JP2001287215A - Mold for patterned panel and method for manufacturing patterned panel using the mold - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mold for molding a patterned panel, and a method for manufacturing the patterned panel using the mold by adding an irregularity to a curing inorganic material wherein inferiority in a transfer property of a decorating mold and a molded body of a required appearance are given though a molding cycle is repeated. SOLUTION: A mold 4 is provided wherein a curing inorganic material 14 is filled in a frame 6 equipped with a decorating mold 5 of an elastic material having an irregular pattern on a surface 5a, and after curing the curing inorganic material 14, a cured material is detached from the decorating mold 5 to manufacture a patterned panel equipped with an irregular pattern on the surface. As a material for the decorating mold 5, an elastic material of <=25% in compression set by the compression set test in JIS K6262 is used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mold for a patterned panel for forming a curable inorganic material with a concavo-convex pattern, and a method for manufacturing a panel with a concavo-convex pattern using the same.

[0002]

2. Description of the Related Art Conventionally, a mold provided with a decorative mold having an uneven pattern on its surface is filled with a curable inorganic material, and after the curable inorganic material is cured, a cured product cured from the decorative mold is released. There is known a method of manufacturing a patterned panel having an uneven pattern on the surface.

In such a patterned panel manufacturing apparatus 1, as shown in FIGS. 1 to 6, for example, a frame-shaped frame 5 is installed on a base 2 having an upper surface as a flat plate 3. Frame 6
A decorative mold 5 made of a rubber material (elastic body) having a concavo-convex pattern is provided on the inside. A flat space 12 surrounded by the mold 6 and the decorative mold 5 is filled with a curable liquid material (inorganic curable composition) 14, and the liquid material 14 is kept at a high temperature for a long time. After the curing, the cured body 14 is separated from the surface of the decorative mold 5 to obtain a patterned panel such as a patterned wall panel.

Here, if an elastic material such as a rubber material is used as the decorative mold 5, a molded article which does not require an undercut uneven pattern or a chamfered edge is directly obtained. Are used, for example, when manufacturing exterior wall panels of buildings.

[0005] Examples of such a manufacturing apparatus 1 and an example of a molding method are described in, for example, Japanese Patent Application Laid-Open No. H11-58342 and other publications by the present applicant. SiO ₂ − as a safe material
The use of Al ₂ O ₃ -based materials, various portland cements and special cements specified in JIS is exemplified.

[0006]

However, when a patterned panel is repeatedly produced several hundred times from a curable inorganic material using a molding die made of a rubber material as such a decorative die, Problems have been found that the transferability of the decorative type becomes poor, and a patterned panel having a desired appearance cannot be obtained.

According to the study by the present inventors, this problem was solved by replacing the decorative mold 5 with a new one.
Further, according to the detailed analysis, when the temperature as a curing condition is high or when the temperature is kept at a high temperature for curing for a long time, this problem becomes remarkable by repeating the molding cycle. In the decorative mold 5 which has been subjected to such a molding cycle, dimensional shrinkage in the plane direction of the decorative mold (the plane direction toward the mold 6) was observed. This was presumed to be the cause of failure to obtain a patterned panel having a desired appearance due to poor transferability of the decorative mold 5 and generation of burrs.

Accordingly, the present invention provides a molding die for forming a curable inorganic material which imparts irregularities to a molding material having a poor transferability of a decorative mold or a molded article having a desired appearance even after repeated molding cycles. It is an object of the present invention to provide a method for manufacturing a patterned panel using the same.

[0009]

According to a first aspect of the present invention, a mold provided with a decorative mold made of an elastic material having an uneven pattern on its surface is filled with a curable inorganic material. A mold for manufacturing a patterned panel having an uneven pattern by releasing the cured product from the decorative mold after curing of the curable inorganic material and transferring the uneven pattern of the decorative mold to the surface, The decorative mold material is a mold for a patterned panel, wherein an elastic material having a compression set of 25% or less in a compression set test of JIS K6262 is used.

According to a second aspect of the present invention, the molding die is a decoration having a relatively small coefficient of linear expansion, and the periphery thereof is regulated in the molding and the concave and convex pattern is disposed facing upward. 2. A mold for a patterned panel according to claim 1, wherein the mold comprises a mold.

According to a third aspect of the present invention, a curable inorganic material is filled in the mold using the mold of the first or second aspect, and the curable inorganic material is brought into contact with the decorative mold. A method for producing a patterned panel, comprising curing the curable inorganic material and releasing the cured body from the decorative surface after curing.

According to a fourth aspect of the present invention, in the method for producing a patterned panel according to the third aspect, the curing conditions are a curing temperature of 50 ° C. or more and a curing time of 30 minutes or more. It is.

According to a fifth aspect of the present invention, in the method for producing a patterned panel according to the third aspect, the curing conditions are a curing temperature of 85 ° C. or more and a curing time of 30 minutes or more. It is.

When a patterned panel is manufactured by using a mold provided with a decorative mold made of such a material, it is hardened at a relatively high temperature for a long time in order to obtain a patterned panel having good mechanical strength. Even if the molding cycle is repeated, it is possible to always obtain a patterned panel having a desired appearance without causing poor transferability of the decorative mold.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below by taking as an example the case where the present invention is applied to the manufacture of an exterior wall panel of a building.

An apparatus 1 for manufacturing an outer wall panel according to an embodiment of the present invention is the same as a conventionally known molding die except that the decorative die has a predetermined compression set. As shown in FIGS. 1 and 2, the manufacturing apparatus 1 has a molding die 4 on which a curable inorganic material is filled on a rectangular flat plate portion 3 which forms an upper part of a metal base 2. are doing. The molding die 4 has a decorative die 5 at the bottom, and the periphery of the decorative die 5 is surrounded by a mold frame 6.

The decorative mold 5 is formed of an elastic material having a predetermined compression set (described later). In order to form an uneven pattern on the surface of the outer wall panel, the surface is provided with unevenness corresponding to the uneven pattern. The decorative surface 5a is provided. Although not shown here, a metal plate such as an iron plate may be adhered to the back surface of the decorative mold 5 in order to improve the handling in order to suppress the contraction of the decorative mold 5.

On the other hand, the formwork 6 plays a role of forming the peripheral portion of the outer wall panel, has good dimensional stability, and is therefore made of, for example, a metal material having a small coefficient of thermal expansion. A release agent may be applied to the inner peripheral surface 6a or the decorative surface 5a that comes into contact with the molding material as needed.

The mold 6 is fixed to the flat plate portion 3 by, for example, welding or the like to form a container, and the decorative mold 5 can be disposed or taken out from the upper opening.

Further, as shown in FIGS. 3 and 4, the form 6 may be configured to be detachable from the flat plate portion 3 instead of welding. Here, positioning holes 7 and 8 are provided in the flat plate portion 3 and the mold frame 6 in this figure, respectively. Bolt 10 and nut 1 through washer 9
The mold frame 6 is fixed to the flat plate portion 3 by 1.

As a result, the decorating mold 5 fits perfectly in the container-like space surrounded by the mold frame 6 along the inner peripheral surface 6a. 6 inner peripheral surface 6
a forms a flat space 12 as a molding space (cavity). In the flat space 12, a curable inorganic material is set at a predetermined temperature (including normal temperature) in a state where it is set to a predetermined temperature (including normal temperature) and is provided with fluidity such as slurry, for example. It is poured into a mold and filled.

Then, as shown in FIG. 5, an upper lid 13 is provided on the upper part of the molding die 4, and the slurry of the curable inorganic material 14 is heated at a predetermined temperature in a state where the inner space in which the mold is closed is closed. It is cured over a predetermined time.

After the curing, as shown in FIG. 6, the upper lid and the mold are removed, and then the outer wall panel as a cured body is pulled by the suction device 15 or the like, and is (possibly transferred). The decorative mold is peeled off to obtain the outer wall panel.

The decorative mold 5 and the mold frame 6 are assembled on the flat plate portion 3 again to form the mold 4 shown in FIG. 4, and this molding cycle is repeated.

The outer wall panel forming die 4 or the manufacturing apparatus 1 includes a supply device for supplying a curable inorganic material, a vibrating device for equalizing the filled material, and a heat insulating material for controlling the forming temperature. Although a heater and the like may be provided, they are omitted in this figure. In addition, other parts and members necessary for the molding apparatus are also omitted.

Although the curing may be carried out at normal temperature, the effect of the present invention is remarkably exhibited when the molding cycle of curing under the condition that the temperature is maintained at a high temperature for a relatively long time is repeated.
The reason can be considered, for example, as follows.

In general, a decorative mold made of an elastic material such as rubber or elastomer has a relatively large coefficient of linear expansion as compared with a mold made of a metal material or the like. For this reason, in the case of using a decorative mold whose periphery is surrounded by a mold, a decorative mold (rubber mold) having a relatively large coefficient of linear expansion when the curing temperature rises increases in accordance with an increase in temperature. An attempt is made to expand, but this expansion is limited to a mold having a relatively low linear expansion coefficient. As a result, stress is generated inside the decorative rubber material. Here, if this state is maintained for a long time (that is, if the curing reaction is performed at a high temperature for a long time), when a conventional rubber material having a large compression set is used, the stress is reduced in the decorative mold during this time. Is caused. Then, due to this stress relaxation, a permanent compression set remains in the decoration mold.

Thereafter, the cured product is released from the mold, and the temperature is lowered to room temperature in order to carry out the next molding cycle. However, the dimensions of the decorative mold are smaller than the dimensions surrounded by the mold by the amount of the remaining compression set. As a result, a slight gap Δ is generated between the inner surface of the molding die and the outer peripheral side surface in contact with the inner surface of the decorative mold.

This gap Δ is increased each time the molding cycle is repeated. After several hundred molding cycles, the gap Δ becomes large, causing a poor transferability of the decorative mold compared to the initial decorative mold, and a wall panel having a desired appearance due to generation of burrs. Is difficult to obtain.

On the other hand, when a decorative mold made of a rubber material having a small compression set is used, even if hardening conditions for maintaining a high temperature for a long time are employed, the stress in the decorative mold during this time is increased. Less relaxation, which reduces residual compression set in the decorating mold. As a result, when a decorative mold having a small compression set is used, even if such a molding cycle is repeated, the decorative mold fits perfectly into the mold when the temperature is returned to normal temperature.

When a decorative mold made of such a material having a small compression set is used, it becomes substantially the same as a decorative mold (new decorative mold) which does not repeat the molding cycle even when used repeatedly. As a result, even if the molding cycle is repeated, the transferability of the decorative mold does not deteriorate, and a wall panel having a desired appearance can always be obtained.

In this regard, as the molding conditions in the present invention, the curing time is long, and the higher the curing temperature, the more the effect of the present invention is exhibited. Therefore, the preferable curing temperature in the present invention is 50 ° C. or more, more preferably 85 ° C. or more, and the curing time at that time is 30 minutes or more.

Here, the decorative mold 5 used in the present invention
Is made of an elastic material such as rubber or elastomer,
JIS K6262 compression set test for rubber materials (strain 25
%, Temperature 100 ° C., time 24 hours) satisfying 25% or less.

The cause of the residual compression set is as follows.
It is considered that the secondary bond between the filler and the rubber molecules wrapped in the rubber material is broken by heat and the generated stress, the cross-linking point of the rubber material is decomposed, and the main chain of the rubber material is decomposed.

Therefore, in order to reduce the compression set to 25% or less, a filler having good compatibility with the rubber molecules is used (specifically, a filler that is suitable for the rubber material or a surface of the filler is used). To match the rubber material),
It is conceivable to increase the heat resistance by crosslinking by peroxide vulcanization (for example, silicone rubber), to increase the crosslinking temperature within an appropriate range, to lengthen the crosslinking time within an appropriate range, and the like.

Specifically, a rubber material having a desired compression set can be obtained by using silicone rubber as a rubber material and fumed silica surface-treated with a silane coupling material as a filler.

Next, the compression set test will be described.

A material test piece having a predetermined size described in JIS is prepared, and the thickness of the test piece at the central portion is measured at a standard temperature in a test room. Then, the test piece is compressed by a compression plate at a rate of 25%. To give 25% distortion at this time, a specified spacer is used. After compressing the test piece, the compressing device is immediately put into a thermostat adjusted to 100 ° C. in advance and heated for 24 hours. After heating, the compression device was taken out of the thermostat, and the test piece was quickly removed from the compression device.
After standing for ± 3 minutes, measure the thickness of the center of the test piece. The compression set is calculated by the following equation.

The _{C S = (t 0 -t 2} ) / (t 0 -t 1) × 100 where, C _S is the compression set (%), t ₀ is the original thickness of the test piece (mm), t ₁ is the thickness of the spacer (mm), t ₂ is the specimen is removed from the compression device, after 30 minutes the thickness (m
m).

In the present invention, it is necessary that the value of the compression set measured by such a test method is 25% or less. If this value is greater than 25%, the permanent mold remains in the decorative mold due to the repetition of the molding cycle and shrinks, causing a gap Δ between the mold 6 and the decorative mold 5 to fill the curable inorganic material. The material flows into the gap Δ, and a patterned panel having a desired appearance cannot be obtained.

On the other hand, the smaller the value, the better, preferably 15% or less, more preferably 10% or less. By selecting and using such an elastic material, it is possible to give a good molded product even when curing for a long time at a high temperature is repeated.

As the material constituting the decorative mold, any material having such a value of compression set and having elasticity may be used, and any of commercially available natural rubber and synthetic rubber (including elastomer) may be used. It can be obtained by conducting a strain test and screening. Further, the composition may be adjusted in-house by changing the composition or the like as needed. Here, a decorative mold can be made from such an elastic material by an ordinary method.

In the present invention, in a manufacturing method for manufacturing a patterned panel by heating, a silicone rubber (or elastomer) having good heat resistance can be cited as an example of a suitable material.

Other materials include, for example, urethane rubber, acrylic rubber, butyl rubber, fluorine rubber, polysulfide rubber, graft rubber, butadiene rubber, 1,2-
Polybutadiene, isoprene rubber, chloroprene rubber,
Polyisobutylene rubber, polybutene rubber, isobutene
Isoprene rubber, acrylate-butadiene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, pyridine-butadiene rubber, styrene-isoprene rubber, acrylonitrile-chloroprene rubber, styrene-chloroprene rubber, styrene-butadiene-styrene copolymer, styrene-hydrogen Styrene-based thermoplastic elastomers such as added polyolefin-styrene copolymers, butadiene-styrene block copolymers, block copolymers such as styrene-rubber intermediate blocks-styrene copolymers, ethylene-propylene rubber, ethylene-propylene copolymers Examples thereof include an elastomer such as a copolymer, an ethylene-propylene-diene copolymer, chlorosulfonated polyethylene, and epichlorohydrin rubber.

These elastic materials may be one kind or a mixture of two or more kinds, and include inorganic fillers such as carbon black, calcium carbonate, magnesium carbonate, clay, talc, mica, silica and alumina, and organic fillers such as starch. What added processing aids, such as a filler, a lubricant, a plasticizer, and a softening agent, may be used.

As the curable inorganic material used in the present invention, an inorganic compound is preferably used in which the curing reaction is accelerated and the quality of the molded product is improved by maintaining the temperature at a higher temperature than at room temperature. These include, for example, cements such as concrete and mortar, and more specifically, Portland cements of ordinary, fast, super fast, moderate heat and sulfate resistance specified in JIS, and blast furnaces and cements also specified in JIS.
Mixed cements such as silica / fly ash cement, and special cements such as white Portland cement, alumina cement, ultra-rapid hardening cement, cement for grout, oil well cement, thermosetting cement, and the like.

Particularly, Japanese Patent Publication No. 4-4 with excellent transferability
A curable inorganic material mainly composed of an SiO ₂ —Al ₂ O ₃ -based inorganic powder, an alkali metal silicate and water described in Japanese Patent No. 5471 is preferred. Such a curable inorganic material is
100 parts by weight of SiO ₂ —Al ₂ O ₃ inorganic powder, 0.2 to 450 parts by weight of alkali metal silicate, and 35 to 15 parts of water
And 100 parts by weight of the curable inorganic material. The details of the curable inorganic material and curing conditions are described in other publications of the present applicant (for example, JP-A-11-58342, JP-A-11-583).
No. 41, etc.), some of which are disclosed in examples described later.

Such a curable inorganic material cures at room temperature, but by curing at 50 to 110 ° C. for about 30 minutes to 8 hours, the curing reaction is accelerated, and the cured body (molded body)
The mechanical properties of the outer wall panel can be improved. The curing conditions are such that the curing temperature is 50 ° C. or higher, preferably 85 ° C. or higher, and the curing time is 30 minutes or longer. For this reason, a method of heating and curing is usually adopted, and if this curable inorganic material is molded into a patterned panel using the molding die of the present invention, the decorative mold shrinks even if molded repeatedly. Therefore, since the decorative type has high durability, a patterned panel can be manufactured at low cost. Example 1 Hereinafter, the effects of the present invention will be described based on an example in which an inorganic dense body and an inorganic foam having the compositions shown in Table 1 are listed as specific examples of the production of the outer wall panel of the curable inorganic material.

Here, the inorganic dense body is made of a predetermined amount of alkali.
NSiO as metal silicate (B) _Two/ M_TwoO (n = 1.
5, M = Na, K; molar ratio 1: 1) in an autoclave
At 130 ° C, 0.7MPa at a predetermined amount of water (C)
Dissolves, wollastonite, silica powder, predetermined SiO_Two-A
l_TwoO_Three-Based inorganic powder (A), calcium stearate
Omni mixer (150 liters made by Chiyoda Giken Co., Ltd.)
To form a uniform paste,
It was poured and cured at 85 ° C. for 6 hours.

On the other hand, the inorganic foam is obtained by adding a foaming agent in the process of producing the above-mentioned inorganic dense body. The foaming agent may be formed by adding the above-mentioned uniform paste immediately before casting to aluminum paste having a particle size of 70 μm or less. A powder (Minarco, trade name; 350F) was added and stirred for 40 seconds, then poured into a mold and foamed for 3 minutes, and then 85 ° C with the mold.
And cured in an oven for 6 hours.

The SiO ₂ —Al ₂ O ₃ -based inorganic powder (A) composing the inorganic dense bodies 1, 2,... 8 and the inorganic foams 1, ₂ ,. ... A8 was used.

As the inorganic powder A1, fly ash (manufactured by Kanden Kako Co., Ltd., average particle size 20 μm; according to JIS A6201) was classified by a classifier (manufactured by Nisshin Engineering Co., Ltd., model: T).
Classified according to C-15) and contains 100% by weight of powder having a particle size of 10 μm or less.

The inorganic powder A2 is made of kaolin (composition: Si
O ₂ 45.7%, Al ₂ O ₃ 38.3% Average particle size: 8
Active inorganic powder (composition: 49.7% SiO ₂ , Al) obtained by spraying a raw material powder having a BET specific surface area of 5.8 m ² / g) at a combustion temperature of 2500 ° C. and a spray particle speed of 50 m / sec.
₂ O ₃ 47.0% Average particle size: 49 μm BET specific surface area: 64.3 m ² / g)

The inorganic powder A3 is made of 30 pieces of fly ash.
It is an inorganic powder that has been melted at 00 ° C., sprayed into the atmosphere at a speed of 80 m / s, and collected. The average particle size of the inorganic powder A3 was 5 μm, and the specific surface area was 9.5 m ² / g.

The inorganic powder A4 is a fired fly ash containing 100% by weight of a powder having a particle size of 10 μm or less, obtained by firing the inorganic powder A1 at a temperature of 600 ° C.

The inorganic powder A5 was made of fly ash (manufactured by Kanden Kako Co., Ltd., average particle size 20 μm, specific surface area 1.8 m ² / g,
100 parts by weight of JIS A 6201) and 0.5 parts by weight of a mixed solution of 25% by weight of triethanolamine and 75% by weight of ethanol were added to Ultra Fine Mill AT-20.
(Mitsubishi Heavy Industries, zirconia ball diameter 10mm used, ball filling rate 85% by volume)
It was obtained by applying kg of mechanical energy.
The applied mechanical energy is represented by the electric power supplied to the ball mill per unit weight of the treated powder.

The inorganic powder A6 is made of kaolin (composition: Si
O ₂ 45.7%, Al ₂ O ₃ 38.3% Average particle size: 8μ
m BET specific surface area: 5.8 m ² / g) 95 parts by weight, quartz (trade name: soft silica, manufactured by Sumitomo Cement Co., Ltd.) 5 parts by weight, and a mixed solution 0.5 of 25 parts by weight of triethanolamine and 75 parts by weight of ethanol A part by weight was supplied to an Ultrafine Mill AT-20 (manufactured by Mitsubishi Heavy Industries, Ltd., using a zirconia ball diameter of 10 mm, and a ball filling rate of 85% by volume), and was obtained by applying mechanical energy of 25 kwh / kg. The applied mechanical energy is represented by the electric power supplied to the ball mill per unit weight of the treated powder.

The inorganic powder A7 is prepared by mixing the inorganic powder 6 with 300
It was obtained by heating at ℃ for 3 hours.

The inorganic powder A8 was composed of 100 parts by weight of metakaolin (SATINTONESP 33, manufactured by Engelhard Co., average particle size 3.3 μm, specific surface area 13.9 m ² / g), 25% by weight of triethanolamine and 75% of ethanol.
0.5 part by weight of a mixed solution of ultra-fine mill AT-20 (manufactured by Mitsubishi Heavy Industries, zirconia ball diameter 1)
0 mm, ball filling rate 85% by volume)
It was obtained by applying kwh / kg of mechanical energy.

[0060]

[Table 1]

[Molding] As a decorative mold, a rubber mold was prepared from five types of commercially available silicone rubbers having different permanent compression strains according to a conventional method. Here, the outer dimensions of the inorganic panel as a molded body are 2880 mm × 920 mm × 31.
Both are common in mm.

The decorating mold was changed, and the slurry of the curable inorganic material was poured into the mold, cured at a predetermined temperature and for a predetermined time, demolded, assembled again with the mold, and poured with the predetermined slurry. The molding cycle for molding was repeated, and the number of molding cycles until a gap Δ of 1 mm or more was generated between the decorative mold and the frame was determined. The results are shown in Table 2.

[0063]

[Table 2]

From Table 2, it can be seen that in the decorative type using a rubber material in which the compression set of the rubber material is 25% or less, all of them are 5%.
A wall panel having good transferability and good appearance was able to be obtained by enduring over 00 molding cycles. On the contrary,
As the compression set of the decorative mold was larger, poorer appearance was observed as the molding cycle was repeated, and it was confirmed that the durability was shorter. [Embodiment 2] In the above-described embodiment 1, JA shown in Table 3 was used.
Using the same five kinds of decorative molds as in Example 1,
The molding was repeated at a curing time of 6 hours at 5 ° C.

[0065]

[Table 3]

In the same manner as in Example 1, a molding cycle in which the gap Δ between the inner surface of the molding frame and the decorative mold was 1 mm or more was evaluated. The results were almost the same as those in Table 2 in Example 1 in any of the formulations 1 to 3.

That is, in the case of the rubber material having a small compression molding strain according to the present invention, no shrinkage occurs in any of the decorative molds even if molding is repeated 500 times or more, and good durability is confirmed. Was done. In the case of a decorative mold having a compression set of 30%, the molding die has a molding cycle of 250 times. In the case of a decorative mold having a compression set of 40%, the molding die has a molding cycle of 100 times. A gap of 1 mm or more was generated, and good durability was not obtained.

It was confirmed that the smaller the compression set, the longer the molding cycle and the better the durability.

Further, it was confirmed that substantially the same effect can be obtained by changing the composition of the inorganic curable composition in improving the durability of the decorative mold.

From the above results, the decorative mold according to the present invention is:
It is particularly suitable for the curable inorganic material having excellent transferability used in Example 1, but the molding object of the mold is not necessarily limited to this, and the curing speed is improved by heating and curing. In addition, any inorganic compound that improves mechanical strength can be suitably used.

[0071]

As described above, according to the first aspect of the present invention, an elastic material having a compression set of 25% or less according to a compression set test of JIS K6262 is used as a decorative material. Even if a molding cycle under curing conditions of curing at a high temperature for a relatively long time is repeated, a molding die having good durability can be provided by suppressing shrinkage of the decorative mold.

According to the second aspect of the present invention, the decorative mold is arranged in a mold having a relatively small coefficient of linear expansion with its periphery regulated, so that even if the molding cycle is repeated, the appearance of the mold can be improved. And a mold that constantly provides a patterned panel with excellent stability.

According to the third aspect of the present invention, there is provided a method of manufacturing a patterned panel from a curable inorganic material using the mold according to the first or second aspect.

According to the fourth or fifth aspect of the present invention, there is provided a method for producing a patterned panel according to the third aspect, which provides a patterned wall panel having improved mechanical strength by increasing the curing temperature. You.

In this way, even if the molding cycle of curing at a relatively high temperature for a long time is repeated in order to obtain a patterned panel having good mechanical strength, the decorative mold does not suffer from poor transferability, A practically effective effect is provided in that a mold for obtaining a patterned panel having a desired appearance and a method for manufacturing a patterned panel using the mold are provided.

[Brief description of the drawings]

FIG. 1 is a plan view showing a molding die of an outer wall panel according to an embodiment.

FIG. 2 is a perspective cross-sectional view illustrating a state cut along the line AA of FIG. 1;

FIG. 3 is a view for explaining another mold for forming an outer wall panel;
It is the longitudinal cross-sectional view cut | disconnected in the length direction of the outer wall panel.

FIG. 4 is an explanatory view showing a state where a decorative mold and a formwork are installed on a base in FIG. 3;

FIG. 5 is an explanatory diagram showing a state in which a mold is filled with a curable inorganic material and an upper lid is installed.

FIG. 6 is a diagram illustrating a state in which a cured body of the curable inorganic material obtained in FIG. 5 is taken out.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 4 Mold 5 Decorative mold 5a Decorative surface 6 Mold frame 6a Inner peripheral surface 13 Top cover 14 Curable inorganic material (cured body)

Claims (5)

[Claims] 1. A mold provided with a decorative mold made of an elastic material having an uneven pattern on its surface is filled with a curable inorganic material, and after the curable inorganic material is cured, the cured product is released from the decorative mold. In the molding die for manufacturing a patterned panel, the material of the decorative mold is an elastic material having a compression set of 25% or less according to a compression set test of JIS K6262. Mold for patterned panels. 2. The molding die is composed of a mold having a relatively small coefficient of linear expansion and a decorative mold whose periphery is regulated in the mold and disposed with the uneven pattern facing upward. The mold for a patterned panel according to claim 1, wherein: 3. A mold according to claim 1 or 2, wherein the mold is filled with a curable inorganic material, and the curable inorganic material is brought into contact with the decorative mold while the curable inorganic material is in contact with the decorating mold. A method for producing a patterned panel, comprising: curing and releasing the cured body from the decorative surface after curing. 4. The method for producing a patterned panel according to claim 3, wherein the curing conditions include a curing temperature of 50 ° C. or more and a curing time of 30 minutes or more. 5. The method for producing a patterned panel according to claim 3, wherein the curing conditions include a curing temperature of 85 ° C. or more and a curing time of 30 minutes or more.