RU2800656C2 - Device for manufacturing building material and method for manufacturing building material - Google Patents

Abstract

FIELD: building materials.

SUBSTANCE: invention relates to a device and method for manufacturing a building material such as a building board. The device for the manufacture of building material comprises a screening unit, which includes a set of sheets, each of which is configured to carry out wave motion during operation of the device, which have an inclination and which are located in the direction of the inclination, and the set of sheets includes the first screening sheet and the second screening sheet located under the first screening sheet, the first screening sheet is a sheet in which a plurality of cells having the same size are arranged with a constant step in the sheet width direction of the set of sheets, and the second screening sheet is a sheet, in which a plurality of cells having two or more different sizes are arranged in the sheet width direction, or a sheet that has a cellular area and a non-cellular area, which are located in the sheet width direction; and a receiver for receiving building raw material that has passed through the cells of the screening unit, the receiver being able to move under a set of sheets.

EFFECT: creating a building material with high strength and high water resistance.

10 cl, 22 dwg

Description

Technical field

[0001]

The present invention relates to an apparatus and method for manufacturing a building material such as a building board.

State of the art

[0002]

Examples of a building material that is a building board for building an exterior wall and an interior wall of a building include inorganic material boards such as fiber reinforced cement cladding boards and ceramic boards, fibreboards such as particle boards, and resin impregnated boards.

[0003]

As a method for manufacturing various types of building materials, a technology is known that includes the following steps: a step of forming a raw material carpet by depositing a powder raw material that is a building material that has been sifted and has a predetermined size onto a receptacle or the like while sieving the powder raw material. material by air sorting; and a heat-pressing step of the raw material carpet. For example, Patent Document 1 describes a building material manufacturing method using such technology.

Link List

Patent Literature

[0004]

Patent Document 1: Japanese Published Unexamined Patent Application No. 7-124926

Disclosure of the essence of the invention

Technical task

[0005]

The existing production apparatus for carrying out the aforementioned building material manufacturing method includes, for example, as a mechanism for the carpet forming step, a sifting unit that performs sieving by air sorting, a raw material supply unit for dropping, and supplying powder raw material to the sieving unit and a receiver. for receiving the sifted starting material having a predetermined size.

[0006]

The screening unit includes a blower that blows air horizontally to the falling powder raw material, and a screening screen that is located at a location where the mesh cells face the air coming from the blower and that is inclined at a predetermined angle so as to be separated from blower. When the device is in operation, the powder raw material is dropped from the raw material supply unit to the position between the blower and the screen mesh, the blower blows air towards the screen mesh, part of the powder raw material passes through the screen mesh or cells of the screen mesh, and then falls and is received by the receiver (the other part of the powder raw material cannot pass through the screen and falls). Then a carpet of starting material is formed when a portion of the powdered starting material that has passed through the screening mesh is deposited on the receptacle.

[0007]

With the existing building material manufacturing apparatus having such a mechanism, it is difficult to change the amount of deposited building raw material on the bin in the bin width direction corresponding to the screen wire width direction. When such a device forms a carpet of raw material on the receptacle using a pattern having a dimple/protrusion pattern that matches the construction surface of the building material to be produced, on its inner surface as a receptacle, the building material is deposited substantially uniformly on the recesses and protrusions of the inner surface of the receptacle. In the building material which is obtained by thermally pressing the raw material carpet thus formed, a difference in texture density is likely to occur between the part where the depression is formed and the part where the protrusion is formed on the construction surface. A building material having a large difference in density is not preferred because it tends to crack.

[0008]

On the other hand, it is possible to provide a building material having high strength and high water resistance by forming end portions of the building material with high density. However, with the existing building material manufacturing apparatus with which it is difficult to change the amount of deposited building raw material on the receptacle in the width direction of the receptacle, it is difficult to form end portions of the building material having a high density while ensuring sufficient thickness of the end portions.

[0009]

The present invention has been made in view of such a prior art, and its object is to provide a building material manufacturing apparatus and a building material manufacturing method, each of which is suitable for changing in the width direction of the receptacle the amount of deposited building raw material on the receptacle for forming a building material, which receives the building raw material under the screening unit, which sifts the building raw material.

The solution of the problem

[0010]

According to a first aspect of the present invention, there is provided a device for manufacturing a building material. This device for the manufacture of building material contains a screening unit and a receiver.

[0011]

The screening unit includes a set of sheets. Each sheet of the set of sheets is made with the possibility of performing a wave movement during operation of the device, has an inclination and is located in the direction of the inclination. The set of sheets includes a first screening sheet and a second screening sheet, which is located under the first screening sheet. The first screening sheet is a sheet in which a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction of the stack of sheets. The second screening sheet is a sheet (first type) in which a plurality of cells having two or more different sizes are arranged in the sheet width direction, or a sheet (second type) which has a mesh area and a non-mesh area which are arranged in the sheet width direction . The sheet width direction is, for example, a direction perpendicular to the direction in which the stack of sheets is arranged.

[0012]

In the present invention, the wave motion of the sheet is, for example, a motion in which the sheet repeats vibration in its thickness direction and which has a vibration antinode. The speed of wave motion increases with decreasing period of oscillations. This wave motion is realized, for example, by operating a vibrator, such as an eccentric vibrator, which is connected to each sheet through a predetermined driving force transmission mechanism.

[0013]

The receiver is designed to receive building raw material that has passed through the cells of the screening unit, and is configured to move under a set of sheets.

[0014]

When the building material manufacturing apparatus is operated, in a state in which each sheet of the screening unit sheet set makes a wave motion as described above, a building raw material such as a powder raw material is dropped onto the sheet, for example, at an upper end in a tilt direction. a set of sheets, and the source material is fed to the screening unit. The building raw material supplied is a mixture of particles of various sizes. In the screening unit of the present apparatus, such a building raw material is screened by each screening sheet included in the sheet set in the downstream process of the sheet set, and is pulverized by colliding with the sheet set in a wave motion state.

[0015]

A portion of the building stock that has been screened by the first screen sheet and thus passed through the cells of the first screen sheet may be deposited on a receptacle at a position below the first screen sheet. In the first screening sheet as described above, a plurality of cells having the same size are arranged at a constant pitch in the width direction of the sheet. The building stock having passed through the cells of the first screening sheet is deposited substantially uniformly on the receptacle and forms a first layer whose thickness in the receptacle width direction corresponding to the sheet width direction is substantially uniform.

[0016]

A portion of the building stock that has been screened by the second screen sheet and thus passed through the cells of the second screen sheet may be deposited on top of the first layer on the receptacle at a position below the second screen sheet. The portion of building stock that has passed through the cells of the second screening sheet forms a second layer on top of the first layer.

[0017]

In the case where the second screening sheet is a first type sheet (a sheet in which a plurality of cells having two or more different sizes are arranged in the width direction of the sheet), with respect to the building raw material forming the second layer on top of the first layer, the settling amount is larger under larger meshes of the second screening sheet, and the settling amount is less under the finer meshes of the second screening sheet. In other words, the raw material carpet, which has such a second layer, which also functions as a deposition amount adjustment layer of the building raw material, in addition to the aforementioned first layer, and which is formed on the receptacle, is a raw material carpet such that the amount of the building raw material to be deposited varies in the direction of the width of the receiver.

[0018]

In the case where the second screening sheet is a second type sheet (a sheet that has a honeycomb area and a non-cellular area that are located in the width direction of the sheet), while the second layer is formed by depositing the building raw material on top of the first layer under the honeycomb area of the second screen sheet, the building raw material is essentially not deposited under the non-cellular area of the second screen sheet. In other words, the raw material mat which has such a second layer, which also functions as a building raw material deposition amount adjustment layer, in addition to the aforementioned first layer, and which is formed on the receptacle, is a raw material mat such that the deposited building raw material amount varies in the direction of the width of the receiver.

[0019]

In the case where the second screening sheet is of the second type, the second screening sheet may have a honeycomb area in which a plurality of cells having two or more different sizes are arranged in the width direction of the sheet. With such a second screen sheet, the aforementioned positive effects are jointly produced in the case where the second screen sheet is a first type screen sheet and the aforementioned positive effects when the second screen sheet is a second type screen sheet.

[0020]

As described above, the building material manufacturing apparatus is suitable for changing, in the width direction of the receptacle, the amount of deposition of the building raw material on the building material forming receptacle receiving the building raw material under the screening unit, which screens the building raw material and thereby performs mechanical sorting of the building raw material.

[0021]

Such a building material manufacturing apparatus is suitable for manufacturing a building material having an indentation/protrusion pattern on its structural surface while reducing density unevenness. An example is the following.

[0022]

In the present building material manufacturing apparatus, when forming a mat of raw material on a receiver using a pattern having a recess/protrusion pattern for the structural surface of the building material, a second screening sheet of the first type or the second type is used as a receiver on its inner surface, together with the pattern, which can change the amount of deposition of the building raw material in accordance with the pattern of recesses/protrusions. The second screening sheet of the first type has, for example, a relatively large mesh in the part corresponding to the recess on the inner surface of the receiver, and a relatively small mesh in the part corresponding to the protrusion on the inner surface of the receiver. The second screening sheet of the second type has, for example, a honeycomb area in a part corresponding to a depression on the inner surface of the receptacle, and a non-cellular area in a part corresponding to a protrusion on the inner surface of the receptacle.

[0023]

By using such a second screening sheet in the present apparatus, it is possible to form a raw material carpet in which the deposition amount of the building raw material on the bin is changed in the bin width direction according to the recess/protrusion pattern of the inner surface of the bin. By thermally pressing such a raw material carpet, it is possible to produce a building material from the raw material carpet in which the difference in texture density between the part where a recess is formed on the structural surface of the building material and the part where a protrusion is formed on the structural surface of the building material, that is, the building material, is reduced. material having low density heterogeneity. A building material having low density non-uniformity is resistant to cracking and is therefore preferred.

[0024]

The building material manufacturing apparatus is suitable for manufacturing a building material whose end portions have sufficient thickness and high density at both ends in the receiver width direction. For example, using a building material manufacturing device, a base material carpet is formed on a receptacle using as a second screening sheet a sheet that has honeycomb areas at both of its end portions in the width direction of the sheet and has at least one non-cellular area between the honeycomb areas. In this case, in the base material mat formed on the receptacle, the deposition amount of the building raw material at both end portions (portions corresponding to the cellular regions) in the width direction of the receptacle is larger than the deposition amount of the building raw material in the portion corresponding to the non-cellular region.

[0025]

By thermally pressing such a raw material carpet, it is easy to produce a building material from the raw material carpet, the end portions of which have sufficient thickness and high density at both ends thereof in the receiver width direction. Forming the end portions of the building material with high density is suitable for providing high strength and high water resistance of the building material.

[0026]

In the present building material making apparatus, it is preferable that the size of each cell of the second screen sheet is larger than the size of each cell of the first screen sheet.

[0027]

Such a configuration is suitable for forming a base material carpet on the receptacle, including a first layer that has a very uniform thickness in the receptacle width direction and that is composed of a relatively fine-grained building base material, and a second layer that also functions as a deposition amount control layer of the building base material. material and which consists of a relatively coarse building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a second layer composed of a relatively coarse-grained building raw material by changing the deposition amount of the building raw material in the width direction of the receptacle. .

[0028]

The first layer in the raw material carpet, which is composed of a relatively fine-grained building raw material, is suitable for the surface layer, which has a denser texture and easily achieves high waterproof performance, in a building material that is formed by thermal pressing of the raw material carpet. The second layer in the raw material mat, which is composed of a relatively coarse-grained building raw material, is suitable for the inner layer, which has a less dense texture and easily provides a high cushioning capacity, in a building material that is formed by thermal pressing of the raw material mat.

[0029]

In the present building material making apparatus, preferably the second screening sheet has a honeycomb area in each of its two end portions in the width direction of the sheet, and has at least one non-cellular area between the honeycomb regions.

[0030]

As described above, such a configuration is suitable for producing a building material whose end portions have sufficient thickness and high density at both ends in the width direction of the receiver.

[0031]

Preferably, in the present building material making apparatus, the set of sheets includes a third screen sheet positioned below the second screen sheet, the third sheet being a sheet in which a plurality of cells having the same size greater than each cell size of the first screen sheet are arranged at a constant step in the direction of the sheet width.

[0032]

Such a configuration is suitable for forming a base material mat on the receptacle, including a first layer that has a very uniform thickness in the receptacle width direction and that is composed of a relatively fine-grained building raw material, a second layer that also functions as a deposition amount control layer of the building raw material. and which is composed of a relatively coarse-grained building raw material, and a third layer, which has a very uniform thickness in the width direction of the receiver and which is composed of a relatively coarse-grained building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a second layer and a third layer composed of a relatively coarse-grained building raw material by changing the deposition amount of the building raw material in receiver width direction.

[0033]

Preferably, in the present building material manufacturing apparatus, the set of sheets includes a third screening sheet disposed between the first screening sheet and the second screening sheet, the third sheet being a sheet in which a plurality of cells having the same size greater than each cell size of the first screening sheet. , are located with a constant step in the direction of the sheet width.

[0034]

Such a configuration is suitable for forming on the receptacle a base material carpet including a first layer which has a very uniform thickness in the receptacle width direction and which is composed of a relatively fine-grained building base material, a third layer which has a very uniform thickness in the receptacle width direction and which is composed of a relatively coarse-grained building raw material, and a second layer which also functions as a deposition amount control layer of the building raw material and which is composed of a relatively coarse-grained building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a third layer and a second layer composed of a relatively coarse-grained building raw material, while changing the deposition amount of the building raw material in receiver width direction.

[0035]

According to a second aspect of the present invention, a method for manufacturing a building material is provided. The manufacturing method is carried out using the following screening unit and receiver.

[0036]

The screening unit includes a set of sheets. The set of sheets has a slope and is located in the direction of the slope. The set of sheets includes a first screening sheet and a second screening sheet, which is located under the first screening sheet. The first screening sheet is a sheet in which a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction of the stack of sheets. The second screening sheet is a sheet (first type) in which a plurality of cells having two or more different sizes are arranged in the sheet width direction, or a sheet (second type) which has a mesh area and a non-mesh area which are arranged in the sheet width direction . The sheet width direction is, for example, a direction perpendicular to the direction in which the stack of sheets is located.

[0037]

The receiver is designed to receive building raw material that has passed through the cells of the screening unit, and is configured to move under a set of sheets.

[0038]

In this manufacturing method, in a state in which each of the screening unit sheet set makes a wave motion as described above, a building raw material such as a powder raw material is dropped onto the sheet, for example, at the upper end in the direction of the inclination of the sheet set, and the source material is fed to the screening unit. The building raw material supplied is a mixture of particles of various sizes. In the screening unit of the present method, such a building raw material is screened by each screening sheet included in the sheet set in the downstream process of the sheet set, and is pulverized by colliding with the sheet set in a wave motion (screening) state.

[0039]

The manufacturing method includes forming a carpet on the receiver, including the first layer formed from the building raw material that passed through the cells of the first screening sheet, and the second layer formed over the first layer from the building raw material that passed through the cells of the second screening sheet. When the carpet of the starting material is subjected to thermal pressing, a predetermined building material is produced in the form of a board.

[0040]

In the building material manufacturing method, a portion of the building raw material that has been screened by the first screen sheet and thus passed through the cells of the first screen sheet may be deposited on a receptacle at a position below the first screen sheet. In the first screening sheet as described above, a plurality of cells having the same size are arranged at a constant pitch in the width direction of the sheet. The building stock having passed through the cells of the first screening sheet is deposited substantially uniformly on the receptacle and forms a first layer whose thickness in the width direction of the receptacle is substantially uniform.

[0041]

With this building material manufacturing method, a portion of the building raw material that has been screened by the second screen sheet and thus passed through the cells of the second screen sheet can be deposited on top of the first layer on the receptacle at a position below the second screen sheet. The portion of building stock that has passed through the cells of the second screening sheet forms a second layer on top of the first layer.

[0042]

In the case where the second screening sheet is a first type sheet (a sheet in which a plurality of cells having two or more different sizes are arranged in the width direction of the sheet), with respect to the building raw material forming the second layer on top of the first layer, the settling amount is greater under the larger meshes of the second screening sheet, and the settling amount is less under the finer meshes of the second screening sheet. In other words, the raw material carpet, which has such a second layer, which also functions as a deposition amount adjustment layer of the building raw material, in addition to the aforementioned first layer, and which is formed on the receptacle, is a raw material carpet such that the amount of the building raw material to be deposited varies in the direction of the width of the receiver.

[0043]

In the case where the second screening sheet is a second type sheet (a sheet that has a honeycomb area and a non-cellular area that are located in the width direction of the sheet), while the second layer is formed by depositing the building raw material on top of the first layer under the honeycomb area of the second screen sheet, the building raw material is essentially not deposited under the non-cellular area of the second screen sheet. In other words, the raw material carpet, which has such a second layer, which also functions as a deposition amount adjustment layer of the building raw material, in addition to the aforementioned first layer, and which is formed on the receptacle, is a raw material carpet such that the amount of the building raw material to be deposited varies in the direction of the width of the receiver.

[0044]

In the case where the second screening sheet is of the second type, the second screening sheet may have a honeycomb area in which a plurality of cells having two or more different sizes are arranged in the width direction of the sheet. With such a second screen sheet, the aforementioned positive effects are jointly produced in the case where the second screen sheet is a first type screen sheet and the aforementioned positive effects when the second screen sheet is a second type screen sheet.

[0045]

As described above, the building material manufacturing method is suitable for changing, in the bin width direction, the amount of deposition of the building raw material on the building material forming bin receiving the building raw material under the screening unit, which screens the building raw material while mechanically sorting the building raw material. In the same manner as described above with respect to the first aspect of the present invention, the building material manufacturing method is suitable for manufacturing a building material having a recess/protrusion pattern on its structural surface, and thereby reduces density non-uniformity, and is also suitable for manufacturing a building material, end sections of which have sufficient thickness and high density at both ends in the direction of the width of the receiver.

[0046]

In the present building material manufacturing method, it is preferable that the size of each cell of the second screen sheet is larger than the size of each cell of the first screen sheet.

[0047]

Such a configuration is suitable for forming a base material carpet on the receptacle, including a first layer that has a very uniform thickness in the receptacle width direction and that is composed of a relatively fine-grained building base material, and a second layer that also functions as a deposition amount control layer of the building base material. material and which consists of a relatively coarse building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a second layer composed of a relatively coarse-grained building raw material by changing the deposition amount of the building raw material in the width direction of the receptacle. .

[0048]

In the present building material manufacturing method, preferably the second screening sheet has a honeycomb area in each of its two end portions in the width direction of the sheet, and has at least one non-cellular area between the honeycomb areas.

[0049]

Such a configuration is suitable for producing a building material whose end portions have sufficient thickness and high density at both ends in the width direction of the receiver.

[0050]

In the present building material manufacturing method, preferably, the set of sheets includes a third screening sheet located below the second screening sheet, the third sheet being a sheet in which a plurality of cells having the same size greater than the size of each cell of the first screening sheet are arranged at a constant pitch. in the direction of the sheet width; and the method includes forming a carpet on the receiver, including a first layer formed from a building raw material that has passed through the cells of the first screening sheet, a second layer formed on top of the first layer of building raw material that has passed through the cells of the second screening sheet, and a third layer, formed on top of the second layer of building material passed through the cells of the third screening sheet.

[0051]

Such a configuration is suitable for forming a base material mat on the receptacle, including a first layer that has a very uniform thickness in the receptacle width direction and that is composed of a relatively fine-grained building raw material, a second layer that also functions as a deposition amount control layer of the building raw material. and which is composed of a relatively coarse-grained building raw material, and a third layer, which has a very uniform thickness in the width direction of the receiver and which is composed of a relatively coarse-grained building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a second layer and a third layer composed of a relatively coarse-grained building raw material by changing the deposition amount of the building raw material in receiver width direction.

[0052]

In the present building material manufacturing method, preferably, the set of sheets includes a third screening sheet located between the first screening sheet and the second screening sheet, the third sheet being a sheet in which a plurality of cells having the same size, greater than the size of each cell of the first screening sheet, arranged with a constant step in the direction of the width of the sheet; and the method includes forming a carpet on the receiver, including a first layer formed from a building raw material that has passed through the cells of the first screening sheet, a third layer formed on top of the first layer of building raw material that has passed through the cells of the third screening sheet, and a second layer, formed on top of the third layer of building material passed through the cells of the second screening sheet.

[0053]

Such a configuration is suitable for forming on the receptacle a base material carpet including a first layer which has a very uniform thickness in the receptacle width direction and which is composed of a relatively fine-grained building base material, a third layer which has a very uniform thickness in the receptacle width direction and which is composed of a relatively coarse-grained building raw material, and a second layer which also functions as a deposition amount control layer of the building raw material and which is composed of a relatively coarse-grained building raw material. Accordingly, this configuration is suitable for forming on the receptacle a raw material carpet including a first layer composed of a relatively fine-grained building raw material and a third layer and a second layer composed of a relatively coarse-grained building raw material, while changing the deposition amount of the building raw material in receiver width direction.

Brief description of the drawings

[0054]

[Fig. 1] FIG. 1 is a schematic view of a building material manufacturing apparatus according to a first embodiment of the present invention.

[Fig. 2] FIG. 2 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. 1.

[Fig. 3] FIG. 3 is a schematic sectional view in the width direction of the receptacle showing how a stack of layers in a carpet is formed on the receptacle of the building material manufacturing apparatus shown in FIG. 1.

[Fig. 4] FIG. 4 is a schematic sectional view in the width direction of the bin showing how a stack of layers in a bin carpet is formed in a modification of the building material manufacturing apparatus shown in FIG. 1.

[Fig. 5] FIG. 5 is a schematic view of a building material manufacturing apparatus according to a second embodiment of the present invention.

[Fig. 6] FIG. 6 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. 5.

[Fig. 7] FIG. 7 is a schematic sectional view in the width direction of the receptacle showing how a stack of layers in a carpet is formed on the receptacle of the building material manufacturing apparatus shown in FIG. 5.

[Fig. 8] FIG. 8 is a schematic view of a building material manufacturing apparatus according to a third embodiment of the present invention.

[Fig. 9] FIG. 9 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. 8.

[Fig. 10] FIG. 10 is a schematic sectional view in the width direction of the receptacle showing how a stack of layers in a carpet is formed on the receptacle of the building material manufacturing apparatus shown in FIG. 8.

[Fig. 11] FIG. 11 is a schematic view of a building material manufacturing apparatus according to a fourth embodiment of the present invention.

[Fig. 12] FIG. 12 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. eleven.

[Fig. 13] FIG. 13 is a schematic sectional view in the width direction of the receptacle showing how a stack of layers in a carpet is formed on the receptacle of the building material manufacturing apparatus shown in FIG. eleven.

[Fig. 14] FIG. 14 shows the layout of sheets in a modification of the building material manufacturing apparatus shown in FIG. eleven.

[Fig. 15] FIG. 15 is a schematic sectional view, in the width direction of the receiver, of the receiver in a modification of the building material manufacturing apparatus shown in FIG. eleven.

[Fig. 16] FIG. 16 is a schematic sectional view in the width direction of the bin showing how a stack of layers in a bin carpet is formed in a modification of the building material manufacturing apparatus shown in FIG. eleven.

[Fig. 17] FIG. 17 is a schematic view of a building material manufacturing apparatus according to a fifth embodiment of the present invention.

[Fig. 18] FIG. 18 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. 17.

[Fig. 19] FIG. 19 is a schematic sectional view in the bin width direction showing how a stack of layers in a bin carpet is formed in the building material manufacturing apparatus shown in FIG. 17.

[Fig. 20] FIG. 20 is a schematic view of a building material manufacturing apparatus according to a sixth embodiment of the present invention.

[Fig. 21] FIG. 21 shows the sheet arrangement of the building material manufacturing apparatus shown in FIG. 20.

[Fig. 22] FIG. 22 is a schematic sectional view in the width direction of the receptacle showing how a stack of layers in a carpet is formed on the receptacle of the building material manufacturing apparatus shown in FIG. 20.

Implementation of the invention

[0055]

On FIG. 1 is a schematic view of a building material manufacturing apparatus X1 according to the first embodiment of the present invention. The building material manufacturing apparatus X1 includes a screening unit 10, a raw material supplying unit 20, and a receptacle 30. The building material manufacturing apparatus X1 can form a building material carpet that becomes a building material after passing through a heat-pressing step by depositing a building raw material of a predetermined size.

[0056]

The sieving unit 10 includes a set of sheets which are capable of performing a wave movement during operation of the device, which are inclined and which are located in the direction of the inclination; and a body 10' to which a set of sheets is attached to carry out the wave movement of each sheet. In the present embodiment, the wave motion of the sheet is a motion in which the sheet repeats the vibration in its thickness direction, and the speed of the wave motion increases as the vibration period decreases.

[0057]

In the present embodiment, the set of sheets in the screening unit 10 includes a receiving sheet 11, a screening sheet 12 as a first screening sheet, a screening sheet 13 as a second screening sheet, a screening sheet 14 as a third screening sheet, and a transfer sheet 15. Each the sheet is an elastic sheet having resilience, and is preferably a urethane-based rubber sheet. The thickness of the sheet is, for example, 2 to 5 mm. The angle of inclination of the set of sheets in the screening unit 10 is, for example, from 6 to 25 degrees relative to the horizontal.

[0058]

On FIG. 2 shows the layout of the sheet set in the present embodiment. In the sheet set in the present embodiment, the sheets are arranged in the following order, starting from its upper end: receiving sheet 11, screening sheet 12, screening sheet 13, transfer sheet 15, and screening sheet 14.

[0059]

The receiving sheet 11 is located at the upper end of the sheet stack and receives the raw material which is discarded when the apparatus is operated. The receiving sheet 11 does not have any cells. As shown in FIG. 1, the screen sheet 12 is below the take-up sheet 11, the screen sheet 13 is below the screen sheet 12, the transfer sheet 15 is below the screen sheet 13, and the screen sheet 14 is below the transfer sheet 15. As shown in FIG. 2, sheets 12, 13 and 14 each have cells.

[0060]

In the screening sheet 12, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction of the sheet set. The size of each cell of the screening sheet 12, that is, the size of the opening, is, for example, from 1 to 30 mm. In the present embodiment, the sheet width direction W is a direction perpendicular to the direction in which the stack of sheets is arranged (layout direction D).

[0061]

The screening sheet 13 has honeycomb regions R1 and non-cellular regions R2, which are located in the width direction W of the sheet. In the present embodiment, the screen sheet 13 has a honeycomb region R1 in a portion corresponding to a depression on the inner surface of the bin 30 (described below) and a non-cellular region R2 in a portion corresponding to a protrusion on the inner surface of the bin 30. In the honeycomb region R1, a plurality of cells having the same size, arranged with a constant step in the W direction of the sheet width. The size of each cell of the cell area R1 is larger than the size of each cell of the screen sheet 12. In particular, the size of each cell of the cell area R1 of the screen sheet 13, that is, the hole size, is, for example, 10 to 40 mm, provided that the hole size is larger. than the size of each cell of the screen sheet 12. In contrast, the non-mesh area R2 has no cells.

[0062]

In the screening sheet 14, a plurality of cells having the same size, which is larger than the size of each cell of the screening sheet 13, are arranged at a constant pitch in the sheet width direction W. The size of each cell of the screen sheet 14, that is, the size of the opening, is, for example, 30 to 50 mm, provided that the size of the opening is larger than the size of each cell of the mesh area R1 of the screen sheet 13.

[0063]

The transfer sheet 15 is a non-cellular sheet, like the receiving sheet 11.

[0064]

The body 10' of the screening unit 10 includes an inner frame, an outer frame, and an eccentric vibrator.

[0065]

The inner frame has a pair of inner side plates extending parallel to each other and a plurality of cross beams (first cross beams) extending in a direction in which the inner side plates are spaced apart and spanning the space between the inner side plates. Each first transverse beam has a sheet fastening section in its upper end part.

[0066]

The outer frame has a pair of outer side plates extending in parallel along a pair of inner side plates at positions outside the inner side plates, and a plurality of cross beams (second cross beams) extending in a direction in which the outer side plates are spaced apart and spanning the space between outer side plates. Every second transverse beam has a sheet fastening section in its upper end part.

[0067]

The inner frame and the outer frame are arranged in such a way that the upper end parts of the first transverse beams (having sheet fastening areas) of the inner frame and the upper end parts of the second transverse beams (having sheet fastening areas) of the outer frame are arranged alternately and in parallel. The outer frame, or a pair of its outer side plates, is suspended by a support leaf spring (not shown) relative to the inner frame, or its pair of inner side plates. In the state in which the outer frame is attached in this way, the inner frame is placed on the base (not shown) having a predetermined inclination through the rubber pad (not shown).

[0068]

The inner frame and the outer frame are connected to an eccentric vibrator (not shown) serving as a vibration source through a driving leaf spring (not shown). Specifically, the inner frame and the outer frame are connected to the eccentric vibrator via a driving leaf spring so that the inner frame and the outer frame can reciprocate having a phase difference of 180 degrees when the eccentric vibrator is driven. The driving speed of the rotational movement of the eccentric vibrator during operation of the device is, for example, 500 to 600 rpm.

[0069]

Each sheet of the above set of sheets of the screening unit 10 is attached to the first and second cross beams, which are adjacent to each other. In particular, one end of each sheet in the sheet direction D is attached to the sheet attachment portion of the first transverse beam, and the other end of each sheet in the sheet arrangement direction D is attached to the sheet attachment portion of the second transverse beam adjacent to the first transverse beam.

[0070]

Examples of the body 10' of the sieve unit 10, that is, the mechanism that causes the set of sheets in the sieve unit 10 to make wave motions, include the body of the "Jumping Screen" sifter (registered trademark) manufactured by URAS TECHNO Co. Ltd.

[0071]

The raw material supply unit 20 for supplying the raw material to the screening unit 10 by dropping the building raw material M onto the receiving sheet 11 in the screening unit 10 includes a conveyor belt 21 and an alignment unit 22 .

[0072]

The conveyor belt 21 transports the building material M to a position above the receiving sheet 11 of the screening unit 10. The leveling unit 22 is a rotary structure for leveling the building material M transported on the conveyor belt 21, and a plurality of leveling blades are provided at its rotary peripheral end. In the present embodiment, the alignment unit 22 is positioned such that the pivoting peripheral end of the alignment unit 22 faces the conveyor belt 21, and the rotation axis of the alignment unit 22 perpendicularly intersects the direction in which the conveyor belt 21 transports the construction raw material M.

[0073]

From the point of view of reducing or preventing an increase in the size of the building material manufacturing apparatus X1 and scaling up the entire plant containing the building material manufacturing apparatus X1, the raw material supply unit 20 is preferably located above the screening unit 10 so that the conveyor belt 21 runs along the horizontal component the direction of the arrangement of the set of sheets in the screening unit 10.

[0074]

In the present embodiment, the receiving sheet 11 of the aforementioned screening unit 10 extends in the same range as the drop area onto which the construction raw material M is dropped from the raw material supply unit 20, or in the range outside the drop area in the sheet width direction W shown in FIG. 2 (a direction perpendicular to the sheet arrangement direction D).

[0075]

The receiver 30 for receiving building raw material M, which has passed through the screening unit 10, is located on the conveyor belt 31, which forms the line of movement of the receiver 30. The conveyor belt 31 runs along the horizontal component of the direction in which the set of sheets in the screening unit 10 is located. The receiver 30 is made movable under the stack of sheets when the conveyor belt 31 is operating. In the present embodiment, the receiver 30 is a template having a predetermined pattern of depressions/protrusions corresponding to the structural surface of the building material to be produced, on its inner surface (the surface that receives the building raw material M) . On FIG. 3 shows an exemplary bin 30 in section along the bin width direction W corresponding to the sheet width direction W.

[0076]

In operation of the building material making apparatus X1, an eccentric vibrator is driven in the body 10' of the screening unit 10 to generate a reciprocating motion in the inner frame and the outer frame. As described above, the phase difference between the two reciprocating movements is 180 degrees. Since the inner frame and the outer frame perform such reciprocating motions, a state in which the sheet is strongly stretched by the aforementioned first and second cross beams and a state in which the sheet is loosened and the sheet performs wave motion alternately occurs in each sheet. The higher the speed of rotation of the eccentric vibrator, the higher the speed of the wave movement of each sheet.

[0077]

When the building material manufacturing apparatus X1 configured as described above is operated, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . The building raw material M is prepared according to the building material to be produced. When the building material to be produced is, for example, a fiber cement cladding board, the building raw material M includes, for example, a water-hardening material and a reinforcing material, and may include a silica material, a hollow material, an additive, a water-repellent agent, and the like.

[0078]

Examples of the water hardening material include cement, gypsum and slag. Examples of cement include conventional Portland cement, high strength Portland cement, alumina cement, blast furnace slag cement, and fly ash cement. Examples of gypsum include gypsum anhydrite, gypsum hemihydrate and gypsum dihydrate. Examples of the slag include blast furnace slag and converter slag.

[0079]

Examples of the reinforcing material include plant-based reinforcing material and synthetic fibers. Examples of the plant-based reinforcing material include wood flour, wood wool, wood chips, wood pulp, wood fiber, wood fiber tow, waste paper, bamboo fiber, flax fiber, bagasse, chaff and rice straw. Examples of synthetic fibers include polyester fibers, polyamide fibers, polyethylene fibers, polypropylene fibers and acrylic fibers.

[0080]

Examples of the siliceous material include silica sand, quartz brick powder, silica dust, coal ash, fly ash, and diatomaceous earth.

[0081]

Examples of the hollow material include styrofoam beads, microspheres, perlite, fly ash beads, sirasu beads, expanded shale, expanded clay, and sintered diatomaceous earth. Examples of microspheroidal particles include acrylic foam.

[0082]

Examples of additives include mica, paper waste ash, silica dust, wollastonite, calcium carbonate, magnesium hydroxide, aluminum hydroxide, vermiculite, sepiolite, xonotlite, kaolinite, and zeolite.

[0083]

Examples of additives also include crushed inorganic boards such as fiber cement facing boards. Examples of shredded inorganic board include shredded product from defective pieces of uncured inorganic board and shredded product from defective pieces of cured inorganic board that are generated during the production of inorganic board; and shredded product from fragments and waste of inorganic board generated at construction sites and the like.

[0084]

Examples of the hydrophobizing agent include wax, paraffin, succinic acid, fatty acids, silicone, and synthetic resin. Examples of the synthetic resin include acrylic resin, polyethylene, ethylene vinyl acetate, urethane resin, and epoxy resin.

[0085]

The building raw material M supplied to the raw material supply unit 20 of the building material manufacturing apparatus X1 is fed, for example, at a constant speed by means of a conveyor belt 21 to a position above the receiving sheet 11 of the screening unit 10. On the conveyor belt 21, the building raw material M is leveled at using the leveling block 22, which rotates, or the leveling blades of the leveling block 22.

[0086]

Then, when the building material manufacturing apparatus X1 is operated, in a state in which the set of sheets of the screening unit 10 makes a wave motion, the building raw material M is dropped from the raw material supply unit 20 to the receiving sheet 11 of the screening unit 10 (the direction in which the raw material dropped from the source material supply unit 20, shown by the dotted arrow).

[0087]

The building raw material M falling from the raw material supply unit 20 includes parts having the shape of large lumps. Such building raw material M first falls on the receiving sheet 11 of the screening unit 10, which does not contain cells and has a large area of contact with the raw material. Such a configuration is suitable for crushing the building raw material M, which is in the form of large lumps, by colliding with the receiving sheet 11, which makes a wave motion, before reaching each screen sheet of the screening unit 10. The more the building raw material is crushed before reaching the screening sheet of the screening unit 10, the more, as a rule, the clogging of the holes of each screening sheet is reduced.

[0088]

In addition, such a configuration in which the building raw material M falling from the raw material supply unit 20 is first received in the screening unit 10 by the receiving sheet 11, which does not contain cells and has a large contact area with the raw material, is suitable for dispersing the building raw material. M, having the shape of large lumps, by colliding with the receiving sheet 11, which makes a wave motion before it reaches each screening sheet of the screening unit 10. The more the building raw material is scattered before reaching the screening sheet of the screening unit 10, the more degree, as a rule, clogging of the holes of each screening sheet is reduced.

[0089]

When the building material making apparatus X1 is operated, the building raw material M, which has been pulverized and dispersed as described above by the wave-moving receiving sheet 11, is screened by each screening sheet in the downstream process of the stack of sheets, and is thereby pulverized by collision. with other sheets, each of which is in a state of performing a wave motion (sieving). Then, from the building raw material M obtained by screening in the screening unit 10, the part that has passed through the cells of the screen sheet 12, the part that has passed through the cells of the screen sheet 13, and the part that has passed through the cells of the screen sheet 14 are successively deposited on the receiver. 30, and a carpet of raw material is formed (the direction of falling of the raw material from the screening unit 10 is shown by a dotted arrow). Features are described below.

[0090]

First, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receiver 30, which is transported by a belt conveyor 31 in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10.

[0091]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. Building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30 substantially evenly. Thus, for example, as shown in FIG. 3(a), a layer L1 (first layer) is formed on the receptacle 30, the thickness of which is substantially uniform in the receptacle width direction W corresponding to the sheet width direction W. The layer L1 is formed by the deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12).

[0092]

Then, the building raw material M, which has passed through the cells of the screen sheet 13, is deposited on the layer L1 on the receiver 30, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screen sheet 13 of the screening unit 10.

[0093]

At this stage, for example, as shown in FIG. 3(b), when the layer L2 (second layer) is formed when the building raw material M is deposited on the layer L1 under the honeycomb area R1 of the screen sheet 13, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13. The layer L2 is formed by deposition of building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13 (the part passed through the honeycomb area of the screen sheet 13 which is coarser than the part passed through the screen sheet 12).

[0094]

The building raw material M, which has not passed through the cells of the cellular region R1 of the screen sheet 13, is crushed and dispersed by collision with the transfer sheet 15, which does not contain cells and has a large area of contact with the source material, before reaching the screen sheet 14. Than the more the building raw material M is crushed and dispersed before reaching the screen sheet 14, the more the clogging of the openings of the screen sheet 14 is generally reduced. moves down on the screening sheet 13, varies quantitatively in the sheet width direction W, the quantitative variation is reduced or eliminated as the building raw material M passes through the transfer sheet 15.

[0095]

Then the building raw material M, which has passed through the cells of the screening sheet 14, is deposited on the layers L1 and L2 on the receiver 30, which is transported by a belt conveyor 31 in the direction of the arrow d1 and passes directly under the screening sheet 14 of the screening unit 10.

[0096]

In the screen sheet 14 as described above, a plurality of cells having the same size, which is larger than the cell size of the screen sheet 13, are arranged at a constant pitch in the sheet width direction W. The building raw material M, which has passed through the cells of the screen sheet 14, is deposited substantially evenly on the layers L1 and L2. Thus, for example, as shown in FIG. 3(c), a layer L3 (third layer) is formed on the layers L1 and L2, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L3 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 (a coarser part than the part that passed through the cell area of the screen sheet 13).

[0097]

The raw material carpet formed as described above includes the aforementioned layers L1, L2 and L3. In other words, the building material manufacturing apparatus X1 can form a raw material carpet having a three-layer structure by obtaining materials having a three-segment particle size distribution from the building raw material M by the aforementioned screening.

[0098]

The layer L1 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine-grained building raw material M (the portion passed through the screen sheet 12). The layer L2 is an element that also functions as a layer for adjusting the deposition amount of the building raw material and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 12. The layer L3 has a high thickness uniformity in the bin width direction W and consists of the building raw material M, which is coarser than the portion passed through the honeycomb area of the screen sheet 13. The raw material carpet, which has the layer L2 also functioning as the building raw material settling amount adjustment layer, in addition to the layers L1 and L3, and which is formed on the receptacle 30, is a carpet of raw material such that the deposition amount of the building raw material varies in the width direction W of the receptacle.

[0099]

Thus, the building material manufacturing apparatus X1 is suitable for forming a raw material mat including the aforementioned layers L1, L2, L3 while changing the deposition amount of the building raw material in the receptacle width direction W. The building material manufacturing apparatus X1 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material on the receiver 30 receiving the building raw material M under the screening unit 10, which screens the building raw material M and thereby performs mechanical sorting of the building raw material.

[0100]

Then, the raw material carpet thus formed, that is, the stack of layers L1, L2, L3, is subjected to a heat-pressing step. At the present stage, the pressing pressure is, for example, 2 to 8 MPa, the heating temperature is, for example, 50 to 80°C, and the pressing time is 6 to 12 hours. Thereafter, autoclave curing is carried out as needed. In such autoclave curing, the temperature condition is, for example, 150° C. or more, and the pressure condition is, for example, 0.5 MPa or more. With respect to these modes in the heat-pressing and autoclave-curing step, the same applies to the heat-pressing and autoclave-curing steps described below.

[0101]

The stack of layers L1, L2, L3 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a multi-layer structure is produced, including a cured layer formed from the L1 layer, a cured layer formed from the L2 layer, and a cured layer formed from layer L3. For example, if the building material to be manufactured is a fiber cement cladding board and the above-described building raw material M includes a water-hardening material, a quartz material, and a reinforcing material, each cured layer has a configuration in which the reinforcing material is dispersed in an inorganic cured matrix formed from a hardening in water material and quartz material.

[0102]

The cured layer formed from the layer L1, which is a deposit of the relatively fine-grained building raw material M, has a denser texture, and thus is suitable for providing high waterproof performance, and is accordingly suitable for forming the outer layer of the building material. Each of the cured layers formed from the layers L2 and L3, which is a deposit of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0103]

By thermally pressing the raw material carpet including the aforementioned layers L1, L2, L3, it is possible to produce from the raw material carpet a building material in which the difference in texture density between the part where a recess is formed in the structural surface of the building material and the part where a protrusion is formed on the structural surface of the building material, that is, the building material having a low density non-uniformity. In other words, the building material manufacturing apparatus X1 is suitable for manufacturing a building material having a recess/protrusion pattern on its structural surface, and thereby reduces density non-uniformity. A building material having low density non-uniformity is resistant to cracking and is therefore preferred.

[0104]

On FIG. 4 is a schematic sectional view in the bin width direction showing how a stack of layers in a bin carpet is formed in a modification of the building material manufacturing apparatus X1. In the present modification, when forming a carpet of raw material using the building material making apparatus X1, the receiver 30A is used instead of the aforementioned receiver 30. The receiver 30A is a pattern that does not have a protruding shape on the inner surface (the surface that receives the building raw material M) at least measure on both of its end sections in the direction W of the width of the receiver. On FIG. 4 shows an exemplary receiver 30A in a section along its width direction. In the present modification, the starting material carpet is formed as follows.

[0105]

First, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30A, which is transported by the conveyor belt 31 shown in FIG. 1 in the direction of the arrow d1 and passes directly under the screen sheet 12 of the screen unit 10.

[0106]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. Building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30A substantially evenly. Thus, for example, as shown in FIG. 4(a), a layer L1 (first layer) is formed on the receptacle 30A, the thickness of which is substantially the same in the receptacle width direction W corresponding to the sheet width direction W. The layer L1 is formed by the deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12).

[0107]

Then, the building raw material M, which has passed through the cells of the screen sheet 13, is deposited on the layer L1 on the receptacle 30A, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screen sheet 13 of the screening unit 10.

[0108]

At this stage, as shown in Fig. 4(b), when the layer L2 (second layer) is formed when the building raw material M is deposited on the layer L1 under the honeycomb area R1 of the screen sheet 13, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13. The layer L2 is formed by deposition of building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13 (the part passed through the honeycomb area of the screen sheet 13 which is coarser than the part passed through the screen sheet 12).

[0109]

Then, a portion of the building raw material M, crushed and dispersed as described above on the transfer sheet 15, reached the screen sheet 14 and passed through the cells of the screen sheet 14, is deposited on the layers L1 and L2 on the receptacle 30A, which is transported by the conveyor belt 31 in the direction of the arrow d1 and passes directly under the screening sheet 14 of the screening unit 10.

[0110]

In the screen sheet 14 as described above, a plurality of cells having the same size, which is larger than the cell size of the screen sheet 13, are arranged at a constant pitch in the sheet width direction W. The building raw material M, which has passed through the cells of the screen sheet 14, is deposited substantially evenly on the layers L1 and L2. Thus, as shown in FIG. 4(c), a layer L3 (third layer) is formed on layers L1 and L2, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L3 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 (a coarser part than the part that passed through the cell area of the screen sheet 13).

[0111]

The raw material carpet formed as described above includes the aforementioned layers L1, L2 and L3. The layer L1 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine-grained building raw material M (the portion passed through the screen sheet 12). The layer L2 is an element that also functions as a layer for adjusting the deposition amount of the building raw material and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 12. The layer L3 has a high thickness uniformity in the bin width direction W and consists of the building raw material M, which is coarser than the portion passed through the honeycomb area of the screen sheet 13. The raw material carpet, which has the layer L2 also functioning as the building raw material settling amount adjustment layer, in addition to the layers L1 and L2, and which is formed on the receptacle 30A, is a carpet of raw material such that the amount of deposition of the building raw material varies in the width direction W of the receptacle.

[0112]

By thermally pressing the raw material carpet including the layers L1, L2, L3, it is easy to produce from the raw material carpet a building material whose end portions have sufficient thickness and high density at both ends thereof in the receiver width direction W. In other words, the building material manufacturing apparatus X1 is also suitable for manufacturing a building material whose end portions have sufficient thickness and high density at both ends in the bin width direction W. Forming the end portions of the building material with high density is suitable for providing high strength and high water resistance of the building material.

[0113]

When forming the base material carpet using the building material making apparatus X1, after forming the above layer L3, the layers composed of the building raw material M can be further stacked on the receptacle 30 while transporting the receptacle 30 under the screening unit 10 in the direction of the arrow d2 from the right end in the drawing to the left end of the drawing using the conveyor belt 31. In this case, the plurality of layers formed on the receptacle 30 while transporting the receptacle 30 in the direction of the arrow d1 are further stacked in the opposite order of their stacking. As a result, a base material carpet having a multi-layer configuration symmetrical in the thickness direction is formed. Further, with regard to the building material manufacturing apparatuses described below, it is possible to form a raw material carpet having a multi-layer configuration that is symmetrical in the thickness direction by reciprocating the receptacle under the screening unit in this way.

[0114]

In the building material manufacturing apparatus X1 as described above, the receiving sheet 11 extends in the same range as the drop area onto which the building raw material M is dropped from the raw material supply unit 20, or in the range outside the drop area in the W direction. sheet width.

[0115]

Such a configuration is preferable for properly receiving all of the building raw material M supplied from the raw material supply unit 20 using the screening unit 10 or the receiving sheet 11 of the screening unit 10. The configuration in which the width of the receiving sheet 11 is larger than the width of the starting material dropping , is suitable for dispersing the building raw material M, which is in the form of large lumps, by colliding with the receiving sheet 11, which makes a wave motion, before reaching each screen sheet of the screening unit 10. The more the building raw material is scattered before reaching the screening sheet of the screening unit 10 , the more, as a rule, the clogging of the holes of each screening sheet is reduced.

[0116]

In the building material manufacturing apparatus X1 as described above, the raw material supply unit 20 includes a belt conveyor 21 for guiding the building raw material M to a position above the receiving sheet 11 of the screening unit 10, and an alignment unit 22 for leveling the building raw material M transported on the belt. conveyor 21.

[0117]

Such a configuration is preferable for reducing clogging of the openings of the screen sheet 12 of the screening unit 10. In particular, leveling with the leveling unit 22 of the building raw material M transported on the conveyor belt 21 of the raw material supply unit 20 is suitable for uniformizing the feeding speed of the building raw material M, which is supplied by dropping from the end end of the conveyor belt 21 to the receiving sheet 11, and is accordingly preferable for reducing the non-uniformity of building raw material on the stack of sheets in the screening unit 10 and for reducing clogging of the holes of each screening sheet.

[0118]

On FIG. 5 is a schematic view of a building material manufacturing apparatus X2 according to a second embodiment of the present invention. The building material manufacturing apparatus X2 includes a screening unit 10A, the aforementioned raw material supply unit 20, and a receiver 30B. The building material manufacturing apparatus X2 differs from the building material manufacturing apparatus X1 according to the first embodiment in that the building material manufacturing apparatus X2 includes a screening unit 10A and a bin 30B instead of a screening unit 10 and a bin 30.

[0119]

The sieving unit 10A includes a set of sheets which are capable of performing a wave motion during operation of the device, which are inclined and which are disposed in the direction of the inclination; and the aforementioned body 10' to which a set of sheets is attached to carry out the wave movement of each sheet. The screening unit 10A differs from the screening unit 10 in that the sheet set includes the screening sheet 13A shown in FIG. 6 instead of the aforementioned screening sheet 13. Other configurations of the screening unit 10A are similar to those of the aforementioned screening unit 10.

[0120]

The screening sheet 13A has honeycomb regions R1 and non-cellular regions R2, which are located in the sheet width direction W. In the mesh area R1 of the screen sheet 13A, a plurality of cells having two or more different sizes are arranged in the sheet width direction W. In the present embodiment, the cell area R1 of the screen sheet 13A has a cell pattern in the sheet width direction W such that the cell corresponding to a deeper depression on the inner surface of the bin 30B (described below) is larger. Each cell of the cell area R1 of the screen sheet 13A has a size that is greater than or equal to the size of each cell of the screen sheet 12. In particular, the size of each cell of the cell area R1 of the screen sheet 13A, that is, the opening size, is, for example, 10 to 40 mm when provided that the hole size is larger than the size of each mesh of the screen sheet 12. In contrast, the non-mesh area R2 of the screen sheet 13A has no mesh.

[0121]

In the present embodiment, the receptacle 30B is a template having a predetermined recess/protrusion pattern corresponding to the structural surface of the building material to be manufactured on its inner surface (the surface that receives the building raw material M). On FIG. 7 shows an exemplary receptacle 30B in a section along the receptacle width direction W corresponding to the sheet width direction W. Other configurations of the receiver 30B are similar to those of the aforementioned receiver 30.

[0122]

When the building material manufacturing apparatus X2 configured as described above is operated, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . The building raw material M is fed, for example, at a constant speed by means of a conveyor belt 21 to a position above the receiving sheet 11 of the screening unit 10A. On the conveyor belt 21, the building raw material M is leveled by means of a leveling block 22 which rotates or by the leveling blades of the leveling block 22 .

[0123]

Then, in a state in which the set of sheets of the screening unit 10A makes a wave motion, the building raw material M is thrown from the raw material supply unit 20 to the receiving sheet 11 of the screening unit 10A (the direction in which the raw material is dropped from the raw material supply unit 20 is shown dotted arrow).

[0124]

The building raw material M supplied from the raw material supply unit 20 is pulverized and dispersed by the receiving sheet 11 which performs wave motion in the same manner as described above with respect to the building material manufacturing apparatus X1. Thus, clogging of the openings of each screen sheet of the screen unit 10A is generally reduced.

[0125]

When the building material making apparatus X2 is operated, the building raw material M, which has been pulverized and dispersed by the receiving sheet 11, which makes a wave motion, is screened by each screening sheet in the process of moving down the stack of sheets, and is pulverized by collision with other sheets, each of which is in the state of performing a wave motion. Then, from the building raw material M obtained by sieving in the screening unit 10A, the part that passed through the cells of the screen sheet 12, the part that passed through the cells of the screen sheet 13A, and the part that passed through the cells of the screen sheet 14 are successively deposited on the receiver. 30B, and a carpet of raw material is formed (the direction of falling of the raw material from the screening unit 10A is shown by a dotted arrow). Features are described below.

[0126]

First, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receiver 30B, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10.

[0127]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. Building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30B substantially evenly. Thus, for example, as shown in FIG. 7(a), a layer L4 (first layer) is formed on the receptacle 30B, the thickness of which is substantially the same in the receptacle width direction W corresponding to the sheet width direction W. Layer L4 is formed by the deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12).

[0128]

Then, the building raw material M, which has passed through the cells of the screen sheet 13A, is deposited on the layer L4 on the receptacle 30B, which is conveyed by the conveyor belt 31 in the direction of the arrow d1 and passes directly under the screen sheet 13A of the screen unit 10A.

[0129]

At this stage, for example, as shown in FIG. 7(b), when the layer L5 (second layer) is formed while the building raw material M is deposited on the layer L4 under the honeycomb region R1 of the screen sheet 13A, the building raw material M is not substantially deposited under the non-cellular region R2 of the screen sheet 13A. In the layer L5, the deposition amount of the building raw material M is generally larger in the part corresponding to the deeper recess in the inner surface of the receptacle 30B. The layer L5 is formed by deposition of the building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13A (the part passed through the honeycomb area of the screen sheet 13A which is coarser than the part passed through the screen sheet 12).

[0130]

The building raw material M, which has not passed through the cells of the mesh area R1 of the screen sheet 13A, is crushed and dispersed by collision with the transfer sheet 15, which does not contain cells and has a large area of contact with the raw material, before reaching the screen sheet 14. Than the more the building raw material M is pulverized and dispersed before reaching the screen sheet 14, the more the clogging of the openings of the screen sheet 14 is generally reduced. moves down on the screening sheet 13A, varies quantitatively in the sheet width direction W, the quantitative variation is reduced or eliminated as the building raw material M passes through the transfer sheet 15.

[0131]

Then, the building raw material M, which has passed through the cells of the screen sheet 14, is deposited on the layers L4 and L5 on the receiver 30B, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screen sheet 14 of the screen unit 10A.

[0132]

In the screening sheet 14, a plurality of cells having the same size, which is larger than the cell size of the screening sheet 13A, are arranged at a constant pitch in the sheet width direction W. The building raw material M, which has passed through the cells of the screen sheet 14, is deposited substantially uniformly on the layers L4 and L5. Thus, for example, as shown in FIG. 7(c), a layer L6 (third layer) is formed on layers L4 and L5, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L6 is formed by the deposition of the building raw material M passed through the meshes of the screen sheet 14 (larger than the portion passed through the screen sheet 13A).

[0133]

The raw material carpet formed as described above includes the aforementioned layers L4, L5 and L6. The layer L4 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine-grained building raw material M (the portion passed through the screen sheet 12). The layer L5 is an element that also functions as a layer for adjusting the deposition amount of the building raw material and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 12. The layer L6 has a high thickness uniformity in the bin width direction W and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 13A. The raw material carpet, which has the layer L5 also functioning as the building raw material deposition amount adjustment layer, in addition to the layers L4 and L6, and which is formed on the receptacle 30B, is a raw material carpet such that the deposition amount of the building raw material varies in the direction W receiver width.

[0134]

Thus, the building material manufacturing apparatus X2 is suitable for forming a raw material mat including the aforementioned layers L4, L5, L6 while changing the deposition amount of the building raw material in the receptacle width direction W. The building material manufacturing apparatus X2 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material at the receiver 30B receiving the building raw material M under the screening unit 10A, which screens the building raw material M and thereby performs mechanical sorting of the building raw material M.

[0135]

Then, the raw material carpet thus formed, that is, the stack of layers L4, L5, L6, is subjected to a heat-pressing step. The stack of layers L4, L5, L6 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a multi-layered cured layer structure formed from said layers is produced.

[0136]

The cured layer formed from the layer L4, which is a deposit of the relatively fine building raw material M, has a denser texture and is thus suitable for high water resistance performance, and is accordingly suitable for forming the outer layer of the building material. Each of the cured layers formed from the layers L5 and L6, which is a deposit of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0137]

By thermally pressing the raw material carpet including the aforementioned layers L4, L5, L6, it is possible to produce, from the raw material carpet, a building material in which the difference in texture density between the part where a recess is formed in the structural surface of the building material and the part where a protrusion is formed on the structural surface of the building material, that is, the building material having a low density non-uniformity. In other words, the building material manufacturing apparatus X2 is suitable for manufacturing a building material having an indentation/protrusion pattern on its structural surface, and thereby reducing density non-uniformity.

[0138]

On FIG. 8 is a schematic view of a building material manufacturing apparatus X3 according to a third embodiment of the present invention. The building material manufacturing apparatus X3 includes a screening unit 10B, the aforementioned raw material supply unit 20, and a receiver 30C. The building material manufacturing apparatus X3 differs from the building material manufacturing apparatus X1 according to the first embodiment in that the building material manufacturing apparatus X3 includes a screening unit 10A and a receptacle 30C instead of a screening unit 10 and a receptacle 30.

[0139]

The sieving unit 10A includes a set of sheets which are capable of performing a wave motion during operation of the device, which are inclined and which are disposed in the direction of the inclination; and the aforementioned body 10' to which a set of sheets is attached to carry out the wave movement of each sheet.

[0140]

Screening unit 10B differs from screening unit 10 in that it includes a set of sheets arranged as shown in FIG. 9 instead of the stack of sheets arranged as described above with reference to FIG. 2. Other configurations of the screening unit 10A are similar to those of the aforementioned screening unit 10.

[0141]

In the set of sheets of the screening unit 10B, the sheets are arranged in the following order, starting from its upper end: the aforementioned receiving sheet 11 having no cells, the aforementioned fine-mesh screening sheet 12 (first screening sheet), the transfer sheet 15, the aforementioned coarse-meshed screening sheet 14 (third screening sheet) and a screen sheet 13B (second screen sheet), the screen sheet 14, which is the third screen sheet, is located between the screen sheet 12, which is the first screen sheet, and the screen sheet 13B, which is the second screen sheet.

[0142]

The screening sheet 13A has honeycomb regions R1 and non-cellular regions R2, which are located in the sheet width direction W. In the present embodiment, the screen sheet 13B has a honeycomb region R1 in a portion corresponding to a depression on the inner surface of the bin 30 and a non-cellular region R2 in a portion corresponding to a protrusion on the inner surface of the bin 30. Each cell of the cellular region R1 has a size that is greater than or equal to the size of each cell of the screen sheet 14. Specifically, the size of each cell of the cell area R1 of the screen sheet 13B, that is, the size of the opening, is, for example, 30 to 60 mm, provided that the size of the opening is larger than the size of each cell of the screen sheets 12 and 14 In contrast, the non-cellular region R2 has no cells.

[0143]

The transfer sheet 15 is a non-cellular sheet, like the receiving sheet 11, and is located between the fine mesh screening sheet 12 and the coarse screening sheet 14.

[0144]

In the present embodiment, the receptacle 30C is a template having a predetermined recess/protrusion pattern corresponding to the construction material construction surface to be manufactured on its inner surface (the surface that receives the construction raw material M). On FIG. 10 shows an exemplary receiver 30C in a section along the width direction W of the receiver. Other configurations of the receiver 30C are similar to those of the aforementioned receiver 30.

[0145]

When the building material manufacturing apparatus X3 configured as described above is operated, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . The building raw material M is fed, for example, at a constant speed by means of a conveyor belt 21 to a position above the receiving sheet 11 of the screening unit 10B. On the conveyor belt 21, the building raw material M is leveled by means of a leveling block 22 which rotates or by the leveling blades of the leveling block 22 .

[0146]

Then, in a state in which the set of sheets of the screening unit 10B makes a wave motion, the building raw material M is thrown from the raw material supply unit 20 to the receiving sheet 11 of the screening unit 10B (the direction in which the raw material is dropped from the raw material supply unit 20 is shown dotted arrow).

[0147]

The building raw material M supplied from the raw material supply unit 20 is pulverized and dispersed by the receiving sheet 11 which performs wave motion in the same manner as in the building material manufacturing apparatus X1. Thus, clogging of the openings of each screen sheet of the screen unit 10A is generally reduced.

[0148]

When the building material making apparatus X3 is operated, the building raw material M which has been pulverized and dispersed by the receiving sheet 11, which makes a wave motion, is screened by each screening sheet in the process of moving down the stack of sheets, and is pulverized by collision with other sheets, each of which is in the state of performing a wave motion. Then, from the building raw material M obtained by sifting in the screening unit 10B, the part that passed through the cells of the screen sheet 12, the part that passed through the cells of the screen sheet 14, and the part that passed through the cells of the screen sheet 13B are successively deposited on the receiver. 30C, and a carpet of raw material is formed (the direction of falling of the raw material from the screening unit 10B is shown by a dotted arrow). Features are described below.

[0149]

First, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receiver 30C, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10.

[0150]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. The building stock M, which has passed through the meshes of the screen sheet 12, is deposited on the receptacle 30C substantially evenly. Thus, for example, as shown in FIG. 10(a), a layer L7 (first layer) is formed on the receptacle 30C, the thickness of which is substantially uniform in the receptacle width direction W corresponding to the sheet width direction W. The layer L7 is formed by the deposition of the fine-grained building raw material M that has passed through the cells of the screening sheet 12.

[0151]

The construction raw material M, which has not passed through the cells of the screen sheet 12, is crushed and dispersed by collision with the transfer sheet 15, which does not contain cells and has a large area of contact with the source material, before reaching the screen sheet 14. The more crushed and If the building raw material M is dispersed before reaching the screen sheet 14, the more the clogging of the openings of the screen sheet 14 and the screen sheet 13B under the screen sheet 14 is generally reduced.

[0152]

Then, the building raw material M, which has passed through the cells of the screen sheet 14, is deposited on the layer L7 on the receptacle 30C, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screen sheet 14 of the screen unit 10B.

[0153]

In the screen sheet 14, a plurality of cells having the same size, which is larger than the cell size of the screen sheet 12, are arranged at a constant pitch in the sheet width direction W. The building raw material M which has passed through the cells of the screen sheet 14 is deposited substantially uniformly on the layer L7. Thus, for example, as shown in FIG. 10(b), a layer L8 (third layer) is formed on the layer L7, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L8 is formed by the deposition of the building raw material M that has passed through the meshes of the screen sheet 14 (the part that is coarser than the part that has passed through the mesh area of the screen sheet 12 and that has passed through the screen sheet 14).

[0154]

Then, the building raw material M, which has passed through the cells of the honeycomb area R1 of the screen sheet 13B, is deposited on the layer L8 on the receptacle 30C, which is transported by the conveyor belt 31 in the direction of the arrow d1 and passes directly under the screen sheet 13B of the screening unit 10B.

[0155]

At this stage, for example, as shown in FIG. 10(c), when the layer L9 (second layer) is formed when the building raw material M is deposited on the layer L8 under the honeycomb area R1 of the screen sheet 13B, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13B. The layer L9 is formed by the deposition of the building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13B (larger than the portion passed through the screen sheet 14).

[0156]

The raw material carpet formed as described above includes the aforementioned layers L7, L8 and L9. Layer L7 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine-grained building raw material M (the portion passed through the screen sheet 12). Layer L8 has a high thickness uniformity in the bin width direction W, and is composed of building raw material M, which is coarser than the portion passed through the screen sheet 12. Layer L9 is an element that also functions as a building raw material settling amount adjustment layer. and consists of the building raw material M, which is coarser than the portion passed through the screen sheet 14. The raw material carpet, which has the layer L9 also functioning as the building raw material settling amount adjustment layer, in addition to the layers L7 and L8 and which is formed on the receptacle 30C is a carpet of raw material such that the deposition amount of the building raw material varies in the width direction W of the receptacle.

[0157]

Thus, the building material making apparatus X3 is suitable for forming a raw material mat including the aforementioned layers L7, L8, L9 while changing the deposition amount of the building raw material in the receiver width direction W. The building material making apparatus X3 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material on the receiver 30C receiving the building raw material M under the screening unit 10B, which screens the building raw material M and thereby performs mechanical sorting of the building raw material M.

[0158]

Then, the thus-formed raw material carpet, that is, the stack of layers L7, L8, L9, is subjected to a heat-pressing step. The stack of layers L7, L8, L9 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a multi-layered cured layer structure formed from said layers is produced.

[0159]

The cured layer formed from layer L7, which is a deposit of relatively fine-grained building raw material M, has a denser texture, and thus is suitable for providing high waterproof performance, and is accordingly suitable for forming an outer layer of a building material. Each of the cured layers formed from the layers L8 and L9, which is a deposit of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0160]

By thermally pressing the raw material carpet including the aforementioned layers L7, L8, L9, it is possible to produce from the raw material carpet a building material in which the difference in texture density between the part where a recess is formed in the structural surface of the building material and the part where a protrusion is formed on the structural surface of the building material, that is, the building material having a low density non-uniformity. In other words, the building material manufacturing apparatus X3 is suitable for manufacturing a building material having an indentation/protrusion pattern on its structural surface while reducing density non-uniformity.

[0161]

In the same way that the layers L1, L2 and L3 are formed on the receptacle 30A (a pattern that does not have a protruding shape on the surface receiving the building material M) using the receptacle 30A instead of the receptacle 30 in the building material manufacturing apparatus X1, the aforementioned layers L7, L8 and L9 can be formed on the receptacle, which is a pattern having no protruding shape on the surface that receives the building material M, using the receptacle instead of the aforementioned receptacle 30C in the building material manufacturing apparatus X3. In this case, just as described above with respect to the modification in which the receiver 30A is used in the building material manufacturing apparatus X1, it is possible to produce a building material whose end portions have sufficient thickness and high density at both ends in the width direction W of the receiver.

[0162]

On FIG. 11 is a schematic view of a building material manufacturing apparatus X4 according to a fourth embodiment of the present invention. The building material manufacturing apparatus X4 includes a screening unit 10C, the aforementioned raw material supply unit 20, and a receiver 30D. The building material manufacturing apparatus X4 differs from the building material manufacturing apparatus X1 according to the first embodiment in that the building material manufacturing apparatus X4 includes a screening unit 10C and a receptacle 30D instead of a screening unit 10 and a receptacle 30.

[0163]

The screening unit 10C includes: a set of sheets that are configured to perform wave motion during operation of the device, which are tilted and which are arranged in the tilt direction; and the aforementioned body 10' to which a set of sheets is attached to carry out the wave movement of each sheet.

[0164]

Screening unit 10C differs from screening unit 10 in that it includes a set of sheets arranged as shown in FIG. 12 instead of the stack of sheets arranged as described above with reference to FIG. 2. Other configurations of the screening unit 10C are similar to those of the aforementioned screening unit 10.

[0165]

In the set of sheets of the screening unit 10C, the sheets are arranged in the following order, starting from its upper end: the aforementioned receiving sheet 11 having no meshes, the aforementioned screening sheet 12 (first screening sheet) having fine meshes, the screening sheet 13C (second screening sheet), the aforementioned transfer sheet 15; and the aforementioned screening sheet 14 (third screening sheet). The screen sheet 14, which is the third screen sheet, is located below the screen sheet 12, which is the first screen sheet, and the screen sheet 13C, which is the second screen sheet.

[0166]

In the screening sheet 13C, a plurality of cells having two or more different sizes are arranged in the sheet width direction W. In the present embodiment, a plurality of cells that are relatively large (first cells) are located in a portion corresponding to a depression of the inner surface of the receiver 30D (described below), and a plurality of cells that are relatively small (second cells) are located in a portion corresponding to a protrusion on the inner surface of the 30D receiver. Each mesh of the screen sheet 13C has a size that is greater than or equal to the size of each mesh of the screen sheet 12. In particular, the size of the first mesh of the screen sheet 13C, that is, the opening size, is, for example, 10 to 40 mm, provided that the opening size is larger than the size of each mesh of the screen sheet 12. The size of the second mesh of the screen sheet 13C, i.e., the opening size, is, for example, 15 to 45 mm, provided that the opening size is larger than the first mesh size, i.e., the opening size.

[0167]

In the present embodiment, the receptacle 30D is a template having a predetermined recess/protrusion pattern corresponding to the structural surface of the building material to be manufactured on its inner surface (the surface that receives the building raw material M). On FIG. 13 shows an exemplary receiver 30D in a section along the width direction W of the receiver. Other configurations of the receiver 30D are similar to those of the aforementioned receiver 30.

[0168]

When the building material manufacturing apparatus X4 configured as described above is operated, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . The building raw material M is fed, for example, at a constant speed by means of a conveyor belt 21 to a position above the receiving sheet 11 of the screening unit 10C. On the conveyor belt 21, the building raw material M is leveled by means of a leveling block 22 which rotates or by the leveling blades of the leveling block 22 .

[0169]

Then, in a state in which the set of sheets of the screening unit 10C makes a wave motion, the building raw material M is dropped from the raw material supply unit 20 to the receiving sheet 11 of the screening unit 10C (the direction in which the raw material is dropped from the raw material supply unit 20 is shown dotted arrow).

[0170]

The building raw material M supplied from the raw material supply unit 20 is pulverized and dispersed by the receiving sheet 11 which performs wave motion in the same manner as described above with respect to the building material manufacturing apparatus X1. Thus, clogging of the openings of each screen sheet of the screen unit 10C is generally reduced.

[0171]

When the building material making apparatus X4 is operated, the building raw material M, which has been pulverized and dispersed by the receiving sheet 11, which makes a wave motion, is screened by each screening sheet in the process of moving down the stack of sheets, and is pulverized by collision with other sheets, each of which is in the state of performing a wave motion. Then, from the building raw material M obtained by sieving in the screening unit 10C, the part that passed through the cells of the screen sheet 12, the part that passed through the cells of the screen sheet 13C, and the part that passed through the cells of the screen sheet 14 are successively deposited on the receiver. 30D, and a carpet of raw material is formed (the direction of falling of the raw material from the screening unit 10C is shown by a dotted arrow). Features are described below.

[0172]

First, the building raw material M, which has passed through the cells of the screen sheet 12, is deposited on the receiver 30D, which is transported by the belt conveyor 31 in the direction of the arrow d1 and passes directly under the screen sheet 12 of the screen unit 10.

[0173]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. Building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30D substantially evenly. Thus, for example, as shown in FIG. 13(a), a layer L10 (first layer) is formed on the receptacle 30D, the thickness of which is substantially uniform in the receptacle width direction W corresponding to the sheet width direction W. Layer L10 is formed by the deposition of the fine building raw material M passed through the meshes of the screen sheet 12 (the portion passed through the screen sheet 12).

[0174]

Then, the building raw material M, which has passed through the cells of the screen sheet 13C, is deposited on the layer L10 on the receptacle 30D, which is conveyed by the conveyor belt 31 in the direction of the arrow d1 and passes directly under the screen sheet 13C of the screening unit 10C. Thus, for example, as shown in FIG. 13(b), layer L11 is formed on layer L10. The layer L11 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 13C (larger than the portion passed through the screen sheet 12).

[0175]

At this stage, the settling amount of the building raw material forming the L11 layer formed on the L10 layer is larger at the position under the larger meshes of the screen sheet 13C, and the settling amount is smaller at the position below the finer meshes of the screen sheet 13C.

[0176]

The construction raw material M, which has not passed through the cells of the screen sheet 13C, is crushed and dispersed by collision with the transfer sheet 15, which does not contain cells and has a large area of contact with the source material, before reaching the screen sheet 14. The more crushed and the building raw material M is dispersed before reaching the screen sheet 14, the more the clogging of the openings of the screen sheet 14 is generally reduced. , varies quantitatively in the sheet width direction W, the quantitative variation is reduced or eliminated as the building raw material M passes through the transfer sheet 15.

[0177]

Then, the building raw material M, which has passed through the cells of the screen sheet 14, is deposited on the layer L11 on the receptacle 30D, which is transported by the conveyor belt 31 in the direction of the arrow d1 and passes directly under the screen sheet 14 of the screen unit 10C.

[0178]

In the screening sheet 14, a plurality of cells having the same size, which is larger than the cell size of the screening sheet 13C, are arranged at a constant pitch in the sheet width direction W. The building raw material M which has passed through the meshes of the screen sheet 14 is deposited substantially uniformly on the layer L11. Thus, for example, as shown in FIG. 13(c), a layer L12 (third layer) is formed on the layer L11, the thickness of which is substantially the same in the width direction W of the receiver. The layer L12 is formed by the deposition of the building raw material M passed through the meshes of the screen sheet 14 (the coarser portion than the part passed through the mesh area of the screen sheet 13C).

[0179]

The raw material carpet formed as described above includes the aforementioned layers L10, L11 and L12. The layer L10 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine-grained building raw material M (the portion passed through the screen sheet 12). The layer L11 is an element that also functions as a layer for adjusting the deposition amount of the building raw material and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 12. The layer L12 has high thickness uniformity in the bin width direction W and consists of the building raw material M, which is coarser than the portion passed through the honeycomb area of the screen sheet 13C. The raw material carpet, which has the layer L11 also functioning as the building raw material deposition amount adjustment layer, in addition to the layers L10 and L12, and which is formed on the receptacle 30D, is a raw material carpet such that the deposition amount of the building raw material varies in the direction W receiver width.

[0180]

Thus, the building material manufacturing apparatus X4 is suitable for forming a raw material mat including the aforementioned layers L10, L11, L12 while changing the deposition amount of the building raw material in the receiver width direction W. The building material manufacturing apparatus X4 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material on the receiver 30D receiving the building raw material M under the screening unit 10C, which screens the building raw material M and thereby performs mechanical sorting of the building raw material M.

[0181]

Then, the raw material carpet thus formed, that is, the stack of layers L10, L11, L12, is subjected to a heat-pressing step. The stack of layers L10, L11, L12 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a multi-layer structure of cured layers formed from said layers is produced.

[0182]

The cured layer formed from the layer L10, which is a deposit of the relatively fine-grained building raw material M, has a denser texture, and thus is suitable for providing high waterproof performance, and is accordingly suitable for forming the outer layer of the building material. Each of the cured layers formed from the layers L11 and L12, which is a deposition of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0183]

By thermally pressing the raw material carpet including the aforementioned layers L10, L11, L12, it is possible to produce from the raw material carpet a building material in which the difference in texture density between the part where a recess is formed in the structural surface of the building material and the part where a protrusion is formed on the structural surface of the building material, that is, the building material having a low density non-uniformity. In other words, the building material manufacturing apparatus X4 is suitable for manufacturing a building material having a recess/protrusion pattern on its structural surface while reducing density non-uniformity.

[0184]

As shown in FIG. 14, the building material manufacturing apparatus X4 may include a screen sheet 13D (second screen sheet) in place of the screen sheet 13C in the sheet set, and the receptacle 30E shown in FIG. 15 instead of receiver 30D. On FIG. 15 is a schematic sectional view of the receiver 30D in the width direction W of the receiver.

[0185]

In the screening sheet 13D, a plurality of cells having two or more different sizes are arranged in the sheet width direction W. The screen sheet 13D has a mesh pattern in the sheet width direction W such that the mesh corresponding to a deeper depression on the inner surface of the bin 30E is larger. Each mesh of the screen sheet 13D has a size that is greater than or equal to the mesh size of the screen sheet 12. In particular, the size of each mesh of the screen sheet 13D, that is, the hole size, is, for example, 10 to 45 mm, provided that the hole size is larger, than the size of each cell of the sieving sheet 12.

[0186]

As shown in FIG. 16, the raw material carpet formed using the building material machine X4 including the screen sheet 13D and the bin 30E instead of the screen sheet 13C and the bin 13D includes layers L10, L13, L12.

[0187]

As described above, the layer L10 is formed by deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12) and has a high thickness uniformity in the bin width direction W.

[0188]

The layer L13 is formed by the deposition of the building raw material M passed through the meshes of the screen sheet 13D (coarser than the portion passed through the screen sheet 12). The settling amount of the building raw material forming the L13 layer is larger at the position under the larger meshes of the screen sheet 13D, and the settling amount is smaller at the position below the finer meshes of the screen sheet 13D. Layer L13 is an element that also functions as a layer for adjusting the amount of deposition of a building raw material in a carpet of raw material.

[0189]

The layer L12 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 (larger than the portion passed through the screen sheet 13D), and has high thickness uniformity in the bin width direction W.

[0190]

The raw material carpet, which has the layer L13 also functioning as the building raw material deposition amount adjustment layer, in addition to the layers L10 and L12, and which is formed on the receptacle 30E, is a raw material carpet such that the deposition amount of the building raw material varies in the direction W receiver width.

[0191]

By thermally pressing the starting material carpet including the layers L10, L13, L12, it is possible to produce from the starting material carpet a building material in which the difference in texture density between the part where a recess is formed in the structural surface of the building material and the part where a protrusion on a structural surface of a building material, that is, a building material having a low density non-uniformity. In other words, the above-described modification of the building material manufacturing apparatus X4 (the modification using the sheet stack including the screening sheet 13D shown in FIG. 14 and the bin 30E) is also suitable for producing building material having a recess/protrusion pattern on its structural surface and at the same time reduces density inhomogeneity, as well as the X4 device for the manufacture of building material.

[0192]

On FIG. 17 is a schematic view of a building material manufacturing apparatus X5 according to a fifth embodiment of the present invention. The building material manufacturing device X5 comprises a section U1, a section U2 and a receptacle 30.

[0193]

Each of the sections U1 and U2 respectively includes a screening unit 10 and a feed unit 20. As described above, the screening unit 10 includes: a set of sheets that are configured to perform wave motion during operation of the apparatus, which are tilted and which are disposed in the tilt direction; and a body 10' to which a set of sheets is attached to carry out the wave movement of each sheet.

[0194]

In the present embodiment, the set of sheets in the screening unit 10 of section U2 is located in the expansion area in the direction D of the set of sheets in the screening unit 10 of section U1. In addition, in the set of sheets of the screening block 10 of the U1 section, the closer the sheet is to the U2 section, the lower it is located, and in the set of sheets of the screening block 10 of the U2 section, the closer the sheet is to the U1 section, the lower it is located.

[0195]

The set of sheets in the screening unit 10 includes, as in the case of the building material machine X1, a receiving sheet 11, a screening sheet 12 (first screening sheet), a screening sheet 13 (second screening sheet), a screening sheet 14 (third screening sheet ) and transfer sheet 15. FIG. 18 shows the layout of the sheets in the building material machine X5 or in sections U1 or U2.

[0196]

In the present embodiment, a receiver 30 for receiving a predetermined building raw material M, which has passed through the screening units 10 of sections U1 and U2, is located on a belt conveyor 31A, which forms a moving line of the receiver 30. The receiver 30 is moved by operation of the belt conveyor 31A, and the receiver 30 is movable in the area in which the receiver 30 can receive the building raw material M that has passed through the screening unit 10 of section U1, and in the area in which the receiver 30 can receive the building raw material M that has passed through the screening unit 10 of the U2 section.

[0197]

In the present embodiment, the receptacle 30 is a template having a predetermined recess/protrusion pattern corresponding to the structural surface of the building material to be manufactured on its inner surface (the surface that receives the building raw material M). On FIG. 19 shows an exemplary receiver 30 in a section along the width direction W of the receiver.

[0198]

When the building material manufacturing apparatus X5 is operated in each of the sections U1 and U2, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . Building raw material M is fed, for example, at a constant speed by means of a belt conveyor 21 to a position above the receiving sheet 11 of the screening unit 10. On each belt conveyor 21, the building raw material M is leveled by means of an alignment unit 22, which rotates, or the leveling blades of the alignment unit 22 .

[0199]

Then, in a state in which the set of sheets of the screening unit 10 makes a wave motion in each section, the building raw material M is dropped from the raw material supply unit 20 to the receiving sheet 11 of the screening unit 10 (the direction in which the raw material is dropped from the raw material supply unit 20). material, shown by the dotted arrow).

[0200]

In each section, the building raw material M supplied from the raw material supply unit 20 is pulverized and dispersed by the receiving sheet 11, which performs wave motion in the receiving unit 10 in the same manner as described above with respect to the building material manufacturing apparatus X1. Thus, clogging of the openings of each screening sheet of the screening unit 10 is generally reduced.

[0201]

By operating the building material manufacturing apparatus X5 configured as described above, it is possible to form layers that become a raw material carpet from parts of the building raw material M obtained by screening in the screening unit 10 of section U1, and it is possible to form layers that become a raw material carpet. material, from parts of the building raw material M obtained by sifting in the screening unit 10 of section U2 (the direction in which the raw material is dropped from each screening unit 10 is shown by a dotted arrow). Features are described below.

[0202]

First, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10 of section U1.

[0203]

In the screen sheet 12, since a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W, the building raw material M that has passed through the cells of the screen sheet 12 is deposited substantially uniformly on the receptacle 30. Thus, for example, as shown in FIG. 19(a), a layer L14 (first layer) is formed on the receptacle 30, the thickness of which is substantially uniform in the receptacle width direction W corresponding to the sheet width direction W. Layer L14 is formed by the deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12).

[0204]

Next, the building raw material M, which has passed through the cells of the screening sheet 13, is deposited on the layer L14 on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 13 of the screening unit 10 of the section U1.

[0205]

At this stage, for example, as shown in FIG. 19(b), when the layer L15 (second layer) is formed when the building raw material M is deposited on the layer L14 under the honeycomb area R1 of the screen sheet 13, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13. The layer L15 is formed by deposition of building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13 (the part passed through the honeycomb area of the screen sheet 13 which is coarser than the part passed through the screen sheet 12).

[0206]

The construction raw material M, which has not passed through the cells of the cellular area R1 of the screen sheet 13, is crushed and dispersed by collision with the transfer sheet 15, which does not contain cells and has a large area of contact with the source material, before reaching the screen sheet 14.

[0207]

Next, the building raw material M, which has passed through the cells of the screening sheet 14, is deposited on the layers L14 and L15 on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 14 of the screening unit 10 of section U1.

[0208]

In the screen sheet 14 as described above, a plurality of cells having the same size, which is larger than the cell size of the screen sheet 13, are arranged at a constant pitch in the sheet width direction W. The building raw material M, which has passed through the cells of the screen sheet 14, is deposited substantially evenly on the layers L14 and L15. Thus, for example, as shown in FIG. 19(c), a layer L16 (third layer) is formed on layers L14 and L15, the thickness of which is substantially the same in the width direction W of the receiver. The layer L16 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 (a coarser part than the part that passed through the cell area of the screen sheet 13).

[0209]

Then, part of the building raw material M crushed and dispersed on the transfer sheet 15 of section U2, reached the screen sheet 14 and passed through the cells of the screen sheet 14, is deposited on the layer L16 on the receptacle 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under screening sheet 14 screening unit 10 section U2. Thus, for example, as shown in FIG. 19(d), a layer L17 (third layer) is formed on the layer L16, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L17 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 of section U2 (the portion passed through the screen sheet 14).

[0210]

Next, part of the building raw material M, which has passed through the cells of the screening sheet 13, is deposited on the layer L17 on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 13 of the screening unit 10 of section U2. At this stage, for example, as shown in FIG. 19(e), when the layer L18 (second layer) is formed while the building raw material M is deposited on the layer L17 under the honeycomb area R1 of the screen sheet 13 of section U2, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13. Layer L18 formed by the deposition of building raw material M passed through the cells of the cellular region R1 of the screen sheet 13 of section U2 (finer than the portion passed through the screen sheet 14).

[0211]

Next, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10 of section U2. Thus, for example, as shown in FIG. 19(f), a layer L19 (first layer) is formed on layers L17 and L18, the thickness of which is substantially uniform in the width direction W of the receiver corresponding to the width direction W of the sheet. The layer L19 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 12 of section U2 (a finer part than the part passed through the screen sheet 13).

[0212]

The starting material carpet formed as described above includes the aforementioned layers L14-L19. Each of the layers L14 and L19 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine building raw material M (the portion passed through the screen sheet 12). Each of the layers L15 and L18 is a member that also functions as a building raw material settling amount adjustment layer, and is composed of a building raw material M that is coarser than the portion passed through the screen sheet 12. Each of the layers L16 and L17 has a high uniformity in thickness in the direction W of the width of the receiver and consists of building raw material M, which is coarser than the part that has passed through the honeycomb area of the screen sheet 13. The carpet of the raw material, which has layers L15 and L18, each of which also functions as a layer adjusting the deposition amount of the building raw material, in addition to the layers L14, L16, L17, L19, and which is formed on the receptacle 30, is a base material carpet such that the deposition amount of the building raw material varies in the width direction W of the receptacle.

[0213]

Thus, the building material making apparatus X5 is suitable for forming a raw material mat including the aforementioned layers L14 to L19 while changing the deposition amount of the building raw material in the receptacle width direction W. The building material making apparatus X5 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material on the receiver 30 receiving the building raw material M under the screening units 10, which screens the building raw material M and mechanically sorting the building raw material.

[0214]

Then, the starting material carpet thus formed, that is, the stack of layers L14-L19, is subjected to a heat-pressing step. The stack of layers L14-L19 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a multi-layered cured layer structure formed from said layers is produced.

[0215]

Each of the cured layers formed from the layers L14 and L19, which is a deposit of the relatively fine-grained building raw material M, has a denser texture, and thus is suitable for providing high waterproof performance, and is accordingly suitable for forming the outer layer of the building material . Each of the cured layers formed from the layers L15 to L18, which is a deposition of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0216]

By thermally pressing the starting material carpet including the above-mentioned layers L14 to L19, it is possible to produce from the starting material carpet a building material in which the difference in texture density between the part where a depression is formed on the structural surface of the building material and the part where the protrusion is formed is reduced. on the structural surface of a building material, that is, a building material having a low density heterogeneity. In other words, the building material manufacturing apparatus X5 is suitable for manufacturing a building material having a recess/protrusion pattern on its structural surface while reducing density non-uniformity.

[0217]

On FIG. 20 is a schematic view of a building material manufacturing apparatus X6 according to a sixth embodiment of the present invention. The building material making apparatus X6 includes a section U1, a section U2, and a receptacle 30. The section U1 of the building material making apparatus X6 includes a screening unit 10D, a raw material supply unit 20, and a raw material supply unit 20A. The section U1 of the building material making machine X6 differs from the section U1 of the building material making machine X5 in that the section U1 of the building material making machine X6 includes a screening unit 10D instead of the screening unit 10, and further includes a raw material supplying unit 20A. The section U2 and the receptacle 30 of the building material making machine X6 have the same configurations as the section U2 and the receptacle 30 of the building material making machine X5.

[0218]

The sifting unit 10D includes: a set of sheets which are capable of performing a wave motion during operation of the device, which are inclined and which are arranged in the direction of the inclination; and a body 10' to which a set of sheets is attached to carry out the wave movement of each sheet. The screening unit 10D of section U1 differs from the aforementioned screening unit 10 in that it contains a stack of sheets arranged as shown in FIG. 21 instead of a stack of sheets arranged as shown in FIG. 18. Other configurations of the screening unit 10D are similar to those of the aforementioned screening unit 10.

[0219]

In the set of sheets of the screening unit 10D, the sheets are arranged in the following order, starting from its upper end: the aforementioned receiving sheet 11 having no cells, the aforementioned fine-mesh screening sheet 12 (first screening sheet), the transfer sheet 15, the aforementioned coarse-meshed screening sheet 14 (third screening sheet) and the aforementioned large-mesh screening sheet 14 (third screening sheet). In the screening unit 10D, the transfer sheet 15, which is a non-cellular sheet like the receiving sheet 11, is located between the fine-meshed screening sheet 12 and the coarse-meshed screening sheet 14.

[0220]

In the present embodiment, the raw material supply unit 20A for supplying raw material to the screening unit 10D by dropping additional building material M onto the transfer sheet 15 in the screening unit 10D in section U1 includes a conveyor belt 21A and an alignment unit 22A. In the present embodiment, the building raw material M supplied from the raw material supply unit 20A is coarser than the building raw material M supplied from the raw material supply unit 20. The building raw material M supplied from the raw material supply unit 20A and the building raw material M supplied from the raw material supply unit 20 may have the same composition or different compositions.

[0221]

The conveyor belt 21A transports the building raw material M to a position above the receiving sheet 15 of the screening unit 10D of section U1. The leveling unit 22A is a rotary structure for leveling the building raw material M transported on the conveyor belt 21A, and a plurality of leveling blades are disposed at its rotary peripheral end. In the present embodiment, the alignment unit 22A is positioned such that the pivoting peripheral end of the alignment unit 22A faces the conveyor belt 21A, and the rotation axis of the alignment unit 22A perpendicularly intersects the direction in which the conveyor belt 21A moves the construction raw material M.

[0222]

From the point of view of reducing or preventing an increase in the size of the building material manufacturing apparatus X6 and scaling up the entire installation containing the building material manufacturing apparatus X6, the raw material supply unit 20A is preferably located above the screening unit 10D so that the conveyor belt 21A runs along the horizontal component the direction of the arrangement of the set of sheets in the screening unit 10D. [0223]

In the present embodiment, the transfer sheet 15 of the aforementioned screening unit 10D of the U1 section passes in the same range as the drop area onto which the construction raw material M is dropped from the raw material supply unit 20A, or in the range outside the drop area in the sheet width direction W, shown in FIG. 21 (direction perpendicular to the sheeting direction D). [0224]

When the building material manufacturing apparatus X6 is operated in each section, the building raw material M is continuously supplied from the raw material storage unit (not shown) to the raw material supply unit 20 . The building raw material M is fed, for example, at a constant speed by means of a conveyor belt 21 to a position above the receiving sheet 11 of the screening unit (screening unit 10D, screening unit 10). On the conveyor belt 21, the building raw material M is leveled by means of a leveling block 22 which rotates or by the leveling blades of the leveling block 22 . Then, in a state in which each of the set of sheets of each screening unit makes a wave motion, the building raw material M is thrown from the raw material supply unit 20 to the receiving sheet 11 of the screening unit (the direction in which the raw material is dropped from each raw material supply unit 20 , shown by the dotted arrow).

[0225]

In each section, the building raw material M supplied from the raw material supply unit 20 is pulverized and dispersed by the receiving sheet 11, which performs wave motion in the same manner as that of the building material manufacturing apparatus X1. Moreover, in section U1, the building raw material M, which does not pass through the cells of the screen sheet 12 when screened by the fine-mesh screen sheet 12 of the screen unit 10D, is pulverized and dispersed by the transfer sheet 15, which performs a wave motion, as in the case of the device X1 for production of building material. Thus, clogging of the openings of each screen sheet in each section is generally reduced.

[0226]

When the building material manufacturing apparatus X6 is operated, the building raw material M is continuously supplied from another raw material storage unit (not shown) to the raw material supply unit 20A of section U1. The building raw material M is fed, for example, at a constant speed by means of a conveyor belt 21A to a position above the transfer sheet 15 of the screening unit 10D. On the conveyor belt 21A, the building raw material M is leveled by the leveling unit 22A, which rotates, or the leveling blades of the leveling unit 22A.

[0227]

Then, in a state in which the set of sheets of the screening unit 10D of section U1 makes a wave motion, the building raw material M is thrown from the raw material supply unit 20A to the transfer sheet 15 of the screening unit 10D (the direction in which the raw material is dropped from the raw material supply unit 20A , shown by the dotted arrow). In section U1, the building raw material M dropped from the raw material supply unit 20A to the screening unit 10D is added on the transfer sheet 15 to the building raw material M that does not pass through the cells of the screening sheet 12 after being dropped from the raw material supply unit 20 to the screening unit. block 10D.

[0228]

By operating the building material manufacturing apparatus X6 configured as described above, it is possible to form layers that become a raw material carpet from parts of the building raw material M obtained by screening in the screening unit 10D of section U1, and it is possible to form layers that become a raw material carpet. material, from parts of the building raw material M obtained by sieving in the screening unit 10 of section U2 (the direction in which the raw material is dropped from each screening unit is shown by a dotted arrow). Features are described below.

[0229]

First, the building raw material M, which has passed through the cells of the screen sheet 12, is deposited on the receptacle 30, which is conveyed by the conveyor belt 31A in the direction of the arrow d1 and passes directly under the screen sheet 12 of the screening unit 10D of section U1.

[0230]

In the screening sheet 12 as described above, a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction W. Building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receptacle 30 substantially evenly. Thus, for example, as shown in FIG. 22(a), a layer L21 (first layer) is formed on the receptacle 30, the thickness of which is substantially the same in the receptacle width direction W corresponding to the sheet width direction W. Layer L21 is formed by the deposition of the fine building raw material M passed through the cells of the screen sheet 12 (the portion passed through the screen sheet 12).

[0231]

Next, the building raw material M, which has passed through the cells of the screen sheet 14, is deposited on the layer L21 on the receptacle 30, which is transported by the conveyor belt 31A in the direction of the arrow d1 and passes directly under the screen sheet 14 (in the present embodiment, under two continuous screen sheets 14) screening unit 10D section U1.

[0232]

In the screen sheet 14 as described above, a plurality of cells having the same size, which is larger than the cell size of the screen sheet 13, are arranged at a constant pitch in the sheet width direction W. The building raw material M which has passed through the meshes of the screen sheet 14 is deposited substantially evenly on the layer L21. Thus, for example, as shown in FIG. 22(b), a layer L22 (third layer) is formed on the layer L21, the thickness of which is substantially uniform in the width direction W of the receiver. Layer L22 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 (larger than the part that passed through the screen sheet 12).

[0233]

Then, part of the building raw material M crushed and dispersed on the transfer sheet 15 of section U2, reached the screen sheet 14 and passed through the cells of the screen sheet 14, is deposited on the layer L21 on the receptacle 30, which is transported by the conveyor belt 31A in the direction of the arrow d1 and passes directly under screening sheet 14 screening unit 10 section U2. Thus, for example, as shown in FIG. 22(c), layer L23 (third layer) is formed on layer L22, the thickness of which is substantially uniform in the width direction W of the receiver. The layer L23 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 14 of section U2 (the portion passed through the screen sheet 14).

[0234]

Next, the building raw material M, which has passed through the cells of the screening sheet 13, is deposited on the layer L23 on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 13 of the screening unit 10 of section U2. At this stage, for example, as shown in FIG. 22(d), when the layer L24 (second layer) is formed while the building raw material M is deposited on the layer L23 under the honeycomb area R1 of the screen sheet 13, the building raw material M is substantially not deposited under the non-cellular area R2 of the screen sheet 13. The layer L24 is formed by deposition of the building raw material M passed through the cells of the honeycomb area R1 of the screen sheet 13 of section U2 (finer than the portion passed through the screen sheet 14).

[0235]

Next, the building raw material M, which has passed through the cells of the screening sheet 12, is deposited on the receiver 30, which is transported by the belt conveyor 31A in the direction of the arrow d1 and passes directly under the screening sheet 12 of the screening unit 10 of section U2. Thus, for example, as shown in FIG. 22(e), a layer L25 (first layer) is formed on layers L23 and L24, the thickness of which is substantially uniform in the width direction W of the receiver corresponding to the width direction W of the sheet. The layer L25 is formed by the deposition of the building raw material M passed through the cells of the screen sheet 12 of section U2 (a finer part than the part passed through the screen sheet 13).

[0236]

The starting material carpet formed as described above includes the aforementioned layers L21-L25. Each of the layers L21 and L25 has a high thickness uniformity in the bin width direction W and is composed of a relatively fine building raw material M (the portion passed through the screen sheet 12). Each of the layers L22 and L23 has a high thickness uniformity in the bin width direction W and is composed of a building raw material M which is coarser than the part that has passed through the honeycomb area of the screen sheet 13. The layer L24 is an element that also functions as a layer the building raw material settling amount adjustment layer, and is composed of the building raw material M, which is coarser than the portion passed through the screen sheet 12. The raw material carpet, which has layer L24 also functioning as the building raw material settling amount adjustment layer, in addition to the layers L21, L22, L23, L25, and which is formed on the receptacle 30, is a carpet of raw material such that the deposition amount of the building raw material varies in the width direction W of the receptacle.

[0237]

Thus, the building material making apparatus X6 is suitable for forming a raw material mat including the aforementioned layers L21 to L25 while changing the deposition amount of the building raw material in the bin width direction W. The building material making apparatus X6 is suitable for changing in the width direction of the receiver the amount of deposition of the building raw material on the receiver 30 receiving the building raw material M under the screening units 10D and 10, which screens the building raw material M while mechanically sorting the building raw material M.

[0238]

Then, the starting material carpet thus formed, that is, the stack of layers L21-L25, is subjected to a heat-pressing step. The stack of layers L21-L25 is subjected to a heat-pressing step or a heat-pressing step and subsequent autoclave curing, and thus a building material having a cured layer formed from each layer is made.

[0239]

Each of the cured layers formed from the layers L21 and L25, which is a deposition of the relatively fine-grained building raw material M, has a denser texture, and thus is suitable for providing high waterproof performance, and is accordingly suitable for forming the outer layer of the building material . Each of the cured layers formed from the layers L22 to L24, which is a deposition of the relatively coarse building raw material M, has a looser and lighter texture, and thus is suitable for providing high cushioning performance, and is accordingly suitable for forming the core layer. building material.

[0240]

By thermally pressing the raw material carpet including the above-mentioned layers L21 to L25, it is possible to produce from the raw material carpet a building material in which the difference in texture density between the part where a depression is formed on the structural surface of the building material and the part where the protrusion is formed is reduced. on the structural surface of a building material, that is, a building material having a low density heterogeneity. In other words, the building material manufacturing apparatus X6 is suitable for manufacturing a building material having an indentation/protrusion pattern on its structural surface, and thereby reduces density non-uniformity.

List of reference positions

[0241]

X1-X6 - device for the manufacture of building material

U1, U2 - section

10, 10A, 10V - screening unit

11 - receiving sheet

12, 12a, 12b - screening sheet

R1 - honeycomb area

R2 - non-cellular area

15 - transfer sheet

D - sheet layout direction

W - sheet width direction

20, 20A - source material supply unit

21, 21A - belt conveyor

22, 22A - alignment block

30, 30A, 30V, 30C, 30D, 30E - receiver

W' - receiver width direction

31, 31A - transportation line

Claims (21)

1. Device for the manufacture of building material, containing: a screening unit including a set of sheets, each of which is configured to carry out a wave movement during operation of the device, which have an inclination and which are located in the direction of the inclination, the set of sheets includes a first screening sheet and a second screening sheet located under the first screening sheet sheet, the first screening sheet is a sheet in which a plurality of cells having the same size are arranged at a constant pitch in the sheet width direction of the set of sheets, and the second screening sheet is a sheet in which a plurality of cells having two or more different sizes are arranged in the sheet width direction, or a sheet which has a honeycomb region and a non-cellular region which are arranged in the sheet width direction; And a receiver for receiving building raw material that has passed through the cells of the screening unit, the receiver being movable under a set of sheets. 2. A building material manufacturing apparatus according to claim 1, wherein the size of each cell of the second screening sheet is larger than the size of each cell of the first screening sheet. 3. The building material manufacturing apparatus according to claim 1, wherein the second screening sheet has a honeycomb area in each of its two end sections in the width direction of the sheet and has at least one non-cellular area between the honeycomb areas. 4. A building material manufacturing device according to claim 1, wherein the set of sheets includes a third screening sheet located under the second screening sheet, the third sheet being a sheet in which a plurality of cells having the same size, exceeding the size of each cell of the first screening sheet are arranged with a constant step in the direction of the sheet width. 5. A building material manufacturing device according to claim 1, wherein the set of sheets includes a third screening sheet located between the first screening sheet and the second screening sheet, the third sheet being a sheet in which a plurality of cells having the same size exceeding the size of each cell of the first screening sheet, are located with a constant step in the direction of the width of the sheet. 6. A method of manufacturing a building material, carried out using: a screening unit that includes a set of sheets that have an inclination and which are located in the direction of the inclination, the set of sheets includes a first screening sheet and a second screening sheet located under the first screening sheet, the first screening sheet is a sheet in which a plurality of cells , having the same size, are arranged at a constant pitch in the sheet width direction of the set of sheets, and the second screening sheet is a sheet in which a plurality of cells having two or more different sizes are located in the sheet width direction, or a sheet that has a cellular area and non-cellular area, which are located in the width direction of the sheet; And a receiver for receiving building raw material that has passed through the cells of the screening unit, the receiver being movable under a set of sheets, wherein the method includes: screening the building raw material using the screening sheet set in a state in which each sheet of the screening sheet set makes a wave motion, and formation on the receiver of a carpet, including a first layer formed from building raw material that passed through the cells of the first screening sheet, and a second layer formed over the first layer of building raw material that passed through the cells of the second screening sheet. 7. The method of manufacturing a building material according to claim 6, wherein the size of each cell of the second screening sheet is larger than the size of each cell of the first screening sheet. 8. The building material manufacturing method according to claim 6, wherein the second screening sheet has a honeycomb area in each of its two end portions in the width direction of the sheet and has at least one non-cellular area between the honeycomb areas. 9. Method for the manufacture of building material according to claim 6, in which the set of sheets includes a third screening sheet located under the second screening sheet, and the third sheet is a sheet in which a plurality of cells having the same size, exceeding the size of each cell of the first screening sheet, are located with a constant step in the width direction of the sheet, And wherein the method includes forming a carpet on the receiver, including a first layer formed from a building raw material that has passed through the cells of the first screening sheet, a second layer formed on top of the first layer of building raw material that has passed through the cells of the second screening sheet, and a third layer, formed on top of the second layer of building material passed through the cells of the third screening sheet. 10. Method for the manufacture of building material according to claim 6, in which the set of sheets includes a third screening sheet located between the first screening sheet and the second screening sheet, and the third sheet is a sheet in which a plurality of cells having the same size, exceeding the size of each cell of the first screening sheet, are located with a constant pitch in sheet width direction, and wherein the method includes forming a carpet on the receiver, including a first layer formed from a building raw material that has passed through the cells of the first screening sheet, a third layer formed over the first layer of building raw material that has passed through the cells of the third screening sheet, and a second layer, formed on top of the third layer of building material passed through the cells of the second screening sheet.