JP2004035337A - Method of manufacturing formed article and formed article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a formed article which has excellent heat resistance and to which various kinds of functions can be added and to provide the formed article. <P>SOLUTION: A member composed of an inorganic material is manufactured by forming a hydraulic material containing cement-based hydraulic powder into an article, and then aging and hardening the formed article. The functions such as abrasion resistance or sliding properties are added to the formed article using cement as a main raw material by adding powder of a metallic compound or a metal in the hydraulic material or a forming material to be used for the forming. A thermoplastic resin or an inorganic fiber may be blended at need. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a molded part such as a fastening part such as a bolt, a sealing material such as a gasket, a cooling fan motor part, a key cylinder, and the like. More specifically, it relates to a material technology used for a manufactured product of the molded product.
[0002]
[Prior art]
Conventionally, bolts, gaskets, and the like are generally manufactured by machining such as grinding or pressing a metal, or by resin molding.
[0003]
[Problems to be solved by the invention]
If these members can be manufactured by molding with an inorganic material, those utilizing characteristics of the inorganic material can be manufactured at low cost. Injection molding, extrusion molding, and press molding of an inorganic material include a cement material, and a technique of manufacturing a paper feed roller using such a material is disclosed in Japanese Patent No. 2999765, Japanese Patent No. 301234, It is disclosed in Japanese Patent No. 3054417.
[0004]
Here, the inventor of the present application proposes to make use of features such as moldability and heat resistance of a cement-based hydraulic composition, and to further improve the properties. It is an object of the present invention to provide a method for producing a molded article, which is excellent in quality and to which various functions can be added, and a molded article.
[0005]
[Means for Solving the Problems]
In order to solve the above problems, in the present invention, after molding a molding material obtained by adding water to a hydraulic material including a cement-based hydraulic powder into a predetermined shape, curing, curing, a molded product manufacturing method, It is characterized in that a powder of a metal compound is added to the hydraulic material or the molding material.
[0006]
In the present invention, since a hydraulic material containing a cement-based hydraulic powder is used, a member made of an inorganic material can be manufactured by molding. In addition, a powder of a metal compound is added to a hydraulic material or a molding material used for molding, and molding is performed using the powder. Can be easily added.
[0007]
In the present invention, the metal compound powder is, for example, an iron-based compound powder.
[0008]
In another embodiment of the present invention, a method for manufacturing a molded article in which a molding material obtained by adding water to a hydraulic material containing a cement-based hydraulic powder is molded into a predetermined shape, and then cured and cured. It is characterized in that metal powder is added to a hard material or a molding material.
[0009]
In the present invention, since a hydraulic material containing a cement-based hydraulic powder is used, a member made of an inorganic material can be manufactured by molding. In addition, since a metal powder is added to a hydraulic material or a molding material used for molding and molding is performed by using the metal powder, a new function can be easily added to a molded product using cement as a main raw material.
[0010]
In the present invention, after the curing, the metal powder may be subjected to a nitriding treatment, a sulfidation treatment, or a carburizing treatment. By performing such a treatment, it is possible to easily add functions such as wear resistance and slidability to a molded article mainly made of cement.
[0011]
In the present invention, it is preferable that a thermoplastic resin such as polyamide, polyethylene terephthalate, or polyphenylene sulfide is added to the hydraulic material or the molding material. With such a configuration, when the materials are mixed in the molding machine, the heat thereof causes the thermoplastic resin to soften or melt, thereby improving the fluidity of the material from the molding machine into the mold.
[0012]
In the present invention, it is preferable to add inorganic fibers such as glass fibers and carbon fibers to the hydraulic material or the molding material. With this configuration, the strength of a molded product using the hydraulic material can be improved.
[0013]
In the present invention, the metal powder is, for example, an iron-based powder.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described.
[0015]
[Basic material]
In the present invention, a molded material obtained by adding water to a hydraulic material including a cement-based hydraulic powder is molded into a predetermined shape, cured, and cured to produce a molded article. Here, in the hydraulic material, in addition to the hydraulic powder, if necessary, a non-hydraulic powder having an average particle diameter that is at least one digit smaller than the average particle diameter of the hydraulic powder, a moldability improver, Processability improvers, thickeners, extenders, etc. are added. As such a hydraulic material, for example, a mixed powder comprising 40 to 80% by weight of a hydraulic powder, 10 to 50% by weight of a non-hydraulic powder, and 10 to 30% by weight of a moldability improver is mixed. It is preferable to include a processability improver blended in a ratio of 2 to 9 parts by weight and a thickener blended in a ratio of 0.5 to 5 parts by weight based on 100 parts by weight of the powder.
[0016]
In the present embodiment, the hydraulic powder is, for example, calcium silicate compound powder, calcium aluminate compound powder, calcium fluoroaluminate compound powder, calcium sulfoaluminate compound, calcium aluminoferrite compound powder, calcium phosphate compound It is a powder such as powder, semi-hydrated or anhydrous gypsum powder, quicklime powder having self-hardening property, powder of a mixture of two or more of these powders, and can be hardened by water. A typical example of hydraulic powder is Portland cement.
[0017]
Regarding the particle size distribution of the hydraulic powder, it is preferable that the Blaine specific surface area is 2500 cm ² / g or more from the viewpoint of securing hydraulic performance with respect to the strength of the molded body. Further, the compounding amount of the hydraulic powder is 40 to 80% by weight, preferably 45 to 55% by weight in terms of the composition ratio of the hydraulic powder, the non-hydraulic powder, and the mixed powder comprising the moldability improver described below. % By weight. If the compounding amount is less than 40% by weight, the strength and the filling rate are low, and if it exceeds 80% by weight, the filling rate for obtaining a molded body is low. This is not preferable because it has an effect such as not being able to withstand the processing stress of.
[0018]
Non-hydraulic powders are powders that do not harden when contacted with water when used alone. Typical examples thereof include calcium hydroxide powder, gypsum gypsum powder, calcium carbonate powder, slag powder, and frying powder. Ash powder, silica powder, clay powder, silica fume powder, and the like.
[0019]
The compounding amount of the non-hydraulic powder is 10 to 50% by weight, preferably 20 to 30% by weight in terms of the composition ratio of the hydraulic powder, the non-hydraulic powder, and the hydraulic material composed of the moldability improver described below. It is preferable that If the compounding amount is less than 10% by weight, the filling rate is low, and if it exceeds 50% by weight, the strength and the filling rate are low. In any case, the physical properties after molding and curing, for example, machining It is not preferable because chipping occurs at the time and dimensional stability is adversely affected. In consideration of machinability and the like, it is preferable to adjust the blending amount of the non-hydraulic powder so that the filling rate does not become too low. By adding the non-hydraulic powder, it is possible to increase the filling rate during molding of the molded article and to reduce the porosity of the obtained molded article. Thereby, the dimensional stability of the molded body can be improved.
[0020]
The moldability improver is a material that improves the slipperiness between the mold and the molded article during injection molding or extrusion molding, further reduces the anisotropy of moldability, and stabilizes the quality. Examples of the moldability improver include inorganic materials such as talc (hydrated magnesium silicate) and mica. This inorganic material is excellent in orientation, imparts lubricity to the surface of the molded product, and can reduce the resistance to a mold or a die to stabilize the quality.
[0021]
The compounding amount of the moldability improver is 10 to 30% by weight, preferably 15 to 25% by weight in the composition ratio in the hydraulic material composed of the hydraulic powder, the non-hydraulic powder and the moldability improver. Is preferred.
[0022]
The workability improver contributes to the improvement of the moldability, mold release, cutting / grindability, and grinding accuracy of the molded product obtained from the hydraulic composition, particularly to the improvement of the cutting / grindability and grinding accuracy. That is, in the hydraulic composition obtained by adding the processability improver, the formability is improved because the processability improver plays a role as a molding aid during pressure molding. In addition, since the fragility of the cement-based cured product is improved by the processability improver, the obtained molded product is released from the mold without any damage at the time of demolding, so that the yield and workability are improved. Further, if a workability improver is added, the occurrence of cracks, chips, etc. can be prevented. Therefore, even in the case of a hydraulic composition, a cutting process or a grinding process using a lathe or the like can be performed as in the case of the metal material.
[0023]
The compounding amount of the processability improver is 2 to 9 parts by weight, preferably 3 to 4 parts by weight, based on 100 parts by weight of the hydraulic material comprising the hydraulic powder, the non-hydraulic powder and the extrudability. It is preferable to use parts by weight. If the amount is less than 2 parts by weight, the machinability decreases, and if it exceeds 9 parts by weight, the grinding accuracy and the dimensional stability after grinding decrease. The particle size is generally 1 μm or less in terms of a single dispersed particle.
[0024]
As the processability improver, vinyl acetate resin, or copolymer resin with vinyl acetate, acrylic resin, or copolymer resin with acrylic, styrene resin, or copolymer resin with styrene, and at least selected from epoxy resin Powders or emulsions of one or more resins can be used. As the vinyl acetate copolymer resin, vinyl acetate acrylic copolymer resin, vinyl acetate veova copolymer resin, vinyl acetate veova terpolymer resin, vinyl acetate malate copolymer resin, vinyl acetate ethylene copolymer resin, vinyl acetate ethylene vinyl chloride copolymer resin Etc. can be used. As the acrylic copolymer resin, an acrylic styrene copolymer resin, an acrylic silicone copolymer resin, or the like can be used. Further, as the styrene copolymer resin, a styrene-butadiene copolymer resin can be used.
[0025]
A thickener is a material that exhibits tackiness when dissolved in water, increases the bonding force between particles of hydraulic powder and non-hydraulic powder, maintains the shape of the molded article after molding, and retains water. It is effective to secure the properties and to form a solid cured product.
[0026]
Examples of the thickener include methyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose and the like.
[0027]
The compounding amount of the thickener is 0.5 to 5 parts by weight, preferably 3 to 4 parts by weight, per 100 parts by weight of the hydraulic material composed of the hydraulic powder, the non-hydraulic powder, and the moldability improver. It is preferable to use a part.
[0028]
As the filler, an aggregate such as silica sand is used in an amount of 10 to 50 parts by weight, preferably 20 to 30 parts by weight, based on 100 parts by weight of a hydraulic material comprising a hydraulic powder, a non-hydraulic powder, and a moldability improver. Can be added at a rate of
[0029]
In order to further improve the moldability, a known ceramic molding aid can be added at a ratio of 1 to 10 parts by weight, preferably 3 to 6 parts by weight, per 100 parts by weight of the mixed powder. Further, in order to suppress dimensional change due to shrinkage or the like during curing of the material, a water repellent such as silicone oil which reduces water absorption is used in an amount of 0.5 to 5 parts by weight, preferably 100 parts by weight of the mixed powder. It can be added in a proportion of 1 to 2 parts by weight.
[0030]
In order to prepare a molding material using a hydraulic material, in addition to the above components, a hydraulic powder, a non-hydraulic powder, and 100 parts by weight of a hydraulic material composed of a moldability improver Water is added in an amount of up to 30 parts by weight, preferably up to 25 parts by weight. In order to reduce drying shrinkage, it is preferable to reduce the amount of water.
[0031]
From the viewpoint of uniform mixing, a mixing method or a mixer capable of applying a strong shearing force to the mixture is preferable.
[0032]
[Embodiment 1]
In the first embodiment of the present invention, a powder of a metal or a metal compound is added in an amount of several% to several tens% to a hydraulic material or a molding material obtained by adding water thereto.
[0033]
The powder of the metal or the metal compound to be added here is powder of iron and iron compounds such as iron powder, stainless steel powder, permalloy powder, sendust powder, iron oxide powder, and magnetic powder. Further, as the metal or metal compound powder, copper powder such as copper powder, brass powder, nickel silver powder, phosphor bronze powder, and copper titanium powder may be added. Further, as the powder of metal or metal compound, in addition to the above-mentioned iron-based powder and copper-based powder, aluminum powder, magnesium powder, nickel powder, tantalum powder, molybdenum powder, tin powder, lead powder, zinc powder, Metal powder such as titanium powder, chromium powder, zirconium powder, and cobalt powder may be added. Furthermore, silicon powder may be added.
[0034]
In producing various molded articles using such materials, in the present embodiment, for example, the following materials: hydraulic material 100 parts by weight hydraulic powder (Portland cement) 40 to 80% by weight
Non-hydraulic powder (silica fume) 10 to 50% by weight
Formability improver (talc) 10-30% by weight
Processability improver (acrylic resin) 2 to 9 parts by weight Thickener (carboxymethylcellulose) 0.5 to 5 parts by weight Metal or metal compound powder 10 parts by weight Water 25 parts by weight is mixed to prepare a molding material I do.
[0035]
Next, these molding materials are supplied to an injection molding machine or an extrusion molding machine and molded into a predetermined shape.
[0036]
Next, the molded article is cured and cured. That is, after pressure molding, it takes several hours to several days from when the mold is removed from the mold to when sufficient strength is exhibited, so that curing is performed. As the curing method, curing at room temperature or curing in water, or steam curing may be used, but when moisture is insufficient, steam curing, particularly steam curing in an autoclave, is preferred. This autoclave curing is performed, for example, at a saturated vapor pressure of 7.15 kg / cm ² and 165 ° C. or higher, preferably at a saturated vapor pressure of 9.10 kg / cm ² or higher. The curing time varies depending on the curing temperature, but is 5 to 15 hours under the condition of 175 ° C. It is preferable that a compressive strength of about 5 N / mm ² is obtained after the pressure molding and before the start of the autoclave curing. This is because if sufficient strength has not been developed before the autoclave curing, cracks occur in the molded body.
[0037]
The molded product obtained through curing and curing in this manner is used as it is or after being machined as various parts. Here, in this embodiment, a member made of an inorganic material is manufactured by molding using a hydraulic material containing a cement-based hydraulic powder. Therefore, various parts can be manufactured at low cost.
[0038]
Further, since a metal compound or a metal powder is added to a hydraulic material or a molding material used for molding and molding is performed by using the metal compound or the molding material, these additives are exposed on the surface of the molded article. Therefore, functions such as abrasion resistance and slidability can be easily added to a molded product using cement as a main raw material.
[0039]
[Embodiment 2]
In Embodiment 2 of the present invention, a metal or a metal compound powder is added to a hydraulic material or a molding material to which water is added, and a polyamide is added to the hydraulic material or the molding material. For example, a thermoplastic resin such as polyethylene terephthalate and polyphenylene sulfide is added in the form of pellets, flakes, or powder, for example, from several percent to several tens percent.
[0040]
When such a material is used, when the materials are mixed by applying temperature and pressure in an injection molding machine, the heat causes the thermoplastic resin to soften or melt to increase the fluidity of the molding material. As a result, the injectability of the molding material into the mold is enhanced, so that a molded product excellent in dimensional accuracy and the like can be manufactured. Also, in the case of extrusion molding, if the fluidity of the molding material is high, effects such as improvement in dimensional accuracy when extruded from a die are exhibited.
[0041]
[Embodiment 3]
In the third embodiment of the present invention, a metal or a metal compound powder is added to a hydraulic material or a molding material obtained by adding water to the hydraulic material or a molding material to which water is added. For example, several percent to several tens percent of inorganic fibers such as glass fibers and carbon fibers adjusted to a size are added.
[0042]
With this configuration, the strength of a molded article using the hydraulic material can be improved, so that cracking, chipping, and the like can be prevented.
[0043]
In addition, by combining Embodiments 2 and 3, a metal or a metal compound powder is added to a hydraulic material or a molding material obtained by adding water thereto, and a hydraulic material or a molding material is added. Then, both a thermoplastic resin such as polyamide, polyethylene terephthalate and polyphenylene sulfide, and an inorganic fiber such as glass fiber and carbon fiber may be added.
[0044]
[Embodiment 4]
In the fourth embodiment of the present invention, a metal powder is added to a hydraulic material or a molding material obtained by adding water thereto, and after curing and hardening, further, machining is performed as necessary. After that, the metal powder is subjected to nitriding, sulfidation, or carburization.
[0045]
The metal powder added here is, for example, a powder of an iron-based compound and an iron-based compound such as iron powder, stainless steel powder, permalloy powder, sendust powder, iron oxide powder, and magnetic powder.
[0046]
In producing various molded articles using such materials, in the present embodiment, for example, the following materials: hydraulic material 100 parts by weight hydraulic powder (Portland cement) 40 to 80% by weight
Non-hydraulic powder (silica fume) 10 to 50% by weight
Formability improver (talc) 10-30% by weight
Processability improver (acrylic resin) 2 to 9 parts by weight Thickener (carboxymethylcellulose) 0.5 to 5 parts by weight Powder of iron-based metal 10 parts by weight 25 parts by weight of water are mixed to prepare a molding material. .
[0047]
Next, these molding materials are supplied to an injection molding machine or an extrusion molding machine and molded into a predetermined shape.
[0048]
Next, the molded article is cured and cured.
[0049]
Then, the metal powder is subjected to a nitriding treatment, a sulfidation treatment, or a carburizing treatment as it is or after machining as necessary.
[0050]
Therefore, since the metal powder exposed on the surface of the molded product is nitrided, sulfurized, or carburized, functions such as wear resistance and slidability are added to the molded product using cement as a main raw material. can do.
[0051]
Note that the thermoplastic resin or glass fiber described in Embodiments 2 and 3 may be added to this embodiment.
[0052]
【The invention's effect】
As described above, in the present invention, since a hydraulic material including a cement-based hydraulic powder is used, a member made of an inorganic material can be manufactured by molding. In addition, a metal compound or metal powder is added to a hydraulic material or a molding material used for molding, and molding is performed using the metal compound or metal powder. Functions can be easily added.

Claims (8)

After molding a molding material obtained by adding water to a hydraulic material containing a cement-based hydraulic powder into a predetermined shape, curing, a method of manufacturing a molded article to be cured,
A method for producing a molded product, comprising adding a powder of a metal compound to the hydraulic material or the molding material. The method according to claim 1, wherein the powder of the metal compound is a powder of an iron-based compound. After molding a molding material obtained by adding water to a hydraulic material containing a cement-based hydraulic powder into a predetermined shape, curing, a method of manufacturing a molded article to be cured,
A method for producing a molded product, comprising adding a metal powder to the hydraulic material or the molding material. 4. The method according to claim 3, wherein after the curing, the metal powder is subjected to a nitriding treatment, a sulfidation treatment, or a carburizing treatment. The method according to claim 3, wherein the metal powder is an iron-based powder. The method for manufacturing a molded product according to any one of claims 1 to 5, wherein a thermoplastic resin is added to the hydraulic material or the molding material. The method for producing a molded product according to any one of claims 1 to 6, wherein inorganic fibers are added to the hydraulic material or the molding material. A molded article manufactured by the method defined in any one of claims 1 to 7.