JP2004330642A - Method for manufacturing sheet building material for protruded corner - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a sheet building material for protruded corners by which the sheet building material with a roughened back making a mortar or an adhesive for application well sticky, can be efficiently manufactured. <P>SOLUTION: In this method for manufacturing the sheet building material 5 by supplying a self-hardening material 3 into a mold 1 and releasing the material 3 from the mold 1 after its curing, a roughened surface is formed on the upper surface of the material 3 in the mold 1 by pressing a patterning material to the main region 3m of the upper surface of the material 3. The preferable patterning material is netting 4 or a nonwoven fabric. A marginal region 3h of the material 3 must be flat. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for supplying a self-hardening material in a molding die, and after the self-hardening material is cured, removing the mold to produce a plate-like building material. The present invention relates to a method for manufacturing a plate-like building material in which a first tree end surface is a design surface such as an uneven surface.
[0002]
[Prior art]
BACKGROUND ART Pseudostones made of a cement molded product, a calcium silicate molded product, or the like having an uneven front surface are widely used for exterior wall materials. By making this uneven surface a split stone surface tone or a masonry tone, a unique wall surface rich in unevenness is constructed.
[0003]
Many of the conventional artificial stones have an uneven surface only on the front surface, and when such artificial stones are arranged at the protruding corners, a flat wooden end surface is exposed, and the design of the wall is impaired.
[0004]
Japanese Patent Application Laid-Open No. 9-60243 describes that an outer corner is formed by using an outer wall outer corner member having an uneven surface on the front surface and one wooden end surface. Since the end surface of the uneven wood is exposed at the protruding corner, the design of the wall surface is good.
[0005]
The same publication describes a method in which a cement-based material is supplied into a molding die, cured, and then demolded to produce a plate-like building material. In this manufacturing method, after the cement molding material is supplied into a mold made of a soft synthetic resin or rubber, the lid is covered to make the upper surface flat, and after the cement-based material is hardened, the mold is expanded right and left. And remove it.
[0006]
[Patent Document 1]
JP-A-9-60243
[Problems to be solved by the invention]
In the plate-like building material manufactured by the method of JP-A-9-60243, the surface pressed by the lid (the upper surface at the time of molding) is the back surface. In the case of a plate-like building material whose back surface is flattened by the lid in this way, the adhesive strength between the mortar or adhesive and the back surface of the plate-like building material is sufficiently high when it is adhered to the base surface with mortar or adhesive It may not be.
[0008]
In the case of tiles, irregularities called soles are formed on the back surface to increase the adhesion of mortar and adhesive, but in the case of cement-based molded products, such irregularities are formed on the back surface. No method has been proposed.
[0009]
An object of the present invention is to provide a method of manufacturing a plate-like building material that can harden a self-hardening material in a molding die and make the back surface of the plate-like building material rough.
[0010]
Another object of the present invention is to provide a method of manufacturing a plate-like building material that can be efficiently attached to a protruding corner of a building or the like.
[0011]
[Means for Solving the Problems]
The method for manufacturing a plate-shaped building material for a corner according to the present invention has a front surface and a rear surface, and first to fourth four wood end surfaces, and the front surface and the first wood end surface are design surfaces. A method for producing a plate-shaped building material for an outgoing corner, comprising supplying a self-hardening material into a molding die, curing the self-hardening material, and removing the mold to produce the plate-shaped building material. Before the material hardens, the embossing material is pressed against a main region of the upper surface of the self-hardening material in the mold except for a side region along the first wood end surface to form a rough surface in the main region. It is characterized by the following.
[0012]
According to the present invention, by pressing the embossing material on the upper surface of the self-hardening material, it is possible to manufacture a protruding corner-shaped plate-like building material in which the main region is roughened on the back surface.
[0013]
The end-of-corner plate-shaped building material is arranged such that the wood end face of a normal plate-shaped building material arranged adjacent to the side area on the back surface with the projected corner interposed therebetween. In this case, the protruding corner plate-shaped building material is attached to the building body or the like so as to protrude (protrude) from the protruding corner edge of the building frame or the like by the thickness of the adjacent normal plate-shaped building material. In order to position the overhang of the protruding corner plate-like building material, the protruding corner plate-like building material is so arranged that the boundary between the side region and the main region extends in a direction substantially parallel to the end face of the first tree. It is preferred to manufacture. This boundary is formed apart from the end face of the first tree by a distance equivalent to the thickness of the adjacent plate-like building material. By aligning this boundary with the corner edge of the frame or the like, positioning of the tabular building material for corner protruding can be easily performed.
[0014]
In this case, it is preferable to form an indication line on the second and fourth tree end faces adjacent to the first tree end face so as to be located on an extension of the boundary. This indication line can also be used as a mark when matching the corner of the frame or the like.
[0015]
A net is preferable as the embossing material. By pressing the net against the upper surface of the self-hardening material, the openings are raised, and the grid portion of the net can be formed with a recessed regular rough surface on the back surface of the plate-like building material.
[0016]
In addition, a nonwoven fabric or the like may be used as the embossing material.
[0017]
In the present invention, of the inner surface of the mold, the bottom surface of the cavity and the side surface for forming the first wood end surface are made uneven, so that the front surface and the first wood end surface of the plate-shaped building material to be manufactured are made uneven surfaces. Can be.
[0018]
By setting the height difference between the most convex portion and the most concave portion of the uneven surface to be 5 to 50 mm, it is possible to construct a protruding corner having a deep uneven surface feeling and rich in design.
[0019]
In the present invention, after a decorating material is attached to the bottom surface of the mold cavity and the side surface for forming the first wood end surface, a self-hardening material is supplied into the mold to decorate the surface of the plate. Building materials can be manufactured.
[0020]
This decorating material may be a powder. When powder is used as a decorating material, it is preferable to spray water after the powder is attached to the cavity surface, so that the powder is easily attached to the outer surface of the molded body.
[0021]
In addition, the plate-shaped building material manufactured by this invention is not limited to a thin plate shape, but may be a brick-shaped thick material.
[0022]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment will be described with reference to FIG.
[0023]
In this embodiment, a pseudo stone A as a plate-like building material is manufactured by using a molding die 1 in which a bottom surface 1a and one side surface 1b of the inner surface of the cavity are irregular surfaces.
[0024]
Since the bottom surface 1a and one side surface 1b of the molding die 1 have an uneven surface, the pseudo stone A to be manufactured has an uneven surface of the front surface 10 and the first tree end surface 11, and this It is suitably distributed to the outside corner.
[0025]
As shown in the drawing, the cavity side surface 1b for forming the first tree end surface also has an uneven surface as shown in the figure, so that the molding die 1 is made of a flexible material such as a soft synthetic resin or rubber for releasing the molded product. It is preferable to be constituted. However, a split mold that opens the side surface sideways may be used.
[0026]
When molding is performed using a molding die, a release agent may be attached to the cavity surface.
[0027]
In this embodiment, a powder is first adhered to the molding die 1, and preferably, water is sprayed on the adhered powder to form a powder adhesion layer 2. By forming the powder adhering layer 2, the surface of the plate-like building material is decorated with coloring derived from powder or decoration such as roughness. However, in the present invention, the powder adhesion layer 2 may not be formed.
[0028]
As the powder, in addition to pigments such as red iron and titanium white, mineral powders such as silica sand powder and feldspar powder can be used. For decoration, it is preferable that at least one pigment is contained in the powder adhesion layer 2.
[0029]
This powder is applied to the cavity surface to be decorated by a method such as sprinkling, attaching with a brush or a brush, or supplying a large amount of powder into the molding die 1 and then tilting and discharging the molding die. Can be attached. After the powder is attached, the powder may be leveled with a brush or a brush. The amount of powder to be applied is preferably about 5 to 10 mg per 1 cm ² of the cavity surface, but may be larger or smaller.
[0030]
After attaching the powder, water may be sprayed toward the powder surface. This causes the powder to stick to the cavity surface. When water accumulates on the bottom surface of the mold 1, it is preferable to discharge the mold 1 by tilting it.
[0031]
The spray amount of water is preferably about 5 to 10 times the volume of the powder attached to the cavity surface.
[0032]
After the powder adhering layer 2 is thus formed as necessary, the self-hardening material 3 is supplied into the mold.
[0033]
Examples of the self-hardening material 3 include a cement-based unhardened mortar, concrete, gypsum-containing slurry, calcium hydroxide-containing slurry, and the like. In the case of a plate-like building material used as a normal wall material, a cement-based mortar is used. Is preferred.
[0034]
A cement-based mortar suitable for use in the present invention is mainly composed of cement and fine aggregate and kneaded with water.
[0035]
Various cements such as ordinary Portland cement, white cement, and fly ash cement can be used as the cement, but if white cement is used, coloring becomes easy and plate-like building materials with excellent design properties can be manufactured. it can.
[0036]
The fine aggregate may be ordinary river sand or the like, or at least a part thereof may be siliceous fine particles. By blending these siliceous fine particles, it is possible to react with calcium hydroxide generated by a hydration reaction of cement to prevent or suppress efflorescence on the surface of the plate-like building material. In addition, by blending the silica-based fine particles, the plate-like building material can be made dense, the water resistance can be improved, and the surface pattern can be made finer.
[0037]
As the siliceous fine particles, silica fume, colloidal silica, microsilica, aerosil, fly ash, and the like are suitable, but a powder of siliceous ore such as silica may be used.
[0038]
At least a part of the fine aggregate may be a lightweight aggregate. By blending this lightweight aggregate, the weight of the plate-like building material can be reduced.
[0039]
Examples of the lightweight aggregate include foams such as pearlite, shirasu balloon, foamed glass balloon, and foamed styrene beads, and non-foamable low specific gravity materials such as diatomaceous earth and low specific gravity resin chips.
[0040]
A fiber material such as pulp, organic fiber, or glass fiber may be blended with the self-hardening material.
[0041]
After supplying the self-hardening material 3, preferably after flattening the upper surface thereof, an embossing material is pressed against the main region 3 m to roughen the main region 3 m. As the embossing material, the illustrated net 4 is preferable, but a nonwoven fabric can also be used.
[0042]
The main region 3m is separated from the cavity side surface 1b for forming the first tree end surface by a predetermined distance. In the upper surface of the self-hardening material, the net 4 is not pressed against the side region 3h along the cavity side surface 1b, and the side region 3h is finished to a flat surface.
[0043]
In this embodiment, an uneven surface is formed by pressing a mold fitting (not shown) on an edge region 3e of the upper surface immediately adjacent to the cavity side surface 1b. Also, of the side surfaces for forming the second and fourth wood end surfaces among the cavity side surfaces, irregularities are formed in an edge region along the side surface 1b. As a result, in the second and fourth wood end surfaces 12 and 14 of the formed pseudo stone A, the edge region near the first wood end surface 11 is an uneven surface.
[0044]
In the case where the self-hardening material 3 has shaping properties such as when it is hardened with a small amount of water, after the self-hardening material 3 is supplied into the molding die 1, an embossing material such as a net can be pressed immediately. However, when the self-hardening material is rich in fluidity and the mark disappears or becomes small even when the embossing material is pressed, it is preferable to press the embossing material after the self-hardening material 3 is hardened to some extent.
[0045]
The embossing material may be left attached until the self-hardening material 3 is hardened. However, since the back surface of the plate-like building material may be damaged when the self-hardening material 3 is peeled off, immediately after embossing, or immediately after the self-hardening material 3 It is preferable to separate the material from the self-hardening material 3 before the curing of the material does not proceed excessively.
[0046]
When the net 4 is used as the embossing material, the diameter of the wire constituting the net is preferably about 0.5 to 2 mm, and the opening of the net is preferably about 1 to 5 mm. As a material of the net, synthetic fibers such as nylon are preferable.
[0047]
When a nonwoven fabric is used as the embossing material, it is preferable to select the bristle length and the basis weight of the nonwoven fabric so that the height difference between the most convex portion and the most concave portion of the formed rough surface is about 0.5 to 2 mm.
[0048]
After the self-hardening material 3 has hardened to a required degree, it is released from the mold 1, and then cured as necessary. This curing may be any of aerial, underwater, steam curing, autoclave curing, and the like, but the autoclave curing can increase the strength of the plate-like building material.
[0049]
As shown in FIG. 1 (c), the pseudo stone A as a plate-like building material manufactured in this manner has an uneven surface on the front surface 10 and the first wood end surface 11, and is excellent in design, and has a back surface. Has a rough surface (a net surface in this embodiment) 15a formed by an embossing material, so that the bonding strength is sufficiently high as described above.
[0050]
On the back surface of the pseudo stone A, a flat surface 15b is formed along the first tree end surface 11, and a boundary between the flat surface 15b and the net surface 15a extends parallel to the first tree end surface 11. ing. Therefore, by aligning this boundary with the protruding corner edge of the skeleton, the first wood end surface 11 side of the pseudo stone A can protrude (protrude) from the corner by a specified length. Thereby, the construction work of the protruding corner can be facilitated.
[0051]
In this embodiment, the indication lines 17 are also provided on the second and fourth wood end faces 12 and 14 of the pseudo stone A on an extension of this boundary line. Therefore, by aligning the indication line 17 with the protruding corner edge of the skeleton, the first wood end surface 11 side of the pseudo stone A can protrude (protrude) from the corner by a specified length. Thereby, the construction work of the protruding corner can be facilitated.
[0052]
The indicating line 17 may be formed by using paint or the like, or a protrusion may be formed on the cavity surface of the mold when forming the pseudo stone A, and the indicating line 17 may be formed as a concave groove. . This indication line 17 is preferably arranged on the rear surface 15 side so as to be invisible after construction. The indication line 17 is preferably provided so as to be continuous with the trailing edges of the wood end faces 12 and 14 as shown in the figure, but may be slightly separated from the trailing edge.
[0053]
Next, an example of constructing a protruding corner using the pseudo stone will be described with reference to FIGS. In this construction example, the pseudo stone B is arranged adjacent to the pseudo stone A with the protruding corner interposed therebetween.
[0054]
2 is a perspective view showing the engagement relationship between the pseudo stone A and the pseudo stone B, FIG. 3 (a) is a front view of the pseudo stone A, and FIG. 3 (b) is a cross section along the line BB in FIG. 3 (a). FIG. 4 is a perspective view showing a corner protruding from a wall constructed by attaching a pseudo stone A and a pseudo stone B to a frame, and FIG. 5 is a cross-sectional view taken along line VV in FIG.
[0055]
As shown in FIG. 3B, on the front surface 10 of the pseudo stone A, the distance between the deepest deepest part 10b of the concave parts and the tallest convex part 10t of the convex parts is defined as a height difference ΔH. The height difference ΔH is 5 to 50 mm, preferably 10 to 40 mm, particularly preferably 15 to 35 mm.
[0056]
Similarly to the front surface 10, the first tree end surface 11 has a height difference ΔH between the most concave portion and the most convex portion of the uneven surface of 5 to 50 mm, preferably 10 to 40 mm, particularly preferably 15 to 35 mm. .
[0057]
Of the flat surface 15b of the rear surface 15 of the pseudo stone A, the edge region 15e along the first wood end surface 11 is also an uneven surface as described above. The height difference ΔH between the most concave portion and the most convex portion of the unevenness of the edge region 15e is 2 to 50 mm, preferably 10 to 40 mm, particularly preferably 15 to 35 mm. The width of the edge region 15e is preferably 10 to 40, particularly preferably 15 to 35 mm.
[0058]
It is preferable that the depth of the irregularities in the edge regions on the first tree end surface 11 side of the second tree end surface 12 and the fourth tree end surface 14 is also the same as the edge region 15e.
[0059]
As shown in FIG. 2, the artificial stone B includes a front surface 20 and a rear surface 25, a first tree end surface 21, a second tree end surface 22 and a fourth tree end surface 24 adjacent to the upper end and the lower end of the first tree end surface 21. It has a substantially rectangular parallelepiped shape having the first tree end surface 21 and the third tree end surface 23 on the opposite side, and the front surface 20 has an uneven surface. The height difference ΔH between the most concave portion and the most convex portion 10 of the front surface 20 of the pseudo stone B is substantially equal to that of the front surface of the pseudo stone A.
[0060]
The first to fourth wood end surfaces 21 to 24 of the pseudo stone B are flat surfaces. Although not shown, the entire back surface 25 of the pseudo stone B is a net surface for a back foot formed in the same manner as the net surface 15a of the pseudo stone A.
[0061]
As shown in FIG. 5, of the first wood end surface 21 of the pseudo stone B, an edge region along the front surface 20 is an uneven surface 21 e. The height difference ΔH and the width of the uneven surface 21e are substantially the same as the uneven surface 15e of the pseudo stone A.
[0062]
Next, a procedure for attaching the pseudo stone A and the pseudo stone B to the frame 30 will be described.
[0063]
First, the elastic adhesive 31 is uniformly applied to the wall surface of the frame 30.
[0064]
Next, of the back surface 15 of the pseudo stone A, the net surface 15a for the back foot is stuck on the elastic adhesive 31. At this time, the pseudo stone A is stuck so that the indication line 17 of the second tree end face 12 matches the corner of the frame 30.
[0065]
Next, the rear surface 25 of the pseudo stone B is attached via an elastic adhesive 31 to a wall surface orthogonal to the wall surface of the frame 30 to which the pseudo stone A is attached. After attaching the pseudo stones A and B to the entire construction target area, the joint gap is filled with joint mortar 32.
[0066]
In this way, a corner protruding from the wall composed of the pseudo stone A and the pseudo stone B is constructed.
[0067]
These pseudo stones A and B have deep irregularities formed on the front surfaces 10 and 20 and the first wood end surface 11, have a deep irregular surface feeling, and are rich in design.
[0068]
In the corner of the wall according to the above embodiment, since the front surface 20 of the pseudo stone B has the same height difference ΔH as the front surface 10 of the pseudo stone A and the first wood end surface 11, the seam of the pseudo stones A and B is natural. It becomes a corner with excellent design. In addition, by aligning the indication line 17 provided on the wood end face 12 or 14 of the pseudo stone A with the corner edge of the frame 30, the first wood end face 11 side of the pseudo stone A can be accurately and easily adjusted by the thickness of the pseudo stone B. It can protrude from the corner of the skeleton. Even if the boundary between the back foot net surface 15a and the flat surface 15b of the rear surface 15 of the pseudo stone A is aligned with the corner line of the frame 30, the first tree end surface 11 side of the pseudo stone A can be accurately and easily adjusted to the frame. Can be extended from the corner.
[0069]
In the above embodiment, as shown in FIG. 5, when the first tree end face 21 of the pseudo stone B is arranged to face the flat surface 15 b of the rear surface 15 of the pseudo stone A, the first tree The edge region along the end surface 21 may be exposed, but even in this case, since the edge region 15e is an uneven surface, the design of the corner on the wall becomes more excellent. I have. Since the same uneven surface is also provided in the edge region along the first tree end surface 11 among the second tree end surface 12 and the fourth tree end surface 14, the second tree end surface 12 and the fourth tree end surface are provided. The design property near the edge of No. 14 is also good.
[0070]
In the above embodiment, the second wood end faces 12, 22 of the pseudo stones A, B are flat surfaces, but as shown in FIGS. , B ′. When these pseudo stones A 'and B' are used at the uppermost part of a wall surface such as a handrail, the uppermost part also becomes an uneven surface.
[0071]
In the above embodiment, the artificial stone is adhered by the elastic adhesive, but may be adhered by mortar.
[0072]
The surface patterns of the pseudo stones A and B are schematic, and the present invention is not limited thereto. As an example of the pseudo stone surface pattern of the present invention, FIG. 8 shows a pseudo stone A ″ having a rugged surface of a masonry tone.
[0073]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the back surface is rough, and the mortar for pasting and the plate-like building material with favorable adhesiveness of an adhesive agent can be manufactured efficiently.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of a method for manufacturing a corner-extruding plate-like building material according to an embodiment.
FIG. 2 is a perspective view showing an engagement relationship between a pseudo stone A and a pseudo stone B for constructing a protruding corner.
FIG. 3A is a front view of a pseudo stone A. FIG. 2B is a cross-sectional view taken along line BB of FIG.
FIG. 4 is a perspective view showing a corner protruding from a wall constructed by attaching pseudo stones A and B to a frame.
FIG. 5 is a sectional view taken along the line VV of FIG. 4;
FIG. 6 is a perspective view of a pseudo stone A ′ and a pseudo stone B ′ according to another embodiment.
FIG. 7 is a front view of the pseudo stone A ′ of FIG. 6;
FIG. 8 is a perspective view of a pseudo stone A ″.
[Explanation of symbols]
A, A ', A ", B, B' pseudo stone 1 Mold 1a Bottom surface 1b Wood end surface 2 Powder adhesion layer 3 Self-hardening material 3m Main region 3h Side region 4 Net 5 Plate-shaped building materials 10, 20 Front surface 10b Most concave portion 10t Most convex portion ΔH Height difference 11, 21 First tree end surface 12, 22 Second tree end surface 13, 23 Third tree end surface 14, 24 Fourth tree end surface 15, 25 Rear surface 15a Net surface 15b Flat surface 15e Uneven surface 17 Wire 21e Uneven surface 30 Body 31 Adhesive mortar or elastic adhesive

Claims (9)

A method for manufacturing a corner-form plate-shaped building material having a front surface and a rear surface, and first to fourth four wood end surfaces, wherein the front surface and the first wood end surface are designed surfaces.
In a method of supplying a self-hardening material in a molding die, and curing the self-hardening material, removing the mold to produce the plate-like building material,
Before the self-hardening material is hardened, the embossing material is pressed against a main region of the upper surface of the self-hardening material in the molding die except for a side region along the first wood end surface, and a rough surface is formed on the main region. Forming a plate-shaped building material for an out-going corner. 2. The manufacturing method according to claim 1, wherein the embossing material is pressed so that a boundary between the side region and the main region extends in a direction substantially parallel to the end surface of the first tree. Method. 3. The corner building plate-shaped building material according to claim 2, wherein an indication line is formed on the second and fourth tree end faces adjacent to the first tree end face so as to be located on an extension of the boundary. Manufacturing method. The method according to any one of claims 1 to 3, wherein the embossing material is a net or a nonwoven fabric. In any one of Claims 1 thru | or 3, the front surface and the 1st tree end surface of the said corner-shaped plate-shaped building material are uneven surfaces, In order to form this uneven surface, the cavity of this shaping | molding die is: A method for producing a corner-form plate-like building material, characterized in that the bottom surface and one side surface are uneven surfaces. The method according to claim 5, wherein the uneven surface has a height difference between the most convex portion and the most concave portion of 5 to 50 mm. 7. The corner forming plate according to claim 5, wherein a self-hardening material is supplied into a molding die after a decorating material is attached to a bottom surface of the cavity and the first forming side surface. Manufacturing method of building materials. The method according to claim 7, wherein the decorating material is a powder. 9. The method according to claim 8, wherein water is sprayed after the powder is attached to the cavity surface.

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