JPS5940791B2 - Extrusion manufacturing method for inorganic products - Google Patents

Description

【発明の詳細な説明】 本発明はセメント、石膏等を主成分とする無機質製品を
押出成形法によつて製造する方法に関するものである。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing inorganic products whose main components are cement, gypsum, etc. by extrusion molding.

セメント、石膏等を主成分とする無機質製品、例えば建
材を押出成形法により製造することは公知である。BACKGROUND OF THE INVENTION It is known to produce inorganic products, such as building materials, whose main components are cement, gypsum, etc., by extrusion.

この場合、製品を機械的に補強するために押出材料に石
綿、ガラス繊維或いは合成樹脂を添加することが知られ
ているが、それぞれ次のような不利、欠点がある。In this case, it is known to add asbestos, glass fiber, or synthetic resin to the extruded material in order to mechanically reinforce the product, but each has the following disadvantages and disadvantages.

すなわち、無機質製品の補強に工業的、商業的に使用可
能な石綿繊維は、Ｊ１５７〜６級のものであり、これら
等の添加により、曲げ強度は添加量の増加と共に増大す
るが、衝撃強度の向上はさして期待できない。In other words, the asbestos fibers that can be used industrially and commercially for reinforcing inorganic products are those of J157-6 grade, and by adding these, the bending strength increases as the amount added increases, but the impact strength decreases. I can't expect much improvement.

無機質製品の補強に使用されているガラス繊維は、通常
繊維長５〜２５ｍｍ程度のものである。Glass fibers used for reinforcing inorganic products usually have a fiber length of about 5 to 25 mm.

しかし、かゝるガラス繊維を押出材料に添加すると、押
出材料がダイス構造部の間隙を通過する際にガラス繊維
が押出間隙につかえ、該間隙が閉塞され、その結果、押
出材料の通過が阻止されて、押出製品に縦に連続的に切
欠き傷が生じるといつた不利、或いは材料が押出スクリ
ューとこの周囲のシリンダー円筒部との間に圧送される
際、硝子繊維が裁断されて、補強効果が著しく減退され
るといつた不利が懸念される。更に押出機内での原料の
混練中に、硝子繊維がモノフィラメントに開繊され、こ
の開繊のために、所定の強度特性が発現できないといつ
た不利も否定できない。無機質製品の補強に使用されて
いる合成繊維は、繊維長２５ｍｍ程度のポリプロピレン
、ビニロン等である。However, when such glass fibers are added to the extruded material, when the extruded material passes through the gap of the die structure, the glass fibers get caught in the extrusion gap, blocking the gap and thus blocking the passage of the extruded material. When the material is pumped between the extrusion screw and the surrounding cylindrical part, the glass fibers are cut and reinforced. There are concerns that there will be disadvantages if the effectiveness is significantly reduced. Furthermore, there is an undeniable disadvantage that the glass fibers are opened into monofilaments during the kneading of the raw materials in the extruder, and due to this opening, it is impossible to develop the desired strength characteristics. Synthetic fibers used for reinforcing inorganic products include polypropylene, vinylon, etc. with a fiber length of about 25 mm.

しかしこれらの繊維を添加した無機質組成物を、押出成
形する場合、他の成形方式、例えば石綿スレートの場合
における抄造方式、石膏ボードの場合の如きスラリー流
延方式等に較べ、混合水分量が低いために材料混合過程
において合成繊維をよく分散させることが至難であり、
合成繊維の塊状化が避けられない。更に押出しの際、押
出しの流れによる合成繊維の配向が顕著であり製品強度
の方向性が回避できない。上記のように、無機質製品を
押出成形により製造する場合、製品強度の増加のために
、石綿、硝子繊維或いは合成樹脂を添加することは問題
である。However, when extrusion molding an inorganic composition containing these fibers, the mixed moisture content is lower than other molding methods, such as a paper forming method for asbestos slate, a slurry casting method for plasterboard, etc. Therefore, it is extremely difficult to disperse synthetic fibers well during the material mixing process.
Clumping of synthetic fibers is unavoidable. Furthermore, during extrusion, the orientation of the synthetic fibers due to the flow of extrusion is significant, making it impossible to avoid the directionality of the product strength. As mentioned above, when producing inorganic products by extrusion molding, it is a problem to add asbestos, glass fiber, or synthetic resin to increase the strength of the product.

もつとも、鉄鋼、鉄線の格子等を無機質製品の押出しの
際、同時に、成形体中に埋入することも公知である。However, it is also known to simultaneously embed a grid of steel or iron wire into a molded product during extrusion of an inorganic product.

しかしながら、かゝる製品においては、金属類とこれを
囲繞するマトリックスとの熱膨張、収縮率の差のために
、剥離が懸念される。又、押出しの際、格子等の存在の
ために液体力学的に陰になる部分に材料が行き渉らず、
気泡が生成され易く、この部分が機械的な弱点箇所にな
り易い。更に製品使用上においては、鋸具等による切断
が至難であるといつた不便もある。上記のように、従来
においては無機質製品の補強、特に曲げ強度に対する補
強を、補強材の添加埋入といつた観点から行つているが
、押出製品の場合か＼る考え方は不適切である。However, in such products, peeling is a concern due to the difference in thermal expansion and contraction rates between the metal and the matrix surrounding it. Also, during extrusion, the material does not reach areas that are hydrodynamically shaded due to the presence of grids, etc.
Bubbles are likely to be generated, and this area is likely to become a mechanically weak point. Furthermore, when using the product, there is an inconvenience in that it is extremely difficult to cut with a saw or the like. As mentioned above, in the past, reinforcement of inorganic products, especially reinforcement for bending strength, has been carried out from the perspective of adding and embedding reinforcing materials, but this approach is inappropriate in the case of extruded products.

無機質製品の曲げ強度の補強手段としては製品自体の断
面形状を曲げ断面係数の大きなものにする手法があり、
押出成形による無機質製品の曲げ補強にはか＼る手法に
依存することが有利である。As a means of reinforcing the bending strength of inorganic products, there is a method of making the cross-sectional shape of the product itself have a large bending section modulus.
It is advantageous to rely on such techniques for bending reinforcement of mineral products by extrusion.

本発明はか＼る前提に立脚するものであり、押出成形製
品は中空製品を対象としている。か＼る中空製品に誤）
ては、衝撃強度に問題があり、本発明はこの衝撃強度の
向上のために、製品の表面近傍にマツトを埋入すること
を目的としている。The present invention is based on this premise, and the extrusion molded product is intended for hollow products. (Incorrect for hollow product)
However, there is a problem with impact strength, and the object of the present invention is to embed mat near the surface of the product in order to improve this impact strength.

本発明に係る無機質製品の押出方法は、セメント、石膏
等の水硬性無機組成物をスクリユ一式押出機のダイスに
より押出成形する場合、硝子繊維、合成繊維等よりなる
マツトに予め上記セメント、石膏等を主成分とせる水硬
性無機質組成物を含浸させ、該含浸材の硬化前に、上記
マツトをダイスより成形体表面層の近傍に埋入すること
を特徴とする方法である。In the method for extruding inorganic products according to the present invention, when a hydraulic inorganic composition such as cement or gypsum is extruded using a die of a screw extruder, the cement, gypsum, etc. This method is characterized by impregnating the molded body with a hydraulic inorganic composition containing as a main component, and embedding the mat in the vicinity of the surface layer of the molded body using a die before the impregnation material hardens.

本発明において製品の曲げ強度は、製品の断面形状に依
存するが、石綿等の繊維を加えることもできる。In the present invention, the bending strength of the product depends on the cross-sectional shape of the product, but fibers such as asbestos can also be added.

以下本発明の詳細を説明する。The details of the present invention will be explained below.

第１図は本発明の実施例を示す説明図である。FIG. 1 is an explanatory diagram showing an embodiment of the present invention.

通常の無機押出成形に用いられる真空押出機１の上部ホ
ツパ一２に水硬性無機押出組成物３を供給する。今、セ
メント系押出組成物を例にとると配合 １混練後、上述
の如くホツパ一２に供給する。A hydraulic inorganic extrusion composition 3 is supplied to an upper hopper 12 of a vacuum extruder 1 used for ordinary inorganic extrusion molding. Now, taking a cement-based extrusion composition as an example, after mixing (1), it is fed to the hopper (2) as described above.

供給された組成物は押出機上段部の第１段スクリユ一４
にて、押出されつ＼回転刃により小粒に切断されて、真
空室５に落下し、この真空室において真空ポンプにより
減圧されて、混合過程において内蔵された気泡が脱気さ
れ、緻密になつた小塊は第２段スクリユ一６により押出
移送され、スクリユ一先端部に取付けたダイス７から押
出される。ダイス先端部のダイスロ８の形状を所望形状
にしておくことにょり、連続的に目的の形状の押出成形
品９が得られる。成形品９はコンベア１０の上を移動し
つ＼ある間に目的の長さにカツタ一２００で切断され、
別に準備せるパレツト１１が横方向からコンベア１０の
下部に供給され、このパレツト１１の上に成形品が移載
され、移載されたパレツト１３はコンベア１２によりス
トツク場所に運搬され、室温、その他各種の条件下で養
生が行われる。一方硝子繊維又は合成繊維等を主材とし
て湿式又は乾式で製造された不織布状のマツト１４を連
続ロール状に準備する。The supplied composition is transferred to the first stage screw 14 in the upper part of the extruder.
The extruded product is cut into small particles by a rotating blade and falls into a vacuum chamber 5, where the pressure is reduced by a vacuum pump and the air bubbles contained in the mixture are degassed during the mixing process, making it dense. The small lump is extruded and transferred by the second stage screw 16, and extruded from a die 7 attached to the tip of the screw 1. By shaping the die slot 8 at the tip of the die into a desired shape, extruded products 9 having the desired shape can be continuously obtained. While the molded product 9 is moving on the conveyor 10, it is cut to a desired length with a cutter 200,
A separately prepared pallet 11 is supplied from the side to the bottom of the conveyor 10, the molded products are transferred onto this pallet 11, and the transferred pallet 13 is transported to a stock location by the conveyor 12, where it is kept at room temperature and other various conditions. Curing is carried out under these conditions. On the other hand, a non-woven mat 14 made of glass fiber or synthetic fiber as a main material by a wet or dry process is prepared in the form of a continuous roll.

硝子繊維としては、中性石膏の場合は通常のＥ硝子繊維
でも充分であるが、セメント系の如く、硬化反応中にア
ルカリが発生する組成物にあつては、耐アルカリ硝子繊
維が望ましく、又合成繊維としても、耐アルカリ性を有
するポリプロピレン、ポリエステル、ビニロン等の如き
耐アルカリ性の有機繊維を用いる。か＼る不織布状のマ
ツトは通常２５〜１２０ｍｍ程度の長繊維を用い、かつ
繊維間を結合固定する際、合成樹脂エマルジヨン等を用
いて接着、加熱プレスしてあるため、繊維間の結合は強
固で、連続的にこれに含浸物を含浸する工程、後述する
挿入工程を経て加工される際にも充分マツトとしての強
度を保持する。As for glass fibers, ordinary E glass fibers are sufficient for neutral gypsum, but alkali-resistant glass fibers are preferable for compositions where alkali is generated during the curing reaction, such as cement-based ones. As the synthetic fibers, alkali-resistant organic fibers such as alkali-resistant polypropylene, polyester, vinylon, etc. are used. Such nonwoven mats usually use long fibers of about 25 to 120 mm, and when bonding and fixing the fibers, they are bonded and hot pressed using synthetic resin emulsion, etc., so the bond between the fibers is strong. It maintains sufficient strength as a mat even when it is processed through the process of continuously impregnating it with an impregnation material and the insertion process described below.

成形品中にあつても繊維同志が結合しているため、引き
抜き抵抗性が増大し、かつ不織布製造時に繊維がランダ
ムに配向されているため、繊維の配列に方向性が無い〇
か＼る不織布状マツトとセメント、石膏等の押出組成物
と同質の水硬性組成物、例えばセメントにあつては、配
合 の如き組成物１７を充填した液槽１５に浸漬して振動ロ
ール１６等を用い、繰返し振動その他繰返し機械的圧縮
含浸の方法を用いて充分に含浸せしめる。Nonwoven fabrics have increased pull-out resistance because the fibers are bonded to each other even when they are in a molded product, and the fibers are randomly oriented during nonwoven fabric manufacture, so the fiber arrangement has no directionality. In the case of a hydraulic composition similar to an extruded composition such as cement or gypsum, for example, cement, it is immersed in a liquid tank 15 filled with a composition 17 of the same composition, and then repeatedly using a vibrating roll 16 or the like. Thoroughly impregnate using vibration or other repeated mechanical compression impregnation methods.

上記配合物は含浸性を顧慮して、通常の押出組成物に比
し、水比の多いスラリー状態としている。含浸後は、弾
゛註のある絞りロール１８により余剰の材料、水分を取
去つて次工程に供給する。上記含浸不織布は硬化前に、
引取りロール１９により送られて、スクリユ一と直角方
向に設けられた挿入口２０より挿入されて、同一ダイス
ロ８を経て、押出組成物と同時に、断面の所定の部分に
挿入されて押出される。上、下２面に挿入する場合は２
枚の含浸布を平行２面に挿入すれば良く、その中、厚み
等は目的により選択できる。In consideration of impregnating properties, the above formulation is in the form of a slurry with a higher water ratio than ordinary extrusion compositions. After impregnation, excess material and moisture are removed by a squeezing roll 18 with elastic notes, and the material is supplied to the next process. Before curing the above impregnated nonwoven fabric,
It is sent by a take-up roll 19, inserted through an insertion opening 20 provided perpendicularly to the screw 1, passes through the same die slot 8, and is inserted into a predetermined part of the cross section at the same time as the extrusion composition and extruded. . If inserting on the top and bottom two sides, select 2.
It is sufficient to insert sheets of impregnated cloth on two parallel sides, and the thickness etc. can be selected depending on the purpose.

上記実施例の如く成形品押出方向をスクリユ一直線上に
配置させても、第２図の如く２台の押出機１，１を直交
させて、その中間部の共通ダイス７ａを設けその後部か
ら含浸布を挿入する方式を用いても、第３図の如く押出
機１とダイスロ８を９０てに配置してダイス７ｂの後部
に挿入口を設けて実施してもよい。Even if the extrusion direction of the molded product is arranged on the same line as in the above embodiment, the two extruders 1, 1 are orthogonally arranged as shown in FIG. Even if a method of inserting the cloth is used, the extruder 1 and the die slot 8 may be arranged at 90 as shown in FIG. 3, and the insertion port may be provided at the rear of the die 7b.

表面に近い所定の部分に含浸布を誘導するためには第４
図の如くダイスロ８の直前にガイド２１を設けて誘導す
ればよい。In order to guide the impregnated cloth to a predetermined part close to the surface, the fourth
As shown in the figure, a guide 21 may be provided just in front of the dice slot 8 to guide it.

斯くして強化された成形品は第５図の如く・中空異形断
面、軽量、断熱性を有し、耐衝撃性が、いわゆるＧＲＣ
，．ＧＲＧ製品なみに向上される。The molded product reinforced in this way has a hollow irregular cross section, light weight, and heat insulation properties, as shown in Figure 5, and has impact resistance that is equivalent to that of the so-called GRC.
、． It will be improved to the same level as GRG products.

しかもＧＲＣ製品等に較べ、強化繊維の使用が断面の局
部に限られるため経済的である。上記において不織布状
マツトは押出材料と同質の組成物で予め含浸されており
、含浸材料が硬化する以前にマツトが押出しと同時に成
形体の表面部に埋入されているから、マツトと成形体と
を確実に密着できる．マツトを非含浸のま＼で埋入する
場合、マツトの気孔中に空気が成形体中に抱き込まれ、
マツトと成形体との確実なる一体化は望めないが本発明
によれば確実なる一体化を達成できる。Moreover, compared to GRC products, etc., it is economical because the use of reinforcing fibers is limited to a local area of the cross section. In the above, the non-woven mat is pre-impregnated with the same composition as the extruded material, and the mat is extruded and embedded in the surface of the molded body before the impregnated material hardens, so the mat and the molded body are can be firmly attached. When embedding the pine without impregnating it, air is trapped in the pores of the pine into the molded body.
Although reliable integration of the mat and the molded body cannot be expected, according to the present invention, reliable integration can be achieved.

実施例 １ 直経３００φの２段式真空押出機を用いて配合 Ａ ポルトランドセメント １００重量部なるセメ
ント組成物を押出しする際、１００９／ＴＩの耐アルカ
リ硝子ペーパー（湿式不織布）に予め、配合 Ｂなる組
成物の含浸液中に含浸し、２本の振動ロールの間で、振
動しつつ中心部まで含浸せしめ、次にフエルトを巻き付
けた２本のロール間でこれを挟みつ＼圧縮し余剰水分を
絞り出す。Example 1 When extruding a cement composition of 100 parts by weight of A Portland cement, which was blended using a two-stage vacuum extruder with a direct diameter of 300φ, it was blended in advance with 1009/TI alkali-resistant glass paper (wet nonwoven fabric).B The composition is impregnated in an impregnating solution, and the core is impregnated while vibrating between two vibrating rolls, and then it is sandwiched and compressed between two rolls wrapped with felt to remove excess water. Squeeze it out.

この含浸シートを上、下より各１枚宛ダイスのダイスロ
直前の挿入口より挿入し、成形品の中空部の上、下２層
中に埋め込んで第５図の如き成形品を得た。第５図は成
形品の断面を示し、肉厚５ｍｍ１総厚２５ｍｍ１巾４５
０ｍＴＩＬである。この成形品は石綿無配合であるにも
か＼わらず、１ｋ９のなす型錘を５ｍの高さより落下し
ても、何ら表裏面に異常が生じなかつた。実施例 ２ 直経２００φの押出機を用いて、 配合 Ｃ なる組成物を押出しする際、別に６０９／ｍ゛のＥ硝子
製不織布を準備しこれを、配合 Ｄ を充填した液槽中に含浸し、２本の合成樹脂製スポンジ
ロール間で絞りつ＼心部まで充分浸透せしめて後、フエ
ルトロール間で脱水、ダイスのダイスロ直前に設けた上
、下２個の挿入口より、挿入しつ＼押出しを行つた。This impregnated sheet was inserted from the top and bottom through the insertion opening of the die just before the die slot, and was embedded in the upper and lower two layers of the hollow part of the molded product to obtain a molded product as shown in FIG. 5. Figure 5 shows the cross section of the molded product, which has a wall thickness of 5 mm, a total thickness of 25 mm, and a width of 45 mm.
It is 0mTIL. Although this molded product does not contain asbestos, no abnormality occurred on the front or back surface even when a 1K9 eggplant mold weight was dropped from a height of 5 m. Example 2 When extruding the composition of formulation C using an extruder with a diameter of 200φ, a 609/m2 E glass nonwoven fabric was separately prepared and impregnated into a liquid bath filled with formulation D. , Squeeze between two synthetic resin sponge rolls to fully penetrate the core, dehydrate between felt rolls, and insert the die through the upper and lower two insertion holes provided just before the die. Performed extrusion.

この押出製品は、成形品の中空部の上、下層の表面層近
くに強化層があり、肉厚２ｍＴＩＬ、総厚１０ｍｍ１巾
３００關の中空体である。This extruded product has a reinforcing layer near the surface layer above and below the hollow part of the molded product, and is a hollow body with a wall thickness of 2 mTIL, a total thickness of 10 mm, and a width of 300 mm.

１ｋ９のなす型錘で２ｍからの落下に耐えた。It withstood a fall from 2m with a 1k9 eggplant-shaped weight.

【図面の簡単な説明】[Brief explanation of drawings]

第１図は本発明の一実施例を示す説明図、第２図、第３
図、第４図は本発明の各種実施例の要部を示す説明図、
第５図は本発明実施例により得られた成形品の断面図で
ある。 図において、１は真空押出機、２は上部ホツパ３は水硬
性無機押出組成物、４は第１段スクリユ一 ５は真空室
、６は第２段スクリユ一、７，７ａ，７ｂはダイス、８
はダイスロ、９は押出成形品、１０は製品送りコンベア
、１１は製品移載パレツト、１２はパレツト移送コンベ
ア、１３はパレツト：１４は不織布状マツト、１５は含
浸液槽、１６は振動ロール、１７は含浸組成物、１８は
絞りロール、１９は引取りロールである。FIG. 1 is an explanatory diagram showing one embodiment of the present invention, FIG.
4 are explanatory diagrams showing essential parts of various embodiments of the present invention,
FIG. 5 is a sectional view of a molded article obtained according to an example of the present invention. In the figure, 1 is a vacuum extruder, 2 is an upper hopper 3 is a hydraulic inorganic extrusion composition, 4 is a first stage screw, 5 is a vacuum chamber, 6 is a second stage screw, 7, 7a, 7b are dies, 8
1 is a die slot, 9 is an extrusion molded product, 10 is a product feed conveyor, 11 is a product transfer pallet, 12 is a pallet transfer conveyor, 13 is a pallet, 14 is a nonwoven mat, 15 is an impregnation liquid tank, 16 is a vibrating roll, 17 18 is an impregnation composition, 18 is a squeezing roll, and 19 is a take-off roll.

Claims (1)

【特許請求の範囲】[Claims] １ セメント、石膏等の水硬性無機組成物をスクリュー
式押出機のダイスにより押出成形する場合、硝子繊維、
合成繊維等よりなるマットに予め上記セメント、石膏等
を主成分とせる水硬性無機質組成物を含浸させ、該含浸
材の硬化前に、上記マットをダイスより成形体表面層の
近傍に埋入することを特徴とする無機質製品の押出製造
方法。1 When extruding hydraulic inorganic compositions such as cement and gypsum using a die of a screw extruder, glass fibers,
A mat made of synthetic fibers or the like is impregnated in advance with the above-mentioned hydraulic inorganic composition mainly composed of cement, gypsum, etc., and before the impregnation material hardens, the above-mentioned mat is embedded in the vicinity of the surface layer of the molded body using a die. A method for producing an inorganic product by extrusion, characterized by: