JPH02303803A - Concrete panel and manufacture thereof - Google Patents

Abstract

PURPOSE:To reduce the manufacturing cost of a concrete panel and also to prevent the shape of the panel from being limited by forming the panel from its mainbody and a surface layer which is composed of a binder layer incorporated with many long fibers. CONSTITUTION:A concrete panel main body 1 is constituted of lightweight cellular concrete such as ALC, PALC. Further, the surface part 1A is formed into an uneven shape. A mold 10 for molding the panel is formed of a mold 10A with the top face formed into an uneven shape and a mold form 10B fitted with this mold 10A. The surface of the mold 10 is preliminarily applied with a mold release agent and a binder (flash setting cement mortar) mixed with many long fibers 3 is blasted thereon by a spray gun 11. A binder layer 4 with the long fibers 3 joined with each other is formed on the top surface of the mold 10A. Furthermore such a state wherein many long fibers 3 project like the lawn is formed on the upper part of this binder layer 4. Concrete slurry is introduced into the mold 10 for molding the panel.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a concrete panel constituting the walls of buildings such as houses and buildings, and a method for manufacturing the same.

[Background technology]

Conventionally, concrete panels have been widely used for the walls of houses, etc., and some of these panels are manufactured by pouring concrete slurry made of materials such as cement and water into concrete molds. Since this concrete panel has the disadvantage of drying shrinkage cracks occurring on the exterior surface, conventional panels have been manufactured by pouring concrete slurry mixed with a large amount of fiber into a concrete mold.

[Problem to be solved by the invention]

However, since concrete panels manufactured by mixing fibers into concrete slurry require a large amount of fibers, the production cost of the concrete panels is high.Furthermore, fibers are mixed into every corner of the concrete panel. However, there is a problem that irregularly shaped panels cannot be manufactured.

SUMMARY OF THE INVENTION An object of the present invention is to provide a concrete panel that can reduce manufacturing costs and is not limited in shape, and a method for manufacturing the same.

[Means to solve the problem]

The concrete panel of the present invention includes a concrete panel main body made of, for example, lightweight aerated concrete, a large number of long fibers anchored to the surface of the panel main body, and a material such as instant setting cement mortar that binds these long fibers to each other. and a surface layer including a binder layer.

In addition, in the method for manufacturing a concrete panel of the present invention, a surface layer is formed by spraying a binder mixed with a large number of long fibers into a panel molding mold using a spray gun, etc., and then,
The method is characterized by pouring concrete slurry into the panel forming mold from above this surface layer.

゛Here, the length of the long fibers varies depending on various conditions such as the thickness of the binder layer, but it is usually desirable to have a length of 20 to 25 mm. If the length of the long fibers is less than 20 kaku, the long fibers will not be able to sufficiently lock onto the concrete panel body, while if the length of the long fibers exceeds 25 kaku, the long fibers will bend. The long fibers are insufficiently anchored to the concrete panel body.

[Effect]

In the present invention having such a structure, a large number of long fibers in the surface layer are bonded to each other by the binder layer, and the portions of the long fibers protruding from the binder layer bite into the surface portion of the concrete panel body due to the anchor effect. The surface layer is securely fixed to the concrete panel main body, and a large amount of fibers are not mixed into the entire concrete panel, thereby preventing the occurrence of drying shrinkage crank on the exterior surface.

〔Example〕

Embodiments of the present invention will be described below based on the drawings.

An embodiment of the concrete panel of the present invention is shown in FIGS. 1 and 2.

In Figure 1, where the entire concrete panel is shown,
The concrete panel body 1 is made of lightweight cellular concrete such as ALClPALC, and its surface portion I
A is formed in an uneven shape.

A surface layer 2 is formed on the surface portion IA of the panel 1. As shown enlarged in FIG. 2, this surface layer 2 is
It is composed of a large number of long fibers 3 held on the surface portion IA and a binder layer 4 that binds these long fibers 3 together. Here, the length of the long fibers 3 varies depending on various conditions such as the thickness of the binder layer 4, but is usually preferably 20 to 25 m.

When the long fiber length is less than 2011I11, the long fiber 3
cannot be sufficiently locked into the concrete panel body 1, and on the other hand, if the length of the long fibers 3 exceeds 25 mm, the long fibers 3 will bend. 1 becomes insufficient.

Furthermore, examples of the material of the material N3 include glass fiber, carbon fiber, synthetic resin fiber, and natural fiber. Further, examples of the binder constituting the binder layer 4 include instant setting cement mortar.

Next, a method for manufacturing the concrete panel will be explained based on FIGS. 3(A) to 4(C) and FIG. 4.

First, as shown in FIG. 3(A), a panel forming mold 1O is made up of a mold 10A having an uneven upper surface and a mold frame 10B to which this mold 10A is attached, and the surface of which has been coated with a mold release agent in advance. A binder (instant setting cement mortar) mixed with a large number of long fibers 3 is sprayed onto the surface using a spray gun 11. The flash-setting cement mortar hardens in about tens of seconds, and as shown in an enlarged view in FIG. A large number of long fibers 3 protrude above the agent layer 4 like grass.

Once the binder layer 4 is hardened, as shown in FIG. 3(B), a concrete slurry is poured into the panel forming mold 10 from above the surface layer 2 consisting of the binder layer 4 mixed with the aforesaid abrasion i3.

Thereafter, as shown in FIG. 3(C), the concrete panel is cured, and then this panel is released from the mold.

Furthermore, as is normally done, after curing at high temperature and high pressure steam (autoclave curing) in a pot, a final coating is applied.

According to this embodiment, a large number of long fibers 3 of the surface layer 2 are bonded to each other by the binder layer 4, and the portions of the long fibers 3 protruding from the binder layer 4 are attached to the concrete panel body by an anchor effect. Since the surface layer 2 bites into the surface portion IA of the concrete panel body 1, the surface layer 2 is reliably engaged with the concrete panel body 1, thereby preventing the occurrence of drying shrinkage cracks on the exterior surface.

Therefore, since it is not necessary to mix a large amount of fiber into the entire concrete panel, the manufacturing cost of the concrete panel can be reduced, and irregularly shaped panels can also be manufactured, and the shape of the panel is not limited. Also,
Conventionally, when manufacturing lightweight aerated concrete panels such as ALC and PALC, a special release agent was used as a mold release agent to be applied to the panel mold 10 in order to prevent air bubbles from disappearing on the panel surface. In this example, since the surface of the concrete panel is the surface layer 2 consisting of long fibers 3 and a binder layer 4, the type of mold release agent is not limited. From this point of view as well, the manufacturing cost of concrete panels can be reduced.

In the above embodiment, the ALC is manufactured by curing the concrete panel body 1 in an autoclave.

Although it is constructed from lightweight aerated concrete such as PALC, the concrete panel body may be constructed from ordinary concrete that can be manufactured without autoclave curing. In this case, since autoclave curing that involves applying high heat is not performed, a binder layer containing a polymer resin as a component can be used. By using this polymer resin binder, it is possible to reliably prevent the occurrence of shrinkage cranks.

Furthermore, in the present invention, when spraying the binder 4 mixed with a large number of long fibers 3 into the panel molding mold 10, an electrostatic field is applied to the panel molding mold 10 to move the long fibers 3 into the panel molding mold. The long fibers 3 may be made to stand up in the panel forming mold 10 by applying an electrostatic field.
This has the effect that the long fibers 3 reliably bite into the concrete panel body 1.

(Effects of the Invention) According to the present invention as described above, manufacturing costs can be reduced and the shape of the panel is not limited.

[Brief explanation of drawings]

FIG. 1 is a vertical cross-sectional view of one embodiment of the concrete panel of the present invention, FIG. 2 is a vertical cross-sectional view showing an enlarged main part of FIG. 1, and FIGS. FIG. 4, which is a diagram for explaining an embodiment of the concrete panel manufacturing method of the invention, is a cross-sectional view showing an enlarged main part of FIG. 3(A). 1...Concrete panel body, IA...surface part,
2... Surface layer, 3... Long fiber, 4... Binder layer,
10... Panel molding mold.

Claims (2)

[Claims] (1) Concrete characterized by comprising a concrete panel body, a surface layer containing a large number of long fibers that are anchored to the surface of the concrete panel body, and a binder layer that binds these long fibers to each other. panel. (2) Spray a binder mixed with a large number of long fibers onto a panel mold to form a surface layer on the top surface of the panel mold, and then pour concrete onto the panel mold from above this surface layer. A method for manufacturing a concrete panel, characterized by pouring slurry.