JP2010253702A - Method of forming uneven pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of forming an uneven pattern which can form a projecting part of the uneven pattern with a different texture from the other spot such as a recessed part to make the uneven pattern variety-rich, can form a delicately different uneven pattern using a single molding die, and has no possibility of generating a non-conforming pattern due to trapped air. <P>SOLUTION: The method includes pressing a molding material 1 using a molding die 2 to form the uneven pattern 4 with a shaping mold part 3 provided at the molding die 2. The molding die 2 has the shaping mold part 3, which is configured of a shaping projecting part 6 for forming the recessed part 5 of the uneven pattern 4 by being pushed into the molding material 1, and a shaping recessed part 8 for forming a projecting part 7 of the uneven pattern 4 by the molding material 1 intruding thereinto, when the molding die 2 is pressed into the molding material 1. Further, at least, in a part of the shaping recessed part 8, the project part 7 is formed in such a state that the molding material 1, intruded into the shaping recessed part 8, is not fettered inside the shaping recessed part 8. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for forming a concavo-convex pattern on a forming plate used as a building material such as an exterior material.

  Conventionally, a molded plate obtained by molding a cement-based molding material has been used as a building material such as an exterior material. This molded plate is produced by forming a decorative concavo-convex pattern on the surface, and it is common to form a concavo-convex pattern when molding a cement-based molding material with a molding die (for example, (See Patent Document 1).

  FIG. 5 shows an example of a method for forming the forming plate A on which the concavo-convex pattern 4 is formed, and the forming die 2 on which the shaping mold portion 3 corresponding to the concavo-convex pattern 4 is formed as shown in FIG. After pressing the cement-based molding material 1 with the molding die 2 as shown in FIG. 5B, the molding die 2 is released from the molding material 1, thereby forming the molding material as shown in FIG. 5C. The concavo-convex pattern 4 obtained by transferring the shaping mold part 3 of the mold 2 to the molding material 1 can be formed. Then, by curing and curing this, a molded plate A having a concavo-convex pattern 4 on the surface can be obtained.

  When the uneven pattern 4 is formed by pressing the shaping mold part 3 provided on the molding die 2 against the molding material 1, the shaping convex part 6 of the shaping mold part 3 is formed on the molding material 1. The concave portion 5 of the concavo-convex pattern 4 is formed by being pushed in and the surface of the shaping convex portion 6 is transferred to the molding material 1, and the molding material 1 pushed away by the shaping convex portion 6. Enters the shaping recess 8 of the shaping mold 3 and the surface of the shaping recess 8 is transferred to the molding material 1, whereby the projection 7 of the concavo-convex pattern 4 is formed.

JP-A-11-90912

  As described above, in the conventional method of forming the concavo-convex pattern 4 by pressing the molding die 2 onto the molding material, the concavo-convex pattern 4 is transferred by transferring the shaping convex portion 6 of the shaping mold portion 3 to the molding material 1. Are formed, and the surface of the shaping concave portion 8 of the shaping mold portion 3 is transferred to the molding material 1 to form the convex portion 7 of the concave / convex pattern 4. Since the convex part 7 is also formed by the transfer of the surface of the mold 2, it is formed with the same texture, and the entire surface of the concave / convex pattern 4 tends to have a uniform image, and the uneven pattern 4 rich in change is formed. There was a problem that it was difficult to form. Moreover, since both the concave portion 5 and the convex portion 7 of the concavo-convex pattern 4 are formed by transferring the shaping convex portion 6 and the shaping concave portion 8 of the shaping mold portion 3, there is a kind of irregularity from one molding die 2. There was also a problem that only the pattern 4 could be formed.

  Further, since the convex portion 7 of the concavo-convex pattern 4 is formed by completely filling the molding material 1 into the shaping concave portion 8 of the shaping die portion 3, an air pool is formed in the shaping concave portion 8. When this occurs, there is a problem that chipping due to voids occurs in the convex portion 7 to be molded, and molding defects are likely to occur. Further, in order to prevent the occurrence of such air accumulation, the shaping concave portion 8 There is a problem that the mold structure is complicated, for example, it is necessary to provide a deaeration hole in the molding die 2 at the location.

  The present invention has been made in view of the above points, and can be formed with a texture that is different from other portions such as recesses and the like, and can form a concavo-convex pattern rich in change, It is an object of the present invention to provide a method for forming a concavo-convex pattern in which a slightly different concavo-convex pattern can be formed with a single mold and there is no risk of occurrence of defects due to air accumulation.

  In the method for forming a concavo-convex pattern according to the present invention, when forming the concavo-convex pattern 4 with the shaping mold part 3 provided in the mold 2 by pressing the molding material 1 with the mold 2, When the mold 2 is pressed into the material 1, the forming convex portion 6 that is pressed into the molding material 1 to form the concave portion 5 of the concave / convex pattern 4, and the convex portion 7 of the concave / convex pattern 4 enters the molding material 1. The molding material 1 that has entered the shaping recess 8 in at least a part of the shaping recess 8 is provided with the shaping die 3 formed with the shaping recess 8 for molding the molding. Is characterized in that the convex portion 7 is molded in a state in which it is not constrained in the shaping concave portion 8.

  According to the present invention, the concave portion 5 of the concave-convex pattern 4 is formed by pressing the shaping convex portion 6 of the shaping mold portion 3 into the molding material 1 and transferring the surface of the shaping convex portion 6. On the other hand, the convex part 7 of the concavo-convex pattern 4 is formed only by the rising of the molding material 1 into the shaping concave part 8 of the shaping mold part 3, and the surface of the shaping concave part 8 is not transferred. In addition, the concave and convex portions 5 and the convex portions 7 of the concavo-convex pattern 4 can be formed with different textures, and the concavo-convex pattern 4 rich in change can be formed. Further, since the convex portions 7 of the concavo-convex pattern 4 are formed without being constrained in the shaping concave portion 8, a plurality of molding materials 1 enter the shaping concave portion 8 in the shaping die portion 3. The shape is different for each shaping concave portion 8 and is different for each molding. The same convex portion 7 is difficult to be formed, and the shape of the convex portion 7 is subtle in one molding die 2. It is possible to form different uneven patterns 4. Furthermore, since the molding material 1 is not filled into the shaping concave portion 8 of the shaping mold portion 3 to form the convex portion 7 of the concavo-convex pattern 4, there is no risk of occurrence of defects due to air accumulation. .

  Further, in the present invention, at least a part of the shaping concave portion 8 of the shaping mold portion 3 is open on a surface opposite to the molding side of the molding die 2.

  According to the present invention, the molding material 1 is pressed with the molding die 2, the irregularity pattern 4 is molded with the shaping mold portion 3 provided on the molding die 2, and then the molding die 2 is released. Since the shaping concave portion 8 of the shaping die portion 3 is in an open state and does not become negative pressure, it can be easily released.

  According to the present invention, the concave portion 5 of the concavo-convex pattern 4 is formed by pressing the shaping convex portion 6 of the shaping mold portion 3 into the molding material 1 and transferring the surface of the shaping convex portion 6. On the other hand, the convex part 7 of the concavo-convex pattern 4 is formed only by the rising of the molding material 1 into the shaping concave part 8 of the shaping mold part 3, and the surface of the shaping concave part 8 is not transferred. The concave portion 5 and the convex portion 7 of the concavo-convex pattern 4 can be formed with different textures, and the concavo-convex pattern 4 rich in change can be formed. Moreover, since the convex part 7 of the concavo-convex pattern 4 is formed in a state that is not restrained in the shaping concave part 8, a plurality of molding materials 1 enter the shaping concave part 8 in the shaping mold part 3. It is different for each shaping concave portion 8 to be formed, and is different every time molding is performed, and the same convex portion 7 is difficult to be formed. It is possible to form different uneven patterns 4. Furthermore, since the molding material 1 is not filled into the shaping concave portion 8 of the shaping mold portion 3 to form the convex portion 7 of the concavo-convex pattern 4, there is no risk of occurrence of defects due to air accumulation. .

An example of embodiment of this invention is shown and (a) thru | or (c) is sectional drawing. It is a top view of the shaping | molding die used for the same as the above. An example of other embodiment of this invention is shown, (a) thru | or (c) are sectional drawings. The measuring method of the softness of the molding material by a Vicat needle device is shown, (a) (b) is a schematic diagram. A conventional example is shown, and (a) to (c) are cross-sectional views.

  Embodiments of the present invention will be described below.

  FIG. 1A and FIG. 2 show a molding die 2 used in an example of an embodiment of the present invention. A plurality of vertical members 12 having a large thickness and a plurality of horizontal members 13 having a small thickness are provided. They are assembled in a grid pattern. In this mold 2, the shaping convex portion 6 is formed by the vertical member 12 and the horizontal member 13, and the shaping concave portion 8 is formed by the space surrounded by the vertical member 12 and the transverse member 13. The shaping mold part 3 is formed from the shaping convex part 6 and the shaping concave part 8. The shaping concave portion 8 of the shaping mold portion 3 is opened above the molding die 2.

  On the other hand, a cement-based hydraulic material is generally used as the molding material 1. First, as shown in FIG. 1A, the molding die 2 is arranged above the molding material 1 supplied on the tray 14 or the like. Then, as shown in FIG. 1B, the molding die 2 is stacked on the molding material 1 and pressed, the molding material 4 is molded with the molding die 2, and then the molding die 2 is released. The concavo-convex pattern 4 can be formed on the molding material 1 as in 1 (c). And the shaping | molding board A which gave the makeup | decoration with the uneven | corrugated pattern 4 can be obtained by curing and curing the molding material 1 which formed such an uneven | corrugated pattern 4 and shape | molded in plate shape by wet heat curing, autoclave curing, etc. Is.

  Here, when the molding material 1 is press-molded with the molding die 2 as shown in FIG. 1B, the shaping convex portion 6 of the shaping die portion 3 is pushed into the molding material 1, and the shaping convexity is obtained. The concave portion 5 of the concavo-convex pattern 4 can be formed by transferring the surface of the portion 6 to the molding material 1, and the molding is pushed away by the shaping convex portion 6 being pushed into the molding material 1. The convex part 7 of the concavo-convex pattern 4 is formed by the material 1 entering the shaping concave part 8 of the shaping mold part 3.

  As described above, the shaping recess 8 is opened above the molding die 2, and the molding material 1 enters the shaping recess 8 without being constrained in the shaping recess 8. The convex part 7 is formed so as to rise into the shaping concave part 8 so as to rise in the shaping concave part 8 without being restricted, and the upper surface is slightly rounded. Since the convex portion 7 is not formed by transferring the surface of the shaping concave portion 8, the convex portion 7 is formed on the surface texture of natural bulge. On the other hand, the concave portion 5 of the concavo-convex pattern 4 is formed by the shaping convex portion 6 being pushed into the molding material 1 and the surface of the shaping convex portion 6 being transferred. The texture of the recesses 5 formed by the transfer of the texture and the texture of the protrusions 7 formed by natural swell are different, and the uneven texture 4 rich in change is formed by the difference in texture between the recesses 5 and the protrusions 7. Is something that can be done.

  Moreover, since the convex part 7 of the concavo-convex pattern 4 is formed in a state that is not regulated in the shaping concave part 8, there are a plurality of molding material 1 entering the shaping concave part 8 in the shaping mold part 3. It is different for each shaping concave portion 8 to be formed, and is different for each molding, and the convex portion 7 is difficult to be formed in exactly the same form. Accordingly, it is possible to form the concavo-convex pattern 4 with slightly different shapes of the convex portions 7 with one mold 2.

  Further, the molding material 1 is not filled into the shaping concave portion 8 to form the convex portion 7 of the concavo-convex pattern 4, and the shaping concave portion 8 is opened upward. Therefore, there is no risk of occurrence of defects due to air accumulation.

  Then, after the molding material 1 is molded with the molding die 2, when the molding die 2 is released as shown in FIG. 1 (c), the shaping concave portion 8 of the shaping die portion 3 is opened upward. When the convex part 7 comes out of the shaping concave part 8, the molding concave part 8 does not become negative pressure, and the mold 2 can be easily released.

  In the above embodiment, all of the shaping recesses 8 provided in the shaping mold part 3 are opened above the molding die 2, but only a part of the shaping recesses 8. In this case, it may be opened upward. Needless to say, the shape of the shaping mold portion 3 is not limited to the lattice shape as in the above embodiment. Further, when the molding material 1 is press-molded with the molding die 2, the molding material 1 efficiently enters the shaping recess 8 of the shaping die 3 without escaping in the plate width direction of the molding die 2. In addition, the periphery of the molding material 1 may be restrained.

  FIG. 3 shows another embodiment of the present invention. In this embodiment, as shown in FIG. 3 (a), the shaping concave portion 8 of the shaping mold portion 3 is opened above the molding die 2. As shown in FIG. Instead, it is formed as a bottomed hole that opens downward. The shaping concave portion 8 is formed with a dimension deeper than the height of the convex portion 7 of the concavo-convex pattern 4.

  In this case, when the molding material 1 is pressed and molded with the molding die 2 as shown in FIG. 3B, the shaping concave portion 8 of the shaping die portion 3 is formed with a deep dimension. The molding material 1 does not penetrate into the shaping recess 8 and can be molded without pressing the molding material 1 entering the shaping recess 8 within the shaping recess 8. Therefore, the molding material 1 enters the shaping concave portion 8 so as to rise in the shaping concave portion 8 without being regulated, and the convex portion 7 is formed in the same form as the embodiment of FIG. It can be formed. The shaping concave portion 8 may be a deep portion in which the molding material 1 does not enter deeply and a shallow shape in which the molding material 1 does not penetrate deeply. The open shaping recess 8 may coexist.

  Here, as the molding material 1 for molding the molding plate A, a cement-based molding material is mainly used. However, when the molding plate A is a building material used outdoors such as an exterior material, it absorbs moisture such as rainwater. It is generally necessary to apply a water resistant coating to the surface to prevent it. However, as in the case of the molded plate A of the present invention, when the uneven pattern 4 rich in change is formed by causing a difference in texture between the concave part 5 and the convex part 7 of the concave / convex pattern 4, The convex part 7 is also covered with the coating film, and the effect of forming the uneven pattern 4 rich in change is hindered.

  Therefore, in the present invention, it is preferable to use, as the molding material 1, a polymer composite cement made of a cement-containing inverse emulsion composition mainly composed of cement, water, and an oily substance. The cured product obtained by molding this cement-containing inverse emulsion composition has low water absorption and excellent water resistance. Therefore, by mixing the cement-containing inverse emulsion composition with the colorant and molding the molded plate A, it is possible to obtain the molded plate A having low water absorption and excellent water resistance without the need for surface coating. The molding plate A of the present invention makes it possible to produce a building material used outdoors such as an exterior material.

  In such a cement-containing inverse emulsion composition, the cement is not particularly limited, and examples thereof include Portland cement, fly ash cement, blast furnace cement, alumina cement, high alumina cement, and silica fume cement. These can be used alone or in combination of two or more. The oily substance is for forming an inverse emulsion (W / O emulsion) with water, and is not particularly limited. Usually, a hydrophobic liquid substance is used, for example, toluene, xylene, kerosene, styrene. , Divinylbenzene, methyl methacrylate, trimethylolpropane trimethacrylate, unsaturated polyester resin, and the like. These can be used alone or in combination of two or more. The blending amount of the oily substance is preferably in the range of 5 to 10% by volume with respect to the total amount of water and solid content in the cement-containing inverse emulsion composition. In addition to the above components, an emulsifier is preferably added to the cement-containing inverse emulsion composition. The emulsifier is blended to impart stability to the inverse emulsion. Ionic surfactants, various anionic surfactants, cationic surfactants, and the like can be used. The blending amount of the emulsifier is preferably in the range of 1 to 3% by volume with respect to the total amount of water and solid content in the cement-containing inverse emulsion composition. An appropriate amount of a reinforcing material and various additives can be further blended in the cement-containing inverse emulsion composition. Examples of reinforcing materials include aggregates such as gravel, perlite, shirasu balloon, glass powder, and alumina silicate, synthetic fibers such as polypropylene fiber, acrylic fiber, vinylon fiber, and aramid fiber, and reinforcement such as carbon fiber, glass fiber, and pulp. Mention may be made of fibers.

  An example of the preparation of the cement-containing inverse emulsion composition is as follows. First, an emulsifier (for example, coconut oil 1.0 to 2.0 parts by mass), styrene monomer 4.0 to 6.0 parts by mass, water 35.0 to An inverse emulsion is prepared by mixing 50.0 parts by mass and an appropriate amount of a crosslinking agent and a polymerization initiator. Next, 100 parts by weight of this inverse emulsion, 70 to 90 parts by weight of cement, 0.3 to 5.0 parts by weight of organic lightening material, 1.0 to 2.0 parts by weight of reinforcing fibers, or the reverse of the above 100 parts by mass of emulsion, 55.0 to 75.0 parts by mass of cement, 15.0 to 35.0 parts by mass of inorganic lightening material, and 1.0 to 2.0 parts by mass of reinforcing fibers A cement-containing inverse emulsion composition can be prepared by mixing in a continuous mixer.

  Further, the molding material 1 is pressed by the molding die 2 as described above, and the molding material 1 that has entered the shaping recess 8 of the shaping die 3 is raised in the shaping recess 8 without being restricted. In order to form the convex portion 7 having a natural surface state, the molding material 1 needs to be soft to some extent. If the molding material 1 is hard, the fluidity becomes insufficient. Therefore, even if the shaping mold part 3 is pressed into the molding material 1, the molding material 1 cannot sufficiently enter the shaping concave part 8, and deep irregularities. The pattern 4 cannot be formed. However, if the molding material 1 is too soft, the fluidity becomes too high, so that the shaping shape by the shaping mold portion 3 is not maintained, and the uneven pattern 4 cannot be molded. As described above, the degree of difficulty of the molding material 1 and the moldability have a predetermined correlation.

  Therefore, the softness of the molding material 1 was measured using a Vicat needle device defined in the setting test of JIS R5201 “Cement physical test method”, and the relationship between the softness of the molding material 1 and the moldability was examined. The Vicat needle device 20 used for the test is formed by providing a rod 22 having a weight of 300 g having a needle 21 having a diameter of 10 mm at the lower end portion so as to be movable down by its own weight, as shown in FIG. After the lower end of the needle 21 is brought into contact with the upper surface of the molding material 1, the rod 22 is moved down by its own weight, and the distance L (length) that the needle 21 enters into the molding material 1 as shown in FIG. mm). Thus, the softness of the molding material 1 can be defined by the entry value of the needle 21 into the molding material 1, and Table 1 shows the relationship between the needle entry value and the moldability.

  As seen in Table 1, it is confirmed that the molding as in the present invention can be performed satisfactorily by using the molding material 1 having a needle entry value in the range of 2 to 9 mm. When the needle entry value is less than 2 mm, the molding material is too hard and the fluidity is insufficient, and when the needle entry value exceeds 9 mm, the molding material is too soft and shape retention becomes difficult. Among the needle entry values of 2 to 9 mm, the molding material 1 having a needle entry value in the range of 4 to 7 mm has particularly good moldability. As the molding material 1 having a needle entry value of 4 to 7 mm, the above-described cement-containing inverse emulsion composition can be used. If vibration is applied to the molding material 1 during press molding, the molding material 1 having a normal needle entry value of less than 2 mm may be molded due to increased fluidity. The application range of the material 1 can be expanded.

DESCRIPTION OF SYMBOLS 1 Molding material 2 Molding die 3 Molding part 4 Concavity and convexity pattern 5 Concavity 6 Shaping convex part 7 Convex part 8 Concave part for shaping

Claims (2)

  When pressing the molding material with a molding die and forming the concavo-convex pattern with the shaping mold provided on the molding die, the concave portion of the concavo-convex pattern is pressed into the molding material when the molding die is pressed into the molding material. At least partly using a forming mold provided with a forming mold part formed with a forming convex part for forming a molding material and a forming concave part for forming a convex part of an uneven pattern with a molding material A method for forming a concavo-convex pattern, characterized in that, in the forming concave portion, the convex portion is formed in a state in which the molding material that has entered the shaping concave portion is not constrained in the shaping concave portion.   A method for forming a concavo-convex pattern, wherein at least a part of the shaping concave portion of the shaping mold portion is opened on a surface opposite to the molding side surface of the molding die.

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