JPH0550410A - Manufacture of hydraulically setting inorganic molding - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing a hydraulically setting inorganic molding having a good contact property between a reinforcing linear mat and a molding even if a molding having a reinforcing structure on at least one of its surfaces is manufactured. CONSTITUTION:For manufacturing a molding wherein reinforcing fiber mats are layered on at least one of the surfaces of the molding, a reinforcing fiber mat is set on one surface of a mold and a slurry containing hydraulically setting inorganic material and water is supplied into the mold to effect vibration pressure molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a hydraulic inorganic molded article which is preferably used for building materials and has a reinforcing structure provided on at least one surface thereof.

[0002]

2. Description of the Related Art Conventionally, a molded body made of a hydraulic inorganic material has been widely used as a non-combustible building material such as roof tiles and outer wall materials. The hydraulic inorganic material includes cement, mortar, linear reinforcing cement, gypsum, calcium silicate and the like. When molding using these hydraulic inorganic materials,
An extrusion method, a pressing method, a papermaking method or the like is used, and it is shaped into an arbitrary shape such as a flat plate shape or a corrugated shape.

By the way, when molding roof tiles, for example,
It is designed to have a high load bearing strength in consideration of the case where a person is placed on the roof. In this case, the load applied to the molded body is mainly a bending load. Therefore, compressive stress is applied to the front side of the molded body, and tensile stress is applied to the back side of the molded body. However, in general, a molded body made of a hydraulic inorganic material has a property of being strong against compressive stress but weak against tensile stress.

Therefore, in order to increase the load-bearing strength of the molded body, it is sufficient to increase the thickness of the roof tile. However, simply increasing the thickness not only increases the weight of the roof tile, but also increases the cost. Reduce workability.

Therefore, in order to increase the load bearing strength without increasing the weight, a structure in which a reinforcing rib or the like is provided on the back surface of the roof tile has been proposed and manufactured. Also, JP-A-63-2232
As disclosed in Japanese Laid-Open Patent Publication No. 52-52, there is proposed a structure in which this rib shape is applied to a corrugated shape and the thickness of the valley portion is larger than that of the mountain portion when viewed from the loading side. Further, the inventors disclose in Japanese Patent Application No. 2-114646 a roof tile having a reinforcing fiber mat fixed to the back surface of a roof tile body made of a hydraulic inorganic material in order to increase the tensile strength of the back surface of the roof tile. did.

[0006]

However, in the structure in which the reinforcing ribs and the like are provided on the back surface, according to the conventional dewatering press method, the molding pressure applied to the rib portion, that is, the thick portion is small, so that the rib portion has poor formability. However, there were problems such as insufficient dehydration, and the rib shape was restricted. In addition, JP-A-63
The method disclosed in Japanese Patent No. 223252 also has a problem that the moldability of the thick portion is poor and the product shape is restricted.

Further, in order to form the roof tile of Japanese Patent Application No. 2-114646, a reinforcing fiber mat is integrally fixed to the roof tile body in the dehydration press process, or the back surface of the roof tile body is subjected to the dehydration press of the roof tile body. A method of separately adhering a reinforcing fiber mat to the above is adopted, but according to the former method, the adhesiveness between the reinforcing fiber mat and the hydraulic inorganic material constituting the roof tile body is poor and a sufficient reinforcing effect is obtained. Hard to get.
In addition, the latter method not only leads to an increase in the number of steps, but also has a problem that product quality tends to vary.

The object of the present invention is to solve the above problems and to provide good adhesion between the reinforcing fiber mat and the molded body, even when manufacturing a molded body having a reinforcing structure on the back side. It is to provide a method for producing a hydraulic inorganic molded body.

[0009]

The hydraulic inorganic material used in the present invention is not particularly limited as long as it is an inorganic substance that shows a hardening property when kneaded with water, and examples thereof include ordinary Portland cement, special Portland cement, and alumina cement. Examples include plain cements such as Roman cement, acid-resistant cements, fire-resistant cements, special cements such as water glass cements, and air-hardening cements such as gypsum, lime, and magnesia cements. Particularly, in terms of strength and water resistance, Portland cement and alumina cement are preferably used.

The slurry used in the present invention comprises the above hydraulic inorganic material and water. The amount of water is not particularly limited, but if the amount of water is less than 20 parts by weight with respect to 100 parts by weight of the inorganic material, the hydraulic inorganic material will not be sufficiently cured, and the inorganic filler or reinforcement described below will be used. The dispersibility of the fibers decreases, and if it exceeds 100 parts by weight, the mechanical strength of the obtained molded product decreases, so 20 to 100 parts by weight is preferable.

The slurry used in the present invention includes:
Further, an inorganic filler may be added if necessary.
The inorganic filler is not particularly limited as long as it does not dissolve in water and does not inhibit the hardening reaction of the hydraulic inorganic material. For example, silica sand, aggregate for cement mortar such as river sand, fly ash, silica flower, silica fu. Examples include mixed cement admixtures such as aluminum, bentonite, and blast furnace slag, and natural minerals such as sepiolite, wollastonite, calcium carbonate, and mica. These may be used alone or in combination of two or more kinds. When the addition amount of the above-mentioned inorganic filler exceeds 200 parts by weight, the mechanical strength of the molded article decreases, so 200 parts by weight or less is preferable.

The slurry used in the present invention includes:
Further, a water-soluble polymer material may be added if necessary. The above water-soluble polymer material dissolves in water to impart viscosity, enhances the dispersibility of the inorganic filler and the reinforcing fibers described below, and enhances the fluidity of the mixture to improve the shapeability, and, It is not particularly limited as long as it is a polymer material that can absorb excess water in the hardened cement material and serve as a binder that fills the voids between the cement particles, for example, methyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, Cellulose esters such as carboxymethyl cellulose and hydroxypropyl methyl cellulose, polyvinyl alcohol
And polyacrylic acid. When the amount of the water-soluble polymer material added exceeds 5 parts by weight, the water resistance of the obtained molded article decreases, so 5 parts by weight or less is preferable.

The slurry used in the present invention includes:
Further, reinforcing fibers may be added if necessary. As the reinforcing fiber, any fiber can be used according to the performance to be imparted to the molded product, and for example, synthetic fiber such as vinylon, polyamide, polyester, polypropylene or the like, or glass fiber can be used. Especially when synthetic fibers are used,
Flexibility can be imparted to the hydraulic inorganic molded body.
Also, if the thickness of the reinforcing fiber is too thin, it will re-aggregate during mixing,
The fiber ball is likely to be formed due to the entanglement, and the strength of the obtained molded body is not further improved. The thickness is preferably 1 to 40 denier and the length is 3 to 15 mm, because the dispersibility and orientation of the compound deteriorate. When the amount of the reinforcing fiber added exceeds 20 parts by weight,
Since the fiber ball is formed by the entanglement of the fibers and the strength of the obtained molded article is lowered, it is preferably 20 parts by weight or less.

The reinforcing fiber mat used in the present invention is composed of fibers having a high elastic modulus for the purpose of imparting a tensile load to the back surface of the molded body. As the constituent material of the reinforcing fiber mat, for example, iron, carbon steel, stainless steel, chrome steel, metal wire or metal fiber such as copper, vinylon, aramid, organic fiber such as polypropylene, glass fiber or resin coated Examples include glass fiber and carbon fiber. The reinforcing fiber mat may be a two-dimensional woven fabric made of the above-mentioned single constituent material or a non-woven fabric. Further, it may be a woven fabric composed of two or more kinds of fibers. The thickness of the fibers and the distance between the meshes are not particularly limited, but if the mesh is coarser than 5 mesh, the adhesiveness between the molded body and the reinforcing fiber mat becomes poor, and it is difficult to obtain a sufficient reinforcing effect. If it is finer than 100 mesh, a slurry containing a hydraulic inorganic material and water will not easily be impregnated into the reinforcing fiber mat, so 5 to 100 mesh is preferable, and the diameter of each fiber constituting the mat is 0.1. ~
It is preferably 1.5 mm. The number of the reinforcing fiber mats to be used is not particularly limited, but when two or more mats are stacked, it is easy to peel between the mats, and therefore it is preferable to use one mat.

According to the method for producing a hydraulic inorganic molded body of the present invention, the reinforcing fiber mat is placed on one surface of a mold, a hydraulic inorganic material and a slurry containing water are supplied, and then vibration pressure molding is performed. It is characterized by

In the vibration pressure molding, the mixture is supplied into a pressing die having a desired product shape, and the pressing is performed while vibrating the die. By performing the vibration pressure molding, the hydraulic inorganic material is filled in the knitting mesh of the reinforcing fiber mat, and the adhesiveness between the molded body and the mat is improved.

The pressing die used in the present invention is a conventionally known pressing die to which a conventionally known vibrator is attached. The pressing die and the mixture supplied into the pressing die are three-dimensionally oriented. In order to give a slight vibration, and to give thixotropic properties to the kneaded product effectively, it is preferable to give the pressing die a frequency of 100 to 10,000 Hz with an amplitude of 1 to 500 μm. An example of a device that can be used for the above-mentioned vibration pressure molding is a vibration press molding machine described in the Aichi Tokoname Ceramics Technology Center-Research Results Report in 1988.

The hydraulic inorganic molded body obtained by the production method of the present invention is heated during molding, for example, during press molding, if a hydraulic inorganic material having a high curing rate such as gypsum is used. Therefore, it can be cured at the same time as molding, and the molded body obtained may be naturally cured over time, but a hydraulic inorganic substance such as Portland cement, which has a slow curing reaction, is used. In this case, it goes without saying that the curing reaction can be promoted and the mechanical properties can be improved by carrying out curing by a conventionally known method such as heating and humidifying the molded body.

[0019]

EXAMPLES The details of the present invention will be described in more detail with reference to examples.
explain. Example 100 parts by weight of ordinary Portland cement, fly assembly
50 parts by weight (bulk specific gravity 0.6, true specific gravity 2.3), thickness 2
Denier, 2 parts by weight of 6 mm vinylon fiber, 35 parts water
The weight part was stirred with a mixer to obtain a slurry. On the other hand, up and down
Vibration press molding machine (Asahie)
Made by Engineering Co., Ltd., product name; SA-50)
Strong fiber mat (made of polypropylene, fiber diameter 1.0m
m, 20 mesh) and then use the above slurry.
I paid. Then 10 kg / cm ²Frequency under pressure
Molded at 1,000 Hz and amplitude of about 10μ, 600 mm x
A plate-shaped molded body of 420 mm × 7.5 mm was obtained. Water above
The hard inorganic material is filled in the knitting of the reinforcing fiber mat.
It was

Comparative Example 1 The slurry obtained in the same manner as in Example was subjected to vibration pressure molding without using a reinforcing fiber mat, and a molded body similar to that in Example was obtained.

Comparative Example 2 After the same reinforcing fiber mat as in the example was laid on the lower mold of a conventional hydraulic press molding machine, the slurry was supplied. After that, molding was performed under a pressure of 60 kg / cm ² to obtain a molded body similar to the example.

The molded articles of Examples and Comparative Examples were heated at a temperature of 60.
After curing and curing for 24 hours in a thermo-hygrostat at a temperature of 90 ° C and a relative humidity of 90%, the bending strength of the obtained molded body was measured according to JIS.
It was measured according to the method of A 1408.

As a result, in the molded body of the example, 19
7 kg / cm²133k in the molded body of Comparative Example 1
g / cm²161 kg / in the molded body of Comparative Example 2
cm ²Bending strength of was obtained.

[0024]

The method for producing a hydraulic inorganic molded article of the present invention comprises vibrating and pressing after supplying a slurry containing a hydraulic inorganic material and water onto a reinforcing fiber mat.
Since the reinforcing fiber mat is effectively impregnated with the slurry, it is possible to obtain a hydraulic inorganic molded body having good adhesion between the reinforcing fiber mat and the molded body. ..

Therefore, according to the manufacturing method of the present invention, it is possible to obtain a hydraulic inorganic molded article having an excellent breaking load even if it is a thin molded article.

Claims (1)

[Claims] 1. When producing a molded article having a reinforcing fiber mat laminated on at least one surface thereof, the reinforcing fiber mat is installed on one surface of a mold, and a slurry containing a hydraulic inorganic material and water is added. A method for producing a hydraulic inorganic molded body, characterized by vibrating and pressing after supplying.