JP3002468B1 - Manufacturing method of cement products - Google Patents

Abstract

An object of the present invention is to provide a method for producing a cement product made of a cement-based material, in which the strength is not reduced on the front and back, and for example, there is no possibility that the pasted product will fall from the skeleton. SOLUTION: A first elastic form 10 for forming a front side shape of a product and a second elastic form 12 for forming a back side shape are prepared. For example, a mortar 16 as a cement material is poured into the respective elastic molds made of urethane rubber, and vibration is applied by a vibration machine 18. Thereafter, the first and second elastic molds 10 and 12 are overlapped, and the mortar 16 in both elastic molds is united. After the combination, the mortar 16 is cured while being set on the receiving member and allowed to stand on the receiving surface of the receiving member.
After drying, it is demolded to obtain a cement product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cast product, such as a tile made of a cement material, which is stretched on a wall or a floor of a house, for example, and more particularly to a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, tiles placed on walls and floors of a house are:
They were extruded using clay materials and pressed using magnetic clay materials.

[0003] However, in each case, it has to be baked after processing, and there has been a problem that the equipment is expensive and cannot be profitable unless it is manufactured in large quantities.

[0004] Therefore, when only a small amount is to be produced, baking is not necessary, and the equipment is inexpensive.

For example, as shown in FIG. 11, a cement-based material 2 is poured into a lower mold 1 having irregularities on the inner surface of the mold, and vibration is applied to obtain a uniform product. After drying for a while, the product was removed from the mold to obtain a product 3 having a surface decoration corresponding to the unevenness of the lower mold 1 on the surface 3a as shown in FIG.

[0006] Thereafter, as shown in FIG.
Of the back surface 3b is attached to the skeleton 5 via a mortar bond 4, for example.

[0007]

However, in such a conventional casting process, the vibration applied during the forming process causes the back surface 3b to impure impurities such as pigments and admixtures (added to increase the product strength) and sand. However, there is a problem that the strength of the back surface 3b decreases because the surface of the rear surface 3b hardens as it is, the back surface 3b side is oxidized by contact with air, or the moisture of the back surface 3b side evaporates.

[0008] For this reason, after a certain period of time, the product 3 is peeled off from the portion where the strength has been reduced and the product 3 has been removed.
There is a problem that there is a risk of falling from the.

Accordingly, an object of the present invention is to provide a method of manufacturing a cement product made of a cement-based material, which does not cause a decrease in strength on the front and back sides and, for example, does not cause the pasted product to drop from the skeleton as described above. It is in.

[0010]

Therefore, a method of manufacturing a cement product according to the present invention comprises the steps of: forming a part of a product, for example, a first elastic mold for forming a front side shape; A second elastic form to be prepared is prepared, a cement-based material such as mortar is poured into each elastic form made of, for example, urethane rubber, and vibration is applied by a vibration machine or the like. The second elastic form is overlapped, the cement-based materials in both elastic forms are combined, dried, and then released to obtain a cement product such as a tile.

After the first and second elastic molds are overlapped and the cement-based material in the two elastic molds is united, they are placed on a receiving member and left to stand. It is advisable to cure the cement-based material by blending it on the surface.

[0012]

Embodiments of the present invention will be described below with reference to the drawings. In the method for manufacturing a cement product according to the present invention, first, as shown in FIG. 1, a first elastic mold 10 and a second elastic mold 12 are prepared. In the illustrated example, first and second elastic molds 10 and 12 made of 100% urethane rubber are connected and provided.

The first elastic frame 10 is for making the shape of the front side of the product, and has an unevenness on the bottom surface 10a corresponding to the surface decoration of the product. The second elastic mold frame 12 is used to form the shape of the back side of the product, and has two rail-shaped ribs 12b having tapered a on both sides as shown in FIG.

On the other hand, as shown in FIG. 3, a mortar 16 is made by putting cement, sand and water in a blow pad 14 and mixing them.

[0015] Then, the mortar 16 thus prepared is inserted into the mortar 16 in FIG.
As shown in (A), it is poured into the elastic molds 10 and 12.

Then, as shown in FIG. 4B, for example, the elastic molds 10 and 12 into which the mortar 16 has been poured are placed on the vibration machine 18, and vibration is applied thereto for about 1 to 5 minutes.

After that, the two elastic molds 10 and 12
Is bent at the connecting portion as shown in FIG.
And the mortars 16 in the two elastic molds 10 and 12 are united.

Next, if necessary, as shown in FIGS. 5 (A) to 5 (C), it is placed on the receiving member 20 and left.
The mortar 16 is hardened by allowing both mold forms to fit into the receiving surface 20 a of the receiving member 20.

In the example shown in FIG. 5A, the form is held flat by fitting it to the mounting surface 20a, and in the example shown in FIG. Then, it is elastically deformed into a concave shape.

Then, as shown in FIG. 6, it is placed in a drying rack 22 and dried for 5 to 24 hours.

After drying, as shown in FIG.
0.12 is peeled off and removed from the mold to obtain a cement product 24 such as a tile. The product shape is, for example, as shown in FIG.
8C, the shape of the receiving member 20 shown in FIG.
Flat as shown in (A), convex as shown in (B),
It becomes concave as shown in FIG.

The front side of the product 24 is made of a first elastic mold 10, and the surface is decorated based on, for example, irregularities formed on the bottom surface 10a of the first elastic mold 10 as shown in FIG. 24a is performed. Further, the back side of the product is formed by the second elastic form 12 and the back side has two grooves having tapered b on both sides based on two ribs 12b formed on the bottom surface 12a of the second elastic form 12, for example. 2
4b is formed.

As shown in FIG. 10, for example, a tile, which is a cement product 24, formed by the manufacturing method according to the present invention, has a back side formed with a mortar bond 30 having a uniform thickness of 3 to 4 mm, as in the prior art. Affix to the frame 32. At this time, the mortar bond 30 enters the groove 24b, and the product 24 is attached to the frame 32 with a strong adhesive force.

In the above-mentioned example, the first elastic mold 10 for forming a part of the product and the second elastic mold 12 for forming the other part are connected to each other. Needless to say, it may be provided. Also, the first elastic form 1
Although the example in which each of the first and second elastic molds 12 is one is shown, for example, one of the elastic molds 10 and 12 has one elastic mold and the other elastic mold has a plurality of elastic molds. Is also good.

In the above-described example, the ribs 12b are rail-shaped. However, the shape of the ribs 12b is not limited to the rail-like shape. Any shape may be used as long as it increases the adhesion to the frame 32. The number of the ribs 12b may be arbitrary.

[0026]

Therefore, according to the present invention, the first and second elastic molds are overlapped and the cement-based material in the two elastic molds is united, so that the strength is reduced by the vibration applied during the forming process. A method of manufacturing a cement product made of a cement-based material can be provided in which a portion is sandwiched and strength is not reduced on the front and back, and for example, there is no risk that the pasted product will fall from the skeleton.

According to the fourth aspect of the present invention, the cement-based material is hardened in a state where it is placed on the receiving member and left to stand, and the both molds are adapted to the mounting surface of the receiving member. In addition, arbitrarily curved cement products can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of first and second elastic molds used in a method for manufacturing a cement product according to the present invention.

FIG. 2 is a longitudinal sectional view of the second elastic mold.

FIG. 3 is a perspective view showing a state in which a mortar, which is a cement-based material, is put into a fan.

FIGS. 4A to 4D are partial process diagrams of a manufacturing method according to the present invention.

FIGS. 5A to 5C are perspective views each showing a state in which elastic molds are superimposed and placed on a receiving member.

FIG. 6 is a perspective view of a drying shelf in which elastic molds overlapped are placed.

FIG. 7 is an explanatory perspective view illustrating a state in which an elastic mold is peeled off and removed.

8 (A) to 8 (C) are perspective views of products which have been removed from the mold.

FIG. 9 is a vertical cross-sectional view of the removed product.

FIG. 10 is a cross-sectional view showing a state in which a product (tile) made by the manufacturing method according to the present invention is attached to a skeleton by mortar bond.

FIG. 11 is an explanatory perspective view illustrating a state in which a cement-based material is poured into a lower mold in a conventional tile manufacturing method.

FIG. 12 is an explanatory cross-sectional view illustrating a drying step after pouring a cement-based material.

FIG. 13 is a cross-sectional view of a product removed from the mold after the drying step is completed.

FIG. 14 is an explanatory longitudinal sectional view for explaining a use state of a product manufactured by the conventional manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 1st elastic form 10a Form bottom 12 Second elastic form 12a Form bottom 12b Rib 14 Funnel 16 Mortar 18 Vibration machine 20 Receiving member 20a Placement surface 22 Drying shelf 24 Cement product 24a Decoration 24b Groove 30 Mortar bond 32 Body a Rib taper b Groove taper

Claims (4)

(57) [Claims] 1. A first elastic form for forming a part of a product and a second elastic form for forming another part are prepared, and a cement material is poured into each of the elastic forms. Then, the first and second elastic molds are overlapped with each other, and the cement-based materials in the two elastic molds are combined. After drying, the mold is removed to obtain a cement product. Method. 2. The method for manufacturing a cement product according to claim 1, wherein the first elastic form forms a front side shape of the product, and the second elastic form forms a back side shape. 3. The method for producing a cement product according to claim 1, wherein the first and second elastic molds are formed using urethane rubber. 4. The first and second elastic molds are superimposed on each other, the cement-based material in both elastic molds is united, and then placed on a receiving member and left to stand. The method for producing a cement product according to claim 1, wherein the cement-based material is cured in a state where the cement-based material is adapted to the mounting surface of the member.