JP2008296404A - Manufacturing method of building material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the manufacturing method of a building material with which a texture such as luxuriousness and genuineness can be obtained. <P>SOLUTION: A molded body 5 is formed by molding a resin molding material 2 in which an aggregate 1 is blended. When the resin part of this molded body 5 is soft, the aggregate 1 is exposed on the surface of the molded body 5 by blasting. Since the aggregate 1 is exposed on the surface of the molded body 5, a grainy texture by the aggregate 1 can be fully developed on the surface. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a building material used as a roofing material or a wall material of a house, or a decorative member such as a pseudo stone tone of a roof or a wall.

  Conventionally, building materials containing aggregates have been proposed (see, for example, Patent Document 1), among which resin-made building materials based on resin molding materials. As shown in FIG. 3 (a), such a building material A is set after placing and setting the resin molding material 2 containing the aggregate 1 in the mold 3, as shown in FIG. 3 (b). It can be manufactured by heating and pressing with the molding machine 4 to form a desired shape, and then demolding. However, when the aggregate 1 is blended in the resin molding material 2 and then molded, as shown in FIG. 3C, the aggregate 1 can be evenly dispersed throughout the building material A. The aggregate 1 is buried in the resin part of the building material A (the part formed from the resin molding material 2) by the pressure, and the graininess (grainy feeling) due to the aggregate 1 is not expressed on the surface of the building material A. The flat surface of the molding surface of the mold 3 is expressed, and there is a problem that it is impossible to obtain a texture such as a high-quality feeling or a real feeling (a texture using a genuine stone material or a brick material).

Therefore, the method shown in FIG. 4 is adopted. In this method, as shown in FIG. 4A, the aggregate 1 is dispersed on the molding surface of the mold 3, and then the resin molding material 2 not blended with the aggregate 1 is placed in the mold 3. Next, as shown in FIG. 4 (b), the building material as shown in FIG. 4 (c) is formed by heating and pressurizing with a press molding machine 4 to form a desired shape, and then demolding. A is manufactured. In this case, the aggregate 1 is likely to gather on the surface side of the building material 1, and the graininess is more easily expressed on the surface of the building material 1 than the method of FIG. 3, and the amount of the aggregate 1 used can be reduced. However, in this method as well, the aggregate 1 is still buried in the resin portion of the building material A, and the graininess due to the aggregate 1 is not sufficiently expressed on the surface of the building material A. In addition, when the resin molding material 2 is deformed and flows during press molding, the aggregate 1 dispersed in the mold 3 also moves together with the resin material 2, and as shown in FIG. 1 is partially biased and cannot be uniformly dispersed on the surface of the building material A, which makes it difficult to express natural design, resulting in a problem that a high-quality feeling or a real feeling cannot be obtained.
JP 2006-192709 A

  This invention is made | formed in view of said point, and it aims at providing the manufacturing method of the building material which can obtain textures, such as a high-class feeling and a real feeling.

  The manufacturing method of building material A according to claim 1 of the present invention forms a molded body 5 by molding a resin molding material 2 in which the aggregate 1 is blended, and blasts when the resin portion of the molded body 5 is in a softened state. By performing the treatment, the aggregate 1 is exposed on the surface of the molded body 5.

  The manufacturing method of building material A according to claim 2 of the present invention is characterized in that, in claim 1, the molded body 5 is heated to make the resin portion soft.

  The manufacturing method of the building material A which concerns on Claim 3 of this invention heats the projection material 6 used for a blasting process, It is characterized by the above-mentioned.

  In the invention of claim 1, since the aggregate 1 is exposed on the surface of the molded body 5, a grainy feeling due to the aggregate 1 can be sufficiently expressed on the surface, and a texture such as a high-class feeling or a real feeling can be obtained. It is something that can be done. Further, since the resin molding material 2 in which the aggregate 1 is blended is molded, the aggregate 1 is not biased to a part of the molded body 5, and a natural design expression without a sense of incongruity becomes possible. Further, since the blasting process is performed when the resin part of the molded body 5 is in the softened state, the resin part is softer than the aggregate 1 and the hardness difference is increased so that only the resin part is selectively blasted. Moreover, the resin portion can be compressed by blasting, and the aggregate 1 can be effectively exposed without substantially reducing the holding effect of the aggregate 1 by the molded body 5. Thus, the time required for the blasting process can be shortened.

  In the second aspect of the invention, the softened state of the resin portion can be adjusted by heating, or the molded body 5 can be changed from the cured state to the softened state, so that the blasting can be performed efficiently.

  In the invention of claim 3, the resin portion can be efficiently removed and compressed by the heated projection material 6 and the time required for the blasting process can be shortened.

  Hereinafter, the best mode for carrying out the present invention will be described.

  In the present invention, the aggregate 1 is not particularly limited, and for example, natural stone, ceramic powder, metal powder and the like can be used, and waste materials such as tiles and bricks (waste tiles and waste bricks) are pulverized. It may be a thing. The particle diameter of the aggregate 1 is in the range of 0.3 to 5.0 mm, preferably 0.5 to 3.0 mm. If the particle size of the aggregate 1 is smaller than 0.3 mm, it is difficult to stand out and the design of the building material A may be deteriorated. Moreover, when the particle size of the aggregate 1 is larger than 5.0 mm, when blended in the resin molding material 2 described later, when molding of the molding material A such as poor flow of the resin molding material 2 is reduced or the building material A is cut. There is a possibility that the workability of the steel may be lowered.

  In the present invention, the resin molding material 2 is not particularly limited, but a molding material in which inorganic powder, a thermoplastic resin, and an elastomer are blended can be used. By this, it is possible to produce a building material A having excellent impact strength while maintaining high bending strength by reusing a large amount of waste materials of ceramic-based inorganic building materials (siding etc.) and plastic products. .

  As said inorganic granular material, what grind | pulverized the inorganic material can be used, for example, what grind | pulverized the waste material of ceramic-based inorganic building materials, such as a fiber cement board, can be used. Waste materials of ceramic-based inorganic building materials are generated from the manufacturing stage to the building demolition stage, and the accumulated amount is large. If the waste material of such ceramics-based inorganic building materials is pulverized and used as a raw material, the waste material can be effectively used and environmental protection can be effectively achieved. In addition to those obtained by pulverizing the above-mentioned ceramics-based inorganic building materials, inorganic pulverized particles may be incinerated ash such as fly ash, paper sludge ash, incinerated ash, and molten slag thereof. Even in these industrial wastes, a large amount of effective reuse becomes possible. Moreover, since these are originally powdery, it is not necessary to perform pulverization, and the manufacturing cost can be kept low. The particle size of the inorganic powder is not particularly limited, but it is preferable to use one having an average particle size in the range of 0.01 to 7 mm.

  Moreover, as said thermoplastic resin, the waste material of the plastic product which consists of a molded article of a thermoplastic resin can be used. The amount of plastic product waste generated in the same way as ceramics-based inorganic building materials is large, so if plastic products are used as raw materials, the waste materials can be effectively used. It does not restrict | limit especially as a thermoplastic resin which comprises a plastic product, Arbitrary things, such as polyethylene and a polypropylene, can be used.

  A molding material can be obtained by blending, mixing and kneading the inorganic powder and the thermoplastic resin, and further blending an elastomer to prepare the molding material. The elastomer is not particularly limited, and appropriate ones such as an olefin elastomer and a styrene elastomer can be used. The blending amount of the inorganic powder, thermoplastic resin and elastomer in the molding material is not particularly limited, and is blended at an appropriate ratio in order to exhibit the properties of each material in a well-balanced manner. Needless to say, in addition to these three components, the molding material may contain trace components such as a colorant as required.

  Further, as the thermoplastic resin and the elastomer compounded in the molding material, a molded product of a thermoplastic resin to which an elastomer is added can be used as a part or all of the thermoplastic resin and the elastomer. Waste plastic products can be used. Since such plastic products are also widely used, for example, as bumpers for automobiles, the amount of waste materials generated is large in the same way as ceramics-based inorganic building materials. However, it is possible to effectively use waste materials.

  Here, although the compounding quantity of each component in the said resin molding material 2 is adjusted suitably, it is preferable to make it content in the range of 50-85 mass% especially in particular for an inorganic granular material. At this time, when the molding material is prepared with an inorganic powder and a plastic product of a thermoplastic resin to which an elastomer is added, the blending amount of the plastic product in the resin molding material 2 is in the range of 50 to 15% by mass. Become. Thus, when the content of the inorganic powder is 85% by mass or less, the flowability when the molding material is melted becomes good, and the occurrence of short-circuits can be suppressed when molding the resin molding material 2. In addition, the bending strength and impact strength can be further improved, and the specific gravity can be reduced. In particular, when the content is less than 65% by mass, the fluidity of the molding material can be further improved, and even when a plastic product having a complicated shape is produced, a defect such as a short circuit is caused. The occurrence rate can be reduced. Moreover, the adhesiveness of the resin molding material 2 can be reduced by making content of an inorganic particle body 50 mass% or more, and the kneading machine at the time of transferring the resin molding material 2 from a kneader etc. to the type | mold 3 is used. Adhesion is less likely to occur and the workability is improved, and the linear expansion coefficient can be further reduced to improve the thermal dimensional stability.

  Then, the above inorganic powder, thermoplastic resin and elastomer are blended, and this is forcibly mixed and kneaded while heating near the melting temperature of the thermoplastic resin, and further, the above aggregate 1 is blended. By forcibly mixing and kneading, the resin molding material 2 in which the aggregate 1 is blended can be obtained. The blending amount of the aggregate 1 is preferably 1.0 to 40% by mass with respect to the total amount of the resin molding material 2 including the aggregate 1 (total amount of the aggregate 1 and the resin molding material 2). For example, when No. 3 silica sand having an average particle diameter of 1.5 mm is used as the aggregate 1, it can be blended at a ratio of 10 mass% with respect to the total amount of the resin molding material 2 including the aggregate 1.

  After preparing the resin molding material 2 blended with the aggregate 1 as described above, the resin molding material 2 blended with the aggregate 1 is placed and set in the mold 3 as shown in FIG. . Next, as shown in FIG. 1 (b), the resin molding material 2 in which the aggregate 1 in the mold 3 is blended is press-molded by a press molding machine 4. Here, the heating and pressing conditions can be appropriately set depending on the composition of the resin molding material 2, the blending amount of the aggregate 1, and the like, as long as the resin molding material 2 can be molded into a desired shape, for example, a temperature of 100 to 120 ° C. , Pressure 4-8 Pa, time 30-120 seconds. Next, it removes from the type | mold 3 and obtains the plate-shaped molded object 5 like FIG.1 (c).

  In this manner, the molded body 5 is obtained by bonding the inorganic powder body and the aggregate 1 using the thermoplastic resin as a binder, and the inorganic powder body and the thermoplastic resin occupy most of the molded body 5. When the waste material of ceramics-based inorganic building materials is used as the inorganic powder and when the waste material of plastic products is used as the thermoplastic resin, these waste materials can be effectively reused in large quantities. Moreover, since the thermoplastic resin is used as a binder, high bending strength can be obtained. Moreover, since the elastomer is blended, impact resistance can be improved, and a building material A having high impact strength in addition to bending strength can be obtained.

  After obtaining the molded body 5 in this way, as shown in FIG. 1D, the surface (upper surface) of the molded body 5 is subjected to blasting (sand blasting). The blasting process is a method in which a projection material (blast material) 6 such as iron powder is sprayed from above the molded body 5 using air pressure or the like (shot blasting), whereby the molded body 5 softer than the aggregate 1 is formed. A building material in which the resin part (part formed from the resin molding material 2) is removed (deleted) or compressed to expose the aggregate 1 on the surface of the molded body 5, as shown in FIG. A can be obtained. The aggregate 1 can expose almost half of the surface (upper side).

In the present invention, when performing the blasting process, at least the surface of the molded body 5 is softened. Here, the “softened state” is soft enough that the projection material 6 does not sink into the surface of the molded body 5, and is, for example, about 45 to 55 in terms of JIS K 6253 type D durometer hardness. When the resin molding material 2 is prepared using the thermoplastic resin as described above, it may be in the vicinity of the softening temperature of the thermoplastic resin. For example, the temperature of the molded body 5 at the time of blasting is between 70 and 120 ° C. If the temperature is preferably about 100 ° C., the molded body 5 has an appropriate softness and is optimal for blasting. If the temperature of the molded body 5 is too high, the molded body 5 is too soft and the projection material 6 is sunk. If the temperature of the molded body 5 is too low, the molded body 5 becomes too hard and the blasting process takes time. In either case, it is not preferable. In order to bring the molded body 5 to the above temperature, the molded body 5 can be heated (heated) with a heater or warm air after being molded. Since it is in the temperature range, the blasting can be performed without separately heating by performing the blasting on the molded body 5 immediately after the molding. Specifically, when the temperature of the molded body 5 immediately after molding is 100 ° C., the blasting process can be performed for about 2 minutes at an air pressure of 60 to 70 Pa (6 to 7 kgf / m ² ). In the present invention, depending on the softened state of the molded body 5, the effect of compressing may be greater than scraping the resin portion of the molded body 5 by blasting. In addition, the fibers used in the waste material of the ceramic inorganic building material in the molded body 5 are less likely to be exposed on the surface of the building material A than when the resin portion of the molded body 5 is shaved when compressed by blasting. Thus, the appearance of the building material A can be prevented from deteriorating.

  Moreover, it is also preferable to spray the projection material 6 heated with a heater etc. with respect to the softened molded object 5, and, thereby, the blasting of the molded object 5 can be performed more efficiently. In this case, it is preferable that the temperature of the projection material 6 immediately before being blown out from the blasting apparatus is higher than the temperature of the molded body 5 in consideration of the temperature drop of the projection material 6 when shot. When the temperature of the molded body 5 is 70 to 120 ° C., it is preferable that the temperature of the projection material 6 immediately before being blown out from the blasting apparatus is about 150 to 200 ° C.

  In the method shown in FIG. 1, the entire molded body 5 is formed of the resin molding material 2 in which the aggregate 1 is blended. In this case, there are many aggregates 1 that are not exposed on the surface inside the molded body 5. This may increase the amount of aggregate 1 used. Therefore, as shown in FIG. 2, a resin molding material 2 containing the aggregate 1 and a resin molding material 7 not containing the aggregate 1 can be used in combination. In this case, first, as shown in FIG. 2A, the molding surface of the mold 3 is formed by placing the resin molding material 2 containing the aggregate 1 below the resin molding material 7 not containing the aggregate 1. Set it in contact with. Next, as shown in FIG. 2 (b), resin molding in which the aggregate 1 is blended by press-molding from above the resin molding material 7 in which the aggregate 1 is not blended using a press molding machine 4. The material 2 and the resin molding material 7 not containing the aggregate 1 are molded into a desired shape. Thereafter, as shown in FIG. 2 (c), by removing the mold, a surface layer made of the resin molding material 2 containing the aggregate 1 and a back layer made of the resin molding material 7 not containing the aggregate 1. Can be obtained. And the building material A can be formed by performing the blast process similar to the above to the surface layer of this molded object 5, and exposing the aggregate 1. FIG. This method is economical because the amount of aggregate 1 used can be reduced.

An example of embodiment of this invention is shown, (a)-(e) is a schematic sectional drawing. The other manufacturing method of a molded object same as the above is shown, (a)-(c) is a schematic sectional drawing. Conventional examples are shown, and (a) to (c) are schematic cross-sectional views. Other conventional examples are shown, and (a) to (c) are schematic cross-sectional views.

Explanation of symbols

1 Aggregate 2 Resin molding material 5 Molded body 6 Projection material

Claims (3)

  It is characterized in that a molded body is formed by molding a resin molding material containing an aggregate, and the aggregate is exposed on the surface of the molded body by performing a blasting process when the resin portion of the molded body is in a softened state. A manufacturing method for building materials.   The method of manufacturing a building material according to claim 1, wherein the molded body is heated to make the resin portion in a softened state. The method of manufacturing a building material according to claim 1, wherein the projection material used for the blasting process is heated.

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