JPH08151249A - Cement panel and its production - Google Patents

Abstract

PURPOSE: To obtain a lightweight, nonflammable cement panel excellent in compressive strength and flexural strength, etc., and easy to nail and cut, etc., by placing a lightweight cement mixture with a specific composition on a projection-bearing aluminum plate. CONSTITUTION: A homogeneous dry mixing of the following five components are made: (A) 1000 pts.wt. of cement (e.g. white Portland cement), (B) 50-150 pts.wt. of a lightweight aggregate, (C) <=50 pts.wt. of water granulated slag, (D) 5-45 pts.wt., on a solid basis, of an emulsion (e.g. acrylic emulsion), and (E) 15-45 pts.wt. of a fibrous material. Second, the resultant mixture is blended with 200-800 pts.wt. of water to carry out a wet mixing to produce a lightweight cement mixture. Third, the bottom of a mold is laid with an aluminum plate 3 having a projection 2 and the lightweight cement mixture is placed into the mold so as to cover the aluminum plate 3 therewith. Subsequently, the mixture is pressed while vibrating the mold to effect monolithic molding of the aluminum plate 3 and the lightweight cement mixture followed by curing to obtain the objective cement panel 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel used in the field of construction, which has a particularly beautiful design, has a low bulk specific gravity, is excellent in cutting, punching and nailing characteristics, is lightweight and has a small change in length. The present invention relates to a cement panel having a low shrinkage rate and a manufacturing method thereof.

[0002]

Double floors used in high-rise offices are constructed of non-combustible materials such as aluminum and cement. On the other hand, a wooden particle board that is easy to nail, cut, and punch is installed in the space that remains between the walls and columns. On the other hand, since the fire load (the weight of the combustible material existing per 1 [m ² ]) is determined for the safety of the building, it is not desirable to use the wooden particle board.

[0003]

As a panel material used in a building, especially a high-rise office, especially a border material, it is lightweight, has bending strength, and can be nailed, cut, punched, etc., and It is desirable that the shrinkage is small. However, the above-mentioned aluminum or cement board or wood particle board has a particularly large amount of change in length and cannot satisfy all of the above requirements. On the other hand, there is a panel in which pearlite is compounded with phenol resin, but a large amount of dust is generated at the time of cutting and the impact force is weak, and there is a risk of cutting the cable under the floor at the time of breaking, so it is a border material for high-rise buildings etc. Is unsuitable as

The present invention was devised in view of the above circumstances and is lightweight, has compressive and bending strength, is nonflammable, and can be nailed, cut and punched, and dust is generated during cutting. It is an object of the present invention to provide a cement panel having a low cutting noise, a low cutting noise, and a low drying shrinkage property, and a method for producing the same.

[0005]

In order to achieve the object, the present invention is a cement panel comprising an aluminum plate having protrusions and a cement lightweight mixture cast thereon, wherein the cement lightweight mixture. However, the cement panel is composed of cement containing lightweight aggregate, emulsion, fiber material and water. More specifically, the cement lightweight mixture is 1000 g of cement.
On the other hand, lightweight aggregate 100 ± 50 [g], emulsion 2
5 ± 25 [g], textile 30 ± 15 [g], water 500 ±
The lightweight aggregate contains 300 [g],
Made of perlite or this containing granulated slag,
The granulated slag is contained in the gemstone in the range of 0 to 50 [g], and the lightweight aggregate contains the gemstone and 10% or less of the granulated slag. ,
The cement panel is characterized in that the cement is white Portland cement, the emulsion is acrylic emulsion, and the fiber material is vinylon fiber. Also, 1
50 parts by weight or more and 150 parts by weight for 000 parts by weight of cement
The total weight of the above-mentioned perovite, 50 parts by weight or less of water granulated slag, 5 parts by weight or more and 45 parts by weight or less of emulsion (as solid matter), and 15 parts by weight or more and 45 parts by weight or less of fibrous material as a whole After dry-mixing until time becomes uniform,
200 parts by weight or more and 800 parts by weight or less of water is added and wet-mixed for a time until it becomes more uniform to form a cement lightweight mixture, and then an aluminum plate having protrusions is laid on the bottom surface of the formwork to form the formwork. Put the cement lightweight mixture inside the aluminum plate, press the cement lightweight mixture while vibrating the mold, after integrally molding the aluminum plate and the cement lightweight mixture, steam curing for a predetermined time Then, the method is characterized by a method for manufacturing a cement panel in which a cement panel in a border panel shape is manufactured by demolding. In addition, the reason why the above-mentioned perlite is set in the range of 50 to 150 parts by weight is that if it is less than 50 parts by weight, the light weight effect is lost, and if it exceeds 150 parts by weight, the strength becomes insufficient.

[0006]

[Function] Since cement is hydraulic, it becomes dense as crystals grow and nails cannot be driven. The aggregate needs to be porous to enable nailing. For this purpose, a lightweight aggregate having a specific gravity of about 0.01 is effective, and gemstone is effective. Granulated slag is vitreous and is mixed with perlite to adjust the specific gravity. The granulated slag may be omitted in some cases. In general, inorganic materials are more susceptible to chipping and less tenacious than wood. This requires emulsions and fibers. In addition, if the mixing ratio of the emulsion is high, it is not possible to ensure incombustibility, so it is necessary to adjust the mixing ratio. Furthermore, the strength of the panel is low only with the cement lightweight mixture. In particular, bending strength and impact strength are low. A cement composite plate in which protrusions are provided on a vinyl chloride steel plate is also conceivable as a reinforcing member, but the vinyl chloride steel plate has poor cutting workability and is not practical. Therefore, we used a light aluminum plate that was easy to process and provided with protrusions. In particular, the cement panel of the present invention is preferably used so that the aluminum plate comes on the side on which the tensile force acts. Further, in the present invention, the material of the cement lightweight mixture, the mixing ratio, and the attachment ratio thereof are specified based on the effect of the experiment described below. However, the present invention is not limited to this specific value.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory block diagram showing a manufacturing process of a cement panel of this embodiment, FIG. 2 is a block diagram showing a concrete example of the manufacturing method, and FIG. 3 shows a mixed state of each element of the cement panel of this embodiment. FIG. 4 is an enlarged cross-sectional view, FIG. 4 is a cross-sectional view showing a state of nailing, cutting, and punching the cement panel of this embodiment,
5 is a diagram showing the shrinkage rate of this example, FIG. 6 is a diagram showing the relationship between the age of this example and the rate of change in length, and FIG. 7 is a line showing the strength and water absorption rate of this example. Figure, Table 1 is a table showing materials and features of the cement panel of the present embodiment, Table 2 is a table showing mixing contents and mixing ratios of each material of the present example, and Table 3 is various kinds of cement panels of the present example. Table 4 shows the test method and the like, and Table 4 shows the test results of the effect of this example.

First, the contents of the constituents of the cement panel 1 of this embodiment will be described. As the constituents, cement, a perlite, a granulated slag, an emulsion, a fibrous material, and water, which constitute a cement lightweight mixture, and an aluminum plate 3 having a protrusion 2 as a reinforcing material, and the like. More specifically, the cement uses white Portland cement to present a beautiful white surface and enhance design aesthetics. Acrylic emulsion is used as the emulsion and vinylon fiber is used as the fiber material. This is because the above functions effectively as the prevention of deficiency. As the water, for example, clean water is used.

In this embodiment, the gemstone used is white white from China. The diameter is 2 to 3 [mm]. This is, for example, natural glass component SiO ₂ is 70%, Al ₂
It contains O ₃ at 14%, and has properties similar to those of pearlite made by burning pearlite in Japan. The gemstone is to make the aggregate porous so as to facilitate nailing as described above.

The water granulated slag adjusts the specific gravity of the cement panel as described above, and the addition rate is 10%.
The range is 0 to 50 [g] with respect to 00 [g].
The upper limit is set to 50 [g], but if it exceeds 50 [g], the specific gravity becomes too high.

The acrylic emulsion is particularly effective in suppressing the scattering of dust at the time of cutting, and also has the effects of preventing corner chipping and reducing water.

Vinylon fibers are effective for chipping corners and nail retention during nailing, and also improve impact resistance. Further, in the present embodiment, for example, a length of 6 [mm] is used, but it is not limited to this.

Table 1 summarizes the characteristics of the materials of the constituents in this embodiment.

[0014]

[Table 1]

As shown in Table 1, the gemstone has a diameter of 3 [mm] and a specific gravity of 0.01, and the granulated slag has a diameter of 5 [m].
m] diameter has a specific gravity of 0.80, acrylic emulsion has a TG: -10 [° C] in terms of 50 [%] solid conversion, and vinylon fiber has a fiber length of 6 [mm] and RMS18.
Two are used.

Next, an example of a method for manufacturing the cement panel 1 of this embodiment will be described with reference to FIGS. 1 and 2. As shown in FIG. 1, white cement 1000 [g] as raw material, gemstone 75 [g], granulated slag 0 [g], acrylic emulsion 25 [g], vinylon fiber 20 [g], water 525
Use [g]. The aluminum material 6 as a reinforcing material is composed of a hook-shaped protrusion 2 and an aluminum plate 3 having a plurality of the protrusions 2 arranged on the upper surface. First, dry mix white cement, gemstone and acrylic emulsion fiber for about 3 minutes. Next, water is added and wet mixing is performed for about 3 minutes. As described above, the mixture 4 of the cement lightweight mixture is formed. On the other hand, as shown in FIG. 1, the aluminum material 6 is placed on the bottom surface of the lower mold 5 with the aluminum plate 3 facing down. On top of that is placed the mixture 4 of the cement lightweight mixture. The upper mold 7 presses the mixture 4 toward the aluminum material 6 side. In this case, the mold 5 and the like are vibrated to assist the pressure driving to be completed. The mixture 4 is entangled with the protrusions 2 made of an aluminum material, and these are integrally formed. Next, steam curing is performed at 60 [° C.] for 4 hours, the mold is removed, and further natural curing is performed. As a result, the desired cement panel 1 (border panel 1) is molded. After inspecting these, they are shipped as products.

FIG. 3 is an enlarged view of a cross section of the cement panel 1 molded by the above manufacturing method.
In the hardened cement material 8, the gemstone 9 is scattered in a granular form, and many short fibers 10 are mixed. Also, hardened cement 8
Is entangled with the protrusion 2 of the aluminum material 6 and is integrally bonded to the aluminum plate 3. It should be noted that an epoxy resin may be applied to the aluminum material 6 in advance to make the fixation with the cement hardened material 8 more reliable.

Next, the samples in which the mixing conditions of the above-mentioned raw materials are changed, their test methods and test results will be described. First, Table 2 shows the mixing contents of the cement panel of this example under the four conditions of A, B, C and D.

[0019]

[Table 2]

As shown in Table 2, among the mixing ratios of A, B, C and D, the addition amounts of white cement (1000 g), vinylon fiber (20 g) and acrylic emulsion (50 g) were made constant, and the amount of the chondrite was adjusted. The addition amount was changed. In addition,
The granulated slag was approximately 10% of the perovite, and the amount of clean water added was such that the flow value was constant at 145 × 145 [mm].

Table 3 shows the test method of the cement panel under the conditions A, B, C and D and the dimensions of the sample.

[0022]

[Table 3]

In Table 3, specific gravity, water absorption rate, compressive strength,
The bending strength and nail retention strength were measured by the test method according to JIS standard. Further, as shown in FIG. 4, the method of perceptually evaluating the perforation, the processed product and the cutting workability by the perforation with the drill 11 and the cutting with the jigs 12 was adopted. Also,
For nail retention, length L = 50 [mm] and diameter 2.75.
A method of driving a round nail of [mm] with a hammer 13 and evaluating the strength (kgf) of pulling out one of them is adopted.

Table 4 shows the test results of each physical property by the above test method. Further, FIGS. 5, 6 and 7 show dimensional stability, length variation, strength, water absorption rate and the like.

[0025]

[Table 4]

FIG. 5 shows the amount of change in length per 1 m of material length on the horizontal axis. In the figure, the cement panel according to the present embodiment is shown by a cement type and a tile carpet in the figure, and is about 0.25 [mm] as compared with 2.2 [mm] of the particle board made of wood,
The rate of change is extremely low. Although there is no great difference between aluminum die casting and asbestos board, aluminum die casting is expensive and easily cooled, and is not suitable for buildings. Asbestos boards are related to pollution and cannot be used for buildings. In FIG. 6, the horizontal axis represents age (day), and the vertical axis represents the rate of change in length [%] between them. As shown in the figure, each of A, B, C and D has a very small change rate of about 0.28%. This value corresponds to the drying shrinkage rate. In FIG. 7, the horizontal axis represents the bulk specific gravity, and the vertical axis represents the strength (compression and bending) and the water absorption. Table 4 shows a summary of the above test results. As shown in Table 4, the cement panel 1 under the respective mixing conditions of A, B, C and D had a bulk specific gravity of 0.79 to 1.28 and a drying shrinkage ratio of 0.
28 [%] Pore workability, cutting workability, and corner chipping are good, and nail holding power is A = 6.3 [kgf / piece], B = 1.
3.0 [kgf / piece], C = 38.0 [kgf / piece],
D = 45.0 [kgf / piece], which is high.

Experimental Example 1 White Portland Cement 1
For 000 [g], gemstone 68 [g], granulated slag 7
[G], acrylic emulsion (solid content conversion) 25
[G], 20 [g] of vinylon fiber having a length of 6 [mm], and 525 [g] of water were mixed to prepare the above-mentioned cement mixture (substantially the same as the conditions). Next, many protrusions 2 are provided on the aluminum plate 3 of 0.5 [mm]. A panel having workability, light weight, noncombustibility, and nailing characteristics could be obtained by placing the cement mixture on the aluminum material 6 as the bottom surface. The physical properties of this panel are excellent in bulk specific gravity of 0.98, drying shrinkage of 0.28 [%], nail holding power of 38 [kgf / piece], no corner chipping, cutting workability, punching workability, etc. It was a thing. This lightweight panel was not only excellent as a general wall material and floor material, but also an excellent panel that did not generate dust when cut as a non-combustible border material for a double floor.

(Experimental Example 2) Using the formulation of Experimental Example 1,
Pressing was performed to form a panel processed into a 50 [cm] square. In ordinary cement-based press working, a pressure of 40 to 45 [kgf / cm ² ] is applied to the material.
With the material of this example, the pressure is too high and the lightweight aggregate is crushed. Therefore, the pressurizing force was reduced to 50% to perform molding, and a good result was obtained.

(Experimental Example 3) An extruded panel having a die size of 30 × 2.5 [cm] was formed by using the above-mentioned formulation.
At this time, methyl cellulose was added to prevent the material from separating. After the extrusion molding was completed, the surface was embossed to obtain a panel for the outer wall. The embossing method can be performed by using either a roller or a press. Also,
Bending strength, impact resistance, and heat insulation can be improved by combining aluminum plates.

[0030]

According to the present invention, the following remarkable effects are obtained. 1) Due to the low specific gravity of perlite, the overall high specific gravity of the cement panel is low, and it is easy to nail, punch, and cut. 2) A composite of gemstone and cement forms a beautiful surface, which can enhance the product value by exhibiting a beautiful design. 3) Since the fibers are mixed, the perovite is finely wrapped and held by the fibers dispersed in the cement, so that the drying shrinkage rate is small. 4) Addition of acrylic emulsion suppresses separation of the mixture. Further, by carrying out the curing according to the method of the present invention, a product without uneven drying on the front and back of the material can be obtained. 5) It is nonflammable and can satisfy the fire load.

[Brief description of drawings]

FIG. 1 is an explanatory block diagram illustrating a method for manufacturing a cement panel according to the present invention.

FIG. 2 is a block diagram showing a manufacturing process of this embodiment.

FIG. 3 is an enlarged cross-sectional view of the cement panel of this example.

FIG. 4 is a cross-sectional view showing a test method for cutting, punching, nailing, etc. in the present embodiment.

FIG. 5 is a diagram showing a length change amount according to the present embodiment.

FIG. 6 is a diagram showing the relationship between the age and the rate of change in length in this example (which shows the drying shrinkage rate).

FIG. 7 is a graph showing the relationship between compression and bending strength, water absorption and bulk specific gravity in this example.

[Explanation of symbols]

 1 Cement panel 2 Projection part 3 Aluminum plate 4 Mixture 5 Formwork 6 Aluminum material 7 Upper mold 8 Cement hardened product 9 Chillistone 10 Short fiber 11 Drill 12 Jigso 13 Hammer

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Claims (6)

[Claims] 1. A cement panel comprising an aluminum plate having protrusions and a cement lightweight mixture cast thereon, wherein the cement lightweight mixture comprises cement containing lightweight aggregate, emulsion, fiber material and water. A cement panel characterized by comprising. 2. The cement lightweight mixture is cement 1.
The cement panel according to claim 1, which contains 100 ± 50 [g] of lightweight aggregate, 25 ± 25 [g] of emulsion, 30 ± 15 [g] of fiber material, and 500 ± 300 [g] of water per 000 g. . 3. The lightweight aggregate is made of perovite or granulated slag contained therein, and the granulated slag is contained in perovite in a range of 0 to 50 [g]. Item 1 cement panel. 4. The gemstone and its 10 are the lightweight aggregates.
4. A granulated slag of [%] or less is contained.
Cement panel. 5. The cement panel according to claim 1, wherein the cement is white Portland cement, the emulsion is acrylic emulsion, and the fiber material is vinylon fiber. 6. 50 parts by weight of 1000 parts by weight of cement
15 parts by weight or more and 150 parts by weight or less of the above-mentioned perovskite, 50 parts by weight or less of water granulated slag, 5 parts by weight or more and 45 parts by weight or less of emulsion (as solid matter), and 15 parts by weight or more and 45 parts by weight or less of fibers After dry-mixing with the product for a time until the whole becomes uniform, add 200 parts by weight or more and 800 parts by weight or less of water and wet-mix for a time until it becomes more uniform to form a cement lightweight mixture. Laying an aluminum plate having a projection on the bottom surface of the frame, throwing the cement lightweight mixture by covering the aluminum plate in the mold, and pressing the cement lightweight mixture while vibrating the mold and the aluminum plate A cement panel characterized by producing a cement panel in the form of a border panel by integrally molding a lightweight cement mixture, steam curing for a predetermined time, and demolding. Manufacturing method Le.