JPH07292846A - External wall panel and production thereof - Google Patents

Abstract

PURPOSE:To reduce the weight and increase the load-resistance, by laminating decoration materials and unify them on one side face of a base material obtained by foaming an inorganic foaming composition made of fly ash powder, alkali metal silicate, water and a foaming agent. CONSTITUTION:A foaming inorganic composition is prepared, which is composed of 100 pts.wt. of fly ash powder containing 80% or more powder having 10mum or finer particle size, 0.2-450 pts.wt. of alkali metal silicate, 35-1500 pts.wt. of water and foaming agent. A decoration material 1 is placed upside down on the bottom of a lower mold and reinforcements are positioned in the upper mold. After the foaming inorganic composition has been charged on the rear face of the decoration material 1, the mold is closed and heated at 50-100 deg.C to foam the composition. After curing, it is removed from the mold to form an external wall panel 10.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to an outer wall panel and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, more and more sophisticated technical seeds have been required for shortening the construction period and safety of buildings. One of them is the curtain wall method for high-rise buildings, the prefabricated method for detached houses, and the unit method. In these construction methods, in order to further reduce the labor required for on-site construction, a lightweight panel is made larger, and moreover, development of a factory production technique capable of supplying members in a timely manner is becoming more and more active.

Tiles and natural stones are often applied as decorative materials on the exterior surfaces of buildings. In recent years, among such exterior building materials, a dry method has been generalized in the building industry, where a curtain wall made of concrete PC board with tiles and natural stones attached in advance is manufactured and attached to a steel frame for construction. Came. Conventionally, when applying an exterior material to these concrete PC boards, a double-sided adhesive tape is applied to the surface of the formwork bed when placing concrete, and then tiles or natural stones are applied, and then concrete is placed. Have been

[0004]

However, in order to obtain workability (fluidity) suitable for cement work, cement concrete material must be added with water in excess of the amount necessary for the hydration reaction of cement. There is. However, P, which is a cosmetic material placed at the same time
In the C plate, this surplus water leaches and adheres to the surface of the decorative material together with the cement milk, and firmly adheres to the surface of the tile after curing and demolding, which requires much labor for cleaning the decorative material. It is difficult to rationalize the whole process, and recently, in order to increase the added value in design, tiles and natural stones of which the surface of the decorative material is not smooth are used, and this cement milk is applied to the surface of the decorative material. Leaching adhesion was a major problem.

Regarding these problems, Japanese Patent Laid-Open No. 5-69
Japanese Patent No. 423 proposes a method of using a magnet sheet as a measure for preventing cement milk leaching on the surface of a decorative material. However, in this method, although a slight improvement can be made, it is difficult to completely eliminate the cement milk that is excessively added to the cement material and leaches onto the surface of the cosmetic material arranged in advance. In addition, concrete and cement materials are steam-cured at a temperature of around 60 ° C for 7 to 8 hours in order to develop strength early and to obtain demolding strength, and in order to reach design strength, further autoclave curing or Secondary curing for several weeks at room temperature is required, and a large amount of molds and
There was a certain limit to mass production in the factory production process because a large site was required for secondary curing after demolding in the factory. The present invention solves the above problems and provides an outer wall material on which a decorative material is attached in advance, without the foamable composition leaching into the decorative material.

[0006]

The fly ash powder used in the present invention contains 80% by weight or more of powder having a particle size of 10 μm or less.

The above fly ash is JIS A 62
The fine ash particles collected from a pulverized coal combustion boiler with a dust collector as specified in 01. Silica 45% or more, moisture content 1% or less, ignition loss 5% or less, specific gravity 1.95 or more, specific ratio Surface area of 2700 cm ² / g or more, 75% of 44 μm standard sieve
The above is what passes.

As a method for obtaining fly ash powder containing 80% by weight or more of powder having a particle size of 10 μm or less from the above fly ash, any conventionally known method is adopted,
Examples include classification by sieving, specific gravity, wind force, wet settling, etc., pulverization by a jet mill, roll mill, ball mill, and the like. These means may be used in combination.

If the amount of the powder having a particle size of 10 μm or less is decreased, the reactivity with the alkali metal silicate is lowered, so that 80
It is limited to the weight% or more.

The alkali metal silicate used in the present invention is a salt represented by M ₂ O.nSiO ₂ (one or more kinds of metal selected from M = K, Na and Li), and the value of n When it is smaller, a dense foam cannot be obtained, and when it is larger, the viscosity of the aqueous solution increases and mixing becomes difficult, so 0.05 to 8 is preferable, and 0.5 to 2.5 is more preferable.

The alkali metal silicate is preferably added in an aqueous solution, and the concentration of the aqueous solution is not particularly limited, but the reactivity with the fly ash powder decreases as the thickness decreases, and solids tend to form when the concentration increases, so 10-60. Weight percent is preferred.

In the above alkali metal silicate aqueous solution, the alkali metal silicate may be dissolved in water as it is under pressure and heating. However, in the alkali metal hydroxide aqueous solution, the SiO ₂ component such as silica sand and silica stone powder is replaced by n. You may melt | dissolve under pressure and heating so that it may become a predetermined amount. The amount of alkali metal silicate is
If the amount is too small, the curing will not be sufficient, and if the amount is too large, the water resistance of the outer wall panel obtained will decrease. Therefore, the amount is limited to 0.2 to 450 parts by weight, preferably 10 to 350 parts by weight, relative to 100 parts by weight of the fly ash powder. And more preferably 20 to 250 parts by weight.

The water used in the present invention may be added as the above-mentioned alkali metal silicate aqueous solution or hydrogen peroxide aqueous solution, or may be added independently. When the amount of water is small, it does not harden sufficiently, and foam breakage easily occurs,
If the amount of the fly ash powder increases, the strength of the resulting foam tends to decrease.
Limited to 1500 parts by weight, preferably 45 to 1000
Parts by weight, more preferably 50 to 500 parts by weight.

The foaming agent used in the present invention reacts with the above-mentioned aqueous solution of alkali metal silicate to generate a gas, and peroxides such as hydrogen peroxide, sodium peroxide, potassium peroxide and sodium perborate, Mg, Ca, Cr, Mn, F
e, Co, Ni, Cu, Zn, Al, Ga, Sn, S
Examples thereof include metal powders such as i and ferrosilicon. These may be used alone or in combination of two or more.

When hydrogen peroxide is used as the blowing agent, it is preferably added as an aqueous solution. When the concentration of the aqueous solution is low, the viscosity of the composition is low and a stable foam cannot be obtained. When the concentration is high, the foaming is too fast and a stable foam cannot be obtained. Therefore, 0.5 to 35% by weight is preferable. It is preferably 5 to 15% by weight.

When a metal powder is used as a foaming agent, if the average particle size of the powder is too small, the reactivity becomes too high, so that a stable foam cannot be obtained. If it becomes too large, the reactivity becomes low and a lightweight outer wall panel is obtained. I can't do it so 1-2
00 μm is preferable.

When the amount of the foaming agent is small, a lightweight outer wall panel cannot be obtained, and when it is large, the foaming occurs, so 0.05 to 8 parts by weight is preferable to 100 parts by weight of fly ash powder.

In the present invention, a foaming aid may be added if necessary. The foaming aid is not particularly limited as long as it uniformly causes foaming, and examples thereof include fatty acid metal salts such as zinc stearate, calcium stearate, and zinc palmitate, silica gel, zeolite, activated carbon, porous powder such as alumina powder, and higher grades. Examples thereof include sulfuric acid ester salts of alcohols, alkyl ether sulfuric acid ester salts, aromatic derivative sulfonates, imidazoline derivatives, fatty acid amides, and foaming agents such as animal proteins. These may be used alone or in combination of two or more. If the amount of the foaming auxiliary increases, the viscosity of the composition increases and foam breakage easily occurs. Therefore, it is preferably 15 parts by weight or less based on 100 parts by weight of the fly ash powder.

In the present invention, an inorganic filler may be added if necessary. Inorganic filler does not dissolve in water,
Not inhibiting the curing reaction of the foamable inorganic composition, is not particularly limited as long as it does not dissolve in the alkali metal silicate aqueous solution, for example, silica sand, river sand, zircon sand, crystalline alumina, rock powder, volcanic ash, silica flour, Examples include silica fume, bentonite, admixture for mixed cement such as blast furnace slag, sepiolite, wollastonite, natural minerals such as mica, calcium carbonate and diatomaceous earth. These may be added alone or in combination of two or more. When the average particle size of the inorganic filler is small, the viscosity of the composition increases, and a lightweight outer wall panel cannot be obtained. When the inorganic filler is large, foaming becomes unstable.
000 μm is preferable. When the amount of the inorganic filler is large, the strength of the obtained outer wall panel is lowered, so that it is preferably 600 parts by weight or less based on 100 parts by weight of the fly ash powder.

In the present invention, reinforcing fibers may be added if necessary. As the reinforcing fiber, any one can be used according to the performance desired to be imparted to the molded product, and examples thereof include vinylon fiber, polyamide fiber, polyester fiber, polypropylene fiber, carbon fiber, aramid fiber, glass fiber, potassium titanate fiber, and steel fiber. Can be used.

If the fiber diameter of the above-mentioned reinforcing fiber becomes thin, it will be re-aggregated at the time of mixing and fiber balls will be easily formed by entanglement, and the strength of the outer wall panel finally obtained will not be improved anymore, but it will become thicker or shorter. If so, the reinforcing effect such as improvement in tensile strength is small, and if the length is long, the dispersibility and orientation of the fibers decrease, so the fiber diameter is 1 to 500 μm,
A fiber length of 1 to 15 mm is preferable. Since the dispersibility of the fibers decreases as the amount of the reinforcing fibers added increases, it is preferably 10 parts by weight or less with respect to 100 parts by weight of the fly ash powder.

For the purpose of further reducing the weight of the outer wall panel, silica balloon, perlite, fly ash balloon,
Shirasu balloon, glass balloon, inorganic natural foam such as foamed clay, foam of synthetic resin such as phenol resin, urethane resin, polyethylene, and vinylidene chloride balloon may be added. These may be added alone or in combination of two or more.

The base material of the outer wall panel of the present invention is the above fly ash powder, fly ash powder, alkali metal silicate,
It is obtained by foaming a foamable inorganic composition comprising water, a foaming agent and, if necessary, a foaming auxiliary agent and, if necessary, a foaming auxiliary agent, an inorganic filler and a reinforcing material.

In the outer wall panel of the present invention, the decorative material is laminated and integrated on one surface of the base material, and the reinforcing bar is embedded and integrated on the other surface of the base material. The reinforcing bar is for imparting mechanical strength that can withstand wind pressure, impact, etc. to the outer wall panel to be molded, and bar-shaped bars or bar-shaped bars are arranged vertically and horizontally, and their intersections are welded or wire, rope, thread, Examples thereof include those bundled using fiber bundles and the like, wires, ropes, yarns, textile bundles and the like processed by textile weaving. Examples of the shape of the reinforcing bar include a lattice or mesh shape, a perforated plate or an expanded metal.

The material of the reinforcing bar is iron, steel, stainless steel,
Examples thereof include metals such as copper and brass, synthetic resins such as vinylon, aramid, and polyester, fiber materials such as carbon and glass, and reinforcing bars whose surfaces are covered with an alkali-resistant synthetic resin. These may be added alone or in combination of two or more.

The wire diameter of the reinforcing bar is preferably 1 to 30 mm,
More preferably, it is 3 to 15 mm.

The decorative material used in the present invention refers to a portion that appears on the outer surface of the outer wall panel, and examples thereof include porcelain tiles and slabs of sandstone and natural stone.

In the manufacturing method of the present invention 2, a first step of placing a cosmetic material with the surface facing downward on the bottom surface of the lower die of the forming die comprising the lower die and the upper die, and placing the reinforcing bar on the upper die. The second step of placing, the third step of filling the back surface of the decorative material with the expandable inorganic composition according to claim 1, and the fourth step of closing the upper mold with the reinforcing bar on the lower side and the lower mold. From the fifth step of heating the mold to 50 to 100 ° C. to foam and cure the foamable inorganic composition, and the sixth step of opening the mold and demolding the molded body. Therefore, the first step and the third to sixth steps are performed in this order.

An example of the manufacturing method of the second invention will be described in more detail with reference to the drawings. FIG. 1 is a side view when a mold used in the present invention 2 is open. The molding die includes a lower die 20, a side wall 21, and an upper die 22. Lower mold 20 and side wall 2
1 is connected by a bolt, and the side wall 21 and the upper mold 22 are connected by a rotary hinge 23. The lower die 20 is provided with a decorative plate positioning grid frame 28 through which a portion for placing the decorative material is provided, and the upper die 22 is provided with a through hole 27. Invention 2
First, in the first step, the decorative plate positioning grid frame 2
The decorative material 1 is placed on the penetrated portion 8 with its surface facing downward.

Then, in the second step, the reinforcing bar 5 is fixedly mounted on the upper die 22 by the insert chuck 8. Further, in the third step, the back surface (upper surface) of the decorative material 1 of the lower mold 20 is filled with the foamable inorganic composition. The method of filling the foamable inorganic composition is as follows.First, the alkali metal silicate is dissolved in at least a part of water under pressure and heating, and the fly ash powder and the remaining water and, if necessary, foaming. Auxiliary agents, reinforcing fibers, inorganic fillers, etc. are mixed to form a paste, and then a foaming agent is added to fill the lower mold 20. The foaming agent may be added in advance by mixing with a component other than the alkali metal silicate aqueous solution.

FIG. 2 is an explanatory view showing a state in which the mold is closed and the foamable inorganic composition is cured. In the fourth step, the upper mold 22 is closed with the lower mold 20 with the reinforcing bar 5 on the lower side, and the mold is closed so that the reinforcing bar 5 is embedded in the foamable inorganic composition 3. Excessive foamable inorganic composition 3 ′ escapes from the through holes 27 of the upper mold 22.

In the fifth step, the mold is heated to 50 to 100 ° C.
Then, the foamable inorganic composition 3 is cured by heating. This is because when the curing temperature is low, the molding time is long, and when it is high, cracks are likely to occur due to the difference in thermal expansion from the reinforcing bars embedded in the base material during curing. In the sixth step, the mold is opened and the molded body is demolded. The first step and the third to sixth steps are performed in this order. The second step may be performed before the fourth step, may be performed before the first step, or may be performed between the first step and the third step. Alternatively, it may be performed after the third step. Further, it may be performed in parallel with the first step or the third step.

The curing temperature may be room temperature, but it is 50 to 110.
By curing at 30 ° C. for 8 minutes, the curing reaction can be promoted and the mechanical properties can be improved. 3 and 4 are partially cutaway sectional views showing the outer wall panel of the present invention obtained by the manufacturing method of the present invention 2. The outer wall panel 3 is a base material 3 obtained by foaming a foamable inorganic composition.
The decorative material 1 is laminated and integrated on one surface, and the grid-like joints 7 are embedded and integrated on the surface inside the base material 3.

[0034]

Embodiments of the present invention will be described in more detail with reference to the drawings. Preparation of foamable inorganic composition fly ash powders 1 and 2 Fly ash (manufactured by Onoda Cement Co., JIS A 6
No. 201) is classified by a classifier (manufactured by Nisshin Engineering Co., model: TC-15), and the particle size is 50 μm.
A fly ash powder containing 100% by weight of the following powder and a fly ash powder containing 100% by weight of a powder having a particle size of more than 10 μm were obtained. Examples 1, 2 and Comparative Examples 1, 2

The side wall 21 having a height of 80 mm was connected to the lower mold 20 of 2860 mm × 920 mm shown in FIG.
A 5 mm thick polyethylene foam sheet (manufactured by Sekisui Chemical Co., Ltd., trade name: Softlon) is formed on the lower mold 20, and a lattice-shaped decorative frame 28 for positioning a decorative plate is pierced at a portion where a decorative material is arranged. Placed. Next, a double-sided tape is attached to the lower mold 20 where the decorative plate positioning grid frame 28 is penetrated, and the decorative material 1 consisting of porcelain tiles having a size of 350 mm × 75 mm and a thickness of 10 mm is 8 in the length direction and the width direction. 11 sheets were placed with the surface facing down.

Then, the reinforcing bar 5 (JIS G
Welded wire mesh equivalent to 3511, wire diameter 5 mm, mesh 100 m
16m for reinforced concrete
It was welded to the insert chuck 8 of m and placed and fixed on the upper mold.

Further, a predetermined amount of alkali metal silicate 1 shown in Table 1 (a molar ratio of SiO ₂ / M ₂ O is 1.4, and M is a molar ratio of sodium and potassium of 1: 1) is placed in an autoclave. It was dissolved in a predetermined amount of water at 130 ° C. and 7 kg / cm ² to obtain a 45% by weight aqueous solution. A predetermined amount of vinylon fiber (manufactured by Kuraray Co., Ltd., trade name: RM-182 * 3), silica sand (manufactured by Marubeni Textile Materials Co., Ltd., trade name: soft silica), fine silica stone (Sumitomo Cement Co., Ltd.) (Blaine value 10,000 g / cm ² ) and zinc stearate were added, and the mixture was stirred and dispersed in the rest of water (manufactured by Toyo Aluminum Co., Ltd .; particle size: 20 μm).
m) and stirred for 1 minute, and the foamable inorganic composition 3 is applied to the back surface (top surface) of the decorative material 1 placed on the lower mold 20.
Was injected to close the upper mold 22, and the excess slurry generated by foaming was removed for foaming for 1 hour.
After heating for a period of time to cure the foamable inorganic composition, remove the insert chuck, open the molding die, demold the molded body, and laminate the decorative material on one surface of the base material. Use a silicone sealant (made by Konishi Co., Ltd.
An outer wall panel having a reinforcing bar embedded in the base material was obtained by filling the base material with a bond modified silicon coke).
The expandable inorganic composition 3 was not leached in the obtained outer wall panel.

The obtained outer wall panel was evaluated under the following conditions, and the results are shown in Table 1.

Foam Density The base layer of the resulting outer wall panel was cut, weighed and divided by volume. Compressed Foam Body Strength The compressive strength of the above-mentioned base material layer was measured according to JIS A 1108. Weight The weight of the outer wall panel was measured and divided by the area. Load bearing capacity: 2675 m between spans according to JIS A 1414
Deflection when a m, 323 kg load was applied was measured. Falling Impact Test A 1kg steel ball was dropped on the outer wall panel from a height of 2m,
Those without scratches were marked with O, and those with scratches were marked with X.

[0040]

[Table 1]

[0041]

INDUSTRIAL APPLICABILITY The outer wall panel of the present invention is as described above, and it is an outer wall that is lightweight, has excellent load resistance and impact resistance, and does not leach the foamable inorganic composition. The outer wall panel of the present invention 2 is as described above, and it is possible to obtain an outer wall that is lightweight, has excellent load resistance, and has excellent impact resistance, and does not leach the foamable inorganic composition.

[Brief description of drawings]

FIG. 1 is a side view of a mold used in the present invention 2 when the mold is open.

FIG. 2 is an explanatory view showing a state in which the mold is closed and the foamable inorganic composition is cured.

FIG. 3 is a partially cutaway sectional view showing an outer wall panel of the present invention.

FIG. 4 is a partially cutaway sectional view showing an outer wall panel of the present invention.

[Explanation of symbols]

 1 Decorative Material 3 Base Material 5 Reinforcing Bar 10 Outer Wall Panel 20 Lower Mold 22 Upper Mold

Claims (2)

[Claims] 1. 80% by weight of powder having a particle size of 10 μm or less
100 parts by weight of fly ash powder containing the above, 0.2 to 450 parts by weight of alkali metal silicate, 35 to 1500 parts of water
A decorative material is laminated and integrated on one surface of a base material obtained by foaming an expandable inorganic composition composed of a weight part and a foaming agent, and a reinforcing bar is embedded and integrated inside the base material. Characteristic outer wall panel. 2. A first step of placing a decorative material on the bottom surface of a lower die of a forming die including a lower die and an upper die with its surface facing downward, and a second step of placing a reinforcing bar on the upper die. A step, a third step of filling the back surface of the decorative material with the expandable inorganic composition according to claim 1, a fourth step of closing the upper mold with the reinforcing bar on the lower side and the lower mold, and molding The method comprises a fifth step of heating the mold to 50 to 100 ° C. to foam and cure the expandable inorganic composition, and a sixth step of opening the molding die and demolding the molded body. A method of manufacturing an outer wall panel, which comprises performing the steps and the third to sixth steps in this order.