JP2020100991A - Roof tile and outer wall material manufacturing method - Google Patents

Abstract

To provide a manufacturing method for manufacturing a roof tile and an outer wall material which are light in weight and have bubbles in a foamed state exposed on a surface and have a rough texture and appearance.SOLUTION: A roof tile 10 is obtained by: molding a foam by heating stock solution mixed of, for example a vinyl chloride resin used as a thermoplastic resin, for example xylene used as an organic solvent, for example azodicarbonamide used as a foaming agent, and for example calcium carbonate used as an inorganic filler; forming an original plate for a roof tile by cutting the foam into a predetermined shape so as a cut surface to be an outer surface; and pressing to deform the original plate for the roof tile with a press mold having a press surface in a roof tile shape under heating.SELECTED DRAWING: Figure 6

Description

TECHNICAL FIELD The present invention relates to manufacturing roof tiles and outer wall materials, which are external building materials for buildings.

Roof tiles made of clay are generally used for the roof as an external building material of the building. Similarly, as an outer wall material, ceramic siding, which mainly uses cement as a raw material, ALC (autoclaved light weight concrete) panels, tiles and the like are used. Patent Documents 1 and 2 are shown as examples of such conventional roof tiles and outer wall materials.

JP, 2008-214954, A JP, 2005-168604, A

However, conventional roof tiles and outer wall materials are difficult to construct due to their heavy weight, and they are not always optimal materials in consideration of disasters such as typhoons and earthquakes. Further, there is also a problem that construction costs and material costs are increased by using conventional roof tiles and outer wall materials even if it is not necessary to spend much money on a temporary building.

In order to solve the above-mentioned problems, in the means 1, a foam formed by heating a stock solution in which a thermoplastic resin, an organic solvent, a foaming agent, and an inorganic filler are mixed is cut into a predetermined shape to form a cut surface. The roof tile is manufactured by forming a roof tile precursor whose outer surface is the outer surface and pressing the roof tile precursor under heating with a press die having a roof tile-shaped pressing surface to deform the roof tile.
In addition, in the means 2, the foam formed by heating the undiluted solution in which the thermoplastic resin, the organic solvent, the foaming agent and the inorganic filler are mixed is cut into a predetermined shape, and the outer surface whose cut surface is the outer surface. A material precursor was prepared, and the outer wall material precursor was manufactured by pressing and deforming the outer wall material precursor with a press die having an outer wall material-shaped pressing surface under heating.
When the roof tile and the outer wall material are manufactured in this manner, it is possible to obtain the roof tile and the outer wall material that are lightweight and have a texture and appearance in which foamed bubbles are exposed on the surface and have a rough texture. Then, if the roof tile or outer wall material has such a texture, a coloring material such as paint or paint can be easily applied when further coloring it, and the roof tile or outer wall material having the conventional texture and appearance even when colored You can get a product like.

The thermoplastic resin required to adjust the stock solution in the above means, for example, styrene-based thermoplastic elastomer, olefin-based thermoplastic resin, urethane-based thermoplastic resin, vinyl chloride-based thermoplastic resin, polyamide-based thermoplastic resin, Ester-based thermoplastic resins, polyethylene, polycarbonate, polyvinyl chloride, polypropylene, polystyrene, polylactic acid, nylon, polyacetal, modified polyphenylene ether, polyethylene terephthalate, polybutylene terephthalate and the like are preferable, and vinyl chloride thermoplastic resin is particularly preferable.
The organic solvent can be widely used as long as it dissolves a generally used thermoplastic resin, but toluene, xylene, acetone, hexane, isopropyl alcohol and the like are particularly preferable. As these organic solvents, suitable solvents are selected according to the type of thermoplastic resin.
As the foaming agent, azodicarbonamide, azobisisobutylnitrile, dinitrosopentatetramine, P-toluenesulfonyl hydrazide, P,P'-oxybis(benzenesulfonyl hydrazide) and the like are preferable in the organic system, and, for example, in the inorganic system, Sodium bicarbonate, ammonium chloride, etc. are preferred.
As the inorganic filler, for example, calcium carbonate, carbonate compounds such as magnesium carbonate, hydroxides such as aluminum hydroxide, magnesium hydroxide, calcium hydroxide, gypsum, compounds having crystal water such as aluminum sulfate, and the like, In addition, compounds such as talc, bentonite and clay, or silicates may be used. These inorganic fillers can be used alone or in combination of two or more.

Further, a plasticizer or a flame retardant may be added to the stock solution. The plasticizer can improve flexibility and weatherability by mixing it.
Examples of the plasticizer include dimethyl phthalate, dibutyl phthalate, diheptyl phthalate, dioctyl phthalate, diisonolyl phthalate, diisodecyl phthalate, butylbenzyl phthalate, dicyclohexyl phthalate, tricresyl phosphate, tributyl phosphate, tris(2). -Ethylhexyl)phosphate, tri(chloroethyl)phosphate, trischloropropylphosphate, ortyldiphenylphosphate, tris(isopropylphenyl)phosphate, cresyldiphenylphosphate, dioctylazelate, paraffin chloride and the like are preferable.
Examples of the flame retardant include tetrabromobisphenol A, 2,2-bis(4-hydroxy-3,5-dibromophenyl)propane, hexabromobenzene, tris(2,3-dibrimopropyl)isocyanurate, 2,2- Bis(4-hydroxyethoxy-3,5-dibromophenyl)propane, decabromodiphenyl oxide ammonium phosphate, tricresyl phosphate, triethyl phosphate, tris(β-chloroethyl)phosphate, trischloroethyl phosphate, trisdichloropropyl phosphate, Cresyl diphenyl phosphate, xylenyl diphenyl phosphate, red phosphorus, tin oxide, antimony trioxide, zirconium hydroxide, barium metaborate, aluminum hydroxide, magnesium hydroxide and the like are preferable.

In the above, when "cutting the foam into a predetermined shape", it is preferable to cut it into a thin plate shape to a degree close to the thinness of the roof tile or the outer wall material. Also, when pressing, unnecessary parts should be cut so as not to interfere with the press die, but when pressing, cut to a size that does not interfere with the press and obtain it when the press is completed. You may make it cut to a roof tile shape (or outer wall material shape). The cutting work may be machine cutting or manual cutting. You may use both together.
In the above, since the roof tile precursor (or outer wall material precursor) "the cut surface becomes the outer surface", the skin layer formed by crushing the surface in contact with the mold by so-called foaming is no longer cut, It has a rough texture and appearance.
In the above description, "the roof tile precursor is heated and deformed by pressing with a press mold having a roof tile-shaped pressing surface" means that the roof tile is warped, bent, or has an uneven pattern on the surface. In that case, a press surface corresponding to the shape is formed on the press die side, and the roof tile precursor is pressed by the press surface to deform the precursor, and the roof tile precursor is heated. The body alone or the press mold may be heated at the same time, and any of them may not be heated. Further, the entire processing work atmosphere may be heated. Further, as a press mode, for example, a roof tile precursor may be arranged and pressed between a pair of male and female mold pieces, and for example, the roof tile precursor may be placed on the press mold to form the roof tile precursor. It may be deformed so as to press against the press die. The same applies to "the outer wall material precursor is pressed and deformed by a press die having a pressing surface in the shape of the outer wall material under heating".
The press die is preferably made of a hard and wear-resistant material such as a metal (iron alloy), a sintered body (baked product) made from clay, stone, or thermosetting plastic. A die as a press die is particularly preferable because it does not deteriorate due to heat. In addition, "roof tiles" include Japanese roof tiles and Western roof tiles. The "outer wall material" is, for example, a siding or tile-like plate material.

In the means 3, the roof tile precursor (or the outer wall material precursor) is preheated before being pressed by the press mold.
This makes it possible to deform the roof tile precursor (or the outer wall material precursor) without necessarily heating the press die. In addition, when the roof tile precursor (or outer wall material precursor) is deformed by heating the press mold, it is not easy to deform unless the precursor side is preheated, and the precursor may crack. Because there is. The preheating condition is not constant depending on the melting point of the thermoplastic resin used, but for example, in the case of vinyl chloride resin, it is preferably about 80 to 100°C.
Further, in the means 4, the press mold is preheated before the roof tile precursor (or the outer wall material precursor) is pressed.
Even if the roof tile precursor (or outer wall material precursor) is preheated or not, the precursor can be surely deformed by preheating the press die, and the precursor once deformed becomes the original shape. It is difficult to return. If the press die is preheated after the precursor is preheated, the precursor is surely deformed and it is difficult to return after solidification.
The preheating temperature is not constant depending on the melting point of the thermoplastic resin used as the precursor and the shape of the precursor used, for example, the thickness, but if the thermoplastic resin is a vinyl chloride resin, it is preferably about 120 to 160°C.
In the means 5, the foam is foamed with homogeneous closed cells.
A foam that is foamed with homogeneous closed cells is suitable as an external building material for this type of building, since water does not pass through the inside during use.
In the means 6, the thermoplastic resin is vinyl chloride resin.
The vinyl chloride resin foam is also excellent in terms of chemical resistance, mechanical strength, etc., and it generates uniform bubbles (foaming) of appropriate size to give the texture of roof tiles and outer wall materials. It is also suitable because it is easy.

Here, an example of suitable conditions when a vinyl chloride resin is used as an example of a thermoplastic resin will be described. Other thermoplastic resins can also be used by appropriately changing the conditions.
(Mixing conditions)
To 50 to 95 parts by weight of a vinyl chloride resin and 50 to 95 parts by weight of an inorganic filler, 30 to 100 parts by weight of an organic solvent and 2 to 20 parts by weight of a foaming agent are added and kneaded to form a compound, and the compound is kneader (mixed). Mix with a continuous machine). At this time, it is important to suppress the temperature so that foaming does not occur, and therefore, it is preferable to appropriately cool the kneader or the like. Foaming does not occur if the temperature is lower than about 50°C.
(Heating condition)
Next, this kneaded material is enclosed in a first mold and heated to uniformly generate bubbles. That is, primary foaming is preferable. The size of the first mold is not particularly limited, but since the plate body is finally molded, it is preferable to use a rectangular mold having a smaller thickness than the length and width. This mold can be heated or cooled from the upper surface and the lower surface, and at the time of primary foaming, it may be heated to about 140 to 170° C. to generate bubbles.
The vinyl chloride resin is gelated by heating. When the inside of the mold becomes hot and bubbles are generated, the volume increases and the inside of the mold becomes high pressure, and the bubbles are uniformly diffused in the gelled vinyl chloride resin and the inorganic filler. Becomes
Then, the press of the first mold is gradually pressed to take out the product (primary foam plate) from the mold. At this point, the primary foam plate has a size of 30 to 40% of the target expansion ratio. The expansion ratio is a value indicating how many times the volume of the obtained foam plate body becomes larger than the initial volume.

Next, the primary foam plate body is transferred to a second mold and heated to grow seed bubbles and expand so as to be 5 to 20 times as much as the desired expansion ratio of the stock solution. That is, secondary foaming is performed to obtain a secondary foam plate. The heating temperature at this time is preferably 100°C to 150°C. The mold at this time is larger than the mold at the time of primary foaming, and it is preferable to use a rectangular mold that is thinner than the length and width like the mold at the time of primary foaming, and then gradually cool to room temperature. To cure. As in the case of the primary foam plate, the temperature of the inside of the mold becomes high due to heating, and seed bubbles grow, so that the volume increases and the inside of the mold becomes high pressure. After that, the product is gradually heated to remove the organic solvent to obtain a product as a foam plate.
In this preferred example, the foam is molded in a plurality of times as an example, but it may be foamed in a single time.

According to the present invention, it is possible to obtain a roof tile or outer wall material that is lightweight and has a texture and appearance in which bubbles in a foamed state are exposed on the surface and are rough.

FIG. 3 is a schematic diagram of a state in which a mold and a heating plate that also serves as a lid that covers the upper part of the mold are alternately stacked in the vertical direction in the first embodiment. Similarly, the explanatory view explaining the image in which the primary foam has come out of the mold. Explanatory drawing explaining the primary foam body similarly accommodated in the storage, and that the primary foam body foamed into a secondary foam body. (A) A schematic view of a state in which the secondary foam is cut into two pieces, and (b) is a schematic view of a state in which the secondary foam cut into two pieces is laminated by applying a load. Explanatory drawing explaining the state which further cut|disconnected the secondary foam body cut into two pieces so that it might become square in planar view. (A) is a perspective view of a roof tile, (b) is a top view, (c) is sectional drawing in the AA line of (b). (A) is explanatory drawing of the state just before pressing the roof tile original plate with the roof tile metal mold|die on the end surface side arrange|positioned facing the ridge side, (b) is explanatory drawing of the same pressed state. (A) is explanatory drawing of the state just before pressing the roof tile original plate with the roof tile metal mold|die on the end surface side arrange|positioned facing the eaves side, (b) is explanatory drawing of the same pressed state. (A) is a perspective view of the tile roof plate, (b) is a perspective view of a tile roof plate obtained by bending the tile roof plate of (a) along a mold, and (c) is a side view of the tile roof plate. The side view of the state which arranged the tile original plate in the cutting die. FIG. 3 is a perspective view of a cutting die.

Hereinafter, the present invention will be described based on embodiments.
(Embodiment 1)
First, an example of a method for manufacturing a foam plate will be described.
1. In the embodiment, vinyl chloride resin is used as the thermoplastic resin, calcium carbonate is used as the inorganic filler, azodicarbonamide is used as the foaming agent, and dimethyl phthalate is used as the plasticizer. Then, xylene is used as an organic solvent, and each predetermined amount is weighed and mixed with a kneader.
2. Primary foaming Filling the kneaded stock solution into a mold 1 having an open upper surface, the mold 1 and a heating plate 2 serving also as a lid covering the upper part of the mold 1 are alternately stacked vertically as shown in FIG. Then, the primary foam 3 is molded by heating for a predetermined time. In FIG. 1, members such as a frame for supporting the stacked mold 1 and the heating plate 2 also serving as the lid are omitted. The heating temperature is set to about 140 to 170° C. (at the surface temperature of the heating plate 2 also serving as the lid). After cooling, the primary foam 3 is depressurized by removing the heating plate that also serves as a lid, and is ejected from the mold 1 to the outside by its own elastic force. Since the upper side of the mold 1 is expanded and the wall surface has a slope, the primary foam 3 swells as the pressure is removed, and the primary foam 3 moves upward with the wall surface as a guide. FIG. 2 is an image-wise illustration of the state where the primary foam 3 has come out of the mold 1.
3. Secondary foam Primary foam 3 is not fully expanded. The bubbles are still in the form of seed bubbles, and there is still room for the primary foam 3 to expand, including the bubbles. Therefore, as shown in FIG. 3, it is housed in the housing 4 and heated by a heater (not shown) for a predetermined time. The heating temperature is set to about 100 to 150°C. As a result, the primary foam 3 expands to fill the inside of the chamber, and the seed cells become the maximum expanded secondary foam 5. The bubbles are closed bubbles. The volume of the secondary foam 5 is about 20 times that of the stock solution.

4. Natural curing The secondary foam 5 molded in this way is allowed to stand as it is until it reaches room temperature.
5. Cut As shown in FIG. 4A, the secondary foam 5 is cut into two pieces in the thickness direction by the cutter C and heated at 100° C. to evaporate the plasticizer. Thereafter, as shown in FIG. 4B, a load is applied (here, a weight plate 8 is placed) so that the cut half of the secondary foam body 5 does not warp, and the stack is left standing. By evaporating the plasticizer, the secondary foam 5 is hardened and thus easy to handle. The cured secondary foamed body 5 is sliced into a plurality of sheets so as to form a plate having a predetermined thickness, and each surface (front side) is ground with sandpaper to have flatness. Then, as shown in FIG. 5, the periphery is cut by a cutter C to completely remove the skin layer, thereby obtaining a flat rectangular parallelepiped foam plate body 6. This foam plate body 6 is further cut vertically and horizontally to obtain a thin roof tile base plate 7 as shown in FIG. 9(a).

The roof tile 10 made of resin is manufactured using the roof tile base plate 7 manufactured as described above. Hereinafter, an example of a method for manufacturing a roof tile will be described.
First, the shape of the roof tile 10 to be manufactured will be described. FIGS. 6A to 6C show a roof tile 10 completed by molding the tile base plate 7. The roof tile 10 is a so-called Spanish roof tile type having a tubular vault shape in which an arch section is extruded horizontally as a whole. In the roof tile 10, the curvature of the arch cross-section changes along the axial direction, the side facing the eaves has a small curvature (a large radius), and the curve becomes a gentle curve, and the side facing the ridge has a large curvature and a sharp curve. Become. In plan view, it is formed in a fan shape such that the side facing the eaves becomes wider. Left and right corners on the eaves side are chamfered portions 10a that are obliquely cut.

The roof tile 10 is manufactured from the tile base plate 7 as follows.
As shown in FIGS. 7 and 8, the roof tile mold 11 includes an upper mold 11A and a lower mold 11B. When both are combined, a space exactly corresponding to the thickness and curve of the roof tile 10 is formed inside. The tile base plate 7 and the roof tile mold 11 are preheated. The roof tile base plate 7 is heated to about 80° C. by a heater (not shown). Further, the roof tile mold 11 is also heated to about 150° C. by a heater (not shown).
As shown in FIGS. 7(a) and 8(a), the worker arranges the roof tile base plate 7 of FIG. 9(a) between the upper mold 11A and the lower mold 11B of the roof tile mold 11 and The mold 11A is brought relatively close to the lower mold 11B side. At this time, since the roof tile base plate 7 is heated, it does not break even if it is pressed and bent by the inner surface shapes of the upper mold 11A and the lower mold 11B. The combination of the two is held for a predetermined time (states of FIG. 7B and FIG. 8B). After that, the upper mold 11A and the lower mold 11B are released from each other, and the roof tile base plate 7 curved (deformed) along the mold is taken out (forms of FIGS. 9B and 9C).
Next, the operator arranges the convex side of the curved roof tile base plate 7 in the cutting die 13 as shown in FIG. The cutting mold 13 is a mold processed into the same inner surface shape as the upper mold 11A of the roof tile mold 11, and the curved curved tile base plate 7 is placed in the longitudinal direction (axial direction) of the roof tile 10. It is a jig for making a parallel shape along the. As shown in FIG. 11, the cutting mold 13 is formed by mixing a curved inner surface shape having the same shape as the upper mold 11A of the roof tile mold 11 with an inclined surface 13a such that the side having a larger curvature in the longitudinal direction becomes lower. There is. When the curved tile roof plate 7 is set at a fixed position in the cutting die 13 as shown in FIG. 10, the upper surface 13b of the die 13 becomes parallel to the longitudinal direction of the curved tile roof plate 7. The roof tile 10 is obtained by cutting along the upper surface 13b with a cutter and cutting the chamfered portion 10a. In this way, the roof tile 10 having a texture and appearance in which all the surfaces have the texture of closed cells is appropriately coated with a paint or dipped in the paint to make a finishing work that looks like a tile.

By using such a roof tile 10, the following effects are exhibited.
(1) Since it is lighter than the conventional roof tile that is sintered, it is advantageous in terms of construction and transportation.
(2) First, a large foam is molded, and the tiles are cut in order to create a large number of roof tile base plates 7, which are then molded. It is less troublesome compared to the conventional method, and can be made faster than molding from the undiluted solution one by one.
(3) Since the skin layer of the roof tile base plate 7 is cut and lost, all the surfaces have a rough texture and appearance of a large number of bubbles. Therefore, the paint is easily fixed in the makeup process, and the appearance after the makeup process has a rough atmosphere, so that it is possible to obtain a product whose appearance is not significantly different from that of a conventional roof roof tile.
(4) Since the bubbles are independent bubbles, rainwater does not soak into the inside of the bubbles.

(Embodiment 2)
Although the roof tile base plate 7 of FIG. 9(a) is held and molded in the roof tile base metal mold 11 in the first embodiment, the roof tile base metal mold 7 is adjusted by adjusting the preheating temperature of the roof tile base plate 7. It is also possible to manufacture the roof tile 10 using the cutting mold 13 of FIG. 11 without using 11.
The operator presses the flat roof tile base plate 7 in FIG. 9A against the inner surface of the cutting die 13. As a result, the roof tile base plate 7 curved as shown in FIG. 10 is arranged in the cutting mold 13. Then, similarly to the above, the roof tile 10 is obtained by cutting with a cutter.
Since the roof tile 10 manufactured as described above is more likely to return to the shape as compared with the case where the roof tile 10 is held in the roof tile mold 11, a tape may be attached to the back surface of the roof tile 10 in order to hold the shape after the makeup processing. Further, it is preferable to preheat the cutting die 13. The same effects as those of the first embodiment are also obtained in the second embodiment. In addition, since the roof tile mold 11 is not limited to the internal space as in the case of using the roof tile mold 11, it is possible to use the tile roof plates 7 having different thicknesses.

The above-described embodiments are merely described as specific embodiments for illustrating the principle and concept of the present invention. That is, the present invention is not limited to the above embodiment. The present invention can also be embodied in the following modified modes.
-In the said embodiment, although the case where a Spanish roof tile was manufactured was mentioned as an example, it is clear that this invention can be applied to various forms of roof tile.
-Although it was an embodiment about a roof tile in the above, it is clear that it can be applied to an outer wall material by changing the die to a master plate size for an outer wall material instead of the roof tile base plate 7.
-In cosmetic processing, other materials may be provided with unevenness on the surface and then the coating material may be applied.
In the above-described embodiment, the foaming process was performed in two stages when obtaining the foamed body (secondary foamed body 5) in which the foaming was completely completed, but depending on the molding method, it may be performed in one stage, or in three or more stages. You may make it foam.
-In the above-mentioned embodiment, the molds 11 and 13 are used, but it is also possible to use a material other than the mold as the press mold.
The present invention is not limited to the configurations described in the above embodiments. The constituent elements of each of the above-described embodiments and modifications may be arbitrarily selected and combined. Further, any constituent element of each embodiment or modification, and any constituent element described in the means for solving the invention or a constituent materializing any constituent element described in the means for solving the invention. And may be combined arbitrarily. With respect to these as well, we have the intention to acquire the right in the amendment or divisional application of this application.
In addition, by applying for a change to a design application, we have the intention to acquire the right for the whole design or partial design. Although the drawing depicts the entire device (article) by a solid line, the drawing includes not only the entire design but also a partial design claimed for a part of the device. For example, it is a drawing in which a part of the device is included in the partial design, and a part of the device is included in the partial design regardless of the members. The part of the device may be a part of the device or a part of the member.

5... Secondary foam as foam, 7... Roof tile precursor as roof tile precursor, 10... Roof tile, 11, 13... Mold.

Claims (10)

A roof tile precursor whose cut surface is the outer surface is created by cutting the foam formed by heating the undiluted solution in which a thermoplastic resin, an organic solvent, a foaming agent and an inorganic filler are mixed, to a predetermined shape. A method for producing a roof tile by pressing the roof tile precursor under heating with a press die having a roof tile-shaped press surface to deform the roof tile. An outer wall material precursor having a cut surface as an outer surface is prepared by cutting a molded foam into a predetermined shape by heating an undiluted solution in which a thermoplastic resin, an organic solvent, a foaming agent and an inorganic filler are mixed. A method of manufacturing an outer wall material, comprising manufacturing the outer wall material by pressing the outer wall material precursor under heating with a press die having a pressing surface having an outer wall material shape to deform the outer wall material precursor. The method for producing a roof tile according to claim 1, wherein the roof tile precursor is preheated before being pressed by the press mold. The method for manufacturing a roof tile according to claim 1 or 3, wherein the press die is preheated before pressing the roof tile precursor. The method for producing a roof tile according to claim 1, wherein the foam is foamed with homogeneous closed cells. The method for producing a roof tile according to any one of claims 1 to 3, wherein the thermoplastic resin is a vinyl chloride resin. The method for producing an outer wall material according to claim 2, wherein the outer wall material precursor is preheated before being pressed by the press die. The method for manufacturing an outer wall material according to claim 2 or 7, wherein the press die is preheated before pressing the outer wall material precursor. 9. The method for manufacturing an outdoor wall material according to claim 2, wherein the foam is foamed with homogeneous closed cells. The said thermoplastic resin is vinyl chloride resin, The manufacturing method of the outer wall material in any one of Claim 2, 7-9 characterized by the above-mentioned.

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