Building material

Abstract

Provided is a building material having excellent durability. The surface of the building material is provided with a convex part, and the convex part is provided with a first side surface part and a second side surface part corresponding to the first side surface part. The building material is composed of a mixture containing a hydraulic material, a mixed material, and a plant-based reinforcing material, and at least the plant-based reinforcing material of the convex portion is distributed in the mixture in a state in which the hydraulic material and the mixed material adhere. The distribution of the plant-based reinforcing material in the first side surface portion is substantially the same as the distribution of the plant-based reinforcing material in the second side surface portion. Preferably, the convex portion has a first edge portion that is an edge portion of the first side surface portion and a second edge portion that is an edge portion of the second side surface portion and corresponds to the first edge portion, and the distribution of the holes formed in the first edge portion is substantially the same as the distribution of the holes formed in the second edge portion.

Description

[0001] This application is a divisional application of the invention patent application filed on September 7, 2018, with application number 201880018083.3 and title "Building Materials and Methods for Manufacturing Building Materials". Technical Field

[0002] This invention relates to building materials and methods for manufacturing building materials. Background Technology

[0003] As building materials, examples include inorganic boards such as kiln wall panels and ceramic panels.

[0004] As a method for manufacturing inorganic boards, Patent Document 1 describes a so-called dry manufacturing method, in which powder raw materials are dispersed onto a support, and the fine powder raw materials are piled up to form a surface layer for building materials.

[0005] In dry formulations, methods such as... Figure 11 The forming apparatus shown. Figure 11 The device includes a forming chamber A, which has a conveyor belt B at its bottom and a supply conveyor belt D at its top. A mold plate C with an embossed surface is placed on the conveyor belt B and conveyed by the conveyor belt B. Additionally, a main blower E is arranged inside the forming chamber A in the conveying direction of the mold plate C, blowing air in the opposite direction to the conveying direction of the mold plate C. Furthermore, a screen frame F is also provided inside the forming chamber A.

[0006] exist Figure 11 In the device, powdered raw materials mixed with cement, wood reinforcement materials, etc., fall into the molding chamber A via a supply conveyor belt D. A main blower E blows air onto the falling powdered raw materials, thereby transporting the finer powdered materials in the opposite direction to the conveying direction X1. It should be noted that the powdered raw materials, which have been blown with air, are sieved by a screen frame F. Therefore, the finer powdered materials fall and accumulate on the mold plate C on the upstream side of the conveying direction X1, while the coarser powdered materials remaining on the screen frame F fall and accumulate on the mold plate C on the downstream side of the conveying direction X1.

[0007] In this way, a surface layer with a structure that becomes smaller in size as it moves downwards is formed on the mold plate C. The lower side of the surface layer is the surface surface, on which unevenness originating from the mold plate C is formed.

[0008] However, as Figure 12 As shown, in the existing molding device, the protrusions of the embossed pattern of the mold plate become a barrier to the air blown from the main blower. There is a problem that the side N of the protrusion C1 of the mold plate opposite to the conveying direction X1 is not easy to fill with fine powder materials, and coarse powder materials are exposed on the lower side of the surface layer, forming a rough surface.

[0009] Therefore, patent document 1 discloses... Figure 13 Other building material manufacturing equipment is shown. Figure 13 The building material manufacturing apparatus disclosed includes an auxiliary blower G that blows air in the conveying direction X1 of the mold plate C, and also blows air from the opposite side, filling the side of the mold plate protrusion C opposite to the conveying direction X1 of the mold plate with fine powder raw materials.

[0010] However, in recent years, there has been a demand for patterns with depth and diversity. It is difficult to fully cover the side N of the mold plate protrusion C opposite to the conveying direction X1 with tiny powder materials using only the auxiliary blower G.

[0011] Furthermore, wood chips are used to improve the performance of the resulting inorganic board. However, wood chips have a low volumetric density, while hydraulic materials such as cement have a high volumetric density. Therefore, if air grading is used, the raw materials may be unevenly packed due to differences in their volumetric density.

[0012] Specifically, hydraulic materials have a higher volumetric density and are less likely to travel long distances, so the influence of the auxiliary blower G is relatively small. Therefore, on the protrusion of the mold plate C, there is a tendency for them to accumulate on the conveying direction side M. On the other hand, wood chips have a lower volumetric density and are therefore more likely to travel long distances and be blown away by the auxiliary blower G. Therefore, on the protrusion of the mold plate C, there is a tendency for them to accumulate on the side N opposite to the conveying direction.

[0013] Furthermore, since the direction of the airflow from the main blower E is opposite to the conveying direction X1 of the mold plate C, the hourly accumulation rate of the powder material piled up by the airflow from the main blower E is faster. On the other hand, the direction of the airflow from the auxiliary blower G is the conveying direction of the mold plate C, so the hourly accumulation rate of the powder material piled up by the airflow from the auxiliary blower G is slower than that of the main blower.

[0014] Therefore, compared with the conveying direction side M of the mold plate protrusion, wood chips tend to accumulate in large quantities on the opposite side N of the mold plate protrusion, resulting in a trend of less accumulation of powder raw materials.

[0015] In the powder material piled on the mold plate, cavities can easily form between the materials. In subsequent processes, even after pressing, cavities may remain in areas with a large amount of wood chips or a small amount of powder material, and the durability will deteriorate because these cavities absorb water.

[0016] Prior art literature

[0017] Patent documents

[0018] Patent Document 1: Japanese Patent Application Publication No. 4-37505 Summary of the Invention

[0019] The problem that the invention aims to solve

[0020] This invention provides a building material with excellent durability.

[0021] Solution for solving the problem

[0022] According to a first aspect of the present invention, a building material is provided. The building material has protrusions formed on its surface, each protrusion having a first side surface and a second side surface corresponding to the first side surface. Furthermore, the building material is composed of a mixture containing a hydraulic material, a blended material, and a plant-based reinforcing material. At least the plant-based reinforcing material of the protrusions is distributed in the mixture in a state where the hydraulic material and the blended material are attached. Moreover, the distribution of the plant-based reinforcing material on the first side surface is substantially the same as the distribution of the plant-based reinforcing material on the second side surface.

[0023] In the first type of building material, at the protrusions where pores are easily formed, the plant-based reinforcing material is distributed in the mixture in a state where it is attached to the hydraulic material and the mixture. Therefore, the attached hydraulic material and the mixture inhibit the moisture absorption of the plant-based reinforcing material and suppress its absorption of water, thereby improving the durability of the building material. Furthermore, since the plant-based reinforcing material, in a state where it is attached to the hydraulic material and the mixture, is distributed in the mixture containing the hydraulic material and the mixture, it is less likely that pores will form between the plant-based reinforcing material and the mixture containing the hydraulic material and the mixture. Therefore, the absorption of water into the building material is suppressed, thereby improving the durability of the building material.

[0024] Furthermore, in the convex portion, the distribution of plant-based reinforcing material on the first side is approximately the same as that on the second side. It should be noted that "approximately the same distribution" means that the dimensions and number of materials within a specified range are the same or similar. As described above, plant-based reinforcing material in a state of being coated with hydraulic materials and mixed materials inhibits water absorption and is less prone to pore formation. Therefore, in the convex portion, when the distribution of plant-based reinforcing material on the first side is approximately the same as that on the second side, water absorption is inhibited on both sides, thereby improving the durability of this building material.

[0025] As described above, the building material of the first aspect of the present invention inhibits water absorption and is suitable for achieving excellent durability.

[0026] The building material of the second aspect of the present invention is based on the first aspect, wherein the protrusion has a first edge portion as an edge portion of a first side surface portion and a second edge portion as an edge portion of a second side surface portion and corresponding to the first edge portion, and the distribution of the cavities formed in the first edge portion is approximately the same as the distribution of the cavities formed in the second edge portion.

[0027] In building materials, the first and second edges are the areas most prone to pore formation. In the second type of building material, the plant-based reinforcing material, in a state of adhering hydraulic material and mixed material, is distributed approximately the same on both the first and second sides of the surface. Therefore, the plant-based reinforcing material, also in a state of adhering hydraulic material and mixed material, is also distributed approximately the same on both the first and second edges. Furthermore, the pore distribution on the first edge is approximately the same as that on the second edge, thus inhibiting water absorption from both edges and improving the durability of the building material.

[0028] The third-party building material of the present invention, based on the first embodiment, has a protrusion having a first edge portion as a first side edge portion and a second edge portion as a second side edge portion and corresponding to the first edge portion, wherein the water absorption of the first edge portion and the water absorption of the second edge portion are approximately the same.

[0029] In the first and second edges of the third-party building material, plant-based reinforcing materials, in a state of adhering hydraulic materials and mixed materials, are also distributed in a substantially similar manner within the mixture containing hydraulic materials and mixed materials. Furthermore, the water absorption of the first and second edges is substantially the same, thus inhibiting water absorption by the first and second edges, thereby improving the durability of this building material.

[0030] The building material of the fourth aspect of the present invention is based on the first aspect, wherein the protrusion has a first edge portion as an edge portion of a first side surface portion and a second edge portion as an edge portion of a second side surface portion and corresponding to the first edge portion, and the freeze-thaw resistance of the first edge portion is approximately the same as that of the second edge portion.

[0031] In building materials, the first and second edges are areas prone to water absorption and are therefore susceptible to degradation due to repeated freezing and thawing, i.e., freeze-thaw cycles. In the fourth type of building material, plant-based reinforcing materials, in a state of adhering hydraulic materials and mixed materials, are also distributed in a roughly similar manner in the mixture containing hydraulic materials and mixed materials in the first and second edges. Furthermore, the freeze-thaw resistance of the first edge is roughly the same as that of the second edge, thus suppressing degradation caused by freeze-thaw cycles from the first and second edges, thereby improving the durability of this building material.

[0032] The fifth embodiment of the present invention, based on the first embodiment, uses at least one of the following mixed materials: fly ash, mica, wollastonite, perlite, and resin beads. This mixed material can adhere to plant-based reinforcing materials and can also be mixed with hydraulic materials, thus the resulting building material is less prone to pore formation. Furthermore, fly ash, mica, and wollastonite are suitable for achieving high-strength building materials with excellent dimensional stability, while perlite and resin beads are suitable for achieving lightweight building materials.

[0033] According to a sixth aspect of the present invention, a method for manufacturing a building material is provided. This method involves feeding a powdered raw material containing a hydraulic material, a mixed material, and a plant-based reinforcing material to which the hydraulic material and the inorganic mixed material are attached, into a screening machine having a mesh-like sieve. By repeatedly stretching and flexing the sieve, the powdered raw material falls through the mesh of the sieve and accumulates on a mold plate below the screening machine. In the sixth aspect of the invention, the building material has a protrusion formed on its surface, the protrusion having a first side surface and a second side surface corresponding to the first side surface. The mold plate has a recess for forming the protrusion. At least the plant-based reinforcing material of the protrusion is distributed in the mixture in a state where the hydraulic material and the mixed material are attached, and the distribution of the plant-based reinforcing material on the first side surface is substantially the same as the distribution of the plant-based reinforcing material on the second side surface.

[0034] In the sixth method, instead of blowing air to the raw material for sieving, a screening machine that repeatedly stretches and flexes the mesh-like screen is used to sieve the powder raw material, while the powder raw material is piled on a mold plate to manufacture building materials.

[0035] The sieve plate contains an elastic material that allows it to stretch and contract. The sieving machine, for example, causes the sieve plate to stretch and flex alternately in a direction parallel to the mold plate, thereby vibrating up and down. This up-and-down vibration causes the powder material to bounce and fall repeatedly. Therefore, even when the powder material is tightly packed together in large lumps, the impact generated by the upward and downward movement of the powder material due to the up-and-down vibration of the sieve plate loosens the lumps, separating them into powder materials of their original size, allowing them to pass through the sieve plate.

[0036] It should be noted that the mold plate has a recess for forming a protrusion in the building material, and is arranged below the screening machine with the recessed side facing upwards.

[0037] A protrusion is formed on the surface of the manufactured building material. This protrusion has a first side surface and a second side surface corresponding to the first side surface. Furthermore, in the protrusion, where pores are easily formed, the plant-based reinforcing material is distributed in the mixture in a state where hydraulic materials and blending materials are attached. Therefore, the attached hydraulic materials and blending materials suppress the moisture absorption of the plant-based reinforcing material, thus inhibiting water absorption and improving the durability of the building material. Additionally, since the plant-based reinforcing material, in a state where hydraulic materials and blending materials are attached, is distributed in the mixture containing hydraulic materials and blending materials, pores are less likely to form between the plant-based reinforcing material and the mixture containing hydraulic materials and blending materials. Therefore, water absorption into the building material is suppressed, thereby improving the durability of the building material.

[0038] Furthermore, in the convex portion, the distribution of plant-based reinforcing material on the first side surface is approximately the same as that on the second side surface. It should be noted that "approximately the same distribution" means that the dimensions and number of the plant-based reinforcing materials within a specified range are the same or similar. As described above, the plant-based reinforcing material in its state with attached hydraulic materials and mixed materials is less prone to cavitation between itself and the mixture containing hydraulic materials and mixed materials. Since the distribution of plant-based reinforcing material on the first side surface is approximately the same as that on the second side surface, water absorption by the first and second side surfaces is suppressed, thereby improving the durability of this building material.

[0039] In the seventh embodiment of the building material manufacturing method of the present invention, based on the sixth embodiment, the sieve has a variety of mesh sizes, and the mold plate is movable below the sieve. By moving the mold plate and causing the powder raw material to fall from the different mesh sizes of the sieve, the powder raw material is thus accumulated on the mold plate.

[0040] The screening machine has various mesh sizes, such as by using screen plates with multiple mesh sizes or screen plates with mesh sizes.

[0041] The mold plate can move below the screening machine, for example, by equipping the screening machine with a conveyor belt or other traveling device, and placing the mold plate on the traveling device.

[0042] In the seventh method, by allowing the powder raw material to fall through meshes of different sizes in a sieve, the powder raw material is accumulated on a mold plate, thus enabling the sequential accumulation of powder raw materials of different sizes. This allows fine powder raw materials to accumulate on the surface of the mold plate, thereby improving the durability of the manufactured building materials.

[0043] In the method for manufacturing building materials according to the eighth aspect of the present invention, the powder raw material is manufactured by adding water to the plant-based reinforcing material and mixing it, followed by adding a hydraulic material and an inorganic mixture and mixing them together. By mixing the plant-based reinforcing material mixed with water with the hydraulic material and the mixture, the adhesion of the hydraulic material and the mixture to the plant-based reinforcing material can be achieved efficiently. The plant-based reinforcing material with the attached hydraulic material and mixture inhibits water absorption and is less prone to cavitation between itself and the mixture containing the hydraulic material and the mixture, thus improving the durability of the manufactured building material.

[0044] Invention Effects

[0045] The building materials and manufacturing method of the present invention can provide building materials with excellent durability. Attached Figure Description

[0046] Figure 1This is a schematic diagram illustrating the method for manufacturing the wall material according to Embodiment 1 of the present invention.

[0047] Figure 2 This is a diagram that details the screening machine.

[0048] Figure 3 This is a schematic diagram illustrating the up-and-down vibration of the sieve and the movement of the powder raw materials.

[0049] Figure 4 This is a schematic cross-sectional view of the wall material surface layer in Embodiment 1.

[0050] Figure 5 This is a simplified cross-sectional view of a wall material manufactured using the wall material manufacturing method of Embodiment 1 of the present invention.

[0051] Figure 6 This is a schematic cross-sectional view of the wall material surface layer in Embodiment 2 of the present invention.

[0052] Figure 7 This is a schematic diagram illustrating the method for manufacturing the wall material according to Embodiment 3 of the present invention.

[0053] Figure 8 This is a schematic diagram illustrating the method for manufacturing the wall material according to Embodiment 4 of the present invention.

[0054] Figure 9 This is a schematic cross-sectional view of the wall material surface layer in Embodiment 4.

[0055] Figure 10 This is a schematic cross-sectional view of the wall material before it is peeled off from the mold plate.

[0056] Figure 11 This is a schematic diagram illustrating existing building material manufacturing equipment.

[0057] Figure 12 It is to utilize Figure 11 A schematic cross-sectional view of the surface layer produced by the device.

[0058] Figure 13 This is a schematic diagram illustrating other existing building material manufacturing equipment.

[0059] Explanation of reference numerals in the attached figures

[0060] 1…beam, 2…screen unit, 2'…first screen unit, 2”…second screen unit, 2A…first screen, 2B…second screen, 2a…mesh, 3…raw material supply section, 4…mold plate, 5…surface layer, 6, 6A…core layer, 7, 7A, 7C…wall material surface layer, 8…central raw material supply section, 10, 10C, 10D…screening machine, 20…traveling device, 21…main rotating roller, 22…auxiliary rotating roller, 30…wall material, F…powder raw material. Detailed Implementation

[0061] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, in these embodiments, wall materials will be used as an example of building materials for explanation.

[0062] (Method for manufacturing wall material according to Embodiment 1)

[0063] Figure 1 This is a schematic diagram illustrating the method for manufacturing the wall material according to Embodiment 1 of the present invention. Figure 2 It contains a detailed diagram of the screening machine. Figure 3 This is a schematic diagram illustrating the up-and-down vibration of the sieve and the movement of the powder raw materials.

[0064] In Embodiment 1, the screen 10 shown in the figure and the traveling device 20 disposed below the screen 10 are used.

[0065] The sieving machine 10 includes: a sieve unit 2, which consists of a first sieve 2A with relatively fine mesh and a second sieve 2B with relatively coarse mesh arranged side by side; and a raw material supply unit 3, which supplies powder raw materials to the first sieve 2A. Each sieve 2A and 2B is formed of an elastic material such as polyurethane and is capable of expansion and contraction. Each sieve 2A and 2B can vibrate freely up and down (in the Y2 direction).

[0066] like Figure 2 As shown, the two parallel crossbeams 1, 1 of the screening machine 10 support screen plates 2A (2B) with a large number of meshes 2a at predetermined intervals. Each crossbeam 1, 1 slides in opposite directions (X2 direction) relative to each other by means of an actuator (not shown), thereby causing the screen plates 2A (2B) supported by each crossbeam 1, 1 to flex in part while being stretched in other parts. It should be noted that it is also possible for only one of the crossbeams 1, 1 to reciprocate by means of an actuator.

[0067] like Figure 3 As shown in the figure above, with the powder raw material F placed on the stretched sieve plate 2A, the following process is then performed... Figure 3 As shown in the middle diagram, sieve plate 2A flexes (Y2 direction), causing the powder material F to sink downwards. Then, as... Figure 3 As shown in the figure below, the sieve plate 2A is stretched and lifted again (in the Y2 direction), causing the powder material F that was sinking downwards to jump upwards.

[0068] In this way, the powder material F is pulverized by the up-and-down vibration (wave motion) of the sieve plate 2A (2B), so that only the powder material F that can pass through the mesh 2a falls downward.

[0069] The sieve plates 2A (2B) vibrate up and down while screening the powder material F, so the mesh 2a is not easily blocked. In addition, there is no need to blow air into the powder material as in existing screening methods, thus enabling the miniaturization of the equipment and eliminating the need for frequent cleaning.

[0070] return Figure 1 The traveling device 20, located below the screening machine 10, consists of a conveyor belt 23 that moves by means of the rotation of the main rotating roller 21 and the auxiliary rotating roller 22. Through the movement of this conveyor belt 23, the mold plate 4 placed on it continuously and freely moves in a constant direction (X1 direction) at a constant speed. It should be noted that the mold plate 4 moves with its uneven surface (not shown) facing upwards via the traveling device 20.

[0071] The sieve unit 2 is inclined downward relative to the traveling direction (X1 direction) of the mold plate 4 with the first sieve 2A as the inclined high side (inclination angle θ). Here, the inclination angle θ of the sieve unit 2 can be set to the angle at which the powder material F naturally rolls down the inclination. This angle varies depending on the powder material used, but for example, it can be set in the range of 12 degrees to 21 degrees.

[0072] Next, in Embodiment 1, a powder raw material is manufactured by mixing a hydraulic material, a blended material, a plant-based reinforcing material, and water. When water is contained in the powder raw material at a concentration of 30 to 45 parts by mass relative to 100 parts by mass of the total solid components, the adhesion of the hydraulic material and the blended material to the plant-based reinforcing material can be achieved efficiently, which is therefore preferred.

[0073] Examples of hydraulic materials include, for example, silicate cement, early-strength cement, alumina cement, blast furnace cement, fly ash cement, silica fume cement, etc.; anhydrous gypsum, hemihydrate gypsum, dihydrate gypsum, etc.; and blast furnace slag, converter slag, etc.

[0074] Examples of suitable blending materials include slag, silica powder, silicon dioxide powder, fly ash, papermaking sludge incineration ash, perlite, silica powder, mica, calcium carbonate, magnesium hydroxide, aluminum hydroxide, vermiculite, sepiolite, diatomite, kaolinite, zeolite, wollastonite, and recycled raw materials from crushed wood-based cement boards. Fly ash, mica, and wollastonite are preferred for achieving high-strength wall materials with excellent dimensional stability. Perlite and resin beads are preferred for achieving lightweight wall materials.

[0075] Examples of plant-based reinforcing materials include wood chips, bamboo chips, wood flour, waste paper, unbleached kraft pulp from coniferous trees (Nadelholz unbleached kraft pulp), unbleached kraft pulp from coniferous trees (Nadelholz bleached kraft pulp), and unbleached kraft pulp from broadleaf trees (Laubholz unbleached kraft pulp).

[0076] In addition to the materials mentioned above, powder raw materials may also contain other materials. Examples of other materials include waterproofing agents and curing accelerators.

[0077] Next, the screening machine 10 and the traveling device 20 are operated to form a wall material surface layer on the moving mold plate 4.

[0078] Specifically, firstly, the powder raw material is made to fall from the first screen plate 2A (Y2 direction) which is vibrating up and down from the raw material supply section 3 (Y1 direction).

[0079] The powder material supplied to the first screen plate 2A, which vibrates up and down (Y2 direction), is pulverized by the up and down vibration of the first screen plate 2A. Only the powder material that can pass through the mesh 2a of the first screen plate 2A falls under its own weight (Y3 direction) onto the moving mold plate 4 and accumulates in layers.

[0080] The powder raw material falls loosely from the sieve plate 2A to the mold plate under its own weight due to the up-and-down vibration of the first sieve plate 2A. Therefore, the plant-based reinforcing material, which is attached with hydraulic material and mixed material, can be deposited on the mold plate 4. In addition, the hydraulic material, mixed material, and plant-based reinforcing material with attached hydraulic material and inorganic mixed material are deposited on the mold plate by their own weight. Therefore, in the concave part of the mold plate, the hydraulic material, mixed material, and plant-based reinforcing material with attached hydraulic material and inorganic mixed material are deposited in approximately the same ratio and in approximately the same amount.

[0081] Powder material that cannot pass through the first screen plate 2A and remains on it naturally rolls down along the inclination (angle θ) of the screen plate unit 2 to the second screen plate 2B. It falls (Y4 direction) onto the moving mold plate 4 through the mesh of the second screen plate 2B which vibrates up and down (Y2 direction) and accumulates in layers.

[0082] Specifically, on the surface layer 5 already formed on the mold plate 4, a core layer 6 is formed, which is composed of powder raw material with relatively large mesh size that has passed through the second sieve plate 2B, so that the wall material surface layer 7 is composed of the surface layer 5 and the core layer 6.

[0083] The powder raw material falls from the sieve plate 2B in a dispersed state due to the up-and-down vibration of the second sieve plate 2B, thus allowing the plant-based reinforcing material, which is attached to the hydraulic material and the mixed material, to accumulate on the mold plate. Furthermore, the hydraulic material, the mixed material, and the plant-based reinforcing material attached to the hydraulic material and the mixed material accumulate on the mold plate by their own weight, resulting in the hydraulic material, the mixed material, and the plant-based reinforcing material being accumulated on the entire surface of the mold plate at approximately the same ratio and in approximately the same amount.

[0084] Figure 4 This is a schematic cross-sectional view of the wall material surface layer formed in Embodiment 1. (Example) Figure 4 As shown, a surface layer 5 is formed on the mold plate 4, consisting of powder material with relatively small mesh size that has passed through the mesh 2a of the first sieve plate 2A. On the surface layer 5, a core layer 6 is formed on the surface layer 5, consisting of powder material with relatively large mesh size that has passed through the mesh 2a of the second sieve plate 2B. It should be noted that both the mold plate 4 and the surface layer 5 have uneven surfaces, but... Figure 4 Not shown in the image.

[0085] The surface layer 5 is a dense and highly water-resistant layer, while the core layer 6 has a lower density, making it lightweight and providing cushioning. Therefore, a wall material surface layer 7 is formed with a lightweight and cushioning core layer 6 formed inside the dense and highly water-resistant surface layer 5.

[0086] like Figure 4 As shown, after forming the wall material surface layer 7, the formed wall material surface layer 7 and the mold plate 4 are pressed and cured to manufacture the wall material.

[0087] In this way, by using the screen 10 and the traveling device 20 that moves the mold plate 4 below it, the wall material surface layer 7 can be formed on the mold plate 4, and the wall material surface layer 7 can be formed efficiently, thereby enabling efficient manufacturing of wall materials.

[0088] (Wall material manufactured according to Embodiment 1)

[0089] Figure 5 A cross-sectional view near the surface of the wall material 30 manufactured according to Embodiment 1 is shown. A plurality of protrusions 31A are formed on the surface of the wall material 30 using the irregularities of the mold plate 4. Each protrusion 31A has a first side surface portion 31A1, a second side surface portion 31A2 corresponding to the first side surface portion 31A1, and a top surface portion connecting the first side surface portion 31A1 and the second side surface portion 31A2. The edge of the first side surface portion 31A1 is a first edge portion 31A11, and the edge of the second side surface portion 31A2 is a second edge portion 31A21. The first edge portion 31A11 and the second edge portion 31A21 face each other across the top surface portion.

[0090] The wall material 30 is manufactured by the loosely dispersed powder raw material falling from the sieve plate to the mold plate under its own weight. Therefore, in the wall material 30, plant-based reinforcing material, in a state of being coated with hydraulic materials and mixed materials, is uniformly distributed in the mixture containing hydraulic materials and mixed materials. The powder raw material also falls loosely under its own weight into the recess of the mold plate used to form the protrusion 31A of the wall material 30. In the protrusion 31A of the wall material 30, plant-based reinforcing material, in a state of being coated with hydraulic materials and mixed materials, is uniformly distributed in the mixture of hydraulic materials and mixed materials.

[0091] Furthermore, the wall material 30 is manufactured by depositing the hydraulic material, the mixed material, and the plant-based reinforcing material to which the hydraulic material and the mixed material are attached on the entire surface of the mold plate at approximately the same ratio and in approximately the same amount. In the recess of the mold plate forming the protrusion 31A of the wall material 30, the hydraulic material, the mixed material, and the plant-based reinforcing material to which the hydraulic material and the mixed material are attached are also deposited at approximately the same ratio and in approximately the same amount. Therefore, the distribution of the plant-based reinforcing material on the first side portion 31A1 of the protrusion 31A is approximately the same as the distribution of the plant-based reinforcing material on the second side portion 31A2 of the protrusion 31A. The plant-based reinforcing material to which the hydraulic material and the mixed material are attached suppresses moisture absorption by the hydraulic material and the mixed material, and gaps are less likely to form between the plant-based reinforcing material and the mixture containing the hydraulic material and the mixed material. Therefore, water absorption by the first side portion 31A1 and the second side portion 31A2 is suppressed, resulting in excellent durability of the wall material 30.

[0092] Furthermore, the distribution of cavities formed at the first edge 31A11 of the protrusion 31A is approximately the same as the distribution of cavities formed at the second edge 31A21 of the protrusion 31A, which inhibits the absorption of water by the first edge 31A11 and the second edge 31A21, thus the wall material 30 has excellent durability.

[0093] Furthermore, the water absorption of the first edge 31A11 of the protrusion 31A is approximately the same as that of the second edge 31A21 of the protrusion 31A. The plant-based reinforcing material distributed on the first edge 31A11 and the second edge 31A21, due to the adhesion of hydraulic materials and mixed materials, inhibits the moisture absorption of the plant-based reinforcing material, thus suppressing water absorption by the first edge 31A11 and the second edge 31A21, resulting in excellent durability of the wall material 30.

[0094] Furthermore, the absorption of water by the first edge 31A11 and the second edge 31A21 is suppressed to approximately the same level, so the freeze-thaw resistance of the first edge 31A11 of the protrusion 31A is approximately the same as that of the second edge 31A21 of the protrusion 31A. Therefore, the wall material 30 exhibits excellent durability.

[0095] (Method for manufacturing wall material according to Embodiment 2)

[0096] In implementation method 2, Figure 1 In the middle, the mold plate 4 reaches the edge of the second screen plate 2B and forms Figure 4 After the surface layer 5 and core layer 6 are stacked as shown, the traveling device 20 is reversed to move the mold plate 4 in the opposite direction (X1' direction), thereby forming a multi-layer wall material surface layer.

[0097] Specifically, the mold plate 4 passes directly beneath the second screen 2B again, thus... Figure 6 As shown, another core layer 6 is formed on top of the core layer 6. It should be noted that the mold plate 4 and the surface layer 5 in contact with the mold plate 4 have uneven surfaces, but... Figure 6 Not shown in the image.

[0098] Furthermore, the mold plate 4 passes directly beneath the first screen plate 2A, thereby... Figure 6 As shown, another surface layer 5 is formed on another core layer 6, thereby forming a wall material surface layer 7A with a double core layer 6 formed between the surface layers 5 on the front and back sides.

[0099] Next, the wall material surface layer 7A and the mold plate 4 are pressed and cured, thereby manufacturing the wall material.

[0100] (Wall material manufactured according to embodiment 2)

[0101] The wall material manufactured according to Embodiment 2 is similar to the wall material 30 manufactured according to Embodiment 1, in that a plurality of protrusions are formed on the surface using the unevenness of the mold plate 4. Each protrusion has a first side surface, a second side surface, a top surface, a first edge, and a second edge.

[0102] The wall material manufactured using Embodiment 2 is also produced by the loosely dispersed powder raw material falling from the sieve sheet to the mold plate 4 under its own weight. Therefore, in the protrusion, the plant-based reinforcing material, which is attached to both the hydraulic material and the mixed material, is evenly distributed in the mixture of the hydraulic material and the mixed material. The distribution of the plant-based reinforcing material is approximately the same on both the first and second side surfaces of the protrusion, resulting in excellent durability.

[0103] Furthermore, the wall material manufactured according to Embodiment 2 is also produced by depositing hydraulic materials, mixed materials, and plant-based reinforcing materials to which hydraulic materials and mixed materials are attached on the entire surface of the mold plate in approximately the same ratio and in approximately the same amount. Therefore, the distribution of pores, water absorption, and freeze-thaw resistance are approximately the same at the first edge and the second edge of the protrusion, resulting in excellent durability of the wall material manufactured according to Embodiment 2.

[0104] Furthermore, the wall material manufactured according to Embodiment 2 has a dense and highly water-resistant layer on both sides, thus exhibiting superior durability compared to the wall material manufactured according to Embodiment 1.

[0105] (Method for manufacturing wall material according to Embodiment 3)

[0106] Figure 7 This is a schematic diagram illustrating the manufacturing method of the wall material according to Embodiment 3.

[0107] In the wall material manufacturing method of Embodiment 3, a screening machine 10C having a first screening unit 2' and a second screening unit 2" is used to manufacture the surface layer for the wall material. The first screening unit 2' has a first screening plate 2A and a second screening plate 2B. The second screening unit 2" has a third screening plate 2A and a fourth screening plate 2B.

[0108] More specifically, a first screen unit 2' is provided on the upstream side of the mold plate 4 in the traveling direction (X1 direction), and a second screen unit 2' is provided on the downstream side.

[0109] The first screen unit 2' is arranged with the first screen 2A as the inclined high side, tilted downwards relative to the traveling direction (X1 direction) of the mold plate 4. The second screen unit 2" is arranged with the third screen 2A as the inclined high side, tilted upwards relative to the traveling direction (X1 direction) of the mold plate 4. In embodiment 3, the screen units 2' and 2" of both sides are arranged in an inverted V-shape.

[0110] Next, water is added to the plant-based reinforcing material and mixed. Then, the resulting plant-based reinforcing material, hydraulic material, and mixture are combined to produce a powder raw material. It should be noted that the materials illustrated in Embodiment 1 can be used as the hydraulic material, mixture, and plant-based reinforcing material.

[0111] It should be noted that adding water in a manner that is 30 to 45 parts by mass relative to 100 parts by mass of the total solid components of the powder raw material enables efficient adhesion of the hydraulic material and the mixture to the plant-based reinforcing material, and is therefore preferred. In Embodiment 3, water can be further added and mixed when mixing the hydraulic material, the mixture, and the plant-based reinforcing material mixed with water. In this case, the resulting powder raw material is manufactured in a manner that contains 30 to 45 parts by mass of water relative to 100 parts by mass of the total solid components of the powder raw material.

[0112] Next, powder material is supplied to the first sieve 2A of the first sieve unit 2', causing the powder material passing through the mesh of the first sieve 2A to fall onto the moving mold plate 4 (Y3 direction), thereby... Figure 4As shown, a surface layer 5 is formed on the mold plate 4. Then, the powder material remaining on the first sieve plate 2A is moved inclined towards the second sieve plate 2B (Z direction), causing the powder material passing through the mesh of the second sieve plate 2B to fall onto the formed surface layer 5 (Y4 direction), thereby... Figure 4 The core layer 6 is formed as shown.

[0113] The mold plate 4 moves toward the second sieve unit 2” by means of the traveling device 20. In the second sieve unit 2”, powder material is supplied to the third sieve 2A, causing the powder material that passes through the mesh of the third sieve 2A to fall downward (Y3 direction), and causing the powder material that does not pass through and remains on the third sieve 2A to roll along the incline toward the fourth sieve 2B, causing the powder material that passes through the mesh of the fourth sieve 2B to fall downward (Y4 direction).

[0114] First, the powder material that has passed through the mesh of the fourth sieve 2B falls onto the mold plate 4, which moves to the second sieve unit 2”. Figure 6 As shown, another core layer 6 is formed on top of the already formed core layer 6.

[0115] The mold plate 4 moves further, and as it passes directly below the third sieve plate 2A, the powder material that has passed through the mesh of the third sieve plate 2A falls down, such as... Figure 6 As shown, another surface layer 5 is formed on the already formed core layer 6.

[0116] By using embodiment 3, the wall material surface layer 7A, which is formed by stacking two core layers 6 on the inner side of the surface layer 5 on both sides, can be formed more efficiently.

[0117] Next, similar to Embodiment 2, multiple sets of wall material surface layer 7A and mold plate 4 are stacked and pressed and cured to manufacture the wall material.

[0118] (Wall material manufactured according to embodiment 3)

[0119] The wall material manufactured according to Embodiment 3 is the same as the wall material 30 manufactured according to Embodiment 1, and a plurality of protrusions are formed on the surface using the unevenness of the mold plate 4. The protrusions have a first side surface, a second side surface, a top surface, a first edge, and a second edge.

[0120] The wall material manufactured according to Embodiment 3 is also produced by the loosely dispersed powder raw material falling from the sieve sheet to the mold plate under its own weight. Therefore, in the protrusion, the plant-based reinforcing material, which is attached to the hydraulic material and the mixture, is evenly distributed in the mixture of the hydraulic material and the mixture. The distribution of the plant-based reinforcing material on the first side and the second side of the protrusion is approximately the same, resulting in excellent durability.

[0121] Furthermore, the wall material manufactured according to Embodiment 3 is also produced by depositing hydraulic materials, mixed materials, and plant-based reinforcing materials to which hydraulic materials and mixed materials are attached on the entire surface of the mold plate in approximately the same ratio and in approximately the same amount. Therefore, the distribution of pores, water absorption, and freeze-thaw resistance are approximately the same at the first edge and the second edge of the protrusion, resulting in excellent durability of the wall material manufactured according to Embodiment 3.

[0122] Furthermore, the wall material manufactured according to Embodiment 3 has a dense and highly water-resistant layer on both sides, thus exhibiting superior durability compared to the wall material manufactured according to Embodiment 1.

[0123] (Method for manufacturing wall material according to Embodiment 4)

[0124] Figure 8 This is a schematic diagram illustrating the method for manufacturing the wall material according to Embodiment 4.

[0125] In the wall material manufacturing method of Embodiment 4, a wall material surface layer is manufactured using a screen 10D with a central raw material supply unit 8 disposed above the first screen plate unit 2' of the screen 10C used in the wall material manufacturing method of Embodiment 3. More specifically, in the screen 10D, the central raw material supply unit 8 is disposed above the second screen plate 2B of the first screen plate unit 2'.

[0126] The powder raw materials and their manufacturing methods used in Embodiment 4 are the same as those in Embodiment 3.

[0127] In embodiment 4, when the mold plate 4 passes through the sieve 2A of the first sieve unit 2', as... Figure 9 As shown, a surface layer 5 is formed on the mold plate 4. Then, a core layer 6A is formed from the powder material remaining on the first sieve 2A and moving obliquely to the second sieve 2B as it passes through the sieve 2A of the first sieve unit 2' on the mold plate 4, and the powder material from the powder material supplied from the central raw material supply unit 8 that passes through the second sieve 2B. It should be noted that the mold plate 4 and the surface layer 5 in contact with the mold plate 4 have uneven surfaces, but... Figure 9 Not shown in the image.

[0128] When the mold plate 4 reaches the second screen unit 2", another core layer 6 and another surface layer 5 are formed during the process of passing through here, thereby forming a wall material surface layer 7C formed by stacking two core layers 6A and 6 on the inner side of the surface layers 5 on both sides.

[0129] It should be noted that the core layer 6A contains powder raw materials supplied from the central raw material supply section 8 in the Y5 direction, and therefore contains powder raw materials with relatively smaller size compared to the core layer 6.

[0130] Moreover, similar to embodiments 1 to 3, multiple sets of wall material surface layer 7C and mold plate 4 are stacked together and pressed and cured to manufacture the wall material.

[0131] (Wall material manufactured according to embodiment 4)

[0132] The wall material manufactured according to Embodiment 4 is the same as the wall material 30 manufactured according to Embodiment 1, and a plurality of protrusions are formed on the surface using the unevenness of the mold plate 4. The protrusions have a first side surface, a second side surface, a top surface, a first edge, and a second edge.

[0133] The wall material manufactured according to Embodiment 4 is also produced by the powder raw material falling loosely from the sieve sheet to the mold plate 4 under its own weight. Therefore, in the protrusion, the plant-based reinforcing material, which is attached to the hydraulic material and the mixed material, is evenly distributed in the mixture of the hydraulic material and the mixed material. The distribution of the plant-based reinforcing material on the first side and the second side of the protrusion is approximately the same, resulting in excellent durability.

[0134] Furthermore, the wall material manufactured according to Embodiment 4 is also produced by depositing hydraulic materials, mixed materials, and plant-based reinforcing materials to which hydraulic materials and mixed materials are attached on the entire surface of the mold plate at approximately the same ratio and in approximately the same amount. Therefore, the distribution of pores, water absorption, and freeze-thaw resistance are approximately the same at the first edge and the second edge of the protrusion, resulting in excellent durability of the wall material manufactured according to Embodiment 4.

[0135] Furthermore, the wall material manufactured according to Embodiment 4 has a dense and highly water-resistant layer on both sides, thus exhibiting superior durability compared to the wall material manufactured according to Embodiment 1.

[0136] (Effect confirmation and results)

[0137] The inventors confirmed the effectiveness. In the embodiments, three wall materials (samples 1 to 3) were manufactured under the same conditions using the wall material manufacturing method of Embodiment 4. On the other hand, in the comparative example, using... Figure 13 The apparatus shown in the figure, which uses air to blow away powder raw materials for sieving, was used to manufacture three wall materials (samples 4-6) under the same conditions.

[0138] In the examples and comparative examples, the powder raw materials were all manufactured by adding silicate cement, fly ash, recycled raw materials made from crushed wood-based cement board, and calcium formate to wood chips obtained by adding water and mixing them. Regarding the solid composition of the powder raw materials, silicate cement accounted for 30% by mass, fly ash for 30% by mass, wood chips for 15% by mass, and recycled raw materials made from crushed wood-based cement board for 25% by mass. In addition, relative to the total solid composition of the powder raw materials, 30% by mass of water and 5% by mass of calcium formate were added.

[0139] A 16mm thick wood-based cement board was manufactured using a mold plate with a fine stone accumulation pattern featuring a 5mm deep, 60-degree upward slope, and a 108mm wide top surface. The wall material surface layer and the mold plate were pressed at a pressure of 4.5MPa and then autoclaved at 165℃ and 0.6MPa for 6 hours.

[0140] It should be noted that, Figure 10 The relationship between the wall material and the mold plate 4, which serves as a sample, is shown. Figure 10 This is a schematic cross-sectional view of the wall material before it is peeled off from the mold plate. Figure 10 In this mold plate, a protrusion 31B of wall material 30A is formed by utilizing the concave portion of the mold plate. The protrusion 31B is formed by a first edge portion 31B11, which is a first side surface edge portion, and a second edge portion 31B21, which is a second side surface edge portion and corresponds to the first edge portion 31B11. The conveying direction of the mold plate 4 is X1. The first edge portion 31B11 is an edge portion of the side surface edge portion formed by a mold plate concave surface inclined in the conveying direction X1 of the mold plate. On the other hand, the second edge portion 31B21 is an edge portion of the side surface edge portion formed by a mold plate concave surface inclined in the opposite direction to the conveying direction X1 of the mold plate.

[0141] Furthermore, the size and number of pores in the obtained wood-based cement board were measured, and water absorption and freeze-thaw resistance tests were conducted based on the tube method.

[0142] The size and number of pores were measured using a Keyence VHX-5000 microscope at 50x magnification. The size and number of pores formed on the first edge 31B11 and the second edge 31B21 were observed. It should be noted that the observation range was set to a width of 108 mm. Furthermore, the pores were categorized into three types based on size: 0-2 pores of the corresponding size were rated as "○" (few), 3-6 pores of the corresponding size as "△" (slightly few), 7-9 pores of the corresponding size as "▲" (slightly more), and 10 or more pores of the corresponding size as "×" (more).

[0143] The water absorption test based on the tube method involves applying a silicone-acrylic emulsion coating at a concentration of 90 g / m³. 2 The coating was applied to the resulting wood-based cement board, and then the first edge 31B11 and the second edge 31B21 were subjected to the tube test specified in JIS A 5422 to determine their water drop height.

[0144] The freeze-thaw resistance test involves applying silicone-acrylic emulsion coatings at a concentration of 90 g / m². 2 The coating was applied to the resulting wood-based cement board, and then subjected to the air-freeze-in-water thawing method as specified in JIS A 1435 for 720 cycles. Furthermore, the first edge 31B11 and the second edge 31B21 were observed using a Keyence VHX-5000 microscope at 50x magnification to confirm the presence or absence of coating cracks. It should be noted that the observation range was set to a width of 108 mm. In cases where coating cracks were present, the number was measured. Zero cracks were rated as "○" (none), 1-4 cracks as "△" (few), and 5-10 cracks as "×" (many). The results of each test are shown in Table 1 below.

[0145] [Table 1]

[0146]

[0147] In samples 1-3 of the embodiments, which are composed of a mixture containing hydraulic materials, mixed materials, and plant-based reinforcing materials, at the first edge, the number of pores larger than 1.0 mm is ○ (few); among the pores between 0.5 and 1.0 mm, there is one ○ (few), one △ (slightly few), and one ▲ (slightly more); among the pores between 0 and 0.5 mm, there is one ▲ (slightly more), and two × (more). On the other hand, at the second edge of samples 1-3 of the embodiments, the number of pores larger than 1.0 mm is ○ (few); among the pores between 0.5 and 1.0 mm, there are two △ (slightly few), and one ▲ (slightly more); among the pores between 0 and 0.5 mm, there are two ▲ (slightly more), and one × (more). The results show that, in the embodiments, the distribution of pores at the first edge and the distribution of pores at the second edge are approximately the same.

[0148] Furthermore, in samples 1-3 of the embodiments, the water drop height in the water absorption test based on the tube method at the first edge was 0-1 mm. On the other hand, in the second edge of samples 1-3 of the embodiments, the water drop height in the water absorption test based on the tube method was 0-2 mm. The results show that, in the embodiments, the water absorption of the first edge and the water absorption of the second edge are approximately the same.

[0149] Furthermore, in samples 1-3 of the embodiments, in the first edge portion, there were 2 instances of ○ (no) and 1 instance of △ (few) in the freeze-thaw resistance test. On the other hand, in the second edge portion of samples 1-3 of the embodiments, all freeze-thaw resistance tests were ○ (no). The results indicate that, in the embodiments, the freeze-thaw resistance of the first edge portion and the freeze-thaw resistance of the second edge portion are approximately the same.

[0150] On the other hand, in comparative examples 4-6, which were composed of the same mixture as in the examples, the number of pores larger than 1.0 mm at the first edge was ○ (few); the number of pores between 0.5 and 1.0 mm was △ (slightly few); and the number of pores between 0 and 0.5 mm was ▲ (slightly more) one and × (more than 2). On the other hand, in the second edge of comparative examples 4-6, the number of pores larger than 1.0 mm was △ (slightly fewer); the number of pores between 0.5 and 1.0 mm was △ (slightly fewer) two and ▲ (slightly more); and the number of pores between 0 and 0.5 mm was × (more than). The results indicate that in the comparative examples, the distribution of pores at the first edge differs from the distribution of pores at the second edge.

[0151] Furthermore, in comparative examples 4-6, the water drop height in the first edge based on the tube method water absorption test was 0-1 mm. On the other hand, in the second edge of comparative examples 4-6, the water drop height in the tube method water absorption test was 2-5 mm. The results indicate that, in the comparative examples, the water absorption of the first edge and the water absorption of the second edge are different.

[0152] Furthermore, in comparative examples 4-6, in the first edge portion, there was one ○ (no) result and two △ (few) results in the freeze-thaw resistance test. On the other hand, in the second edge portion of comparative examples 4-6, there were two △ (few) results and one × result in the freeze-thaw resistance test. As a result, in the comparative examples, the freeze-thaw resistance of the first edge portion and the freeze-thaw resistance of the second edge portion are shown to be different.

[0153] Comparing the examples and comparative examples, in the second edge of samples 1-3 of the examples, the number of pores larger than 1.0 mm is ○ (few); among the pores between 0.5 and 1.0 mm, there are 2 △ (slightly fewer) and 1 ▲ (slightly more); among the pores between 0 and 0.5 mm, there are 2 ▲ (slightly more) and 1 × (more). On the other hand, in the second edge of samples 4-6 of the comparative examples, the number of pores larger than 1.0 mm is △ (slightly fewer); among the pores between 0.5 and 1.0 mm, there are 2 △ (slightly fewer) and 1 ▲ (slightly more); among the pores between 0 and 0.5 mm, there are × (more). The results show that the distribution of pores in the second edge of the examples is different from that in the comparative examples, and the number of pores in the second edge of the examples is less than that in the comparative examples.

[0154] Furthermore, in the second edge of samples 1-3 of the embodiments, the water drop height in the water absorption test based on the tube method was 0-2 mm. On the other hand, in the second edge of comparative examples 4-6, the water drop height in the water absorption test based on the tube method was 2-5 mm. The results show that the water absorption of the second edge of the embodiments differs from that of the second edge of the comparative examples, and the second edge of the embodiments is less prone to water absorption than the second edge of the comparative examples.

[0155] Furthermore, in the second edges of samples 1-3 of the Examples, the freeze-thaw resistance test results were all ○ (none). On the other hand, in the second edges of samples 4-6 of the Comparative Examples, the freeze-thaw resistance test results showed two △ (few) and one × (most). The results indicate that the freeze-thaw resistance of the second edges of the Examples differs from that of the Comparative Examples, and the freeze-thaw resistance of the second edges of the Examples is superior to that of the Comparative Examples.

[0156] The above test results show that the wood-based cement board in the embodiment has roughly the same pore distribution, water absorption, and freeze-thaw resistance in the first and second edges, thus exhibiting excellent durability.

[0157] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the specific structure is not limited to these embodiments. Any design changes that do not depart from the spirit of the present invention are included in the present invention.

Claims

1. A building material having a protrusion formed on its surface, the protrusion comprising a first side surface portion and a second side surface portion corresponding to the first side surface portion, wherein, The building material is formed from a mixture containing hydraulic materials, a blend of materials, and a plant-based reinforcing material to which the hydraulic materials and the blend of materials are attached. The mixture comprises about 30% by weight of the hydraulic material, about 40% by weight of the blended material, and about 30% by weight of the plant-based reinforcing material. At least the plant-based reinforcing material of the protrusions is distributed in the mixture in a state where the hydraulic material and the mixed material are attached. The distribution of the plant-based reinforcing material on the first side surface is approximately the same as the distribution of the plant-based reinforcing material on the second side surface. The building material includes a first surface layer having the protrusion, a first core layer disposed on the first surface layer, a second core layer disposed on the first core layer, and a second surface layer disposed on the second core layer, wherein the first core layer is formed of powder having a smaller size than the powder forming the second core layer. The building material is formed in the following manner: I) The mixture is fed into a sieve having mesh-like sieve plates; and II) By repeatedly stretching and flexing the sieve plates, the mixture falls under its own weight toward a recessed mold plate without artificial lateral wind, the mold plate continuously traveling at a constant speed in a constant direction below the sieve, such that i) the mixture accumulates on the entire surface of the mold plate in approximately the same ratio and in approximately the same amount, the recesses of the mold plate corresponding to the protrusions of the building material, and ii) the building material is formed from the mixture, which is formed from powder raw materials falling under their own weight in a loose state without artificial lateral wind. The protrusion has a first edge portion that serves as the edge portion of the first side surface, and a second edge portion that serves as the edge portion of the second side surface and corresponds to the first edge portion. The distribution of cavities formed on the first edge is roughly the same as the distribution of cavities formed on the second edge.

2. The building material according to claim 1, wherein, The water absorption of the first edge is approximately the same as that of the second edge.

3. The building material according to claim 1, wherein, The freeze-thaw resistance of the first edge is approximately the same as that of the second edge.

4. The building material according to claim 1, wherein, The mixed material is at least one of coal ash, mica, wollastonite, perlite, and resin beads.

5. The building material according to claim 1, wherein, The mixed material is resin beads.

6. The building material according to claim 1, wherein, The powder material is supplied to the upper and lower sides of the sieve plate, which is inclined downward relative to the direction of travel of the mold plate.

7. The building material according to claim 1, wherein, The hydraulic material includes silicate cement. The mixed material includes fly ash and pulverized wood-based cement board. The plant-based reinforcing materials include wood.

8. A building material having a protrusion formed on its surface, the protrusion comprising a first side surface portion and a second side surface portion corresponding to the first side surface portion, wherein... The building material is formed from a mixture containing hydraulic materials, a blend of materials, and a plant-based reinforcing material to which the hydraulic materials and the blend of materials are attached. The mixture comprises about 30% by mass of the hydraulic material, about 40% by mass of the blended material, and about 30% by mass of the plant-based reinforcing material. At least the plant-based reinforcing material of the protrusions is distributed in the mixture in a state where the hydraulic material and the mixed material are attached. The distribution of the plant-based reinforcing material on the first side surface is approximately the same as the distribution of the plant-based reinforcing material on the second side surface. The building material includes a first surface layer having the protrusion, a first core layer disposed on the first surface layer, a second core layer disposed on the first core layer, and a second surface layer disposed on the second core layer, wherein the first core layer is formed of powder having a smaller size than the powder forming the second core layer. The building material is formed in the following manner: I) The mixture is supplied to the first screening machine from the first raw material supply unit at the upstream portion of the first screening machine having a first screening plate with a mesh shape, and the mixture is supplied to the first screening machine from the second raw material supply unit at the downstream portion of the first screening machine; II) By repeatedly stretching and flexing the first screen plate, the first screen plate is made to vibrate vertically and the mixture is made to fall under its own weight toward a mold plate with a concave portion without artificial lateral wind, the mold plate continuously moving at a constant speed in a constant direction below the first screen, such that i) the mixture accumulates on the entire surface of the mold plate in approximately the same ratio and in approximately the same amount, the concave portion of the mold plate corresponding to the convex portion of the building material, and ii) the first surface layer and the first core layer disposed on the first surface layer are formed by the mixture, the mixture being formed from powder raw materials falling under their own weight in a loose state without artificial lateral wind; III) The mixture is supplied to the second screening machine from the third raw material supply section at the upstream portion of the second screening machine, which has a second screening plate with a mesh-like second screen; and IV) By repeatedly stretching and flexing the second sieve, the second sieve vibrates vertically and the mixture falls under its own weight toward the mold plate without artificial lateral wind, the mold plate continuously traveling at a constant speed in a constant direction below the second sieve, such that i) the mixture accumulates on the entire surface of the mold plate in approximately the same ratio and in approximately the same amount, and ii) the second core layer disposed on the first surface layer and the second surface layer disposed on the second core layer are formed by the mixture, which is formed from powder raw materials falling under their own weight in a loose state without artificial lateral wind. The first screening machine is configured to tilt along the constant direction of travel of the mold plate, such that the upstream portion of the first screening machine is higher than the downstream portion. The second screening machine is configured to tilt along the constant direction of travel of the mold plate, such that the upstream portion of the second screening machine where the mixture is added is higher than the downstream portion. The protrusion has a first edge portion that serves as the edge portion of the first side surface, and a second edge portion that serves as the edge portion of the second side surface and corresponds to the first edge portion. The distribution of cavities formed on the first edge is roughly the same as the distribution of cavities formed on the second edge.

9. The building material according to claim 8, wherein, The water absorption of the first edge is approximately the same as that of the second edge.

10. The building material according to claim 8, wherein, The freeze-thaw resistance of the first edge is approximately the same as that of the second edge.

11. The building material according to claim 8, wherein, The mixed material is at least one of coal ash, mica, wollastonite, perlite, and resin beads.

12. The building material according to claim 8, wherein, The mixed material is resin beads.

13. The building material according to claim 8, wherein, The hydraulic material includes silicate cement. The mixed material includes fly ash and pulverized wood-based cement board. The plant-based reinforcing materials include wood.

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