Gypsum board manufacturing method

Abstract

To provide a novel gypsum board production method.SOLUTION: A gypsum board production method has: a first installation step in which a vessel-shaped first mold 4 is installed with a first base paper 6 comprising a first bottom base paper 61 superimposed on a first bottom part 41 and a first peripheral wall base paper 62 superimposed on a first peripheral wall part 42; a second installation step in which a vessel-shaped second mold is installed with a second base paper comprising a second bottom base paper superimposed on a second bottom part and a second peripheral wall base paper superimposed on a second peripheral wall part; a first feed step in which a calcined gypsum slurry S is made to flow into the first mold; a second feed step in which a calcined gypsum slurry is made to flow into the second mold; a mold closing step in which the first mold and the second mold are closed; a mold opening step in which the closed first mold and second mold are opened to take out a base paper-fitted molded body covered with the first base paper and the second base paper; and a drying step in which the base paper-fitted molded body is dried to obtain a gypsum board.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a gypsum board. [Background technology]

[0002] Gypsum boards are plate-shaped components whose main component is gypsum, and are excellent in fire resistance, sound insulation, ease of installation, etc. Therefore, this type of gypsum board is widely used as a building material for constructing walls, ceilings, etc.

[0003] Known gypsum boards include, for example, those having a plate-shaped core material whose main component is gypsum and base paper laminated on both sides of the core material (so-called gypsum boards). As shown in Patent Document 1, for example, this gypsum board is obtained by filling a slurry consisting of a mixture of calcined gypsum (hemihydrate gypsum) and water between a lower base paper flowing on a belt conveyor and an upper base paper flowing parallel to the lower base paper, and then drying the laminate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2017 / 104473 Summary of the Invention [Problem to be solved by the invention]

[0005] Conventional methods for manufacturing gypsum boards have had problems, such as making it difficult to increase the thickness of the gypsum board (core material) or to place members for the purpose of reinforcement at predetermined locations inside the core material. Due to these circumstances, a new method for manufacturing gypsum boards has been desired.

[0006] An object of the present invention is to provide a new method for manufacturing gypsum boards. [Means for solving the problem]

[0007] <1> a first setting step in which a first base paper including a first bottom base paper to be laid on the first bottom and a first peripheral wall base paper to be laid on the first peripheral wall is set on a container-shaped first mold having a plate-shaped first bottom, a first peripheral wall portion rising from the periphery of the first bottom, and a frame-shaped first joint portion consisting of an end face of the first peripheral wall; a second setting step in which a second base paper including a second bottom base paper to be laid on the second bottom and a second peripheral wall base paper to be laid on the second peripheral wall is set on a container-shaped second mold having a plate-shaped second bottom, a second peripheral wall portion rising from the periphery of the second bottom, and a frame-shaped second joint portion consisting of an end face of the second peripheral wall; a first supply step in which a calcined gypsum slurry formed by kneading a composition containing calcined gypsum and water is poured into the first mold on which the first base paper is set; a mold closing process in which the first mold and the second mold are closed so that the first and second joints are closely attached to each other after the fluidity of the calcined gypsum slurry is reduced and solidified, thereby forming a first slurry layer covered with the first base paper in the first mold and a second slurry layer covered with the second base paper in the second mold by reducing the fluidity of the calcined gypsum slurry and solidifying, a mold opening process in which the closed first mold and the closed second mold are opened, the first slurry layer and the second slurry layer are integrated while overlapping each other, and a molded body with base paper covered with the first and second base papers is removed, and a drying process in which the molded body with base paper is dried to obtain a gypsum board.

[0008] <2> An adhesion improving layer for improving adhesion with the calcined gypsum slurry is formed on at least a surface of the first base paper on the side where the first bottom base paper comes into contact with the calcined gypsum slurry, and on at least a surface of the second base paper on the side where the second bottom base paper comes into contact with the calcined gypsum slurry, respectively. <1> The method for manufacturing a gypsum board according to claim 1.

[0009] <3> The adhesion improving layer is made of a high density slurry having a gypsum component with a higher density than the calcined gypsum slurry. <2> The method for manufacturing a gypsum board according to claim 1.

[0010] <4> a first supplying step in which a calcined gypsum slurry obtained by kneading a composition containing calcined gypsum and water is poured into a container-shaped first mold having a plate-shaped first bottom, a first peripheral wall rising from the periphery of the first bottom, and a frame-shaped first joint formed from an end face of the first peripheral wall; a second supplying step in which the calcined gypsum slurry is poured into a container-shaped second mold having a plate-shaped second bottom, a second peripheral wall rising from the periphery of the second bottom, and a frame-shaped second joint formed from an end face of the second peripheral wall; and a second supplying step in which the calcined gypsum slurry is poured into a container-shaped second mold having a plate-shaped second bottom, a second peripheral wall rising from the periphery of the second bottom, and a frame-shaped second joint formed from an end face of the second peripheral wall. A method for manufacturing a gypsum board, comprising: a mold closing process in which a first slurry layer is formed in a first mold and a second slurry layer is formed in the second mold as the fluidity of the calcined gypsum slurry decreases and solidifies, and then the first mold and the second mold are closed so that the first joint portion and the second joint portion are in close contact; a mold opening process in which the closed first mold and the closed second mold are opened and a molded body in which the first slurry layer and the second slurry layer are overlapped and integrated with each other is removed; and a drying process in which the molded body is dried to obtain a gypsum board.

[0011] <5> The method further includes an embedding step of embedding a solid member in the calcined gypsum slurry in the first mold after the first supplying step and / or the calcined gypsum slurry in the second mold after the second supplying step. <1> ~ <4> A method for manufacturing a gypsum board according to any one of the above.

[0012] <6> The solid member is a longitudinal hollow member. <5> The method for manufacturing a gypsum board according to claim 1. [Effects of the Invention]

[0013] According to the present invention, a new method for manufacturing a gypsum board can be provided. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is an explanatory diagram showing each step of a gypsum board manufacturing method according to embodiment 1. [Figure 2] FIG. 1 is an explanatory diagram schematically illustrating the configuration of a gypsum board manufactured by the manufacturing method of embodiment 1. [Figure 3] An explanatory diagram showing the first supply step in a schematic manner. [Figure 4] An explanatory diagram of the first base paper in a flat state [Figure 5] FIG. 10 is an explanatory diagram showing a state in which the calcined gypsum slurry is filled into the first mold by the first supplying step. [Figure 6] Schematic diagram of the mold closing process [Figure 7] FIG. 10 is an explanatory diagram showing a state in which an integrated slurry layer is formed inside the first and second molds that are closed. [Figure 8] FIG. 10 is an explanatory diagram showing each step of a gypsum board manufacturing method according to embodiment 2. [Figure 9] FIG. 10 is an explanatory diagram schematically illustrating the configuration of a gypsum board manufactured by the manufacturing method of embodiment 2. [Figure 10] Cross section of line AA in Figure 9 [Figure 11] An explanatory diagram showing the details of the embedding process [Figure 12] FIG. 10 is an explanatory diagram illustrating the mold closing step in the manufacturing method of the second embodiment. [Figure 13] FIG. 10 is an explanatory diagram showing a state in which an integrated slurry layer is formed inside the first and second molds that are closed, with the pipe embedded inside. [Figure 14] FIG. 10 is an explanatory diagram showing each step of a gypsum board manufacturing method according to embodiment 3. [Figure 15] FIG. 10 is an explanatory diagram schematically illustrating the configuration of a gypsum board manufactured by the manufacturing method of embodiment 3. [Figure 16] Cross section of line BB in Figure 15 [Figure 17] An explanatory diagram showing the details of the embedding process [Figure 18] FIG. 10 is an explanatory diagram illustrating the mold closing step in the manufacturing method of the third embodiment. [Figure 19] FIG. 10 is an explanatory diagram showing a state in which an integrated slurry layer is formed inside the first and second molds that are closed, with the pipe embedded inside. [Figure 20] FIG. 10 is an explanatory diagram schematically illustrating the configuration of a gypsum board manufactured by the manufacturing method of embodiment 4. [Figure 21] An explanatory diagram showing the first installation process [Figure 22] An explanatory diagram showing the first supply step in a schematic manner. [Figure 23] FIG. 10 is an explanatory diagram showing a state in which the calcined gypsum slurry is filled into the first mold by the first supplying step. [Figure 24] FIG. 10 is an explanatory diagram illustrating the mold closing step in the manufacturing method of the fourth embodiment. [Figure 25] FIG. 10 is an explanatory diagram showing a state in which an integrated slurry layer is formed inside the first and second molds that are closed. DETAILED DESCRIPTION OF THE INVENTION

[0015] <Embodiment 1> Hereinafter, a method for manufacturing a gypsum board according to a first embodiment of the present invention will be described with reference to Figs. 1 to 7. Fig. 1 is an explanatory diagram showing each step of the method for manufacturing a gypsum board according to the first embodiment, and Fig. 2 is an explanatory diagram schematically showing the configuration of a gypsum board 1 manufactured by the manufacturing method of the first embodiment. First, the gypsum board 1 manufactured by the manufacturing method of this embodiment will be described. Note that Fig. 2 schematically shows the cross-sectional configuration of the gypsum board 1 cut in the short direction.

[0016] The gypsum board 1 of this embodiment includes a plate-shaped core material 2 and base paper (base paper for gypsum board) 3 that covers the surface of the core material 2. The base paper 3 is made up of a first base paper 6 and a second base paper 7, as described below.

[0017] The core material 2 is a plate-shaped (board-shaped) member containing gypsum (gypsum component) mainly consisting of gypsum dihydrate (CaSO4·2H2O). The core material 2 is made of a hardened calcined gypsum slurry obtained by kneading a composition containing calcined gypsum (CaSO4·1 / 2H2O) and water. The thickness, density, and other conditions of the core material 2 are set appropriately depending on the purpose. Various known additives such as oxidized starch, water reducing agent, foaming agent, hardening accelerator, hardening retarder, mildew inhibitor, waterproofing agent, and inorganic fiber may be added to the calcined gypsum slurry as needed.

[0018] The base paper 3 is usually made of the same material as base paper used in this industry (for example, corrugated cardboard, thick paper). The type of material and thickness of the base paper 3 and other conditions are set appropriately depending on the purpose. The base paper 3 is adhered to the surface of the core material 2 so as to cover the surface of the core material 2. The shape of the base paper 3 will be described later.

[0019] The method for manufacturing a gypsum board of this embodiment for manufacturing such a gypsum board 1 includes the steps shown in Fig. 1. Furthermore, in the method for manufacturing a gypsum board of this embodiment, a set of molds (first mold 4, second mold 5) is used, as will be described later. As shown in Fig. 1, the method for manufacturing a gypsum board of this embodiment includes a first installation step S11, a second installation step S12, a first supply step S13, a second supply step S14, a mold closing step S15, a mold opening step S16, and a drying step S17. Note that Fig. 3 is an explanatory diagram that schematically shows the contents of the first supply step S13.

[0020] The first installation process S11 is a process in which a first base paper 6 including a first bottom base paper 61 to be superimposed on the first bottom 41 and a first peripheral wall base paper 62 to be superimposed on the first peripheral wall 42 is installed in a container-shaped first mold 4 having a plate-shaped first bottom 41 having a predetermined thickness, a plate-shaped first peripheral wall 42 having a predetermined thickness rising from the periphery 41a of the first bottom 41, and a frame-shaped first joint portion 42a consisting of the end face of the first peripheral wall 42.

[0021] The first mold 4 is generally shaped like a shallow container that is open upward and made of a metallic material such as a metal or alloy, or a heat-resistant synthetic resin (such as an engineering plastic). In this embodiment, the first mold 4 is made of a metallic plate processed into a predetermined shape. The first mold 4 has a first bottom 41, a first peripheral wall 42, and a first joint 42a.

[0022] The first bottom 41 has a rectangular plate shape in a plan view. The surface of the first bottom 41 that forms the inner surface of the first mold 4 is referred to as the "front surface 41b," and the opposite surface facing outward is referred to as the "back surface 41c." The first mold 4 is placed on the floor F with the back surface 41c of the first bottom 41 facing the floor F.

[0023] The first peripheral wall portion 42 has a plate shape rising from the peripheral edge 41a of the first bottom portion 41. The first peripheral wall portion 42 has a cylindrical (frame-like) shape overall that surrounds the first bottom portion 41. In the present embodiment, the first peripheral wall portion 42 has a rectangular shape in a plan view and includes two sets of walls (i.e., four walls) that are arranged parallel to each other. The surface of the first peripheral wall portion 42 that forms the inner surface of the first mold 4 is referred to as the "inner surface 42b," and the surface facing outward on the opposite side is referred to as the "outer surface 42c."

[0024] The first mating portion 42a is formed by the upper end surface 42a of the first peripheral wall portion 42, which has a rectangular frame shape in plan view. The height position of the first mating portion 42a (the height position from the surface 41b of the first bottom portion 41) is set to be uniform throughout.

[0025] In the first installation step S11, a first base paper 6 is installed to cover the inner surface of the first mold 4. FIG. 4 is an explanatory diagram of the first base paper 6 in a flat, unfolded state. The first base paper 6 consists of a first bottom base paper 61 that is overlapped on the surface 41b of the rectangular first bottom portion 41 to cover the surface 41b, and a first peripheral wall base paper 62 that is overlapped on the inner surface 42b of the first peripheral wall portion 52 to cover the inner surface 42b. In this embodiment, the first peripheral wall base paper 62 consists of four parts, each connected to a location corresponding to each side of the rectangular first bottom base paper 61. The first base paper 6 is folded at each boundary 63 between the first bottom base paper 61 and the first peripheral wall base paper 62, and is installed in the first mold 4 in the shape of a container that is open upward. In this embodiment, the inner surface of the first mold 4 is entirely covered by the first base paper 6.

[0026] The second installation process S12 is a process in which a second base paper 7 including a second bottom base paper 71 to be superimposed on the second bottom 51 and a second peripheral wall base paper 72 to be superimposed on the second peripheral wall 52 is installed on a container-shaped second mold 5 having a plate-shaped second bottom 51 having a predetermined thickness, a plate-shaped second peripheral wall 52 having a predetermined thickness rising from the periphery 51a of the second bottom 51, and a frame-shaped second joint portion 52a consisting of the end face of the second peripheral wall 52.

[0027] The second mold 5 has the same shape, size, etc. as the above-described first mold 4. The second base paper 7 also has the same shape, size, etc. as the above-described first base paper 6. In other words, the second setting step S12 is a step in which the second base paper 7 is placed inside the second mold 5, similar to the first base paper 6 being placed inside the first mold 4 in the first setting step S11. Therefore, a detailed description of the second setting step S12 will be omitted.

[0028] The first supplying step S13 is a step of pouring a calcined gypsum slurry S, which is obtained by kneading a composition containing calcined gypsum and water, into the first mold 4 on which the first base paper 6 is placed. The calcined gypsum slurry S is made by kneading a composition containing at least a predetermined amount of calcined gypsum and water, and is prepared by a known method. When the calcined gypsum is mixed with water, it undergoes a hydration reaction to become gypsum dihydrate. The calcined gypsum slurry S prepared in this manner is placed, for example, in a predetermined container 8, and then the calcined gypsum slurry S is poured from the container 8 into the inside of the first mold 4 on which the first base paper 6 is placed. The first mold 4 on which the first base paper 6 is placed is placed on a horizontal floor F, and the calcined gypsum slurry S is supplied into the inside of the first mold 4 in this state.

[0029] 5 is an explanatory diagram showing a state in which the calcined gypsum slurry S is filled into the first mold 4 in the first supplying step S13. As shown in FIG. 5, the calcined gypsum slurry S is filled up to the height position of the end face (first joint portion 42a) of the first peripheral wall portion 42. Such calcined gypsum slurry S is contained in the first mold 4 in a state in which it is covered with the box-shaped first base paper 6 that is open upward.

[0030] After the first supply step S13, the first mold 4 filled with the calcined gypsum slurry S is left in an environment at room temperature (for example, 20°C). The calcined gypsum slurry S in the first mold 4 is left until its fluidity decreases and it hardens to such an extent that its shape can be maintained within the first mold 4 so that it does not spill out of the first mold 4 in a mold closing step S15 described later.

[0031] The second supplying step S14 is a step of pouring the calcined gypsum slurry S into the second mold 5 on which the second base paper 7 is placed. The second supplying step S14 is a step of pouring the calcined gypsum slurry S into the second mold 5 on which the first base paper 6 is placed, similar to the first supplying step S13 in which the calcined gypsum slurry S is poured into the first mold 4 on which the first base paper 6 is placed. Therefore, a detailed description of the second supplying step S14 will be omitted.

[0032] After the second supply step S14, the second mold 5 filled with the calcined gypsum slurry S is left in a room temperature environment, similar to the first mold 4 after the first supply step S13, until its fluidity decreases and it hardens to the extent that its shape can be maintained within the first mold 4.

[0033] The mold closing process S15 is a process in which the fluidity of the calcined gypsum slurry S decreases and solidifies, thereby forming a first slurry layer S1 covered with the first base paper 6 within the first mold 4, and the fluidity of the calcined gypsum slurry S decreases and solidifies, thereby forming a second slurry layer S2 covered with the second base paper 7 within the second mold 5, and then the first mold 4 and the second mold 5 are closed so that the first joint portion 42a and the second joint portion 52a are in close contact with each other.

[0034] As described above, the first mold 4 and the second mold 5 are each filled with the calcined gypsum slurry S and then left to stand, whereby a first slurry layer S1 covered with the first base paper 6 is formed in the first mold 4, and a second slurry layer S2 covered with the second base paper 7 is formed in the second mold 5. In the mold closing step S15, the first mold 4 and the second mold 5 are closed to overlap the first slurry layer S1 formed in the first mold 4 and the second slurry layer S2 formed in the second mold 5.

[0035] 6 is an explanatory diagram schematically illustrating the mold closing step S15. The mold closing step S15 is performed, for example, by using a mold closing device 9 as shown in FIG. 6. The mold closing device 9 includes a first mounting table 91 on which the first mold 4 having the first slurry layer S1 formed thereon is placed, a second mounting table 92 on which the second mold 5 having the second slurry layer S2 formed thereon is placed, and a main body 93 interposed between the first mounting table 91 and the second mounting table 92 and holding the first mounting table 91 and the second mounting table 92 in a rotatable state. The first mounting table 91 and the second mounting table 92 of the mold closing device 9 of this embodiment basically have a bilaterally symmetrical structure with the main body 93 at the center.

[0036] The first mounting table 91 has a flat first mounting surface 91a, and the first die 4 is placed on the first mounting surface 91a with the first bottom 41 facing the first mounting surface 91a. The first die 4 is positioned and fixed at a predetermined location on the first mounting surface 91a by using a locking mechanism (not shown) provided on the first mounting surface 91a of the first mounting table 91. The first mounting table 91 is fixed to the main body 93 via a known rotation mechanism 94.

[0037] The second mounting table 92 has a flat second mounting surface 92a, and the second die 5 is mounted on the second mounting surface 92a with the second bottom 51 facing the second mounting surface 92a. The second die 5 is positioned and fixed at a predetermined location on the second mounting surface 92a by utilizing a locking mechanism (not shown) provided on the second mounting surface 92a of the second mounting table 92. The second mounting table 92 is fixed to the main body 93 via a known rotation mechanism 95.

[0038] After the first mold 4 containing the first slurry layer S1 covered with the first base paper 6 and the second mold 5 containing the second slurry layer S2 covered with the second base paper 7 are placed on the first mounting table 91 and the second mounting table 92 of such a mold closing device 9, respectively, the first mounting table 91 and the second mounting table 92 are rotated to approach each other, and the first mold 4 and the second mold 5 are pressed against each other between the first mounting table 91 and the second mounting table 92 so that the frame-shaped first mating portion 42a of the first mold 4 and the frame-shaped second mating portion 52a of the second mold 5 are in close contact with each other without any gaps.

[0039] In this way, when the first mold 4 and the second mold 5 are closed, the first slurry layer S1 and the second slurry layer S2 are superimposed with the exposed surface S1a of the first slurry layer S1 in the first mold 4 and the exposed surface S2a of the second slurry layer S2 in the second mold 5 in close contact with each other.

[0040] After the molds are closed, the first and second molds 4 and 5 may be fixed to each other using a fastening means (not shown). After the mold closing step S15, the first and second molds 4 and 5 in the closed state are appropriately removed from the mold closing device 9 and left on the floor or the like. The first and second molds 4 and 5 are left to harden and integrate the first and second slurry layers S1 and S2 inside the molds 4 and 5. The first and second slurry layers S1 and S2 finally integrate to form a single layer (slurry layer) S3. FIG. 7 is an explanatory diagram showing the integrated slurry layer S3 formed inside the closed first and second molds 4 and 5. The slurry layer S3 is covered with the first and second base papers 6 and 7 inside the first and second molds 4 and 5. The slurry layer S3 thus covered with the first and second base papers 6 and 7 is referred to as a molded body with base paper 10.

[0041] In the mold opening step S16, the closed first mold 4 and second mold 5 are opened, the first slurry layer S1 and the second slurry layer S2 are integrated while overlapping each other, and the molded body with base paper 10 covered with the first base paper 6 and the second base paper 7 is removed. As described above, after the mold closing step S15, the molded body with base paper 10 is formed inside the first mold 4 and the second mold 5, and in the mold opening step S16, the first mold 4 and the second mold 5 are opened so as to be removed from the molded body with base paper 10. When the molds are opened in this manner, the molded body with base paper 10 is obtained.

[0042] The drying step S17 is a step in which the molded article 10 with base paper is dried to obtain a gypsum board 1. This drying step S17 can be performed using equipment similar to that used in the drying step of a general gypsum board (gypsum board). The molded article 10 with base paper is placed in a drying device set at, for example, 60 to 200°C and heated for a predetermined time.

[0043] The gypsum board 1 of this embodiment is manufactured through the steps described above. The gypsum board manufacturing method of this embodiment manufactures the gypsum board 1 using a set of molds (first mold 4, second mold 5). Therefore, the thickness of the gypsum board 1 can be changed by appropriately setting the heights (depths) of the first mold 4 and second mold 5. For example, the thickness of the gypsum board 1 (thickness of the core material 2) can be increased by increasing the heights (depths) of the first mold 4 and second mold 5.

[0044] <Embodiment 2> Next, a method for manufacturing a gypsum board according to a second embodiment of the present invention will be described with reference to Figs. 8 to 13. Fig. 8 is an explanatory diagram showing each step of the method for manufacturing a gypsum board according to the second embodiment, Fig. 9 is an explanatory diagram schematically showing the configuration of a gypsum board 1A manufactured by the manufacturing method of the second embodiment, and Fig. 10 is a cross-sectional view taken along line AA in Fig. 9. First, the gypsum board 1A manufactured by the manufacturing method of this embodiment will be described. Note that Fig. 9 schematically shows the cross-sectional configuration of the gypsum board 1A cut in the short direction.

[0045] The gypsum board 1A of this embodiment has a pipe (an example of a solid member and an example of a longitudinal hollow member) disposed therein, and its basic configuration is the same as that of the gypsum board 1 of embodiment 1. Therefore, in each drawing, parts corresponding to those of embodiment 1 are given the same reference numerals as those of embodiment 1 with the addition of the reference numeral "A," and detailed explanations thereof will be omitted.

[0046] As shown in FIGS. 9 and 10, the gypsum board 1A includes a plate-shaped core material 2A having a predetermined thickness, a longitudinal pipe 11 embedded inside the core material 2A, and base paper (plasterboard base paper) 3A covering the surface of the core material 2A. The base paper 3 is made of a first base paper 6A and a second base paper 7A, as described below. The first base paper 6A is made of a first bottom base paper 61A and a first peripheral wall base paper 62A. The second base paper 7A is made of a second bottom base paper 71A and a second peripheral wall base paper 72A. The pipe 11 is a cylindrical member with both ends closed. The pipe 11 is made of, for example, a metal material such as aluminum, or a molded product made of a synthetic resin with excellent heat resistance. The pipe 11 is preferably installed inside the core material 2A for the purpose of reducing the weight of the gypsum board 1A, reinforcing it, etc. A plurality of pipes 11 may be arranged inside the core material 2A.

[0047] Such a gypsum board 1A is manufactured, for example, through the steps shown in Fig. 8. As shown in Fig. 8, the manufacturing method for a gypsum board of this embodiment includes a first installation step S21, a second installation step S22, a first supply step S23, a second supply step S24, an embedding step S28, a mold closing step S25, a mold opening step S26, and a drying step S27. The manufacturing method for a gypsum board of this embodiment basically adds an embedding step S28 to the respective steps of the manufacturing method of embodiment 1, and the content of each step other than the embedding step S28 is the same as the content of the corresponding step of embodiment 1. Therefore, the description of each step other than the embedding step S28 will be omitted as appropriate.

[0048] The molds (one set of molds) used in the manufacturing method of this embodiment are the same as those in embodiment 1. Therefore, in each drawing, parts of the molds (one set of molds) used in the manufacturing method of this embodiment that correspond to those in embodiment 1 are denoted by the same reference numerals as in embodiment 1 with the addition of the reference numeral "A," and detailed explanations thereof will be omitted.

[0049] 8, the method for manufacturing a gypsum board of this embodiment includes a first installation step S21, a second installation step S22, a first supply step S23, and a second supply step S24, similar to embodiment 1. The method for manufacturing a gypsum board of this embodiment further includes an embedding step S28 that is performed after the second supply step S24.

[0050] The embedding step S28 is a step of embedding a pipe 11, which is a solid member, in the calcined gypsum slurry SA in the first mold 4A after the first supply step S23 and / or the calcined gypsum slurry SA in the second mold 5A after the second supply step S24. Fig. 11 is an explanatory diagram schematically showing the contents of the embedding step S28. In the case of this embodiment, the pipe 11 is embedded only in the calcined gypsum slurry S in the first mold 4A after the first supply step S23.

[0051] The embedding step S28 is performed before the calcined gypsum slurry SA in the first mold 4A hardens. FIG. 11 shows the first mold 4A placed on a floor F, and the calcined gypsum slurry SA is filled inside the first mold 4A with the first base paper 6A placed therein. The pipe 11 is placed in the calcined gypsum slurry SA in the first mold 4A so that a portion of the pipe 11 is exposed from the surface (exposed surface) of the calcined gypsum slurry SA and the remaining portion is embedded inside the calcined gypsum slurry SA. Note that the solid member (pipe 11, etc.) is a member that does not dissolve in the calcined gypsum slurry SA even when placed in the calcined gypsum slurry SA and maintains its shape.

[0052] After this embedding step S28, the calcined gypsum slurry SA in the first mold 4A is left to harden until its fluidity decreases and it hardens to the extent that it can maintain its shape within the first mold 4A, and as soon as the calcined gypsum slurry SA in the second mold 5A hardens, the mold closing step S25 is performed.

[0053] 12 is an explanatory diagram schematically illustrating the mold closing step S25 in the manufacturing method of embodiment 2. The mold closing step S25 is basically the same as the mold closing step S15 in embodiment 1, and is performed using the same mold closing device 9 as in embodiment 1.

[0054] The mold closing process S25 is a process in which the fluidity of the calcined gypsum slurry SA decreases and solidifies, forming a first slurry layer SA1 covered with the first base paper 6A within the first mold 4A, and the fluidity of the calcined gypsum slurry SA decreases and solidifies, forming a second slurry layer SA2 covered with the second base paper 7A within the second mold 5A, and then the first mold 4A and the second mold 5A are closed so that the first joint 42Aa consisting of the end face of the first peripheral wall portion 42A and the second joint 52Aa consisting of the end face of the second peripheral wall portion 52A are in close contact with each other.

[0055] In the mold closing step S25, when the first mold 4A and the second mold 5A are closed, the first slurry layer SA1 and the second slurry layer SA2 are overlapped with each other such that the exposed surface SA1a of the first slurry layer SA1 in the first mold 4A and the exposed surface SA2a of the second slurry layer SA2 in the second mold 5A are in close contact with each other. Then, the pipe 11 arranged on the exposed surface SA1a of the first slurry layer SA1 is sandwiched between the first slurry layer SA1 and the second slurry layer SA2.

[0056] After the mold closing step S25, the first mold 4A and the second mold 5A in the mold-closed state are appropriately removed from the mold closing device 9 and left on the floor or the like, as in the first embodiment. The first mold 4A and the second mold 5A are then left until the first slurry layer SA1 and the second slurry layer SA2 inside them harden and become integrated. The first slurry layer SA1 and the second slurry layer SA2 finally become integrated to form a single layer (slurry layer) SA3.

[0057] 13 is an explanatory diagram showing a state in which a slurry layer SA3 is formed inside the closed first mold 4A and second mold 5A, with the pipe 11 embedded and integrated. The slurry layer SA3 is covered with the first base paper 6A and the second base paper 7A inside the first mold 4A and the second mold 5A. The slurry layer SA3 covered with the first base paper 6A and the second base paper 7A in this way is called a molded body with base paper 10A.

[0058] In the method for manufacturing a gypsum board of this embodiment, after the mold closing step S25, the mold opening step S26 is performed as in embodiment 1, and the molded body with base paper 10A is removed from the first mold 4A and the second mold 5A. Then, as in embodiment 1, the removed molded body with base paper 10A is subjected to the drying step S26, and the molded body with base paper 10A is dried. By going through each of the steps as described above, a gypsum board 1A is obtained. According to the method for manufacturing a gypsum board of this embodiment, it is possible to easily manufacture a gypsum board 1A in which a solid member (pipe 11) is installed in the core material 2A for the purpose of weight reduction, reinforcement, etc.

[0059] <Embodiment 3> Next, a method for manufacturing a gypsum board according to a third embodiment of the present invention will be described with reference to Figs. 14 to 19. Fig. 14 is an explanatory diagram showing each step of the method for manufacturing a gypsum board according to the third embodiment, Fig. 15 is an explanatory diagram schematically showing the configuration of a gypsum board 1B manufactured by the manufacturing method of the third embodiment, and Fig. 16 is a cross-sectional view taken along line BB in Fig. 15. Here, first, the gypsum board 1B manufactured by the manufacturing method of this embodiment will be described. Note that Fig. 15 schematically shows the cross-sectional configuration of the gypsum board 1B cut in the short direction.

[0060] The surface of the gypsum board 1B of this embodiment is not covered with base paper, and the core material 2B is exposed. Furthermore, a pipe 11B is arranged inside the core material 2B of this gypsum board 1B, as in embodiment 2. Other configurations of this gypsum board 1B are the same as those of the gypsum board 1 of embodiment 1. Therefore, in each drawing, parts corresponding to embodiment 1 are assigned the same reference numerals as embodiment 1 with the addition of the reference numeral "B," and detailed explanations are omitted. Note that the pipe 11B is the same as the pipe 11 of embodiment 2, and detailed explanations are omitted.

[0061] 15 and 16, the gypsum board 1B includes a plate-shaped core material 2B and a pipe 11B embedded inside the core material 2B. The surface of the core material 2B of the gypsum board 1B is not covered with base paper and is exposed.

[0062] Such a gypsum board 1B is manufactured, for example, through the steps shown in FIG. 14. As shown in FIG. 14, the manufacturing method for a gypsum board of this embodiment includes a first supply step S33, a second supply step S34, an embedding step S38, a mold closing step S35, a mold opening step S36, and a drying step S37. In the manufacturing method for a gypsum board of this embodiment, the first supply step S33, the second supply step S34, the mold closing step S35, the mold opening step S36, and the drying step S37 are basically the same as the corresponding steps in embodiment 1. Furthermore, the embedding step S38 is basically the same as the embedding step S28 in embodiment 2. Therefore, details of each step will be omitted as appropriate.

[0063] The molds (one set of molds) used in the manufacturing method of this embodiment are the same as those in embodiment 1. Therefore, in each drawing, parts of the molds (one set of molds) used in the manufacturing method of this embodiment that correspond to those in embodiment 1 are denoted by the same reference numerals as in embodiment 1 with the addition of the reference numeral "B," and detailed explanations thereof will be omitted.

[0064] As shown in FIG. 14, in the method for manufacturing a gypsum board of this embodiment, a first supplying step S33 and a second supplying step S34 are performed, similarly to the first embodiment.

[0065] The first supplying step S33 is a step performed on the first mold 4B on which no base paper is placed. Specifically, the first supplying step S33 is a step in which a calcined gypsum slurry SB obtained by kneading a composition containing calcined gypsum and water is poured into a container-shaped first mold 4B having a plate-shaped first bottom 41B, a first peripheral wall 42B rising from a peripheral edge 41Ba of the first bottom 41B, and a frame-shaped first joint 42Ba formed by an end face of the first peripheral wall 42B.

[0066] Similarly, the second supply step S34 is a step performed on the second mold 5B on which no base paper is placed. Specifically, it is a step of pouring the calcined gypsum slurry SB into the container-shaped second mold 5B having a plate-shaped second bottom 51B, a second peripheral wall 52B rising from a peripheral edge 51Ba of the second bottom 51B, and a frame-shaped second joint 52Ba formed by an end face of the second peripheral wall 52B.

[0067] In this embodiment, after the second supplying step S34, the embedding step S38 is performed.

[0068] The embedding step S38 is a step of embedding a pipe 11B, which is a solid member, in the calcined gypsum slurry SB in the first mold 4B after the first supply step S33 and / or in the calcined gypsum slurry SB in the second mold 5B after the second supply step S34. Fig. 17 is an explanatory diagram schematically showing the contents of the embedding step S38. In the case of this embodiment, the pipe 11B is embedded only in the calcined gypsum slurry SB in the first mold 4B after the first supply step S33.

[0069] The embedding step S38 is performed before the calcined gypsum slurry SB in the first mold 4B hardens, as in the second embodiment. Fig. 17 shows the first mold 4B placed on the floor F, and the calcined gypsum slurry SA is filled inside the first mold 4B so as to be in direct contact with the first bottom portion 41B and the first peripheral wall portion 42B. The pipe 11B is arranged so that a portion of the calcined gypsum slurry SB in the first mold 4B is exposed from the surface (exposed surface) of the calcined gypsum slurry SB, and the remaining portion is embedded inside the calcined gypsum slurry SB.

[0070] After this embedding step S38, the calcined gypsum slurry SB in the first mold 4B is left until its fluidity decreases and it hardens to the extent that its shape can be maintained in the first mold 4B, and then, as soon as the calcined gypsum slurry SB in the second mold 5B hardens, the mold closing step S35 is performed.

[0071] 18 is an explanatory diagram schematically illustrating the mold closing step S35 in the manufacturing method of embodiment 3. The mold closing step S35 is basically the same as the mold closing step S15 in embodiment 1, and is performed using the same mold closing device 9 as in embodiment 1.

[0072] The mold closing process S35 is a process in which the fluidity of the calcined gypsum slurry SB decreases and solidifies to form a first slurry layer SB1 in the first mold 4B, and the fluidity of the calcined gypsum slurry SB decreases and solidifies to form a second slurry layer SB2 in the second mold 5B, and then the first mold 4B and the second mold 5B are closed so that the first joint portion 42Ba and the second joint portion 52Ba are in close contact with each other.

[0073] In the mold closing step S35, when the first mold 4B and the second mold 5B are closed, the first slurry layer SB1 and the second slurry layer SB2 are overlapped with each other such that the exposed surface SB1a of the first slurry layer SB1 in the first mold 4B and the exposed surface SB2a of the second slurry layer SB2 in the second mold 5B are in close contact with each other. Then, the pipe 11B arranged on the exposed surface SB1a of the first slurry layer SB1 is sandwiched between the first slurry layer SB1 and the second slurry layer SB2.

[0074] After the mold closing step S35, the first mold 4B and the second mold 5B in the mold-closed state are appropriately removed from the mold closing device 9 and left on the floor or the like, as in the first embodiment. The first mold 4B and the second mold 5B are then left until the first slurry layer SB1 and the second slurry layer SB2 inside them harden and become integrated. The first slurry layer SB1 and the second slurry layer SB2 finally integrate to become one layer (slurry layer) SB3.

[0075] 19 is an explanatory diagram showing a state in which a slurry layer SB3 is formed inside the closed first mold 4B and second mold 5B with the pipe 11B embedded therein. In this embodiment, the slurry layer SB3 formed inside the first mold 4B and second mold 5B is referred to as a compact 10B.

[0076] In the method for manufacturing a gypsum board of this embodiment, after the mold closing step S35, a mold opening step S36 is performed, as in embodiment 1, and the molded body 10B is removed from the first mold 4B and the second mold 5B. Then, as in embodiment 1, the removed molded body 10B is subjected to a drying step S36, and the molded body 10B is dried. By going through each of the steps described above, a gypsum board 1B is obtained. According to the method for manufacturing a gypsum board of this embodiment, it is possible to easily manufacture a gypsum board 1B in which a solid member (pipe 11B) is installed in the core material 2B for the purpose of weight reduction, reinforcement, etc. Furthermore, according to this embodiment, it is possible to easily manufacture a gypsum board 1B consisting only of a core material 2B whose surface is not covered with base paper.

[0077] <Embodiment 4> Next, a method for manufacturing a gypsum board according to a fourth embodiment of the present invention will be described with reference to FIGS. 20 to 25. The method for manufacturing a gypsum board according to this embodiment manufactures a gypsum board 1C in which the adhesion between a core material 2C and base paper 3C (first base paper 6C, second base paper 7C) is improved. The method for manufacturing a gypsum board according to this embodiment differs from that according to the first embodiment in that the base paper 3C used is provided with an adhesion-improving layer X, which will be described later. FIG. 20 is an explanatory diagram that schematically shows the configuration of a gypsum board 1C manufactured by the manufacturing method according to the fourth embodiment. First, the gypsum board 1C manufactured by the manufacturing method according to this embodiment will be described.

[0078] In the gypsum board 1C of this embodiment, the base paper 3C and the core material 2C are bonded to each other via an adhesion improving layer X. Specifically, the first bottom base paper 61C and the core material 2C of the first base paper 6C, and the second bottom base paper 71C and the core material 2C of the second base paper 7C are bonded to each other via an adhesion improving layer X. The first base paper 6C is made up of a first bottom base paper 61C and a first peripheral wall base paper 62C. The second base paper 7C is made up of a second bottom base paper 71C and a second peripheral wall base paper 72C.

[0079] The adhesion improving layer X is mainly composed of gypsum, just like the core material 2C. However, the adhesion improving layer X is made of gypsum with a higher density than the core material 2C. The adhesion improving layer X is formed so as to entirely cover the surface of the first bottom base paper 61C and the surface of the second bottom base paper 71C. The thickness of the adhesion improving layer X is set to, for example, about 0.1 mm to 5 mm.

[0080] The configuration of the gypsum board 1C other than the adhesion-improving layer X is basically the same as that of the gypsum board 1 of embodiment 1. Therefore, in each drawing, parts corresponding to those of embodiment 1 are denoted by the same reference numerals as those of embodiment 1 with the addition of the reference numeral "C," and detailed explanations thereof will be omitted.

[0081] This type of gypsum board 1C is manufactured through a first installation process, a second installation process, a first supply process, a second supply process, a mold closing process, a mold opening process, and a drying process, similar to the first embodiment. The molds (one set of molds) used in the manufacturing method of this embodiment are the same as those in the first embodiment. Therefore, in each drawing, for the molds (one set of molds) used in the manufacturing method of this embodiment, parts corresponding to those in the first embodiment are given the same reference numerals as in the first embodiment with the addition of the reference numeral "C," and detailed explanations will be omitted.

[0082] 21 is an explanatory diagram that schematically shows the contents of the first setting step. In the first setting step of this embodiment, a first base paper 6C on which an uncured adhesion improving layer X (a layer of high-density slurry having a higher density of gypsum components than the calcined gypsum slurry SC) is formed in advance is set in a container-shaped first mold 4C. The uncured adhesion improving layer X is formed in an uncured state on the surface of at least the first bottom base paper 61C of the first base paper 6C that comes into contact with the calcined gypsum slurry SC.

[0083] In the second installation step of this embodiment, a second base paper 7C on which an uncured adhesion improving layer (a layer of high-density slurry having a higher density of gypsum components than the calcined gypsum slurry SC) X is formed in advance is installed in a container-shaped second mold 5C. The uncured adhesion improving layer X is formed in an uncured state on the surface of the second base paper 7C on at least the side where the second bottom base paper 71C comes into contact with the calcined gypsum slurry SC.

[0084] After such first and second installation steps, as in embodiment 1, a first supply step is performed in which a calcined gypsum slurry SC, which is made by kneading a composition containing calcined gypsum and water, is poured into a first mold 4C in which a first base paper 6C is placed, and a second supply step is performed in which the calcined gypsum slurry SC is poured into a second mold 5C in which a second base paper 7C is placed.

[0085] 22 is an explanatory diagram schematically showing the contents of the first supplying step. The calcined gypsum slurry SC is placed in, for example, a predetermined container 8C, and then the calcined gypsum slurry SC is poured from the container 8C into the inside of the first mold 4C on which the first base paper 6C is placed. The first mold 4C on which the first base paper 6C including the adhesion improving layer X is placed is placed on a horizontal floor surface F, and the calcined gypsum slurry SC is supplied into the inside of the first mold 4C in this state.

[0086] 23 is an explanatory diagram showing a state in which the calcined gypsum slurry SC is filled into the first mold 4C by the first supplying step. The calcined gypsum slurry SC is supplied into the inside of the first base paper 6C formed in a box shape so as to cover the first bottom base paper 41C on which the adhesion improving layer X is formed. As shown in FIG. 23, the calcined gypsum slurry SC is filled up to the height position of the end face (first joint portion 42Ca) of the first peripheral wall portion 42C.

[0087] After the first supplying step, the first mold 4C filled with the calcined gypsum slurry SC is left in an environment at room temperature (for example, 20°C). The calcined gypsum slurry SC in the first mold 4C is left until its fluidity decreases and it hardens to such an extent that its shape can be maintained within the first mold 4C so that it does not spill out of the first mold 4C in a mold closing step described later.

[0088] After the second supply step, the second mold 5C filled with the calcined gypsum slurry SC is left in a room temperature environment, similar to the first mold 4C after the first supply step, until its fluidity decreases and it hardens to the extent that its shape can be maintained within the first mold 4C.

[0089] Thereafter, the mold closing step is performed in the same manner as in embodiment 1. Fig. 24 is an explanatory diagram that schematically shows the mold closing step in the manufacturing method of embodiment 4. The mold closing step of this embodiment is basically the same as the mold closing step S15 of embodiment 1, and is performed using the same mold closing device 9 as in embodiment 1.

[0090] In the mold closing step, the fluidity of the calcined gypsum slurry SC decreases and solidifies to form a first slurry layer SC1 in the first mold 4C, and the fluidity of the calcined gypsum slurry SC decreases and solidifies to form a second slurry layer SC2 in the second mold 5C, and then the first mold 4C and the second mold 5C are closed so that the first joint portion 42Ca and the second joint portion 52Ca come into close contact with each other. When the first mold 4C and the second mold 5C are closed, the first slurry layer SC1 and the second slurry layer SC2 are superposed on each other in such a manner that the exposed surface SC1a of the first slurry layer SC1 in the first mold 4C and the exposed surface SC2a of the second slurry layer SC2 in the second mold 5C come into close contact with each other.

[0091] After this mold closing step, the first mold 4C and the second mold 5C in the mold-closed state are appropriately removed from the mold closing device 9 and left on the floor or the like, as in the first embodiment. The first mold 4C and the second mold 5C are then left until the first slurry layer SC1 and the second slurry layer SC2 inside them harden and become integrated. The first slurry layer SC1 and the second slurry layer SC2 finally become integrated to form a single layer (slurry layer) SC3.

[0092] 25 is an explanatory diagram showing the state in which an integrated slurry layer SC3 is formed inside the closed first mold 4C and second mold 5C. The slurry layer SC3 is covered with the first base paper 6C and the second base paper 7C inside the first mold 4C and the second mold 5C. An adhesion improving layer X is interposed between the slurry layer SC3 and the first bottom base paper 61C of the first base paper 6C, and between the slurry layer SC3 and the second bottom base paper 71C of the second base paper 7C. The slurry layer SC3 covered with the first base paper 6C and the second base paper 7C in this way is called a molded body with base paper 10C.

[0093] In the method for manufacturing a gypsum board of this embodiment, after the mold closing step, a mold opening step is performed as in Embodiment 1, and a molded body 10C with base paper is removed from the first mold 4C and the second mold 5C. Then, as in Embodiment 1, the removed molded body 10C with base paper is subjected to a drying step, and the molded body 10C with base paper is dried. By going through each of the steps described above, a gypsum board 1C is obtained. According to the method for manufacturing a gypsum board of this embodiment, a gypsum board 1C with improved adhesion between the core material 2C and the base paper 3C (first base paper 6C, second base paper 7C) can be manufactured. Furthermore, for example, by setting the density of the calcined gypsum slurry SC for forming the core material 2C low, the weight of the core material 2C and, ultimately, the weight of the entire gypsum board 1C can be reduced.

[0094] <Other embodiments> The present invention is not limited to the embodiments described above and illustrated in the drawings, and the following embodiments, for example, are also included within the technical scope of the present invention.

[0095] (1) In the above-mentioned embodiment 1, etc., the second setting process is performed after the first setting process, but the present invention is not limited to this. For example, in other embodiments, the first setting process and the second setting process may be performed simultaneously in parallel.

[0096] (2) In the above-mentioned embodiment 1, the second supply process is carried out after the first supply process, but the present invention is not limited to this. For example, in other embodiments, the first supply process and the second supply process may be carried out simultaneously in parallel. [Explanation of symbols]

[0097] 1... gypsum board, 2... core material, 3... base paper, 4... first mold, 5... second mold, 6... first base paper, 7... second base paper, 8... container, 9... mold closing device, 10... molded body with base paper, S... calcined gypsum slurry, S1... first slurry layer, S2... second slurry layer, S3... integrated slurry layer, 11... pipe (solid member)

Claims

1. a first installation step in which first base papers including a first bottom base paper to be overlaid on the first bottom and a first peripheral wall base paper to be overlaid on the first peripheral wall are installed in a container-shaped first mold having a plate-shaped first bottom, a first peripheral wall portion rising from the periphery of the first bottom, and a frame-shaped first joining portion formed by an end face of the first peripheral wall portion; a second installation step in which second base papers including a second bottom base paper to be overlaid on the second bottom and a second peripheral wall base paper to be overlaid on the second peripheral wall are installed in a container-shaped second mold having a plate-shaped second bottom, a second peripheral wall portion rising from the periphery of the second bottom, and a frame-shaped second joining portion formed by an end face of the second peripheral wall portion; A first supplying step in which a calcined gypsum slurry obtained by kneading a composition containing calcined gypsum and water is poured into the first mold in which the first base paper is placed; A second supplying step in which the calcined gypsum slurry is poured into the second mold in which the second base paper is placed; a mold closing process in which the fluidity of the calcined gypsum slurry is reduced and solidified to form a first slurry layer covered with the first base paper in the first mold, and the fluidity of the calcined gypsum slurry is reduced and solidified to form a second slurry layer covered with the second base paper in the second mold, and then the first mold and the second mold are closed so that the first joint portion and the second joint portion are in close contact with each other; a mold opening step in which the closed first mold and the closed second mold are opened, the first slurry layer and the second slurry layer are superimposed on each other and integrated, and a molded body with base paper covered with the first base paper and the second base paper is taken out; A method for manufacturing a gypsum board, comprising a drying step in which the molded body with base paper is dried to obtain a gypsum board.

2. The method for manufacturing a gypsum board according to claim 1, wherein an adhesion improving layer is formed on the surface of the first base paper on the side where at least the first bottom base paper comes into contact with the calcined gypsum slurry, and on the surface of the second base paper on the side where at least the second bottom base paper comes into contact with the calcined gypsum slurry.

3. The method for manufacturing a gypsum board according to claim 2, wherein the adhesion improving layer is made of a high-density slurry having a higher density of gypsum components than the calcined gypsum slurry.

4. The calcined gypsum slurry in the first mold after the first supply step and / or the calcined gypsum slurry in the second mold after the second supply step. An embedding step of embedding a solid member in the calcined gypsum slurry in the second mold after the second supply step. The method for manufacturing a gypsum board according to any one of claims 1 to 3.

5. The method for manufacturing a gypsum board according to claim 4, wherein the solid member is a longitudinal hollow member.

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