JP2880659B2 - Manufacturing method of ceramic building boards - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the production of a ceramic building board in which a slurry-forming molding material is injected into a lower mold cavity, the upper mold is lowered while decompressing and dewatering, and the ceramic building board is press-formed. It is about the method.

[0002]

2. Description of the Related Art Conventionally, as a method of forming a concrete product, for example, Japanese Patent Publication No.
As disclosed in Japanese Patent No. 75860, there is known a dehydration molding method in which a molding material in a cavity is depressurized and dehydrated by a decompression dehydrator while an upper mold is lowered and press-molded.

[0003]

The present inventor has attempted to apply this dehydration molding method to the molding of ceramic building boards, but has the following problems. That is, the molding material used in the conventional dehydration molding method is a mixture of cement and coarse aggregate, which has good drainage inside the molding material and relatively low filtration resistance, but is attached to the outer wall of the house. The molding material used for the molding of ceramic building boards is a slurry made by mixing a fibrous material such as pulp and organic synthetic fiber with water in an inorganic hydraulic fine particle material such as cement, and has a fine texture. Compared with a molding material containing coarse aggregate, drainage inside the molding material is poor and filtration resistance is large.
For this reason, even if the molding material is dehydrated under reduced pressure, the dehydration rate is slow, and a long dehydration time is required to perform sufficient dehydration, resulting in poor molding efficiency. Moreover, if the upper mold is lowered and press-molded in a state where the dehydration is insufficient, a molding material having a large amount of water leaks from the periphery of the upper mold, and the yield is deteriorated.

In the dehydration molding method disclosed in Japanese Patent Publication No. 6-75860, a filter cloth is stretched on the upper surface of a vacuum dehydrator and the molding material is dewatered on the filter cloth and press-molded. The clogging of the filter cloth is fast, and the operation of stopping the molding apparatus during the molding operation and replacing the filter cloth has to be performed, so that the operation rate of the molding apparatus also deteriorates, which also deteriorates the molding efficiency. Cause.

Furthermore, since the molded product lifted together with the upper mold after the press molding is pushed down onto a pallet by a press plate and transferred, there is a disadvantage that the surface of the molded product is easily damaged and the yield is deteriorated.

In view of such circumstances, a first object of the present invention is to enable sufficient dehydration under reduced pressure without impairing the molding efficiency.
It is an object of the present invention to prevent the molded product from being damaged in the process of removing and transferring the molded product.

[0007]

According to a first aspect of the present invention, there is provided a method for manufacturing a ceramic building board according to the first aspect of the present invention, wherein a slurry-forming molding material is injected into a cavity of a lower mold. A method of press-molding a ceramic building board by lowering the upper mold while dewatering under reduced pressure, wherein a plurality of lower molds are provided so as to be slidable, and a molding material in the cavity is provided below each lower mold. A vacuum dewatering device for dehydrating under reduced pressure is provided, and a molding material is injected in a state where a filter pad is laid in the cavity of each of the lower dies. While the lower mold having been completed is sequentially slid to the press molding position, the molding material in the cavity of the lower mold is lowered at the press molding position while continuously decompressing and dehydrating the molding material in the cavity of the lower mold. It is intended to press molding.

According to a second aspect of the present invention, a roller is provided on the plurality of lower dies, and a guide rail is provided so as to be able to move up and down in correspondence with the rollers. Then, the guide rail is lifted, and the roller is placed on the guide rail and lifted, so that the lower mold is floated from the gantry. In this state, the lower mold is pressed along the guide rail. Then, at the time of press molding, the guide rail is lowered to return the lower die to a state of being placed on the press base plate, and press molding is performed.

According to a third aspect of the present invention, a U-shaped rubber member for both air suction and sealing is attached to the entire periphery of the lower surface of the upper die with its groove opening facing inward. The air suction port formed in the upper portion is communicated with an external air suction device through a through hole formed in the upper die, and during press molding, the air suction device allows the air suction device to pass through the groove of the U-shaped rubber member into the cavity. Press-molding while sucking the air in the upper part of the U-shaped rubber member, and as the press-forming proceeds, the lower surface of the U-grooved rubber member is crushed and the air suction port is closed by the lower surface of the U-grooved rubber member. It is made to become.

According to a fourth aspect of the present invention, in removing the press-formed product from the cavity, the press-formed product is adsorbed to the upper mold together with the filter pad by an air suction force. And taken out, transferred to a filter pad separating step, and in this filter pad separating step, a curved suction pad made of a soft sponge is addressed to the upper surface of the press-formed product and sucked by air suction force, The press-formed product is temporarily deformed along the curved shape of the suction pad to separate the press-formed product from the filter pad.

[0011]

According to the first aspect of the present invention, the molding material is poured in a state where the filter pad is laid in the cavities of the plurality of lower molds, and the molding material on the filter pad is preliminarily dehydrated by the reduced pressure dehydrating device. The lower mold after the preliminary dewatering is slid to the press molding position sequentially, and the molding material in the cavity of the lower mold is depressurized and dewatered by the vacuum dehydrator at the press molding position, and the upper mold is lowered to perform press molding. Therefore, even if there is a situation where the filtration resistance of the molding material used for molding ceramic building plates is large, the pre-dehydration is performed with another lower mold using a reduced pressure dehydrator in parallel with the press molding, so that the molding efficiency can be improved. The molding material can be sufficiently dehydrated under reduced pressure without damage.

In addition, the molding material is injected with the filter pad being laid in the cavity of each lower mold, and the molding material is depressurized and depressurized on the filter pad. There is no need to stretch the filter cloth on which the filter cloth is to be placed, so that the conventional troublesome work of replacing the filter cloth is not required. The filter pad which functions as a filter cloth in the present invention only needs to be laid in the cavity, and does not impair the molding efficiency.

According to the second aspect of the present invention, when the lower mold after the preliminary dewatering is slid to the press forming position, the guide rail is raised, and the lower mold roller is placed on the guide rail and lifted. In a state of being floated from the gantry. In this state, the lower mold can be easily slid to the press forming position by rolling the rollers of the lower mold along the guide rails. At the time of press forming, the guide rail is lowered to return the lower die to a state of being placed on the press base plate, and press forming is performed. Thereby, the press pressure can be received and supported by the press base plate.

According to a third aspect of the present invention, a U-shaped rubber member for both air suction and sealing is attached to the entire lower surface of the upper die with its groove opening facing inward. The air suction port formed in the upper portion is communicated with an external air suction device through a through hole formed in the upper die, and during press molding, the air suction device allows the air suction device to pass through the groove of the U-shaped rubber member into the cavity. Press molding while inhaling the air above. As a result, excess water in the upper part of the cavity is sucked out together with air,
Dehydration under reduced pressure is also performed from the upper side in the cavity, and the dehydration rate is increased.

At this time, as the press molding proceeds, the lower surface of the U-groove rubber member is crushed, and the air suction port is closed by the lower surface of the U-groove rubber member. Will be stopped. Accordingly, it is possible to prevent the molding material in the upper portion of the cavity from being sucked out, and after the press molding is completed, the press molded product can be taken out together with the filter pad into the upper die by the air suction force and taken out.

According to a fourth aspect of the present invention, when the press-formed product is taken out of the cavity, the press-formed product is taken out of the cavity together with the filter pad by the air suction force and transferred to a filter pad separating step. . Since this transfer is performed while the filter pad is attached to the lower surface of the press-formed product, the lower surface of the press-formed product is protected by the filter pad and is not damaged. Then, in the filter pad separation step, a curved suction pad made of a soft sponge is addressed to the upper surface of the pressed product and is suctioned by air suction force, so that the pressed product is temporarily moved along the curved shape of the suction pad. To separate the pressed product from the filter pad. At this time, since the suction pad addressed to the upper surface of the pressed product is formed of a soft sponge, the pressed product can be separated from the filter pad without damaging the upper surface of the pressed product.

[0017]

An embodiment of the present invention will be described below with reference to the drawings. First, the configuration of the entire molding apparatus will be described. A pair of press cylinders 13 for vertically moving the upper die 12 are attached to the press body base 11. Upper mold 1
2 is mounted on a mold holder 15 fixed to a rod 14 of a press cylinder 13.

On the other hand, a gantry 17 is installed on the base 16 so as to pass below the upper mold 12, and, for example, two lower dies 18 are placed on the gantry 17. Each lower die 18
Constitutes a cavity 21 by left and right end plates 19 and front and rear side plates 20 (see FIGS. 2 and 3). Lower mold 18
As shown in FIGS. 2 and 3, the side plate 20 is pressed by a side plate presser die 40, and the side plate presser die 40 performs a mold clamping and mold opening operation by a presser die cylinder 41. Has become.

As shown in FIG. 3, a suction box 22 (vacuum dehydrator) for sucking air is provided at the bottom of each lower mold 18. A large number of water passage holes 24 are formed in the upper surface of the suction box 22, and the molding material 25 in the cavity 21 is dehydrated under reduced pressure through the water passage holes 24. An intake port 26 is formed at the upper side of the suction box 22, and the intake port 26 is connected to an external vacuum pump (not shown) via an air hose 27. A drain port 28 is formed at the lower end of the other side surface of the suction box 22. The drain port 28 is connected to an external drain pump (not shown) via a drain hose 29.

A filter pad 30 for filtering the molding material 25 is provided on the upper surface of the suction box 22 (ie, the bottom surface of the cavity 21). The filter pad 30 is mounted such that a filter material 32 made of filter cloth or canvas is wound around a mesh-like core material 31 made of metal or plastic (see FIG. 4).

Next, a structure for sliding the lower die 18 along the gantry 17 will be described. As shown in FIGS. 1 and 3, the gantry 17 is provided with two guide rails 33 so as to be vertically movable by a plurality of cams 34, respectively.
Each cam 34 is driven by a rail vertical movement cylinder 36. According to the guide rail 33, each lower die 18
Rollers 37 are rotatably provided at the lower portions on both side surfaces of the lower die 18. When the guide rails 33 are lifted, the rollers 37 of the lower die 18 are placed on the guide rails 33 and lifted, thereby lowering the lower die 18 to the gantry 17 (or The lower die 18 is allowed to slide freely along the guide rails 33 while being floated from the press base plate 57). In this state, the lower die 18 is pushed (or pulled) by the lower die slide cylinder 38 to the pre-dehydration position (I) or (III).
Between press and the press forming position (II).

On the other hand, the lower surface of the upper mold 12 is shown in FIGS.
As shown in the figure, an uneven pattern for press molding is formed. A U-shaped rubber member 43 for both air suction and sealing is attached to the entire lower surface of the upper die 12 with its groove opening facing inward. An air inlet 44 formed at the four corners of the upper surface of the U-shaped rubber member 43 and the center of the long side has a through hole 45 formed in the upper die 12 and an air hose 46 (FIG. 1).
) Is connected to an external air suction device (not shown) through the U-shaped rubber member 43 and press-formed while suctioning the upper air in the cavity 21 through the groove of the U-shaped rubber member 43 during press-forming. I have.

After the completion of the press molding, the press molded product 50 is attracted to the upper die 12 together with the filter pad 30 by an air suction force, taken out of the cavity 21, and placed on a conveyor 51 as shown in FIG. Transfer to pad separation process. The filter pad separating device 52 that separates the press molded product 50 from the filter pad 30 in the filter pad separating step has the following configuration.

That is, as shown in FIG. 8 (b), the suction box 53 movably provided up and down
4 is connected to a high-pressure blower (not shown). On the other hand, a curved suction pad 55 made of a soft sponge is attached to the lower surface of the suction box 53 by bonding or the like, and suction pressure is applied to the lower surface of the suction pad 55 through a number of suction holes formed on the entire lower surface of the suction box 53. FIG. 8 (c)
As shown in FIG. 7, the press-formed product 50 is curvedly deformed and separated from the filter pad 30. After the separation, the air hose 54 is switched from a high pressure blower to a compressed air source by switching a valve (not shown), and the compressed air is sent to the suction pad 55 to release the suction.

The process of manufacturing a ceramic building plate using the molding apparatus having the above-described structure will be described. An overview of the entire process is shown in FIG. In FIG. 1, (I) and (III)
Is the preliminary dewatering position, and the position (II) is the press forming position. The lower die 18 that has been subjected to the preliminary dehydration at the preliminary dehydration position (I) is slid to the press molding position (II),
Along with this, the lower die 18 of the press forming position (II) is pushed out to the preliminary dewatering position (III). Each time press molding is performed, the slide direction is reversed from the previous
To perform press molding continuously.

At the preliminary dewatering position (I) or (III), a predetermined amount of molding material 25 is charged into the cavity 21 from a material supply device (not shown). At this time, cavity 2
A filter pad 30 is laid on the bottom surface of 1, and the molding material 25 falls on the filter pad 30. The molding material 25 is made of an inorganic hydraulic fine particle material such as cement,
It is a slurry obtained by mixing a fibrous material such as an organic synthetic fiber and water with water.

After the molding material 25 is charged into the cavity 21, the inside of the suction box 22 below the cavity 21 is sucked by a vacuum pump (not shown) to reduce the pressure inside the suction box 22, thereby reducing the pressure of the molding material 25.
Is sucked into the suction box 22 from the water holes 24 through the filter pad 30. The sucked water is discharged from the drain port 28 to the outside of the suction box 22.

While the molding material 25 in the cavity 21 is being preliminarily dehydrated at the preliminary dewatering position (I) or (III), the lower mold 18 is lowered at the press molding position (II). Perform press molding. At this press molding position (II), dewatering is continued under reduced pressure to increase the dewatering rate. Further, at the time of the press forming, the press forming is performed while the upper air in the cavity 21 is sucked through the groove of the U-shaped rubber member 43 on the lower surface of the lower die 18. Thereby, the cavity 2
The excess water in the upper part of 1 is sucked out together with the air,
Dehydration under reduced pressure is also performed from the upper side in the cavity 21, and the dehydration rate is effectively increased.

At this time, the press molding proceeds and the cavity 2
As the suction of the air in the upper part of the inside 1 progresses, the U-shaped rubber member 43
Is crushed, the air suction port 44 is closed by the lower surface of the U-shaped rubber member 43, and the air suction is automatically stopped. This prevents the upper molding material 25 in the cavity 21 from being sucked out. After the completion of the press molding, the press molded product 50 is adsorbed to the upper mold 12 together with the filter pad 30 by an air suction force, taken out, placed on a conveyor 51, and transferred to a filter pad separating step. Since this transfer is performed with the filter pad 30 attached to the lower surface of the press-formed product 50,
The lower surface of the press-formed product 50 is protected by the filter pad 30 and is not damaged.

On the other hand, when the press-formed product 50 is adsorbed to the upper die 12 together with the filter pad 30 and is taken out, the lower die 1 having been subjected to the preliminary dehydration at the preliminary dehydration position (I) or (III).
8 is slid to the press forming position (II) as follows. First, the cam 34 is driven by the rail up / down operation cylinder 36 to raise the guide rail 33. As a result, the roller 37 of the lower die 18 is lifted by placing it on the guide rails 33, and the lower die 18 is lifted from the gantry 17, so that the lower die 18 can be freely slid along the guide rails 33. In this state, the lower slide cylinder 38
Pushes (or pulls) the lower die 18 to move the lower die 18 in the preliminary dewatering position (I) or (III) to the press forming position (I
The lower die 18 of the press forming position (II) is slid to the preliminary dewatering position (III) or (I).

When the slide is completed, the cam 34 is returned to the original position, the guide rail 33 is lowered, and the lower die 18 in the preliminary dewatering position (I) or (III) is placed on the gantry 17 and pressed. The lower die 18 at the position (II) is placed on the press base plate 57, and the press pressure is received and supported by the press base plate 57. Thereafter, the pre-dehydration and the press molding are performed in parallel, so that the press-forming is continuously performed while the pre-dehydration is performed. Therefore, even if there is a situation that the filtration resistance of the molding material 25 used for molding the ceramic building board is large, the pre-dehydration is performed with the other lower mold 18 during the press molding, so that the molding efficiency is not impaired. The material 25 can be sufficiently dehydrated under reduced pressure.

In addition, since the molding material 25 is injected with the filter pad 30 laid in the cavity 21 of each lower mold 18 and the molding material 25 is subjected to reduced pressure dehydration and press molding on the filter pad 30, a conventional method is used. As described above, there is no need to stretch the filter cloth on which the molding material is placed on the upper surface of the vacuum dehydrating apparatus, so that the conventional troublesome work of changing the filter cloth is unnecessary. In this embodiment, the filter pad 30 serving as a filter cloth only needs to be laid in the cavity 21 and does not impair the molding efficiency.

On the other hand, in the filter pad separating step, FIG.
As shown in FIG. 5, a curved suction pad 55 made of a soft sponge is applied to the upper surface of the press-formed product 50 and is suctioned by the air suction force of a high-pressure blower.
Is temporarily deformed along the curved shape of the suction pad 55 to separate the press-formed product 50 from the filter pad 30. At this time, since the suction pad 55 addressed to the upper surface of the press molded product 50 is formed of a soft sponge, the press molded product 50 is separated from the filter pad 30 without damaging the upper surface of the press molded product 50. can do.

The press-formed product 50 thus separated from the filter pad 30 is hardened and cured as shown in FIG.
It becomes a product after curing process, drying / cutting process, and painting process. On the other hand, the filter pad 30 is returned to the press forming step with or without passing through a cleaning device, and is laid in the lower mold 18 in the preliminary dewatering position (I) or (III).

In the above embodiment, the preliminary dewatering and the press molding are performed in parallel by using two lower dies 18, but a plurality of lower dies are used by using three or more lower dies 18. Press-forming may be performed using another lower mold 18 while performing the preliminary dewatering at 18, and the longer the number of lower dies 18, the longer the preliminary dewatering time can be taken.

[0036]

As is apparent from the above description, according to the method for manufacturing a ceramic building board of the first aspect of the present invention, a molding material is formed while a filter pad is laid in a plurality of lower mold cavities. Injection, the molding material on the filter pad was pre-dewatered, and the pre-dewatered lower mold was slid to the press molding position in order to press-mold, so that the molding material used for molding ceramic building plates Even under circumstances where filtration resistance is high, by performing preliminary dewatering in another lower mold in parallel with press molding, the molding material can be sufficiently dewatered under reduced pressure without impairing molding efficiency. Accordingly, it is possible to prevent the molding material having a large amount of moisture from leaking from the periphery of the upper mold, and to improve the yield. Moreover, since the decompression dehydration and press molding of the molding material are performed on the filter pad laid in the cavity of each lower mold, there is no need to stretch a filter cloth for placing the molding material on the upper surface of the decompression dehydrator as in the conventional case. The conventional troublesome work of replacing the filter cloth is not required.

According to the second aspect of the present invention, when the lower mold after the preliminary dewatering is slid to the press forming position, the guide rail is raised, and the lower mold roller is placed on the guide rail and lifted. Is made to float from the gantry, so that the lower die can be easily slid to the press molding position. In addition, during press forming, the guide rail is lowered and the lower mold is returned to the state where it is placed on the press base plate, and press forming is performed, so press pressure can be received and supported by the press base plate, and stable press forming is possible. is there.

On the other hand, in claim 3, the entire periphery of the lower surface of the upper die is
A U-groove rubber member serving both as an air intake and a seal is mounted with its groove opening facing inward, and press-molded during press molding while sucking the upper air in the cavity through the groove of the U-groove rubber member. So the excess water in the upper part of the cavity can be sucked out together with the air,
Dehydration under reduced pressure can be performed also from the upper side in the cavity, and the dehydration rate can be further increased. In addition, as the press molding proceeds, the lower surface of the U-shaped rubber member is crushed and the air suction port is closed by the lower surface of the U-shaped rubber member, so that the upper molding material in the cavity is sucked out. In addition to preventing press molding, after completion of press molding, the press molded product can be taken out together with the filter pad by suction onto the upper die.

According to the fourth aspect of the present invention, the work of taking out the press-formed product from the cavity and transferring it to the filter pad separating step is performed with the filter pad attached to the lower surface of the press-formed product. The lower surface can be protected by the filter pad, and the press molded product can be prevented from being damaged. Then, in the filter pad separation step, a curved suction pad made of a soft sponge is addressed to the upper surface of the pressed product and is suctioned by air suction force, so that the pressed product is temporarily moved along the curved shape of the suction pad. In order to separate the press-formed product from the filter pad, the separation of the filter pad can be automated, and a soft sponge suction pad can be used to filter the press-formed product without damaging the upper surface of the press-formed product. Can be separated from the pad.

[Brief description of the drawings]

FIG. 1 is a front view of a molding apparatus showing one embodiment of the present invention.

FIG. 2 is a plan view of a molding apparatus.

FIG. 3 is an enlarged sectional view taken along line AA of FIG. 1;

FIG. 4 is a perspective view of a filter pad.

FIG. 5 is a perspective view of an upper mold.

6A is a sectional view taken along line BB of FIG. 5, and FIG. 6B is a sectional view taken along line CC of FIG.

FIG. 7A is an enlarged sectional view of an air inlet portion of a U-shaped rubber member, and FIG. 7B is an enlarged sectional view of another portion of the U-shaped rubber member.

FIG. 8 is a process diagram illustrating a filter pad separation process.
(A) is a diagram showing a state before separation, (b) is a diagram showing a state when the suction pad is addressed to the upper surface of the press-formed product,
(C) is a diagram showing a state when the press-formed product is adsorbed on the suction pad and separated from the filter pad.

FIG. 9 is a process diagram showing a manufacturing process of a ceramic building board.

[Explanation of symbols]

12 ... upper mold, 17 ... stand, 18 ... lower mold, 21 ... cavity, 22 ... suction box (decompression dehydrator), 24
... water passage hole, 25 ... molding material, 26 ... intake port, 28 ... drain port, 30 ... filter pad, 33 ... guide rail, 34
... Cam, 36 ... Cylinder for vertical movement of rail, 37 ... Roller, 38 ... Cylinder for lower die slide, 43 ... U-shaped rubber member, 44 ... Air intake port, 45 ... Through hole, 50 ... Press molded product, 51 ... Conveyor, 52: Filter pad separation device, 53: Suction box, 55: Suction pad, 5
7 ... Press base plate.

────────────────────────────────────────────────── ─── Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B28B 5/04 B28B 3/02

Claims (4)

(57) [Claims] 1. A method of injecting a molding material slurried into a cavity of a lower mold, press-forming a ceramic building plate by lowering the upper mold while dehydrating under reduced pressure, and slidingly moving a plurality of lower molds. Provided as possible, provided in the lower part of each lower mold, a reduced pressure dehydrator for decompressing and dehydrating the molding material in the cavity, injecting the molding material with a filter pad laid in the cavity of each lower mold, The molding material on the filter pad is preliminarily dehydrated by the decompression dewatering device, and the lower mold after the preliminary dehydration is sequentially slid to a press molding position, and the molding material in the cavity of the lower mold is depressurized at the press molding position. A method for manufacturing a ceramic building board, comprising lowering the upper die and press-molding the same while continuously dehydrating under reduced pressure by a dehydrator. 2. A plurality of lower dies are provided with rollers, and guide rails are provided correspondingly to the rollers so as to be able to move up and down. By raising the roller on the guide rail to lift the lower mold from the gantry, in this state, slide the lower mold to the press forming position along the guide rail, The method for manufacturing a ceramic building board according to claim 1, wherein at the time of press forming, the guide rail is lowered to return the lower mold to a state of being placed on a press base plate and press forming is performed. 3. A U-shaped rubber member serving both as an air intake and a seal is attached to the entire periphery of the lower surface of the upper die with its groove opening facing inward, and is formed on the upper surface of the U-shaped rubber member. The air suction port is communicated with an external air suction device through a through hole formed in the upper mold, and at the time of press molding, the upper air in the cavity is passed through the groove of the U-shaped rubber member by the air suction device by the air suction device. The press-forming is performed while inhaling, and as the press-forming proceeds, the lower surface of the U-grooved rubber member is crushed and the air suction port is closed by the lower surface of the U-grooved rubber member. The method for producing a ceramic building board according to claim 1. 4. When taking out the press-formed product from the cavity, the press-formed product is taken out together with the filter pad by suction to the upper die by an air suction force, and is transferred to a filter pad separating step. In the separation step, a curved suction pad made of a soft sponge is addressed to the upper surface of the press-formed product and is suctioned by an air suction force, so that the press-formed product is temporarily moved along the curved shape of the suction pad. The method for manufacturing a ceramic building board according to claim 3, wherein the press-formed product is separated from the filter pad by deforming the press-formed product.