admixture used in the present invention is generally from about 2 to about 10 parts C per 100 parts dry weight of cement.
This is range 1.

If it is less than about 1 part, the effect will not be sufficient, and if it exceeds about 20 parts, the strength of the mortar itself will decrease and cracks will tend to occur.

1. The thin or relatively thin thickness of the cement-based surface layer of the present invention means a thickness that does not cause cracks during firing, and is generally 5 to 40 mm, usually 7 to 30 mm, preferably 1 to 20 mm. This is the extent of

- Effect Glazing the surface of the relatively thin cement-based surface layer and fusing the foam intermediate layer are performed at the same time by firing.

A cementitious non-fired back layer is then applied to the rough porous surface of the foam layer and cured and bonded; it is lightweight and has sufficient strength for practical use as a panel.

It has excellent surface appearance and durability, as well as excellent heat insulation, sound insulation, and fire resistance, and does not cause cracks or ruptures or pinholes on the glaze surface during firing.
It is also possible to advantageously obtain a glazed cement panel whose energy cost during firing is lower than that of conventional products.

Example 1 Aggregate 2 consisting of 1 part by weight of inorganic cement material, 100 parts of ordinary Poldranodosemet, and crushed ceramics.
00 parts, stainless steel fiber 5 parts, water 40 parts.

A mixture consisting of 1 part water reducing agent was used. This blend material was poured and vacuumed to form a 1m x 1m x 15m
A plate-shaped molded product with a thickness of m (thickness) was obtained.

This f: Leave it in the air for 3 days for initial curing, dry it at 200'C for 30 minutes, and spray it on the top surface of the molded product using a glaze whose main components are 7 liters, pigments, and water. Glazed.

After the glaze had substantially dried, 9 parts by weight of a foam raw material consisting of 95 parts of glass powder and 5 parts of dolomite was filled onto the back surface of the molded product, and these were fired at 850°C for 30 minutes and then baked for 1 day. Steam cured. The thickness of the foam layer is approximately 30 on
It was +.

The above admixture material was then poured onto the back side of the foam layer of the composite to a thickness of about 10 mm and steam cured for one day.

Results of inspection of the obtained glazed cement panel.

The glazed surface was uniform and had no pinholes, no cracks were observed in the fired core layer, and the surface layer, middle layer, and back layer were each firmly adhered.

Example 2 1mX1mxism instead of the plate-shaped molded product in Example 1
A container-shaped molded product having a thickness of m (thickness) and a container-shaped space having a depth of 40 mm was used. The cement mixture for the back layer further contained 5 parts by weight of an expandable admixture (C8A). Other procedures were carried out in the same manner as in Example 1 to obtain a panel in which the back layer was in close contact with the container-shaped frame.

Effects of the Invention All of the problems described in the column of problems to be solved have been advantageously solved. According to the present invention, the glazed cement-based surface layer is thinner than conventional products, but this is because reinforcing material is mixed into the surface layer (and the cement-based back layer) as necessary, so that the strength can be reduced by 5%. Weight reduction can be achieved without any problems. It is also insulated by two strongly bonded foam interlayers.

Effects such as fire resistance and sound insulation can also be achieved.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a glazed cement-based panel of the present invention. FIG. 2 is a cross-sectional view of a panel according to another embodiment of the present invention. , FIG. 3 is a cross-sectional view of a conventional glazed cement panel. 1alb,...Glazed cement-based panel, 2--Cement surface layer, 3--Glazed surface, 4--Foam intermediate layer. 5...Cement-based back layer. 2; Cement-based surface 1 Procedures Yes (Voluntary) January 1, 1985 78 1. Indication of the incident 1988 Patent Application No. 220975 2. Title of the invention Glazed cement/foam panel and its manufacturing method 3. Relationship with the case of the person making the amendment Patent applicant address 3-6 Koiegicho, Tokoname City, Aichi Prefecture 479 05693-5-2700 4. Date of amendment order 6, Contents of amendment (1) First line of the application ``Patent application'' will be corrected to ``Patent application (patent application pursuant to the proviso to Article 38 of the Patent Patent Act) J. Insert the number of inventions 2. (3) Based on the name change notification submitted on April 30, 1985, the applicant's name will be changed to Inax Co., Ltd. 7. List of attached documents

Claims (3)

[Claims] (1) A relatively thin inorganic cement-based surface layer that is glazed and fired on the surface, an inorganic foam intermediate layer that is baked and integrated with the back side of the cement-based fired surface layer by fusion adhesive,
and a glazed cementitious panel consisting essentially of an inorganic cementitious unfired back layer having an inorganic cementitious bond to the rough porous back surface of the foam layer. (2) the cementitious surface layer has at least two side layers extending downwardly from its ends, at least the upper surface of the surface layer is glazed; The glazed cementitious panel of claim 1, wherein the foam intermediate layer and the cementitious back layer are surrounded by the side layer. (3) Apply a glaze to the surface of a relatively thin inorganic cement-based pre-hydration-hardened surface layer molding, and fill the back side of the molded surface layer with an inorganic foam raw material for the intermediate layer. glazing, characterized by the step of firing both to achieve glazing and foaming and adhesion between the two, and applying an inorganic cement-based aqueous mixture onto the rough porous surface on the back side of the fired foam intermediate layer. An inorganic cement-based surface layer, an inorganic foam intermediate layer with a fusible adhesive on the back side of the surface layer, and an inorganic cement-based intermediate layer with an inorganic cement adhesive on the porous rough surface on the back side of the intermediate layer. A method of manufacturing glazed cement-based panels consisting essentially of an unfired back layer.