JPH06155482A - Integrally-molded lightweight composite material - Google Patents
Integrally-molded lightweight composite materialInfo
- Publication number
- JPH06155482A JPH06155482A JP3355438A JP35543891A JPH06155482A JP H06155482 A JPH06155482 A JP H06155482A JP 3355438 A JP3355438 A JP 3355438A JP 35543891 A JP35543891 A JP 35543891A JP H06155482 A JPH06155482 A JP H06155482A
- Authority
- JP
- Japan
- Prior art keywords
- layer
- foam
- mixed
- density layer
- foaming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 20
- 239000000463 material Substances 0.000 claims abstract description 56
- 238000005187 foaming Methods 0.000 claims abstract description 19
- 239000006261 foam material Substances 0.000 claims description 34
- 239000003562 lightweight material Substances 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 239000000203 mixture Substances 0.000 claims description 10
- 239000004568 cement Substances 0.000 claims description 8
- 229920006328 Styrofoam Polymers 0.000 claims description 6
- 239000008261 styrofoam Substances 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 239000012530 fluid Substances 0.000 claims description 3
- 230000005484 gravity Effects 0.000 claims description 3
- 238000000465 moulding Methods 0.000 claims description 2
- 239000011347 resin Substances 0.000 claims description 2
- 229920005989 resin Polymers 0.000 claims description 2
- -1 which is organic Substances 0.000 claims 1
- 230000006835 compression Effects 0.000 abstract description 5
- 238000007906 compression Methods 0.000 abstract description 5
- 238000000034 method Methods 0.000 abstract description 4
- 238000003825 pressing Methods 0.000 abstract description 2
- 239000006260 foam Substances 0.000 description 19
- 230000000903 blocking effect Effects 0.000 description 17
- 239000004567 concrete Substances 0.000 description 5
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 239000004566 building material Substances 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000011381 foam concrete Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 239000012260 resinous material Substances 0.000 description 1
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
Description
【発明の詳細な説明】
［産業上の利用分野］本発明は無機質性及び樹脂性を基
材とし発泡材とを混合し、高密度層、発泡材混合層とを
造り、高密度層に発泡材が混入しないように発泡材遮断
用網を高密度層と発泡材混合層の中間に組み合わせ、金
型から振動を与えながら、混合材との比重差を利用し、
複合一体成型軽量材を製造し建築壁材として利用出来る
製造方法に関する。
［従来の技術］従来セメントや、樹脂からなる複合材は
多種存在する、例えば気泡コンクリートなどがある、建
築材として利用されている、セメントに金属アルミニゥ
ム粉末を混合し、発泡材として製造方法等があるが発泡
後に切断する為めに切断面が脆く、耐久性に問題があ
る。
［発明が解決しようとする問題点］従来の技術におい
て、永年建築材として、利用されている、気泡コンクリ
ート壁材がある、所定の硬さになった、気泡コンクリー
ト、ケーキは型枠が外され、自動切断機に移動し、自動
切断機のピアノ線によって、所定の寸法に切断されま
す。この時に表面の弱層を造りだし、荒れてざらざらと
なり、雨水が浸透すやすく、耐久性の問題がある。そこ
で本発明の目的は比較的軽量でしかも製造が簡単でその
手順を示すと高密度層、発泡材混合層とから構成され、
高密度層と発泡材混合層とが区別をして複合一体成形軽
量材を製造する方法により、高密度層に発泡材だけを、
混入しないようにする為めの、発泡材遮断用網を高密度
層との上に載置し、その発泡材遮断用網の上に発泡材混
合層とに成る、無機質性、及び、樹脂性を基材とした混
合材とを定量分、金型により流し込む、このようにして
複合一体成型軽量材を製造しることが出来る雨水の浸透
を防止出来、耐久性のある効果建築壁材として利用する
ことが目的である。
［課題を解決するための手段］そこで本発明は、無機質
性、樹脂性流動複合材の基材を利用して、軽くて耐候性
がある強度の高い建築壁材を、高密度層と発泡材混合層
とを設けて、発泡材遮断用網によって、発泡材とを網目
により振り分け高密度層に発泡材だけを混入しないよぅ
うにした、複合一体成型軽量材を製造するようにしたも
のである。
［作用］金型６の表面に高密度層となる２を流し込み３
の発泡材遮断用網を２の高密度層の上に、載置する。３
の発泡材遮断用網に５なる発泡材混合層を、流し込む、
この時に４の発泡材だけが３の発泡材遮断用網に遮断さ
れて、一部の混合材だけは、３なる発泡材遮断用網を潜
りぬけて２の高密度層とが結合されていく５の発泡材混
合層に３の発泡材遮断用を載置す、高密度層となる２を
流して、７の金型から、プレス機により、圧縮して製造
したものである。
［実施例］図の（イ）〜（ヘ）は本発明の工程を説明す
る概略図である。図（イ）は複合一体成型軽量材断面図
を示すものである。（図中拡大部（Ａ）参照）６なる金
型の表面に、２の高密度層の混合材料を流した状態を示
す。２の高密度層は、複合一体成型軽量材の表面となる
所に当り、耐磨耗、耐火材、耐衝撃などの必要とする建
築壁材として利用される使用材料を説明し、セメント、
砂、水、カーボン繊維、金属繊維などにより製造され
る。３は発泡材遮断用網により、高密度層に発泡材が混
入されたら高密度層でなくなり、耐磨耗や耐水性、耐衝
撃性の役割をすることが出来ないために、どうしても３
の発泡材遮断用網により、発泡材だけを遮断するしくみ
になっている。５の発泡材混合層に混入してある４の発
泡材は、発泡スチロール材である、４．０φ〜４．２φ
の丸玉状を実地例では使用し、３の発泡材遮断用網目は
約３ミリφを使用した事によって４の発泡材を遮断出来
た。このように形成された５の発泡材混合層の上にもう
一枚の３なる発泡材遮断用網を載置して、２なる高密度
層が流し込んだ断面図である。５の発泡材混合層の材料
は、２の高密度層の混合材料に発泡スチロールを混入し
たものである。これらの組み合わせの工程が終り（ヘ）
６、７から８の圧縮プレスで圧縮しながら振動を与える
事によって２の高密度と３の発泡材遮断用網からは、そ
れぞれ目的に合うように網目から混合材だけが潜りぬけ
る役割を果たし２の高密度層、３の発泡材遮断用網、５
の発泡材混合層、６金型、７圧縮金型、８プレスによっ
て圧縮されそれぞれの層が結合されて、蒸気室養生によ
って後に硬化する、金型から脱型されて図イに示す、複
合一体成型軽量材が製造される。次に格、層についての
機能性を説明する。２の高密度層は表面にあたる役割を
するために壁材として利用されることによっては、雨水
の浸透を防止することや耐火材、耐衝撃 耐磨耗の目的
を果たす、３発泡材遮断用網は、発泡材４とが２の高密
度層に混入するのを防止する役割を果たし、多層の層を
自由に選択しながら製造する目的を果たす。５発泡材混
合層は、発泡材４を設計にもとづいてその量を調整しな
がら混入することによって軽量材を製造することができ
る。４の発泡材に金属アルミニューム粉末をまぶして、
セメントに混入すると気泡コンクリートになるが４の発
泡材を発泡スチロール玉を利用して、５の混合層に混入
したことによって４発泡スチロール玉の独立気泡体とそ
の周囲にまぶしてあるアルミニューム粉末とセメントと
の化学反応とによつてのコンクリート気泡体ができ、合
体された双方との機能性を持つた、発泡スチロールの独
立気泡は約４，０ｍｍ その表面の外周は気泡コンクリ
ートの気泡体となって従来との技術にもない、複合一体
成型軽量材や複合一体成型軽量材サンドイッチの構造と
して製造もできるのである。次に複合一体成型軽量材を
製造するための実施れによって、使用された材量名と重
さを説明します。
厚さ３０ミリ×１、０００、ミリ×１、０００，ミリ
イ…セメント４，０ｋｇ
ロ…砂 ８，０ｋｇ
ハ…金属繊維１，０ｋｇ
ニ…発泡スチロール１００ｇ
ホ…カーボン繊維 ８０ｇ
ヘ…アルミニユーム粉末１０ｇ
ト…発泡材遮断用網…２，０ｍ２…重さ１、０ｋｇ
以上の材料を混合して金型に振動を与えながら、混合材
と混入してある発泡材との比重差を利用しながら、高密
度層と、発泡材混合層との２層から成型することもでき
ることやサンドイッチ構造体の複合一体成型軽量材を製
造することも可能である。
［発明の効果］以上のように本発明によると、コンクリ
ート建築材を三層構造や多数の層を造るためには、発泡
材遮断用網により混合材の中に混合してある発泡材を網
目によりふりわけて、表面の高密度層や発泡材混合とを
結合させながら、複雑な形状であっても、複合一体成型
軽量材を製造することができるものである。DETAILED DESCRIPTION OF THE INVENTION [Industrial field of use] The present invention mixes a foam material with inorganic and resinous materials as base materials to form a high density layer and a foam material mixed layer, and foams the high density layer. In order to prevent the material from mixing in, combine a foam blocking net in the middle of the high density layer and the foam mixed layer, and use the difference in specific gravity from the mixed material while applying vibration from the mold.
The present invention relates to a manufacturing method capable of manufacturing a composite integrally molded lightweight material and using it as a building wall material. [Prior Art] Conventionally, there are various kinds of composite materials composed of cement and resin, for example, there are aerated concrete, etc., which are used as building materials, there is a method of mixing metal aluminum powder with cement and producing it as a foam material. However, since it is cut after foaming, the cut surface is fragile and there is a problem in durability. [Problems to be Solved by the Invention] In the prior art, a foam concrete wall material, which has been used as a building material for many years, has an aerated concrete wall material, has a predetermined hardness, and the mold is removed. Move to the automatic cutting machine, and cut it to the specified size by the piano wire of the automatic cutting machine. At this time, a weak layer on the surface is created, and it becomes rough and rough, and rainwater easily penetrates, and there is a problem of durability. Therefore, an object of the present invention is to be relatively lightweight and easy to manufacture, and its procedure is to be composed of a high-density layer and a foam material mixture layer,
By the method of manufacturing a composite integrally molded lightweight material by distinguishing the high-density layer and the foam material mixed layer, only the foam material is added to the high-density layer.
In order to prevent mixing, place a foam blocking net on top of the high density layer, and form a foam mixed layer on the foam blocking net. Inorganic and resinous A fixed amount of the mixed material containing as a base material is poured by a mold. In this way, it is possible to manufacture a composite integrally molded lightweight material. It is possible to prevent rainwater from penetrating and to be used as a durable building wall material. The purpose is to do. [Means for Solving the Problems] Therefore, the present invention utilizes a base material of an inorganic, resinous fluid composite material to provide a light and weather resistant building wall material having high strength, a high density layer and a foam material. A composite integrated light-weight material is provided in which a mixed layer is provided, and the foam material is distributed by the mesh by the foam material blocking net so that only the foam material is not mixed in the high density layer. [Function] 2 which becomes a high density layer is poured on the surface of the mold 6 3
2. Place the foam blocking net on the two high density layers. Three
Pour the foam material mixture layer 5 into the foam material blocking net of
At this time, only the foaming material of 4 is blocked by the foaming material blocking net of 3, and only a part of the mixed material goes through the foaming material blocking mesh of 3 and is bonded to the high density layer of 2. The foamed material mixture layer of 5 is placed on the foamed material blocking layer of 3, the high density layer of 2 is poured, and the mixture is manufactured from the die of 7 by a pressing machine. [Examples] (a) to (f) in the drawings are schematic views illustrating the steps of the present invention. Figure (a) shows a cross-sectional view of a composite integrally molded lightweight material. (Refer to the enlarged portion (A) in the figure) A state in which the mixed material of the two high-density layers is flown on the surface of the die 6 is shown. The high-density layer of 2 hits the surface of the composite integrally molded lightweight material and explains the materials used as building wall materials that require abrasion resistance, fire resistance, impact resistance, cement,
Manufactured from sand, water, carbon fiber, metal fiber, etc. 3 is a foam blocking net, and once the high density layer is mixed with the foam, the high density layer disappears and cannot play the role of abrasion resistance, water resistance and impact resistance.
The mesh for blocking the foam material is designed to block only the foam material. The foam material of 4 mixed in the foam material mixed layer of 5 is a polystyrene foam material, 4.0φ to 4.2φ.
In the practical example, the round ball shape of No. 3 was used, and the foaming material blocking mesh of No. 3 was about 3 mmφ, so that four foaming materials could be blocked. FIG. 5 is a cross-sectional view in which another foam material blocking net made of 3 is placed on the foam material mixed layer 5 thus formed, and the high density layer 2 is poured. The material of the foamed material mixed layer 5 is a mixture of expanded polystyrene with the mixed material of the high density layer 2. The process of combining these is over (f)
By vibrating while compressing with 6, 7 to 8 compression presses, the high density of 2 and the foam blocking mesh of 3 play the role of only the mixed material submerged from the mesh to suit the purpose respectively. High density layer, 3 foam blocking net, 5
The foam mixed layer, 6 molds, 7 compression molds, 8 presses are combined to combine the layers, which are then cured by steam chamber curing, demolded from the mold and shown in FIG. Molded lightweight materials are manufactured. Next, the functionality of cases and layers will be described. The high-density layer of 2 is used as a wall material to act as a surface, and thus it has the purpose of preventing the infiltration of rainwater, fireproof materials, impact resistance and abrasion resistance. Plays a role of preventing the foam material 4 and the high density layer 2 from being mixed with each other, and serves the purpose of manufacturing while freely selecting a multilayer layer. The 5-foam material mixed layer can be manufactured as a lightweight material by mixing the foam material 4 while adjusting the amount thereof based on the design. Sprinkle the foam material of 4 with metal aluminum powder,
When mixed with cement, it becomes aerated concrete, but by using the foamed styrene ball to mix the foamed material of 4 into the mixed layer of 5, the closed-cell body of 4 styrene foam and the aluminum powder and cement sprinkled around it. Due to the chemical reaction of the concrete foam, which has the functionality of both coalesced, the closed cells of Styrofoam are about 40 mm, and the outer circumference of the surface becomes a foam concrete foam. It can also be manufactured as a structure of a composite integrally molded lightweight material or a composite integrated molded lightweight material sandwich, which is not available in the above technology. Next, we will explain the name and weight of the materials used in the manufacturing process for composite integrated lightweight materials. Thickness 30 mm x 1,000 mm x 1,000 mm, Millie ... Cement 4,0 kg Ro ... Sand 8,0 kg Ha ... Metal fiber 1,0 kg D ... Styrofoam 100 g E ... Carbon fiber 80 g F ... Aluminum powder 10 g ... Foam interception net… 2,0 m 2 … Weight of 1.0 kg or more is mixed while applying vibration to the mold, and utilizing the difference in specific gravity between the mixed material and the mixed foam material, It is also possible to mold from two layers of a density layer and a foam material mixed layer, and it is also possible to manufacture a composite integrally molded lightweight material of a sandwich structure. [Effect of the Invention] As described above, according to the present invention, in order to form a three-layer structure or a large number of layers of a concrete building material, the foam material mixed in the mixture material by the foam material blocking net has a mesh structure. Therefore, it is possible to produce a composite integrally molded lightweight material even if it has a complicated shape while combining the high density layer on the surface and the mixture of foam materials.
【図面の簡単な説明】
図面は、本発明の工程を示す概略図である。
イ−−−複合一体成型軽量材（図中拡大部（Ａ）参照）
示す
ロ−−−６の金型に２高密度層を流し込み
ハ−−−３の発泡材遮断用網を２の上に載置する。
ニ−−−４、５発泡材混合層を３の上に流し
ホ−−−３発泡材遮断用網を５の発泡材混合層の上に載
置する。２は高密度層を示す。
ヘ−−−６金型、７圧縮用金型により８の圧縮プレスを
示す。BRIEF DESCRIPTION OF THE DRAWINGS The drawings are schematic diagrams showing the steps of the present invention. E --- Composite integrated molding lightweight material (See enlarged part (A) in the figure)
The two high-density layers are poured into the mold shown in FIG. D--4, 5 foam layer mixed layer is flown on 3 and H--3 foam blocking net is placed on 5 foam layer mixed layer. 2 indicates a high density layer. 6 shows a compression press of 8 with a mold of 6 and a compression mold of 7.
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.5 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ３２Ｂ 7/04 9267−4Ｆ 13/04 13/12 27/30 Ｂ 8115−4Ｆ // Ｂ２９Ｌ 9:00 4Ｆ ─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 5 Identification code Internal reference number FI technical display location B32B 7/04 9267-4F 13/04 13/12 27/30 B 8115-4F // B29L 9: 00 4F
Claims (1)
材を混合して成型する軽量材に高密度層と発泡材混合層
とを設けて、高密度層に発泡材が混入しないように発泡
材遮断用網により発泡材を遮断する機能性網を高密度層
と発泡材混合層との中間に組み合わせ複合一体成型軽量
材を製造する方法を特徴とする。 （ロ）無機質性流動材に、発泡材を混合して金型に流
し、金型から振動を与えながら、混合材との比重差を利
用して、高密度層と軽量発泡材層とを造り、複合一体成
型軽量材をつくる方法を特徴とする。 （ハ）有機質性、発泡スチロール材と、金属アルミニユ
ーム粉末とを発泡スチロール材にまぶして、セメントに
混合して、発泡スチロール材の独立気泡とセメントと金
属アルミニユーム粉末との気泡が合体されて、複合一体
成軽量材がサンドイッチの構造体となる、製造法方を特
徴とする。Claims: (a) A high density layer and a foam material mixture layer are provided in a lightweight material formed by mixing an inorganic resin fluid composite with a foam material and a hollow foam material, and foaming is performed in the high density layer. A feature is a method of manufacturing a composite integrally molded lightweight material by combining a functional mesh that blocks a foam material with a foam material shielding mesh in the middle of a high density layer and a foam material mixture layer so that the material does not mix. (B) Mixing a foaming material with an inorganic fluid material, flowing it into a mold, and applying a vibration from the mold, making use of the difference in specific gravity from the mixing material to create a high-density layer and a lightweight foaming material layer. , A method of making a composite integrated molding lightweight material. (C) Styrofoam material, which is organic, and Styrofoam material are sprinkled on Styrofoam material, mixed with cement, and the closed cells of the Styrofoam material and the air bubbles of cement and metal aluminum powder are combined to form a composite integrated lightweight It features a manufacturing method in which the material becomes a sandwich structure.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP35543891A JP3172725B2 (en) | 1991-11-25 | 1991-11-25 | Composite monolithic lightweight material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP35543891A JP3172725B2 (en) | 1991-11-25 | 1991-11-25 | Composite monolithic lightweight material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH06155482A true JPH06155482A (en) | 1994-06-03 |
| JP3172725B2 JP3172725B2 (en) | 2001-06-04 |
Family
ID=18443958
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP35543891A Expired - Fee Related JP3172725B2 (en) | 1991-11-25 | 1991-11-25 | Composite monolithic lightweight material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3172725B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1996031541A3 (en) * | 1995-03-29 | 1997-01-30 | Du Pont | One-step process for producing solid surface material with foam backing |
-
1991
- 1991-11-25 JP JP35543891A patent/JP3172725B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1996031541A3 (en) * | 1995-03-29 | 1997-01-30 | Du Pont | One-step process for producing solid surface material with foam backing |
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| JP3172725B2 (en) | 2001-06-04 |
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