JP2002028907A - Method for manufacturing homogeneous projected corner or homogeneous internal corner for ceramic outer wall material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mold a projected corner for enhancing productivity by preventing a deformation at a mold releasing time. SOLUTION: A method for manufacturing a homogeneous projected corner or a homogeneous internal corner for a cement outer wall material comprises the steps of inserting a kneaded and preformed cement molding material 100 into an elastic form 18 made of a rubber-like elastic material, and pressurizing the form 18 by a press 23 in a state in which the form 18 is placed on a curing tray 17, thereby obtaining the molding 100 closely contacted with the form 18. The method further comprises the steps of primarily curing the molding 100 together with the form 18 until the molding 100 is solidified, and then taking out the molding from the elastic form 18.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the production of a homogeneous outgoing corner and a homogeneous outgoing corner for ceramic exterior wall materials.

[0002]

2. Description of the Related Art As a technique for producing a uniform corner for a ceramic exterior wall material, there are a lamination method, an extrusion molding method, and a press molding method. Hereinafter, each method will be described.

1) Laminating method FIG. 8 (b) is a plan view of a corner of the same quality of the laminating method, and FIG.
FIG. 9B is a sectional view taken along line BB of FIG. This method is a method of manufacturing by sticking cut pieces 201 and 202 from the same plate material as the outer wall material in a protruding corner shape. Most of the current homogeneous corners are manufactured in this way and have the following advantages and disadvantages.

<Advantages>-The design is the same as the outer wall material.・ Outer wall materials can be used. <Disadvantages> ・ Because the chamfered portion is largely chamfered, it becomes a design defect. -Poor durability at the bonded part. Usually, the sunshine is different on the left and right surfaces, so that a difference occurs in the expansion and contraction of the material on the left and right sides, and acts as a stress on the bonding portion (laminated portion). Due to this repetitive stress, the bonded portion is destroyed after the application, which leads to the generation of cracks.

2) Extrusion molding method FIG. 8 (c) is a plan view of a corner of the same quality in the extrusion molding method, and FIG. 9 (c) is a sectional view taken along the line CC of FIG. 8 (c). This method is used as a long product at an extruded corner 200 formed by extrusion, and has the following advantages and disadvantages.

<Advantages>-Good durability. There is no crack after construction because of the integral molding and the small expansion and contraction rate in the length direction. -Good workability. It is usually used at 3030 mm and can shorten the installation work. <Disadvantages>-Poor design. Since the direction of the design of the outer wall material and the direction of the extrusion are at right angles, the same design cannot be obtained. It is usually used in a solid state or in a state where a step pattern or the like is provided in the length direction. Or, it has a fixed pitch with a design different from the outer wall material. A relatively shallow pattern with no repetitive patterns is used. -The joint cannot be adjusted. It is technically difficult to match a vertical overlapping joint of the outer wall material or a lateral joint pattern of the outer wall material itself with a joint pattern of an extruded corner formed by extrusion (which is perpendicular to the extrusion direction).

In the current extrusion technique, a pattern is set by a pattern roller set at the exit of a mold. However, a joint pattern having a constant pitch perpendicular to the extrusion direction cannot be formed. The reason is that the production speed of the extrusion speed and the take-up speed of the molded product cannot be made to match 100% continuously. Instantly possible,
Slight changes in the material (eg, moisture in the raw material, particle size,
The extrusion speed is slightly affected by the fiber length, etc., and the balance with the take-up speed changes.

If the speed ratio is the same, the pitch is constant, but if the speed ratio changes even slightly, the pitch changes. As the extrusion speed decreases, the pitch increases, and conversely, as the extrusion speed increases, the pitch decreases.

3) Press molding method FIG. 8A is a plan view of a corner of the same quality in the press molding method, and FIG.
FIG. 9A is a sectional view taken along line AA of FIG. Homogeneous corner 2
Most of the 00 are manufactured by the above methods 1) and 2), but press molding is considered to be technically possible.

However, at present, it is not actually on the market and has not been put to practical use. Problems in this press molding method are considered as follows.
It can be inferred that it has not been put to practical use.

<Possible problem>-Deformation occurs when the mold is removed, and the yield rate is extremely poor. -The molding cycle is long and productivity is extremely poor. -The fitting part cannot be formed simultaneously with molding.・ Cost is higher than bonded products.

[0012]

However, in recent years, the design of outer wall materials has become more and more sophisticated, and a deeply carved design has been required. Therefore, even for the same quality appearance corner of the same design, the appearance corner having the same quality design as the outer wall material is not the conventional corner with the chamfered ridge part as in the past and the design defect. It has been requested.

[0013]

Means for Solving the Problems The present inventor has conducted intensive studies to meet the above-mentioned demands. As a result, if the molding is performed by the following manufacturing method, it is possible to prevent deformation at the time of demolding and increase productivity. Was found. That is, in a mold made of a rubber-like elastic material, mixed and kneaded, a pre-formed cement-based molding material is inserted, and by pressing this, a molded body in close contact with the mold is obtained. After performing primary curing together with the mold until the molded body is hardened, the molded body is taken out from the elastic mold.

According to such a molding method, since the molding method is the same as the press molding method, it is possible to satisfy even a deeply carved design requirement. In addition, since the molded article is removed after the molded article is cured, and the rubber-like elastic body is used as the mold, the molded article can be prevented from being deformed at the time of removing the molded article. Furthermore, the number of molds is necessary for the molded body to be primary cured together with the molds, but if each mold is filled with a molding material in advance and press-molded sequentially,
Compared to the conventional press molding method in which the mold is released immediately after press molding, more efficient press molding can be performed, and the molding cycle can be shortened.

The cured body may be subjected to a secondary curing such as an autoclave if necessary after the primary curing. Further, in the same-corner-exposed corner, a fitting portion for fitting with the same-corner-exposed corner is formed above and below,
The formation of the fitting portion can be performed simultaneously with the formation of the entire protruding corner.

Further, these molding methods can be applied not only to corners of the same quality but also to corners of the same quality and molded products having other shapes.

As the material of the elastic mold, among materials having elasticity such as PU (polyurethane), EPDM, silicon, and rubber, those having a hardness of 70 to 85 degrees in JIS A hardness are most suitable. It is. If the hardness is less than 70 degrees, it is difficult to faithfully copy the pattern, and if the hardness exceeds 85 degrees, it is difficult to remove the molded product from the mold.

It is necessary to form the pattern of the surface of the same-exposed corner in advance on the inner surface of the mold, and this pattern can be attached by, for example, engraving on a mold or casting from a master model. The method generally adopted can be adopted.

As the molding material for the corners of the same quality, any material can be used as long as it has the same composition as the outer wall material and the accessory made by extrusion molding. For example, a material that hardens by reaction with water, such as a cement system or a gypsum slag system, can be used. In general, a light weight aggregate, a reinforcing agent, a molding aid, etc. are dispersed and mixed in a mixture of silica and silica powder in a cement, and water is further dispersed and mixed, followed by kneading to obtain a molding material. Can be. In addition, in order to reduce the weight of the same corner, it is possible to use pearlite, shirasu balloon, calcium silicate or the like, which is generally called a lightweight aggregate regardless of whether it is natural or artificial.

As the reinforcing agent, pulp, PP fiber, mineral fiber and the like can be used similarly to the outer wall material. As a molding aid, methylcellulose and other materials having similar performance can be used for the purpose of imparting water retention to the kneaded material. In addition, a surfactant can be used as a molding aid for the purpose of improving the dispersion of the mixed material. Further, a curing accelerator can be used as a molding aid for the purpose of accelerating the hydration reaction.

The preforming of the molding material is based on the following reasons. In other words, the mixed and kneaded molding material of the same-extruded corner can be weighed and packed in the elastic form as it is, but has a suitable shape through a vacuum extruder, for example, similar to the same-exposed corner. This is because, by inserting a pre-molded product into a shape having a cross-sectional shape, it is possible to obtain a higher quality homogeneous corner. By passing through a vacuum extruder, air trapped in the material during the mixing and kneading can be removed, and not only can the performance be improved, but also the kneading effect can be further increased and the ease of molding can be obtained.

In the press molding of the molding material, a pressure is applied to the molding material inserted into the elastic mold so that the molding material is brought into close contact with the elastic mold. As a pressing method, a hydraulic press or a crank type press can be used. . The press molding machine is desirably a facility that produces a pressure of at least 10 kg / cm ² or more, depending on the molding material. It is desirable that the press die be configured to continuously press the four sides of the portion corresponding to both sides of the elastic mold and the portion related to the fitting from the beginning to the end of the pressing.

The curing tray is used for facilitating the insertion of the elastic mold and the molding material into the press die and for curing the molding material pressed by the press machine without giving any deformation. Required. The trays are stacked and placed in the curing room with the elastic mold and the molding material placed on the curing tray.

In order to prevent the molding material from adhering to the press die and to form a concave groove at the apex of the inner surface of the formed homogenous corner, a plate-like material having a convex shape at the apex. For example, a stainless steel plate or the like press-formed in such a manner can be used as a forming lid. In addition, the concave groove on the inner surface of the homogenous corner is for ensuring adhesion to a pillar or the like at the time of constructing the homogenous corner.

A stab having the same shape as the concave portion is provided in the mold in the fitting portion of the same-exposed corner, and the concave portion can be formed at the same time as the molding by inserting the stab in advance or during or after pressing. it can.

After the molding material has been cured by the hydration reaction during the primary curing, the molded article (cured molding material) is removed from the elastic mold.
Can be taken out. Since the mold is released after curing, the molded article is not distorted at the time of removal from the mold, and defects such as chipping and abrasion are not given. After the mold is released, the elastic mold can be reused by applying a release agent or the like.

Further, in the case of primary curing, when heat is applied to the elastic form, the elastic form expands due to linear expansion.
Elongation of the mold that occurs until the molded article is cured has a significant adverse effect on the molded article. For example, when a urethane elastomer is used as the elastic form, if the coefficient of linear expansion is about 2.4 × 10 ^-4 , the product length is 455 mm, and the curing temperature is 70 ° C., the elastic form is not cured. About 5.5mm
Will also grow. To prevent this elongation, the following measures can be taken. 1) Cure at room temperature. -Add a room temperature curing accelerator to the molding material and cure at room temperature.・ Extend the pressurizing time.

By using the above measures alone or in combination, curing at room temperature becomes possible. 2) Heat curing is performed while holding down the surface to be suppressed by a metal mold or the like so as not to stretch the elastic mold.

[0029]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a perspective view of the same corner for ceramic outer wall material, and FIG.

As shown in FIG. 1, a homogeneous corner 1 has a convex corner where right and left plate-like bodies intersect at right angles at the corner of the building, and has a surface similar to the ceramic outer wall material 2 on the surface thereof. The pattern is formed.

As shown in FIG. 2, the forming process of the same corner 1 is as follows.
It is roughly divided into a preforming step, a press forming step, a curing step, and a demolding step. The preforming apparatus 10 used in the preforming step includes a mixer 11 and a kneader / ruder 12 for mixing and kneading molding materials, and a vacuum extruder 13 for extruding the material kneaded by the kneader / ruder in a predetermined shape. And a cutting machine 14 for cutting the molding material extruded from the extruder 13 into a predetermined length.

In the vacuum extruder 13, by extruding a preformed product having a similar cross-sectional shape with respect to the same-exposed corner from the extrusion die, a higher-quality, same-exposed corner can be obtained. . Further, by passing the material through the vacuum extruder 13, the air caught in the material during the mixing and kneading is removed, and the kneading effect is enhanced to facilitate molding.

The material cut by the cutting machine 14 is conveyed by a fast-forward conveyor 15 to a material insertion section 16 where the material is inserted into an elastic form 18 placed on a curing tray 17. Further, a conveyor 19 is provided between the kneader / ruder 12 and the extruder 13.

In the press molding step, a cover insertion portion 21 for inserting the cover 20 above the mold 18 into which the molding material has been inserted, and the molding material-containing mold 18 delivered from the cover insertion portion 21 are placed in a curing tray. In order to transfer the molding material pressurized by the press machine 23 together with the mold 18 and the curing tray 17 to the curing step, the curing tray 1
And a transfer machine 24 for stacking 7 in a curing rack 25. Except for the press machine 23, its structure is well-known, and a description thereof will be omitted. The press machine 23 will be described later.

The equipment used in the curing process is a transfer machine 24
The primary curing room 26 with a hot air generator for curing the molded products stacked on the curing rack 25 by the above process, and the molded product and the elastic mold 18 taken out from the curing room 26 are taken out together with the curing tray 17 and demolded. And a transfer machine 28 for sending out to the process.

The demolding machine 30 used in the demolding step has a well-known structure, and separates the curing tray 17 from the elastic mold 18 containing the molded product. The separated curing tray 17 is moved from the tray collection line 31 to the material insertion section 16.
Transported to At the subsequent stage of the demolding machine 30, the elastic form 18,
A mold release part 31 is provided for separating the molded lid 20 and the molded product from each other. The elastic form 18 separated by the removal part 31
Are placed on the curing tray 17 at the form insertion line 32 at the end of the tray collection line 31 after washing. Although not shown, the demolded molded product is deburred and then cured in a secondary curing room to be a finished product.

FIG. 3 is a sectional view of the press machine, and FIG.
FIG. 5 is an exploded perspective view showing a cured state of the molded body, FIG. 6 is a perspective view of an elastic mold, and FIG. 7 is a view showing a method of molding a fitting portion at a protruding corner. As shown, the press machine 23
The upper mold 40 and the lower mold 41 form a cavity 43 having a substantially L-shaped cross section into which the curing tray 17, the elastic mold frame 18, and the molding lid 20 can be inserted, and can exert a pressing force of 10 kg / cm ² or more. It has become. In the upper die 40, an edge holder 45 is projected downward on both sides of the cavity, and a coil spring 46 is provided inside the upper die 40 so as to urge the edge holder 45 downward.

In this embodiment, two cavities 43 are provided side by side so that two molded products can be obtained at the same time, and the curing tray 17 can be placed on the lower mold 41 across both cavities 43. In this way, a tray intervention space is provided.

At both ends in the longitudinal direction of the dies 40 and 41 of the press machine 23, an end retainer 47 and a stab 48 are provided. The sashimi 48 is for forming an uneven fitting portion at the mouth of the molded product, and is movably held in the sashimi holder 49 fixed to the end of the lower mold 41 in the length direction. I have.

The moving mechanism of the needle 48 is as shown in FIG.
An inclined surface 50 formed at the outer end of the needle 48, and a pressing rod 51 formed at an end of the upper die 40 facing the inclined surface.
When the holding rod 51 is lowered, the inclined surface 52 formed on the inner surface of the lower end thereof is inclined
To move the needle 48 inward in the length direction. The holder 49 has
An opening 53 through which the holding rod 51 can be interposed is formed.

The curing tray 17 is obtained by press-molding a stainless steel plate, and has two L-shaped mounting portions 17 formed in parallel so that two elastic molds 18 can be mounted thereon.
a, 17b and a connecting portion 17c connecting these mounting portions
And projecting portions 17d, 17e projecting outward from the mounting portions 17a, 17b.
A stepped cylinder 55 having a rectangular cylindrical shape is welded and fixed to 17e.
The stacking cylinder 55 has a positioning pin 56 projecting from the upper surface thereof, and an opening 57 into which the positioning pin 56 of the lower curing tray 17 can be fitted.

The elastic mold 18 is formed from a polyurethane elastomer for casting (rubber hardness: 80) to have an L-shaped cross section.
A mold concave portion 60 is formed on the inner surface to match the shape of the protruding corner, and an inverted pattern 71 having a pattern similar to the outer wall material is formed on the bottom surface. The peripheral wall on one end side in the length direction of the formwork 18 has a step 61 formed in accordance with the shape of the fitting portion at the protruding corner, and the peripheral wall on the other end side has an opening through which the needle 48 can intervene. 63 are formed.

The molding lid 20 is formed by press-molding a stainless steel plate. At the apex thereof, a molding material is prevented from adhering to the press die, and a concave groove is formed at the apex of the inner surface of the formed homogeneously formed corner. A convex portion is formed at the vertex for the purpose of manufacturing.

<Molding Method> Next, a method of forming a protruding corner using the molding apparatus having the above-described structure will be described. The molding material shown in Table 1 was used as the molding material for the outer corner.

[0045]

[Table 1]

"Preliminary molding" Of the above ingredients, powder except water is mixed by a high-speed mixer 11 for 3 minutes, water is further added and dispersed, and then kneading is performed for 2 minutes. Next, the mixture is transferred to a kneader ruder 12 and kneaded for 5 minutes.
The kneaded material is supplied to a vacuum extruder 13, extruded in a predetermined shape by the extruder 13, and then cut by a cutting machine 14.
Then, the material is cut into a predetermined length, and the material is inserted into the mold 18 at the material insertion section 16.

In the process of passing through the vacuum extruder 13, the kneaded material is formed into a predetermined shape when passing through the die while removing the bubbles contained during the mixing and kneading. Here, the predetermined shape refers to a shape formed by increasing the cross section of the formed corner by 12% and a length cut by 90% with respect to the formed corner.

[Press Forming] Curing tray 1 provided with a stopper for suppressing thermal expansion of elastic mold 18 below the press die set on the lower plate of press machine 23.
7 is set. Next, the elastic mold 18 is placed on the curing tray 1.
7 is set at a predetermined position. The preformed molding material is inserted into the elastic mold 18 and the molding lid 20 is set. Next, a predetermined pressure is applied to the molding material 100 by lowering the upper platen surface of the press in which the upper part of the press die is fixed. Sashimi 48 for forming a concave portion of a fitting portion in a molded product
Is pressed in after pressurization, and it is pulled out after holding for 25 seconds.

This pressure causes the molding material 100 to move
It is necessary to cover all the corners and to obtain a predetermined thickness (in this case, 14 mm). Depending on the molding material and the pattern and shape of the molded product, it is 25 kg / cm ^{2 in} this embodiment. The molding was performed under the conditions of holding for 30 seconds under the pressure of.

After the “primary curing” press is completed, the curing tray 1
The sample was taken out of the press mold while being placed on No. 8 and subjected to primary curing at 70 ° C. for 8 hours. After the molding material was cured by primary curing, the molded product was taken out of the elastic mold and deburred. Since the conditions for the primary curing differ depending on the molding material, the conditions of the press, and the like, it is necessary to find the optimal curing conditions for each condition.

The molded product demolded from the "secondary curing" can be obtained by subjecting it to an autoclave treatment, if necessary, to promote necessary performance such as its practical strength. In this test, 8
Curing was performed for 8 hours under the conditions of kg / cm ² and 160 ° C.

The molded product obtained by the above process has an excellent appearance in design without chamfering on the ridge line, has the same workability as a bonded product, and has the same performance such as durability and strength as an extruded product. Has both.

It should be noted that the present invention is not limited to the above-described embodiment, and it goes without saying that many modifications and changes can be made within the scope of the present invention. For example, in the above-described embodiment, the method of forming the protruding corner has been described. However, it is needless to say that the present invention may be applied to a concavity in which a corner portion is recessed contrary to the protruding corner.

[0054]

As is apparent from the above description, according to the present invention, a cement-based molding material that has been mixed and kneaded and preformed is inserted into a mold made of a rubber-like elastic material, and the mold is assembled. By pressing with a pressing machine in a state of being placed on the curing tray, a molded body at an outgoing corner or an inward corner in close contact with the mold is obtained, and after performing primary curing together with the mold until the molded body is solidified, the molded body Is removed from the elastic mold, deformation during removal of the mold is prevented, and productivity is improved.

[Brief description of the drawings]

FIG. 1 is a perspective view of a corner of the same quality for a ceramic exterior wall material.

FIG. 2 is a process diagram of forming a corner.

FIG. 3 is a sectional view of a press machine.

FIG. 4 is a sectional view taken along the line DD of FIG. 3;

FIG. 5 is an exploded perspective view showing a cured state of a molded body.

FIG. 6 is a perspective view of an elastic mold.

FIG. 7 is a diagram showing a method of forming a fitting portion at a protruding corner;

8 (a), (b) and (c) are plan views of a conventional press-formed product, a bonded product and an extruded product, respectively.

9 (a), (b) and (c) are AA cross section, BB cross section, and CC cross section of FIG. 8, respectively.

[Explanation of symbols]

 1 Outer corner 17 Curing tray 18 Elastic form 20 Molding lid 23 Press machine 40 Upper die 41 Lower die 48 Sashiko

Continued on the front page F term (reference) 4G053 AA17 AA19 BF01 CA03 CA23 EA03 EA32 EA33 EA34 EB06 EB11 4G054 AA01 AC04 AC06 BA02 BA45 BD14 DA01

Claims (6)

[Claims] A mold made of a rubber-like elastic material having an inverted shape similar to that of a ceramic outer wall material on its inner surface is filled with a hydraulically curable ceramic molding material under pressure, and the molding material is formed into a mold. A method for producing a homogeneous outgoing corner or a homogeneous outgoing corner for a ceramic outer wall material, which comprises curing and curing in a filled state and then removing the mold from a mold. 2. When the molding material is pressurized, the mold is press-molded with a press mold while the mold is placed on a curing tray, and then the mold filled with the molding material is molded together with the curing tray. The manufacturing method according to claim 1, wherein the molding material is taken out of the mold and cured together with the mold. 3. The production method according to claim 1, wherein the water-curable ceramic material is mixed and kneaded, deaerated through a vacuum extruder, and preformed into a predetermined shape by an extrusion die and filled in an elastic mold. . 4. A stab for forming an uneven fitting portion at the mouth of the molded product is inserted in advance, during or after pressurization, or after pressurization, and fitted simultaneously with curing of the water-curable ceramic molding material. The method according to claim 1, wherein the portion is formed. 5. The manufacturing method according to claim 1, wherein the form made of the rubber-like elastic body is held in a metal tray, and the form is heated and cured while suppressing expansion of the form due to heat. 6. The method according to claim 1, wherein a curing accelerator is added to the water-curable ceramic material to promote curing at room temperature.