JP2012232467A - Method of manufacturing cement molded article - Google Patents

Method of manufacturing cement molded article Download PDF

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JP2012232467A
JP2012232467A JP2011102133A JP2011102133A JP2012232467A JP 2012232467 A JP2012232467 A JP 2012232467A JP 2011102133 A JP2011102133 A JP 2011102133A JP 2011102133 A JP2011102133 A JP 2011102133A JP 2012232467 A JP2012232467 A JP 2012232467A
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cement
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mold
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JP5792507B2 (en
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Atsushi Yamamoto
敦史 山本
Motoyuki Mizuno
素行 水野
Yasuhiro Nishiura
靖裕 西浦
Kimihiro Kimura
公洋 木村
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KMEW Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a cement molded article by which molding failure can be reduced without deteriorating productivity.SOLUTION: The method of manufacturing the cement molded article is for press-molding a cement material containing cement and water. An upper limit press temperature is set which is higher by a prescribed amount than a gelling temperature of a thickening agent blended in the cement material. Press-molding is performed at a temperature of the upper limit press temperature or lower.

Description

本発明は、セメント材料をプレス成形して得られるセメント成形品の製造方法に関するものである。   The present invention relates to a method for producing a cement molded article obtained by press molding a cement material.

従来より、成形型(型枠)を用いてセメント材料を連続してプレス成形することが行われている。このようなプレス成形の工程で、同じ成形型にて何度もプレス成形すると、成形型にセメント材料が付着し、製品の意匠を損なってしまうことがあった。このように成形型からのセメント成形品の離型は、生産時の不良率の低減や成形型のメンテナンス回数の低減等、製造面や品質面において大きな影響を与える技術であり、成形型へのセメント材料の付着を防止するものとして、成形型へ離型剤を塗布することが一般的であり、よく知られた技術である。また、成形型を熱し、離型する技術も公知であり(例えば、特許文献1参照)、離型技術の一つと言える。   Conventionally, cement material is continuously press-molded using a mold (form). In such a press molding process, if the same mold is pressed many times, a cement material may adhere to the mold and the design of the product may be impaired. In this way, the release of cement molded products from the mold is a technology that has a major impact on manufacturing and quality, such as reducing the defective rate during production and reducing the number of maintenance of the mold. In order to prevent adhesion of cement material, it is common to apply a release agent to a mold, which is a well-known technique. A technique for heating and releasing a mold is also known (see, for example, Patent Document 1), and can be said to be one of the release techniques.

特開平4−363206号公報JP-A-4-363206

しかし、成形型へ離型剤を塗布する技術は、一回のプレス成形毎に成形型に離型剤を塗布する必要があり、生産性の低下を招くおそれがあった。   However, the technique of applying a release agent to a mold requires applying the release agent to the mold every press molding, which may lead to a decrease in productivity.

また、成形型を高温化し、離型する技術は、設定温度範囲の根拠もなく、実際に温度が低いと成形型にセメント材料が付着してしまい、上手く離型できないことがあった。また、適正温度以上に成形型を暖めると、製品表面にシワ(材料切れ)等の成形不良が発生してしまい、製品として成り立たないことがあった。   In addition, the technology for increasing the temperature of the mold and releasing the mold does not provide a basis for the set temperature range, and if the temperature is actually low, the cement material adheres to the mold and may not be released successfully. Further, if the mold is warmed to a temperature higher than the appropriate temperature, molding defects such as wrinkles (out of material) may occur on the product surface, and the product may not be realized.

本発明は上記の点に鑑みてなされたものであり、生産性を低下させることがほとんどなく、成形不良を低減することができるセメント成形品の製造方法を提供することを目的とするものである。   The present invention has been made in view of the above points, and an object of the present invention is to provide a method for producing a cement molded article that can reduce the molding defects with little reduction in productivity. .

本発明に係るセメント成形品の製造方法は、セメント及び水を含有するセメント材料をプレス成形するセメント成形品の製造方法であって、前記セメント材料に配合された増粘剤のゲル化温度よりも所定温度だけ高い上限プレス温度を設定し、この上限プレス温度以下の温度でプレス成形することを特徴とするものである。   The method for producing a cement molded article according to the present invention is a method for producing a cement molded article by press molding a cement material containing cement and water, and is higher than the gelation temperature of the thickener blended in the cement material. An upper limit press temperature higher by a predetermined temperature is set, and press molding is performed at a temperature equal to or lower than the upper limit press temperature.

本発明において、前記増粘剤のゲル化温度より高い下限プレス温度を設定し、この下限プレス温度以上の温度でプレス成形することが好ましい。   In the present invention, it is preferable to set a lower limit press temperature higher than the gelation temperature of the thickener and press-mold at a temperature equal to or higher than the lower limit press temperature.

本発明において、前記増粘剤がメチルセルロースであって、前記上限プレス温度が前記メチルセルロースのゲル化温度より20℃高い温度であることが好ましい。   In this invention, it is preferable that the said thickener is methylcellulose and the said upper limit press temperature is 20 degreeC higher than the gelling temperature of the said methylcellulose.

本発明において、成形型に離型剤を不使用であることが好ましい。   In the present invention, it is preferable that a mold release agent is not used in the mold.

本発明は、生産性を低下させることがほとんどなく、成形不良を低減することができるものである。   The present invention hardly reduces productivity and can reduce molding defects.

本発明の実施の形態の一例を示す概略図である。It is the schematic which shows an example of embodiment of this invention.

以下、本発明を実施するための形態を説明する。   Hereinafter, modes for carrying out the present invention will be described.

本発明のセメント成形品の製造方法は、セメント及び水を含有するセメント材料をプレス成形して所望の形状に成形し、この後、所望の形状に成形されたセメント材料を硬化させてセメント成形品を製造する方法である。   In the method for producing a cement molded product of the present invention, a cement material containing cement and water is press-molded into a desired shape, and then the cement material molded into the desired shape is cured to obtain a cement molded product. It is a method of manufacturing.

上記のセメントとしては、例えば、ポルトランドセメント、フライアッシュセメント、高炉セメント、アルミナセメントなどが挙げられる。複数種類のセメントを併用することもできる。   Examples of the cement include Portland cement, fly ash cement, blast furnace cement, and alumina cement. Multiple types of cement can be used in combination.

上記のセメント材料には増粘剤が配合される。増粘剤はセメント材料に粘性を付与し、プレス成形後のセメント材料の表面を平滑する作用を有するものである。増粘剤としては、メチルセルロース(MC)などのセルロース誘導体などを用いることができる。   A thickener is blended in the cement material. The thickener has a function of imparting viscosity to the cement material and smoothing the surface of the cement material after press molding. As the thickener, cellulose derivatives such as methylcellulose (MC) can be used.

上記のセメント材料には、必要に応じて、セメント成形品の機械的強度などの物理的特性を向上させるために補強材を配合することができる。具体的には、繊維状補強材として、ポリプロピレン繊維、アクリル繊維、ビニロン繊維、アラミド繊維等の合成繊維や、炭素繊維、ガラス繊維、パルプなどを用いることができる。また、粒子状補強材として、砂利、パーライト、シラスバルーン、ガラス粉、アルミナシリケートなどの無機粒子を使用することができ、この場合、多孔質状あるいは中空状の無機粒子を使用することもできる。これらの他に、セメント材料には、必要に応じて、混和材、軽量骨材、分散剤などを配合することもできる。   If necessary, a reinforcing material can be blended with the above cement material in order to improve physical properties such as mechanical strength of the cement molded product. Specifically, synthetic fibers such as polypropylene fibers, acrylic fibers, vinylon fibers, and aramid fibers, carbon fibers, glass fibers, and pulp can be used as the fibrous reinforcing material. In addition, inorganic particles such as gravel, pearlite, shirasu balloon, glass powder, and alumina silicate can be used as the particulate reinforcing material. In this case, porous or hollow inorganic particles can also be used. In addition to these, an admixture, a lightweight aggregate, a dispersant, and the like can be blended in the cement material as necessary.

そして、セメントと増粘剤と補強材及び水、並びにその他の材料とを配合して混合することによって、セメント材料を調製することができる。この場合、各成分の配合量(配合割合)は適宜設定することが可能であるが、例えば、セメント50〜80質量部、増粘剤0.1〜5質量部、補強材0〜5質量部、水20〜35質量部、混和材0〜40質量部、軽量骨材0〜10質量部、分散剤0〜5質量部とすることができる。   And a cement material can be prepared by mix | blending and mixing a cement, a thickener, a reinforcing material, water, and another material. In this case, although the compounding quantity (mixing ratio) of each component can be set as appropriate, for example, 50 to 80 parts by mass of cement, 0.1 to 5 parts by mass of a thickener, and 0 to 5 parts by mass of a reinforcing material. 20 to 35 parts by mass of water, 0 to 40 parts by mass of the admixture, 0 to 10 parts by mass of the lightweight aggregate, and 0 to 5 parts by mass of the dispersant.

このセメント材料は、プレス成形により所望の形状に成形されたり、表面に凹凸模様が付与されたりする。また、プレス成形の前に、セメント材料を押出成形により平板等の所望の形状に成形し、押出成形後のセメント材料にプレス成形を施しても良い。また、プレス成形は、複数のセメント材料に対して連続的に行うことができ、また、長尺のセメント材料の複数箇所に連続的に行うようにすることもできる。   This cement material is formed into a desired shape by press molding, or an uneven pattern is given to the surface. Further, before the press molding, the cement material may be molded into a desired shape such as a flat plate by extrusion molding, and the cement material after extrusion molding may be press molded. Moreover, press molding can be continuously performed on a plurality of cement materials, and can also be performed continuously at a plurality of locations on a long cement material.

そして、本発明では、プレス成形時の成形型の成形面(成形時にセメント材料と接触する面)の温度をセメント材料に配合した増粘剤のゲル化温度によって規定するものである。すなわち、増粘剤のゲル化温度よりも所定温度だけ高い温度を上限プレス温度とし、この上限プレス温度以下の温度に成形型の成形面を調整してプレス成形するものである。これにより、成形型の成形面からのセメント材料の離型性が向上し、製品表面にシワ(材料切れ)等の成形不良が発生しにくくなるものである。また、成形型に離型剤を塗布しておく必要もなく、生産性を向上させることができるものである。   And in this invention, the temperature of the shaping | molding surface (surface which contacts cement material at the time of shaping | molding) at the time of press molding prescribes | regulates the temperature of the thickener mix | blended with cement material. That is, the temperature higher than the gelling temperature of the thickener by a predetermined temperature is set as the upper limit press temperature, and the molding surface of the mold is adjusted to a temperature equal to or lower than the upper limit press temperature for press molding. As a result, the releasability of the cement material from the molding surface of the molding die is improved, and molding defects such as wrinkles (out of material) are less likely to occur on the product surface. Further, it is not necessary to apply a release agent to the mold, and productivity can be improved.

ここで、増粘剤としてメチルセルロースを用いた場合、そのゲル化温度が約60〜80℃のものが想定される。また、上限プレス温度としてはゲル化温度よりも20℃高い温度を設定することが好ましい。従って、上限プレス温度は約80〜100℃となり、この温度以下でプレス成形するものである。   Here, when methylcellulose is used as a thickener, a gelation temperature of about 60 to 80 ° C. is assumed. Moreover, as an upper limit press temperature, it is preferable to set the temperature 20 degreeC higher than a gelling temperature. Accordingly, the upper limit pressing temperature is about 80 to 100 ° C., and press molding is performed at this temperature or lower.

また、プレス成形時の成形型の成形面の温度は下限プレス温度よりも高い温度に設定するのが好ましい。下限プレス温度は、セメント材料に配合した増粘剤のゲル化温度よりも高い温度で、上限プレス温度よりも低い温度である。これにより、成形型の成形面からのセメント材料の離型性が向上し、製品表面にシワ(材料切れ)等の成形不良が発生しにくくなるものである。また、成形型に離型剤を塗布しておく必要もなく、生産性を向上させることができるものである。増粘剤としてメチルセルロースを用いた場合、そのゲル化温度が約60〜80℃のものが想定されるので、下限プレス温度は60〜80℃よりも高い温度となる。   Moreover, it is preferable to set the temperature of the shaping | molding surface of the shaping | molding die at the time of press molding to temperature higher than minimum press temperature. The lower limit pressing temperature is a temperature higher than the gelation temperature of the thickener blended in the cement material and lower than the upper limit pressing temperature. As a result, the releasability of the cement material from the molding surface of the molding die is improved, and molding defects such as wrinkles (out of material) are less likely to occur on the product surface. Further, it is not necessary to apply a release agent to the mold, and productivity can be improved. When methylcellulose is used as the thickener, the gelation temperature is assumed to be about 60 to 80 ° C., so the lower limit press temperature is higher than 60 to 80 ° C.

尚、プレス成形時の成形圧力は0.5〜10MPa、成形時間は0.1〜30秒間とすることができるが、これに限定されるものではない。   In addition, although the shaping | molding pressure at the time of press molding can be 0.5-10 MPa and shaping | molding time can be 0.1-30 seconds, it is not limited to this.

上記のようにしてプレス成形した後のセメント材料を養生硬化することによって、セメント成形品を製造することができる。ここで、養生硬化の条件としては、温度が約90℃で時間が約24時間とすることができるが、これに限定されるものではない。   A cement-molded article can be produced by curing and curing the cement material after press-molding as described above. Here, as curing curing conditions, the temperature can be about 90 ° C. and the time can be about 24 hours, but is not limited thereto.

以下、本発明を実施例によって具体的に説明する。   Hereinafter, the present invention will be specifically described by way of examples.

セメント80質量部と、増粘剤であるメチルセルロース0.5質量部と、水27.5質量部と、補強材である有機繊維2質量部の割合で混合してセメント材料を調製した。次に、このセメント材料100gをプレス成形した。プレス成形は、図1に示すように、上側のプレス板1と下側のプレス板2との間に成形型3として、厚さ1mmの上下一対のステンレス鋼板(SUS板)を配置し、この上下の成形型3、3の間にセメント材料4を配置した。また、下側のプレス板2の上面には高さ8mmのスペーサ5を配置した。そして、上側のプレス板1をスペーサ5の上面に接触するまで下動させ、この状態で10秒間保持した。プレス成形時の成形圧力は1MPaとした。尚、離型剤は使用していない。次に、プレス成形した後、成形後のセメント材料を脱型し、温度90℃で24時間養生硬化してセメント成形品を製造した。   A cement material was prepared by mixing 80 parts by mass of cement, 0.5 parts by mass of methylcellulose as a thickener, 27.5 parts by mass of water, and 2 parts by mass of organic fibers as a reinforcing material. Next, 100 g of this cement material was press-molded. As shown in FIG. 1, the press molding is performed by placing a pair of upper and lower stainless steel plates (SUS plates) having a thickness of 1 mm between the upper press plate 1 and the lower press plate 2 as a forming die 3. The cement material 4 was disposed between the upper and lower molds 3 and 3. A spacer 5 having a height of 8 mm was disposed on the upper surface of the lower press plate 2. Then, the upper press plate 1 was moved down until it contacted the upper surface of the spacer 5, and held in this state for 10 seconds. The molding pressure during press molding was 1 MPa. No release agent is used. Next, after press molding, the cement material after molding was demolded and cured at a temperature of 90 ° C. for 24 hours to produce a cement molded product.

このようなセメント成形品の製造方法において、ゲル化温度の異なる三種類のメチルセルロースを用いると共に成形温度(成形型3の成形面の温度)を50〜110℃で10℃ずつ変えた。そして、セメント材料の成形型からの離型性とプレス成形後のセメント材料の表面のシワの発生状況を評価した。   In such a method for producing a cement molded product, three types of methyl cellulose having different gelation temperatures were used, and the molding temperature (the temperature of the molding surface of the mold 3) was changed by 10 ° C. from 50 to 110 ° C. Then, the releasability of the cement material from the mold and the occurrence of wrinkles on the surface of the cement material after press molding were evaluated.

セメント材料の成形型からの離型性は、成形型にセメント材料が付着せずに離型できたものを○、成形型にセメント材料がほとんど付着せずに離型できたものを△、成形型にセメント材料が付着して離型できなかったものを×とした。   The releasability of the cement material from the mold is ○ when the mold can be released without adhering the cement material, and when the mold can be released with almost no cement material adhering. The case where the cement material adhered to the mold and could not be released was marked with x.

プレス成形後のセメント材料の表面のシワの発生状況は、シワが無いものを◎、シワが極少のものを○、シワが少ないものを△、シワが多いものを×とした。   As for the occurrence of wrinkles on the surface of the cement material after press molding, ◎ indicates that there are no wrinkles, ○ indicates that there are few wrinkles, Δ indicates that there are few wrinkles, and × indicates that there are many wrinkles.

結果を表1に示す。   The results are shown in Table 1.

Figure 2012232467
Figure 2012232467

表1から明らかなように、離型性及びシワの発生状況の両方が良好なものは、増粘剤のゲル化温度が60℃で成形温度が70℃(ゲル化温度よりも10℃高い温度)、増粘剤のゲル化温度が70℃で成形温度が80〜90℃(ゲル化温度よりも10〜20℃高い温度)、増粘剤のゲル化温度が80℃で成形温度が90℃(ゲル化温度よりも10℃高い温度)の場合であった。   As can be seen from Table 1, both the release property and the state of occurrence of wrinkles are those in which the gelling temperature of the thickener is 60 ° C. and the molding temperature is 70 ° C. (temperature higher by 10 ° C. than the gelling temperature). ), The gelling temperature of the thickener is 70 ° C. and the molding temperature is 80 to 90 ° C. (temperature higher by 10 to 20 ° C. than the gelling temperature), the gelling temperature of the thickener is 80 ° C. and the molding temperature is 90 ° C. This was the case of (temperature 10 ° C. higher than the gelation temperature).

増粘剤がゲル化温度60℃〜80℃のメチルセルロースの場合は、下限プレス温度をゲル化温度より高く、且つ上限プレス温度をゲル化温度から20℃高い温度より低く設定するのが最適である。このようにプレス温度を設定することで、離型剤を用いなくても容易に離型することができ、しかも材料表面にシワが発生するのを抑制することができる。なお、成形型表面が非常に複雑な形状の場合には、補助的に離型剤を併用してもよいものである。   When the thickener is methyl cellulose having a gelation temperature of 60 ° C to 80 ° C, it is optimal to set the lower limit press temperature higher than the gelation temperature and the upper limit press temperature lower than the temperature 20 ° C higher than the gelation temperature. . By setting the press temperature in this manner, the mold can be easily released without using a release agent, and the generation of wrinkles on the material surface can be suppressed. In addition, when the mold surface has a very complicated shape, a release agent may be used in combination.

Claims (4)

セメント及び水を含有するセメント材料をプレス成形するセメント成形品の製造方法であって、前記セメント材料に配合された増粘剤のゲル化温度よりも所定温度だけ高い上限プレス温度を設定し、この上限プレス温度以下の温度でプレス成形することを特徴とするセメント成形品の製造方法。   A method for producing a cement molded article comprising press molding a cement material containing cement and water, wherein an upper limit pressing temperature higher than a gelling temperature of a thickener blended in the cement material is set by a predetermined temperature. A method for producing a cement-molded article, wherein the molding is performed at a temperature equal to or lower than an upper limit pressing temperature. 請求項1に記載された発明において、前記増粘剤のゲル化温度より高い下限プレス温度を設定し、この下限プレス温度以上の温度でプレス成形することを特徴とするセメント成形品の製造方法。   The method according to claim 1, wherein a lower limit press temperature higher than the gelling temperature of the thickener is set, and press molding is performed at a temperature equal to or higher than the lower limit press temperature. 請求項1又は2に記載された発明において、前記増粘剤がメチルセルロースであって、前記上限プレス温度が前記メチルセルロースのゲル化温度より20℃高い温度であることを特徴とするセメント成形品の製造方法。   3. The production of a cement molded article according to claim 1, wherein the thickener is methylcellulose, and the upper limit pressing temperature is 20 ° C. higher than the gelation temperature of the methylcellulose. Method. 請求項1乃至3のいずれか一項に記載された発明において、成形型に離型剤を不使用であることを特徴とするセメント成形品の製造方法。
4. The method for producing a cement molded article according to any one of claims 1 to 3, wherein a mold release agent is not used in the mold.
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JP2018202812A (en) * 2017-06-08 2018-12-27 ケイミュー株式会社 Method for producing cement molding

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JP2018202812A (en) * 2017-06-08 2018-12-27 ケイミュー株式会社 Method for producing cement molding

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