JP2000025020A - Production of molded body with pattern - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a molded body with a pattern in which the molded body having complex and various design and a function is produced with good productivity at a low cost by using a granule. SOLUTION: In a method for producing the molded body with a pattern by using holding bodies 21, a granule 10 for temporary packing which is <=600 μm and has large fluidity and is easily removed, is filled into each holding space of the holding bodies 21 arranged on a standard face 62. After empty holes are formed by removing the granule 10 for temporary packing in the insides of the prescribed holding spaces, granules 11-13 for molding are filled into the empty holes. This treatment is repeated and all granules 10 for temporary packing are removed and the empty holes are substituted for the granules 11-13 for molding. Thereafter, the holding bodies 21 are removed and a backing layer 3 is overlapped and solidified into one body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned concrete molded body, a patterned artificial stone molded body, a patterned ceramic molded body using a powder and granular material layer forming apparatus,
The present invention relates to a method for producing a patterned molded article for producing a patterned molded article such as a patterned ceramic molded article, a thick-coated molded article, a plastic molded article, and a molded food.

[0002]

2. Description of the Related Art The applicant of the present invention has proposed a method of manufacturing a molded article with a pattern in Japanese Patent Application Laid-Open No. 5-253910.

[0003]

However, with the diversification of design and the diversification of functions, there is a demand for a more complicated molded article with a pattern. , Adhesiveness, hardness, weight, etc.Various things have been used alone or in combination, for example, in the case of tiles, crushed granules of fired ceramics are mixed to increase the slip resistance value Various measures such as using raw materials are required.

[0004] In order to meet the above demand, in order to form a molded body having a more complicated pattern, it is necessary to make the holding interval of the holding body of the granular material as narrow as possible to express a fine portion. There are also demands for manufacturing technology that are incompatible with each other, such as using a powder having the largest possible particle size. As a result, the holding interval of the holding body is narrow, and the molding powder to be filled has a particle size, shape, adhesiveness, etc. that can finally fit in the narrow holding interval. In the manufacturing method which has been performed, it takes a long time to manufacture, and the productivity is decreasing.

[0005] While there is a demand for cost reduction,
When the particle size of the granular material is large, when the granular material having a large particle size and the granular material having a small particle size are combined, the shape, adhesion,
In the case of complex mixed granules combining different granules with different hardness, weight, etc., it takes time to remove the granules from the holding body, and the cost increases due to increased wear of equipment. It is becoming.

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned disadvantages, and is intended to provide a low-cost, high-productivity molded article having complicated and diverse designs and functions using powder and granules. It is intended to provide a method for producing a patterned molded article that can be formed.

[0007]

According to the present invention, there is provided a method of manufacturing a patterned molded article using a holder, wherein the holding space of the holder disposed on the reference surface has a large fluidity of 600 μm or less in each holding space. After filling the powder particles for temporary filling, which is easy to perform, removing the powder particles for temporary filling in the predetermined holding space to form holes, and repeatedly filling the holes with the powder particles for molding. The method is characterized in that after removing all of the temporary filling powders and replacing them with two or more types of molding powders, the holding body is removed and solidified as it is or by stacking a backing layer.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION As powders for temporary filling according to the present invention, various food powders, various stone powders, coal powders, bone powders, shell powders,
Ash, soil, clay, cement powder, glass powder, various ceramic powders, various metal powders, various plastic powders, various powdery chemical products, various powdery chemicals, various powder coatings, various fiber powders, leather powder, wood powder , Paper powder and other powdery and dry powders can be used.

[0009] The above-mentioned removal of the powdery particles for temporary filling must be performed as quickly as possible because each hole is sequentially removed.
For this reason, the above-mentioned powder for temporary filling has a particle size of 600 μm.
By using a material having a particle size of m or less, the fluidity is increased, the powdery and granular materials in a narrow space can be removed reliably and at a high speed, and a complicated pattern can be accurately formed. The powder for temporary packing having a particle diameter of 600 μm or less as described above can be obtained by classifying fine powders existing in the natural world, or pulverizing or classifying using various known pulverizers.

In addition, even if the molding powder contains at least one of water, oil, solvent, lubricating binder, plasticizer and hardener, water, oil, solvent, lubricating binder, plasticizer, Although a dry material which is not kneaded with any of the curing agents and can be easily disassembled and supplied is used, the adhesion may be increased with various additives or the like in order to improve the function of the molded article.

In the case of removing the temporarily-filled particles at a predetermined position in the holding body and forming holes as described above, since the holes are formed one by one, a high speed is required. However, since the powder for molding can be simultaneously filled into a plurality of formed holes,
A powder having low fluidity can be used. Among these particles having low fluidity, there are many particles that are indispensable for diversification of expression.

Further, at least one of the densely packed cells 21 shown in FIG. 2 or the forest solid 22 shown in FIG. 7 is used as the holding body, and the holding body is in a single-leaf state, and can be moved up and down and horizontally. The holding body is used in at least one of a holding body supported in a normal state, a holding body supported in a reversible state, and a holding body supported in an endless state.

The removal of the temporary filling powder and granules is performed by at least one of suction removal and blow removal. The removal of the temporary filling powder and particles and the filling of the molding powder and particles are performed in a plurality of cycles. Form a layer. Furthermore, combination with a mask,
Alternatively, since various combinations with other devices, auxiliary tools, and the like are possible, the present invention is not limited to each embodiment described below, and various methods and expressions based on various combinations are possible.

The molded article 1 shown in FIG.
According to the embodiment, a pattern layer 2 containing a pattern of Mt. Fuji
Has a backing layer 3 on the lower side (back side). For the pattern layer 2, a molding material obtained by mixing relatively large and hard particles obtained by crushing a material once hardened and a relatively small and new powder material is used, and for the backing layer 3, another molding material is used. Is used. FIG. 3 shows an example of a molding apparatus for molding the molded body 1.

In FIG. 3, reference numeral 31 denotes a scanner.
Two parallel guide rails 32, two support bars 33, 34 straddling the pair of guide rails 32 and movably mounted along the guide rails 32; And a support bar moving mechanism (not shown) for moving the guide 34 along the guide rail 32. The reference surface 6 is provided between the two guide rails 32.
A cell dense body 21 having a plurality of holding spaces is arranged on 2.

Reference numeral 41 denotes a suction device, a suction nozzle 42 movably attached to a support bar 33, a hose 43 having one end connected to the discharge side of the suction nozzle 42, and a hose 43 connected to the other end of the hose 43. Powder material recovery mechanism 44
And a suction control mechanism (not shown) for controlling the suction and stop of the air into the powder material recovery mechanism 44.

Reference numeral 51 denotes a powder supply unit, and the support bar 3
4, a supply nozzle 52 having a plurality of supply nozzle ports movably attached thereto, a plurality of hoses 53 having one end connected to the inflow side of the supply nozzle 52, and a plurality of hoses 53 connected to the other end of the plurality of hoses 53. A supply hopper 54 and a control mechanism (not shown) for controlling the supply and stop of the molding powder to be filled.

Next, a method of manufacturing the molded body 1 shown in FIG. 1 will be described. As shown in FIG. 4 (a), first, the granular material for temporary filling is placed in each holding space of the densely packed cells 21 placed on the reference surface 62 of the support plate 61 by using a predetermined granular material supply device. Fill 10 Next, while operating the scanner 31 and operating and stopping the suction device 41, as shown in FIG. After the suction and removal by the nozzle 42, while operating the scanner 31 and operating and stopping the powder and granular material supply device 51, FIG.
As shown in (c), the supply nozzle 52 fills the first molding powder / particle 11 in which gray relatively large and hard particles of 1 mm to 1.5 mm are mixed in the white powder / particle.

Then, while operating the scanner 31,
As shown in FIG. 4D, while the suction device 41 is being operated or stopped, the temporary filling powder and granular material 10 representing the sky is suctioned and removed by the suction nozzle 42, and then the scanner 31 is operated. As shown in FIG. 4 (e), while operating and stopping the powder and granular material supply device 51,
1 m gray in the blue powder by the supply nozzle 52
The second molding powder 12 mixed with relatively large and hard crushed particles having a size of m to 1.5 mm is filled.

Further, while operating the scanner 31,
As shown in FIG. 4 (f), while the suction device 41 is being operated or stopped, the temporary filling powder and granular material 10 representing the mountain is suctioned and removed by the suction nozzle 42, and then the scanner 31 is operated. As shown in FIG. 4 (g), while operating and stopping the powder and granular material supply device 51,
1m in gray in brown powder by supply nozzle 52
The third molding powder 13 mixed with crushed relatively large and hard particles of m to 1.5 mm is filled.

When all of the temporarily packed powder particles 10 have been replaced with the respective forming powder particles 11 to 13 as shown in FIG.
As shown in (h), after removing the cell dense body 21 and opening the powder layer for molding on the reference surface 62, as shown in FIG. 4 (i), the backing layer 3 is overlaid and pressed. And solidify and mold integrally. In addition, the cell dense body 21 shown in FIG.
FIG. 5 is a perspective view of a state in which is removed, and FIG. 6 is a perspective view of a state in which the backing layer 3 shown in FIG.

Here, the first embodiment will be described in detail. To be specific, the granules 10 having a size of 600 μm or less are used as the granules 10 for temporary filling, and the cell cluster 21 is a cluster of hexagonal cells 1.5 mm on a side. And the thing whose height was 20 mm was used. Then, the cell dense body 21 and the suction nozzle 42 of the suction device 41
Was set to 700 μm. The suction nozzle 42 is set on the scanner 31 so that scanning can be performed at an arbitrary speed.

As described above, according to the first embodiment of the present invention, since the granules 10 having a size of 600 μm or less are used as the granules 10 for temporary filling, particles having a size larger than 600 μm are removed by suction. The powdery granules 10 for temporary filling can be removed by suction at twice to three times the speed, and
By filling and removing the following temporary packing powder and granules 10,
The risk of filling and removing molding powder particles larger than 600 μm, that is, the wear of the cell densely packed body 21 and the abrasion of the suction nozzle 42 due to the high-speed removal of large or hard powder particles are avoided. Can be reduced.

Furthermore, the smaller the particle size of the temporarily packed powder granules 10 is, the closer the distance between the cell densely packed body 21 and the suction nozzle 42 becomes. Since the powders 10 can be accurately removed, the compact 1 can be finished finely. When removing the temporary-packing granular material 10 using the suction nozzle 42, the particle size of the temporary-packing granular material 10 is determined using the cell dense body 21 and the suction nozzle 4.
When the suction nozzle 42 is moved at a high speed, the cell dense body 21 and the suction nozzle 42
And the temporary filling powder and granules 10 are no longer sandwiched between them, so that the suction error of the temporary filling powder and granules 10 does not occur and the productivity is improved.

The particle size of the temporarily packed powder particles 10 may be determined according to the gap between the cell densely packed body 21 and the suction nozzle 42, and can easily pass through the space between the cell densely packed body 21 and the suction nozzle 42. It is preferable to do so. And it does not limit about the surface property etc. of the granular material 10 for temporary filling,
The temporary filling powder and granular material 10 is preferably dry and smooth because it can be efficiently removed, and the temporary filling powder and granular material 10 is mixed with various additives such as a surfactant, an antistatic agent, a flame retardant, and a flame retardant. When used and modified, it is easy to separate easily and it becomes difficult to burn, so that it is in a preferable state.

Although a cell dense body 21 in which a large number of cells are densely arranged adjacent to each other is used as a holder, as shown in FIG. It can also be used as a holder. further,
Although a method using suction is used as a means for removing the temporary-packing powder granules 10, a method for removing the particles by blowing air may be used, or both may be removed in combination.

The molded article 1 shown in FIG.
According to the embodiment, as in the first embodiment, a backing layer 3 is provided on the lower side (back side) of the pattern layer 2 containing the eggplant pattern. Next, a method for manufacturing the molded body 1 shown in FIG. 8 will be described. First, as shown in FIG. 4A, the cell dense body 21 mounted on the reference surface 62 of the support plate 61 is used by using the cell dense body 21 in which a large number of cells are densely arranged as shown in FIG.
Is filled with the temporary filling powder granules 10 in each holding interval.

Next, while activating and stopping the suction device 41 while operating the scanner 31, FIG.
As shown in (b), after removing the granule 10 for temporary filling of the portion expressing the ridge of the eggplant, the scanner 31 is operated while the granule supply device 51 is operated or stopped. As shown in FIG. 4 (c), the first molding powder 11 having a uniform green particle is filled.

Then, while operating the scanner 31,
While operating and stopping the suction device 41, as shown in FIG. 4 (d), after removing the portion of the temporarily-filled powdery granules 10 representing eggplant nuts, the scanner 31 is operated. As shown in FIG. 4 (e), the second molding powder / granules 12 having uniform purple particles are filled while the powder / particle supply device 51 is operated or stopped.

Further, while operating the scanner 31,
As shown in FIG. 4F, while the suction device 41 is being operated or stopped, the portion of the temporary-stuffing granule 10 that expresses the background is removed, and the While operating and stopping the body supply device 51, as shown in FIG. 4 (g), the third molding powder 13 having uniform white particles is filled.

After all the temporarily packed powder particles 10 have been replaced with the respective forming powder particles 11 to 13 as shown in FIG.
As shown in (h), after removing the cell dense body 21 and opening the powder layer for molding on the reference surface 62, as shown in FIG. 4 (i), the backing layer 3 is overlaid and pressed. And solidify and mold integrally.

Here, the second embodiment will be described in detail. A powder particle of 100 μm or less is used as the temporary filling powder particle 10, and the cell densely packed body 21 is composed of densely packed hexagonal cells each having a side of 1.5 mm. And the thing with a height of 10 mm was used. Then, the cell dense body 21 and the suction nozzle 42 of the suction device 41
Was set to 200 μm.

As described above, according to the second embodiment of the present invention, since the granules 10 having a size of 100 μm or less are used as the granules 10 for temporary filling, the size of the granules 10 is smaller than that in the case of removing large particles by suction. The temporary filling powder and granules 10 can be suctioned and removed at twice to three times the speed, and the high-speed removal and high-speed filling can be performed by filling the molding powders 11 to 13 having a uniform particle diameter of 1 mm or less. Will be possible. Therefore, as shown in FIG. 9, immediately after high-speed removal by the suction nozzle 42 of the suction device 41, filling can be performed at a high speed from the supply nozzle 52 of the granular material supply device 51.

In addition, the particle size of the temporarily packed powder granules 10 is set to 100
μm or less, the cell dense body 21 and the suction nozzle 42
Can be approached to 200 μm, and the temporary-packing powder particles 10 can be accurately removed from the holding space of the cell densely packed body 21, so that the molded body 1 can be finely finished. Furthermore, using the suction nozzle 42,
In the case where 0 is removed, the particle size of the temporarily packed powder granules 10 is set to be equal to or less than the distance between the cell dense body 21 and the suction nozzle 42. Therefore, when moving the suction nozzle 42 at high speed, the cell dense body 21 and the suction nozzle The temporary packing powder and granules 10 are no longer sandwiched between the temporary packing powder granules 10 and 42, so that the suction error of the temporary packing powder and granules 10 is eliminated and the productivity is improved.

Further, the particle size of the temporarily packed powder granules 10 is 100
Since it is as small as μm or less, the suction nozzle 42 can be finely suction-removed by making the diameter of the suction nozzle 42 smaller than that in the first embodiment, so that a finer expression can be achieved. The particle size of the temporarily packed powder particles 10 may be determined according to the distance between the cell dense body 21 and the suction nozzle 42.
It is preferable to easily pass through the gap between the nozzle and the suction nozzle 42.

Although there is no limitation on the surface properties and the like of the temporary-packing powder and granules, the temporary-packing powder and granules 10 are preferable in that they can be efficiently removed when they are dry and dry. Is modified by using various additives such as a surfactant, an antistatic agent, a flame retardant, and a flame retardant.

A molded product 1 shown in FIG. 10 is according to a third embodiment of the present invention, and has a pattern layer 2 having a tree pattern.
It consists only of: In order to form the compact 1, the cell dense body 21 shown in FIG.
And the scanner 31 shown in FIG.
1, a blow device 45 (shown in FIG. 11) to which a blow nozzle 46 is attached similarly to the suction nozzle 42 of the suction device 41
And a blow control mechanism (not shown) for controlling the blowing and stopping of the air from the blow nozzle 46.

Next, a method of manufacturing the molded body 1 shown in FIG. 10 will be described. First, as shown in FIG. 11, using the cell dense body 21 in which a large number of cells are densely packed, as shown in FIG. The granules 10 are filled. Next, while operating the scanner 31 and operating and stopping the blowing device 45, as shown in FIG. The green and highly adherent first molding powder 11 is filled while operating and stopping the powder supply device 51 while operating 31.

Then, while operating the scanner 31,
While operating and stopping the blow device 45,
As shown in FIG. 11, after removing the temporarily-filled granular material 10 in a portion expressing a trunk and a branch, while operating the scanner 31 and operating or stopping the granular material supply device 51, Second molding powder 12 having a brown and high adhesion property
Fill.

Further, while operating the scanner 31,
While operating and stopping the blow device 45,
As shown in FIG. 11, after removing the portion of the temporary granular material 10 representing the soil, while operating the scanner 31,
The third molding powder 13 having a soil color and high adhesiveness is filled while the powder supplying device 51 is being operated or stopped.

Further, while operating the scanner 31 and operating and stopping the blow device 45, as shown in FIG. While operating the scanner 31,
While operating or stopping the powder supply unit 51, the white powder powder 14 having high adhesiveness is filled. When all of the temporarily-filled granules 10 have been replaced with the respective compacted granules 11 to 14 in this way, the cell dense body 21 is removed and the compacted granule layer is opened on the reference plane 62. rear,
It is solidified and formed integrally by applying pressure.

Here, the third embodiment will be described in detail. The powdery granules having a size of 100 μm or less are used as the temporarily packed powdery granules 10, and the cell densely packed body 21 is composed of densely packed hexagonal cells each having a side of 1.5 mm. And the thing whose height was 20 mm was used. Then, the distance (distance) between the cell dense body 21 and the blow nozzle 46 of the blow device 45 was set to 200 μm.

As described above, according to the third embodiment of the present invention, the same effects as those of the first and second embodiments can be obtained. The blow nozzle 46 is attached to the cell
By setting the diameter closer to 00 μm, it is possible to blow out and remove the powder for temporary filling 10 accurately and at a high speed approximately three times as fast as when blowing out and removing highly adherent particles and large particles.

The molded body 1 shown in FIG. 12 is according to the fourth embodiment of the present invention, and comprises only a pattern layer 2 having a tree pattern, as in the third embodiment. This molded body 1 is manufactured in the same process as in the third embodiment,
The difference from the embodiment is that each of the molding granules 11 to 14 has 5
The point where large grains of 7 mm to 7 mm are contained, and the cell dense body 21 densely collects square cells each having a side of 10 mm, and is 30 m
The point of having a height of m and the bottom having air permeability, and the point of arranging the blow nozzle 46 below the cell dense body 21 as shown in FIG.

In each of the above embodiments, the powdery granules for temporary filling include various food powders, various stone powders, coal powders, bone powders, shell powders, ash, soil, clay, cement powders, glass powders, and various ceramic powders. , Various metal powders, various plastic powders,
Various powdery chemical products, various powdery chemicals, various powder coatings, various fiber powders, leather powders, wood powders, paper powders, and other powdery and dry powders can be used. In consideration of the fact that they do not become mixed, it is preferable that the material is a material that is burned out in a later step such as sintering, or a material of the same type as a molded body to be molded, and more preferably a homogeneous material.

In the case of using the suction nozzle to remove the temporary-packing powder particles, the particle size of the temporary-packing powder particles should be smaller than the distance (distance) between the holder and the suction nozzle or the blow nozzle. When moving the suction nozzle or the blow nozzle at a high speed, the temporary filling powder and granules no longer get caught between the holding body and the suction nozzle or the blowing nozzle, and a suction mistake or a blow mistake of the temporary filling powder or granule occurs. Disappears and productivity increases. In addition, the particle size of the powder for temporary filling may be determined according to the distance between the holder and the suction nozzle or the blow nozzle, so that the distance between the holder and the suction nozzle or the blow nozzle can be easily passed. Is preferred.

Further, the particle size of the temporarily packed powder is set to 600 μm.
When the particle size is set to 300 μm or less, the powder can be removed at a higher speed. In addition, the smaller the particle size of the temporary-packing particles, the closer the distance between the holding body and the suction nozzle or the blow nozzle can be. Therefore, the particle size of the temporary-packing particles is 100 μm or less. It is preferable that the smaller the particle size of the powder for temporary filling is, the smaller the diameters of the suction nozzle and the blow nozzle can be.

Further, when the particle size of the powder is reduced, the distance between the holder and the nozzle can be made substantially zero, and the air can be prevented from flowing around. Then, when the distance between the holding body and the suction nozzle or the blow nozzle is reduced, the powder for temporary filling can be accurately removed from the holding space of the holding body, so that the molded body can be finely finished.
In addition, the powder and granules for temporary filling are preferable because those that are dry and dry (having a high fluidity) can be efficiently removed.

Furthermore, if the powder for temporary filling is modified with various additives such as a surfactant, an antistatic agent, a flame retardant, a flame retardant, etc., it becomes easy to separate easily and becomes difficult to burn. The risk of filling and removing filling granules,
That is, it is possible to avoid or reduce the wear of the holder and the wear of the removing mechanism due to the high-speed removal of the molding granules. In addition, as shown in FIG. 9, the supply method for filling the recesses (voids) of the holding body with the forming granules is as follows. By controlling the opening and closing of the supply port in a column or a row corresponding to each concave portion of the dense body 21), the supply port may be supplied from the hopper 53, or may be supplied by a bottle or other methods.

When the molding powder is continuously filled after the formation of the recess as shown in FIG. 9, if the molding powder having a uniform particle size is used, the fluidity is good and the filling can be performed quickly. Powdered granules having a size of 2 mm or less, which are granulated by various granulation methods such as a dryer, are preferable because they have good fluidity and can cope with fine cells and stand intervals. In addition, as the holding body, a cell dense body 21 in which a large number of cells are densely arranged in an adjacent manner, or a forest solid body 22 in which a large number of standing pieces are in a forest can be used, and various shapes, materials, or combinations thereof can be used. Can be.

As the cell shape of the cell dense body 21, in addition to a polygon such as a triangle, a square, and a hexagon, a cylinder, and the like,
Various shapes can be used. In addition, the cell dense body 21 may have a continuous partition wall, or may have a discontinuous partition wall or a cut in the partition wall if it does not interfere with expressing a pattern. Becomes a deformable holder. The standing piece of the forest solid 22 is
In addition to a pin, a small piece, a ring (pile, a loop), a brush, a bristle, a flock, and the like, a pipe and other shapes can also be used.

Further, as the holding body, in addition to the planar shape shown in FIG. 2, a rotating drum 25 in which a large number of cells are provided in a matrix on the peripheral surface as shown in FIG. When forming a pattern shaped article by using the rotary drum 25, as shown in FIG. 16, the order as soon as 1 zone Z ₁ downstream of the temporary packed for granule feed hopper 71, a second zone Z _2, · ..., an n-th zone Z _n is provided, and an _n- th zone
Zone Z downstream of _n, drop preventing plate 7 for molding powder particles can be held so as not come off from each cell of the rotary drum 25
4 disposed in each zone Z ₁ to Z _n, as shown in FIG. 17, removal nozzles arranged in the axial direction of the rotary drum 25 so as to be able to remove the temporary packed for granular material from cells in the corresponding position 72 and a molding powder supply hopper 73 that can supply the molding powder of a corresponding color to each cell.

[0053 Then, it rotates the rotary drum 25 in the direction of the arrow, first, supplying a temporary packed a powdery grains from the temporarily packed for particulate material feed hopper 71 into each cell, the first color in the first zone Z ₁ The operation of supplying and filling the first color molding granules from the molding powder supply hopper 73 after removing the temporary filling granules from the corresponding cell by the removal nozzle 72 is sequentially performed on the nth color granules. after up to n zones Z _n, by sequentially placed on the reference surface 62 of the support plate 61 which travels in the arrow direction at the same speed as the peripheral speed of the rotary drum 25, using a rotating drum 25 an endless manner, the aforementioned Thus, a molded article can be manufactured.

It should be noted that the present invention is not limited to a densely packed cell, and a forest solid can be used in an endless manner. Further, the holding interval of the holding member is preferably 10 mm or less in that a fine expression can be obtained, and 5 m is required for a more detailed expression.
m or less, and preferably 2.5 mm or less for more detailed expression. The height of the holder may be determined in consideration of the finished thickness of the pattern.

Although the number of cells and forest solids is reduced for convenience of explanation, the number of cells and forest solids is not limited, and if one side is 1 mm to 2 mm like a cell actually used, Since tens of thousands to millions of dots are formed per molded body, fine expression is possible. And, as the material of the holder, metal, ceramics, plastic, rubber, paper,
A nonwoven fabric, a woven fabric, or the like can be used, and it is preferable to use a combination of materials that can be in close contact with each other between the reference surface and the holder in order to express a clearly partitioned pattern.

Further, if air permeability, liquid permeability, and liquid absorption are added by using a nonwoven fabric, a woven fabric, paper, or the like to form the reference surface, deaeration is assisted and excess liquid is removed. It is preferable to keep the strength uniform, and is also preferable in that when the holding body is removed, it plays a role of preventing the material from slipping due to friction. Further, when the powder for temporary filling is removed by blowing (blowing) as shown in FIG. 13, it is preferable to make the bottom surface of the holder air-permeable, and metals, fibers, plastics, ceramics, Various nonwoven fabrics made of rubber or the like, a woven fabric, a mesh, a perforated sheet, a perforated panel, a porous sheet, a porous panel, and the like can be used, but the nonwoven fabric is preferable because it is easy to handle and the cost is low.

The bottom surface of the holder may be integrally attached to the holder or may be arranged separately from the holder. The reference surface may be a mold bottom plate, a sheet, a belt, a plate, or any other type, a double-acting press bottom plate may be used as a reference surface, a bottom surface of a setter or the like, or a mold placed on a conveyor. A frame bottom plate may be used, or an endless thing such as a belt conveyor may be used as a reference surface, or a powder layer may be placed on a board or sheet as a reference surface by directly or inverting the powder layer. Good.

When a material having a slight bulkiness or elasticity such as rubber, sponge, paper, or non-woven fabric is used as a material for the reference surface, when the holder is pressed, the gap between the reference surface and the holder is reduced. Play can be taken, the holder can be easily positioned in the height direction, and the holding member is firmly defined by the partition wall and the standing pieces, so that sharp lines can be drawn. Similarly, even if the holding member is pressed against a part or the whole of the supporting member using an elastic body such as a spring or rubber, a thread or a string-like elastic material is attached to the contact surface with the reference surface of the holding member. And so on.

Further, as a means for removing the temporary-packing powder or granules, one or both of a method by suction and a method by air blowing can be used. And, since the particle size of the powder for temporary filling was reduced,
Even if the diameter of the suction port or the outlet is reduced, it can be removed and a finer expression can be obtained. However, for the finer expression, the diameter of the suction port is 5 mm or less, and the diameter of the outlet is 3 mm or less. It is preferable that the diameter of the suction port be 2.5 mm or less and the diameter of the blowout port be 1.5 mm or less for a fine expression.

Regardless of whether it is blown or sucked, even if it has a single outlet or suction port, or if it is arranged in a line,
It may be in the form of a matrix dot or slit, and may be blow-only, suction-only, or a combination of both. In addition, by applying vibration to the holding body, each molding powder can be filled evenly when filling within the holding interval, and when the holding body is removed, collapse of each molding powder may occur. It is preferable because it can proceed and can be molded densely.

Further, the molding may be performed one by one, or a plurality of moldings may be formed at a time, solidified, and then cut individually. In addition, how to express is arbitrary, and by combining various devices and various expression methods, not only the above-described embodiment, but also various pattern expressions and molded articles can be manufactured. Whether each material supplied on the reference surface is provisionally formed on the reference surface or fully formed, or formed by adding water, solvent, oil, lubricating binder, plasticizer, hardener, etc. Depending on the molding material, the molding method of pressing, heating or firing the powder or granules, or molding them in combination, may be selected.

In the case of producing a molded article according to the present invention, the dry molding powder to be deposited on the reference surface is made of water, oil,
Even if it contains one or more of lubricating binders, solvents, hardeners and plasticizers, it is not kneaded with water, oil, lubricating binders, solvents, hardeners or plasticizers and is easily disintegrated. Use a dry material that can be supplied as a product. Further, even if a dry material is used as a material of the backing layer, a material kneaded with one or more of wet water, oil, a lubricating binder, a solvent, a curing agent, and a plasticizer may be used, Other materials, for example, boards such as metal, wood, cement, glass, and ceramics, and sheets such as paper, nonwoven fabric, woven fabric, and plastics can be used.

When boards or sheets are used as the material of the backing layer, the boards or sheets are used as a reference surface. They may be layered and integrated. Further, as the above-mentioned various materials for manufacturing the molded body, different materials or different finishes such as colors, luster, texture, etc. can be used depending on the molded body to be manufactured.

Next, as a dry molding granule for producing a concrete molding, cement powder, resin alone, or a mixture thereof, or a mixture obtained by adding a pigment or fine aggregate to them. Can be used. In addition, as a material of the backing layer, a cement powder or a simple resin or a mixture thereof, or a mixture obtained by adding a fine aggregate to them, as a main component, and a pigment, a coarse aggregate and various A mixture containing one or both of fibers, which is as dry as the granular material layered on the reference surface, or a wet material such as ready-mixed concrete mixed with water or the like can be used.

Wood chips may be used as aggregates or fine aggregates for both the dry molding powder and the material for the backing layer, as required, and granite and marble crushed and crushed powder, slag,
Particles that reflect light, inorganic hollow bodies such as shirasu balloons,
Mix crushed granules and powders of ceramics, granules and powders of New Cerax, powders and granules of metals and other minerals, and mix with setting and hardening accelerators, waterproofing agents, swelling agents, and other admixtures. You may. In addition, as the various fibers described above, metal fibers,
Carbon fiber, synthetic fiber, glass fiber and the like can be used.

Then, in order to solidify integrally in a mold or the like,
Put all the materials in a mold, etc., and then add the necessary amount of water or the like, but when using a wet backing layer material together, consider the amount of water leaching from the backing layer material It is better to reduce it. Further, the material may be solidified integrally using another material for the backing layer, for example, a board such as metal, wood, cement, glass, and ceramics, or a sheet such as paper, nonwoven fabric, or woven fabric. Further, a patterned asphalt concrete or the like can be manufactured using a hot-melt material such as asphalt.

Next, as a dry molding powder for producing an artificial stone molded product, granules such as rock particles, ceramic particles, new ceramic particles, glass particles, plastics particles, wood chips, metal particles and the like can be used. One or two or more of them can be used as a main component, and if necessary, a mixed aggregate containing a pigment or the like may be used. In addition, as a material of the backing layer, it is possible to use one or more of particles such as rock grains, porcelain grains, new ceramic grains, glass grains, plastics grains, wood chips, and metal grains. If necessary, a mixed aggregate containing a pigment or the like may be used, either as a dry or a wet one.
What mixed the hardening | curing agent added in order to couple | bond the said aggregate is mentioned.

The hardener to be filled in the gaps of the dry molding powder or the hardener to be mixed with the material of the backing layer may be cement powder and water, cement powder and resin and water, or resin and water or solvent, or These are mixed with rocks, ceramics, new ceramics, glass, and powders consisting of one or more of plastics as a main component, and are mixed with pigments and coloring agents as necessary. Powders or granules, various fibers, various admixtures and various additives may be mixed.

Examples of the above-mentioned various powders or particles include slag, fly ash, particles that reflect light, and other substances. Examples of various fibers include metal fibers, carbon fibers, synthetic fibers, and glass fibers. Examples of the various admixtures and additives include a shrinkage inhibitor, a setting-hardening accelerator, a retarder, a waterproofing agent, a swelling agent, a water reducing agent, and a fluidizing agent. Further, in order to improve the adhesiveness with the curing agent, the dry molding powder may be sprayed with water, a solvent, a surface treatment agent, or the like as necessary, or may be immersed in these. It is not easy to understand and it is good.

Then, in order to solidify in a mold or the like,
After putting all the materials in a mold or the like, the hardener may be spread between the aggregates by vacuum suction or centrifugal force, or a material in which the aggregate and the hardener are mixed in advance as a material for the backing layer is used. You may. Also, other backing layer materials, such as metal, wood,
Boards such as cement, glass, and ceramics, or paper,
It may be layered on a sheet of nonwoven fabric, knitted fabric, plastics, or the like and solidified integrally.

Next, as a green body for sintering a ceramic molded body and a dry molding powder for producing the ceramic molded body, powders or granules of clay, rock or glass, powders or granules of new ceramics, fine ceramics One or more powders or granules, powder glazes, or a mixture of these with pigments and colorants as a main component. Even from dry bone, even with water or lubricating binder, knead with water or lubricating binder. It is not possible to use a material that can be easily disassembled and supplied.

Further, as the material of the backing layer, one or two or more of powders or grains of clay, rock or glass, powders or grains of new ceramics, powders or grains of fine ceramics, or a mixture of these with pigments or colorants As a main component, a dry material like a dry molding powder or a wet material kneaded with water or a lubricating binder can be used. In addition, both the dry molding powder and the material of the backing layer may be made of a substance such as an inorganic hollow body such as a shirasu balloon, a crushed or crushed ceramic, a metal or other mineral powder or a grain, as necessary. You may mix and mix various foaming agents, flow inhibitors, fining agents, lubricants, binders, adhesion promoters, and other additives.

Then, in order to solidify integrally in a mold or the like,
After putting all the materials in a mold, etc., or add the required amount of water or lubricating binder, give plasticity, pressurize and demold to make a base, sinter, or refractory setter Put all the materials in a mold and then heat and melt or fuse them together to remove them after unifying, or layer a pattern material on a metal plate, glass plate, ceramic, ceramic plate, etc. Then, depending on the method of heating or melting or fusing to integrate the plates together, a patterned enamel, stained glass, a crystalline glass molded article, or the like can be manufactured.

Next, one or two or more of various metal powders or grains, various alloy powders or grains, or lubrication with these powders may be used as dry compacting powders for producing a metal compact for sintering. The main component is a mixture with the agent, even if it contains a lubricant from absolutely dry, it is not kneaded with a lubricant,
What can be supplied easily can be used. In addition, as a material of the backing layer, one or two or more of various metal powders or grains, various alloy powders or grains, or a mixture of these and a lubricant is used as a main component. Even if it is dry, it is kneaded with a lubricant. Wet materials can also be used.

It is to be noted that zinc stearate and other substances may be used as a lubricant, and various substances may be added as a binder or an additive to the material of the dry molding powder and the backing layer. In addition, to solidify in a formwork, etc.,
Put all the materials in a mold, etc., pressurize them and remove them from the mold to form a base, sinter, or integrate with the material layered on a metal plate, glass plate, porcelain, ceramics plate, etc. Press molding and sintering the whole plate.

Next, various powder coatings can be used as dry molding powders for producing thick-coated moldings, and metals, woods, cements, ceramics and the like can be used as a material for the backing layer. Boards, sheets, or other shapes. Examples of the above various powder coatings include acrylic resins, polyester resins, acrylic-polyester hybrid resins, fluororesins, and other resins to which a pigment or a coloring agent is added.

In order to solidify each material integrally, a powder coating is layered on a board or sheet of the material of the backing layer and heated, and the board or sheet is melted, fused and baked. And the like, but may be pressurized as necessary when it is integrated. By this method, a thick coating board or a sheet can be manufactured.

Next, powders or granules of various plastics or a mixture of these with a pigment or a coloring agent as a main component, and a plasticizer or a solvent are used as dry molding powders for producing a plastic molded body. Even if it contains such a substance, it can be used that is not kneaded with a plasticizer or a solvent and can be easily disassembled and supplied. As the material of the backing layer, in addition to the above-mentioned dry material, a material kneaded with a wet plasticizer or a solvent can be used. As powder or granules of various plastics mentioned above,
Polyethylene, nylon, polypropylene, polycarbonate, acetal, polystyrene, epoxy, vinyl chloride, natural rubber, synthetic rubber, ABS, PPO, EVA,
Fluoro resins and other thermoplastic and thermosetting resins can be used.

The dry molding powder and the material of the backing layer may be used, if necessary, as a foaming agent, an antioxidant, a heat stabilizer, a cross-linking agent, other various additives, and inorganic materials. Various powders and granules can be added. Then, in order to solidify each material integrally, it is heated or melted or fused by heating while applying pressure as needed, and integrated, but in this method, a molded article of patterned styrofoam, a patterned plastic bath tub, a floor tile, etc. Etc. can be manufactured. In this case, it may be layered on another material, for example, a board such as metal, wood, cement, or ceramics, or a sheet such as paper, nonwoven fabric, woven fabric, or plastic, and may be integrated.

Next, dry molding granules for producing confectionery and other molded foods include wheat, rice, potato,
Red beans, sugar powder or granules, one or more corns, or a mixture of these with seasonings and spices, containing oil or water, etc., but kneaded with oil or water Instead, it is possible to use a material that can be easily supplied and supplied. Further, as the material of the backing layer, in addition to the above-mentioned dry material, a material kneaded with wet oil or water can be used.

In addition, an expanding agent and other additives can be added to both the dry molding powder and the material of the backing layer, if necessary. Then, in order to solidify each material in the mold, etc., remove all the molds after putting all the materials in the mold, etc. or pressurizing with plasticity with the required amount of oil or water, etc. This can be baked as a base material, or all the materials can be put into a mold and baked as a unit. By this method, various types of patterned baked goods can be manufactured. Also, in addition to the above-mentioned food materials, as a material for the dry molding powder and the backing layer, powder or granules of a heat-meltable material such as chocolate is used, and is heated or melted or fused to form a chocolate having a pattern. Can also be manufactured.

The materials used in the present invention are not limited to the examples, and various materials may be used in combination with different finishes such as colors, luster, texture, etc., depending on the molded product, so that various materials can be used. In the case of a molded body, for example, in the case of the same process, different materials can be combined, and in the same baking and hardening process, in the case of a metal molded body and a ceramic molded body, a pattern is formed by a metal powder and a ceramic powder. It is also possible to express and make a cloisonne all at once, and it is also possible to produce a concrete compact and an artificial stone compact in a similar manner. Also, when vibration is applied when supplying the molding powder to the holding body, the movement of the powder becomes smooth, and the boundary of the pattern of the dry molding powder is brushed, combed,
The pattern can also be blurred by disturbing with an air jet or water jet.

Further, at the time of molding, by laying a nonwoven fabric, paper, or other water-absorbing or oil-absorbing mat on the reference surface or the material layer, excess water, oil, lubricating binder, plasticizer The solvent can be absorbed by the mat, and some of the material can be replenished with excess water, oil, lubricating binders, plasticizers, and other parts that lack the solvent, and water, oil, and lubrication of the entire molding Binder, plasticizer, and solvent can be made uniform,
Since the ratio of water (auxiliary agent) to cement (resin) on the surface can be reduced, the strength of the molded body can be improved.

When a gas permeable mat is used for pressure molding, a dense compact can be produced by assisting deaeration, and when it is hardened, dry molding powder or material for the backing layer can be produced. When vibration or pressure is applied to the body, the body becomes dense, so that the strength of the molded body can be improved. In addition, various long fibers and short fibers can be put between and in the layer of the dry molding powder and the material of the backing layer, and wire mesh or reinforcing steel can be used to reinforce the material. By using molded articles by extrusion or extrusion, or by using various boards and sheets, building panels and boards,
Can be used for molded products for various uses such as wall sheets and tiles.

Further, the reference surface may be an existing surface, for example, a surface of a concrete molded product, and a pattern layer may be superimposed on the reference surface so as to be integrally fixed with the existing object. Furthermore, if a deformable mat or a deformable mat is used for part or all of the mold after supplying the granular material, a finished surface such as a curved surface other than a flat surface can be made as well as a flat surface as the reference surface. it can.

[0086]

As described above, according to the present invention, according to the diversification of design and the diversification of functions, a holding body having a narrow holding interval and a powder having a small particle diameter are temporarily packed. By using it as a body, it is possible to form a molded body with complicated patterns and functions, and also to make the holding interval of the holding body as narrow as possible and to express finely. This makes it possible to satisfy the demands that are contradictory in terms of manufacturing technology, such as those that can be finally settled in the holding interval narrowed due to properties, hardness, weight, and the like. As a result, it is possible to remove the defect of the product caused by using the complex powder and granular material, to improve the productivity, and to produce a high-performance molded body.

The temporary filling powder / granules may be improved in masking function and pursued such properties that they can be easily removed. The temporary filling powder / granules may have functions specified for their intended use. Therefore, various additives such as water, oil, solvent, lubricating binder, plasticizer, hardener, etc. necessary at the time of molding added to the molding granules, and thickener added for improving the function of the molded body Since the powder for temporary filling can be removed without being affected by various additives such as adhesives and other chemical products, a pattern can be formed at high speed.

Further, since there is no influence of the particle size (size), shape, hardness, weight, adhesion of the particles, etc. of the powder for molding, the suction force and the blowing force are variously changed. In addition, it is possible to remove the temporary filling powder particles smoothly without difficulty, thereby improving the productivity and reducing the cost. Furthermore, since the temporarily packed powder and granules that have undergone functional differentiation can be collected and reused as they are, the cost can be reduced by repeatedly using them, and an environmentally friendly and low-cost manufacturing method can be achieved.

In addition, even if the shape of the holding body is changed in various ways, it is possible to easily remove the temporary filling powder and granules,
A molded article having a complicated pattern can be formed, and variations can be expanded. Then, even if the diameter of the suction port or the outlet is reduced, the powder for temporary filling can be removed, so that a finer expression is possible.

Further, the present invention can be compared with a case where a holding body is damaged or a removing device is damaged when removing a molding powder having a large particle size or a hard molding powder by a conventional method. By using the temporary packing powder having a small particle size, it is possible to reduce the wear of the holder and to avoid the risk, and also in this respect, the cost can be reduced. Further, when the particle size of the temporary-packing granules is set to 300 μm or less and the particle size of the molding granules is uniform, the temporary-packing granules can be replaced with the molding granules at a high speed, thereby further increasing productivity. Can be improved.

[Brief description of the drawings]

FIG. 1 is a perspective view of a molded body manufactured according to a first embodiment of the present invention.

FIG. 2 is a perspective view showing an example of a holder.

FIG. 3 is a perspective view showing an example of a molding apparatus for carrying out the method for producing a patterned molded body of the present invention.

FIGS. 4A to 4I are explanatory views showing manufacturing steps.

FIG. 5 is a perspective view of a state where a pattern layer is manufactured on a reference surface.

FIG. 6 is a perspective view showing a state in which a backing layer is overlaid on a pattern layer.

FIG. 7 is a perspective view showing another example of the holder.

FIG. 8 is a perspective view of a molded body manufactured in a second embodiment of the present invention.

FIG. 9 is an explanatory diagram illustrating an example of a suction device and a granular material supply device.

FIG. 10 is a perspective view of a molded body manufactured according to a third embodiment of the present invention.

FIG. 11 is an explanatory diagram illustrating an example of a blow device.

FIG. 12 is a perspective view of a molded body manufactured according to a fourth embodiment of the present invention.

FIG. 13 is an explanatory view showing another example of the blowing device.

FIG. 14 is an explanatory view showing another example of the granular material supply device.

FIG. 15 is a perspective view showing still another example of the holder.

FIG. 16 is an explanatory diagram showing an example of use of the holder shown in FIG.

FIG. 17 is an explanatory diagram showing the configuration of each zone shown in FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Molded body 2 Pattern layer 3 Backing layer 10 Temporary filling granular material 11 1st molding granular material 12 2nd molding granular material 13 3rd molding granular material 14 4th molding granular material 21 holding Body (cell densely packed body) 22 Holder (Hayashi 3D) 23 Support sheet 24 Standing piece 25 Rotary drum 31 Scanner 32 Guide rail 33, 34 Support bar 41 Suction device 42 Suction nozzle 43 Hose 44 Powder material recovery device 45 Blow device 46 blow nozzle 51 granular material feeder 52 supplying nozzle 53 hose 54 hopper 61 supporting plate 62 the reference plane 71 provisionally packed for granule feed hopper 72 removal nozzle 73 prevents molding granular material feed hopper 74 fall plate Z ₁ to Z _n Each zone

Claims (3)

[Claims] 1. A method of manufacturing a patterned molded body using a holder, comprising: a step of placing 600 in each holding space of the holder disposed on a reference plane;
μm or less, the fluidity is large, the powder for temporary filling is easily filled, and after removing the powder for temporary filling in the predetermined holding space to form a void, the void is formed. After repeatedly filling the molding granules, removing all of the temporary filling granules and replacing them with two or more types of the molding granules, removing the holding body and solidifying integrally. A method for producing a patterned molded article, which is a feature of the present invention. 2. A method of manufacturing a patterned molded body using a holder, comprising: a step of placing 600 in each holding space of the holder disposed on a reference plane;
μm or less, the flowability is large, and the temporary filling powder particles that are easily removed are filled, and the temporary filling powder particles in the predetermined holding space are removed to form voids. After repeatedly filling the molding powder, the temporary filling powder is completely removed and replaced with two or more types of the molding powder, and then the backing layer is removed and the backing layer is laminated and integrated. A method for producing a patterned molded body, comprising: 3. The method for producing a patterned molded product according to claim 1 or 2, wherein the molding fluid to be filled in the voids is a powder having a lower fluidity than the temporary-packing powder. A method for producing a patterned molded body, which is a granule.