JP3075597B2 - Method for producing molded article made of hydraulic inorganic substance - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a molded article such as a corner of a building made of a hydraulic inorganic material.

[0002]

2. Description of the Related Art Conventionally, in order to manufacture a molded body having an undercut portion on a side surface using a molding material mainly composed of a hydraulic inorganic substance such as cement, gypsum, calcium silicate, etc., a molding die is divided. Alternatively, the side surface portion of the mold corresponding to the undercut portion is movable so that the hydraulic inorganic material is not damaged when the mold is opened.

[0003]

However, the above-mentioned conventional mold has a complicated structure and is expensive.
In addition, when the mold is opened, there is a problem that the molded body may adhere to the mold surface and damage the molded body.

To prevent this problem, Japanese Patent Application Laid-Open No.
As disclosed in Japanese Patent Publication No. 303, a mold release agent is applied to a molded article for each press, and thereafter, the molded article is subjected to a painting finish in a final step to produce a product.
There was a problem that the release agent had an adverse effect on the performance of the coating film and extremely reduced the performance of the coating film in a practical stage.

An object of the present invention is to solve the above-mentioned conventional problems.

That is, it is possible to uniformly press the entire upper surface of the molded body during the formation of the decorative pattern, and to reliably and efficiently form a molded body having a deep uneven pattern, joint pattern or undercut portion. It is an object of the present invention to provide a method for producing a molded article made of a hydraulic inorganic substance that can be used.

[0007]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention provides a method for manufacturing a molded article formed by decorating and forming a decorative pattern on an extruded molded article made of an uncured hydraulic inorganic material. In the above, the stretched stretchable material is attached to the pattern forming mold attached to the decorative surface side of the upper mold, and the uncured molded body is formed by the pattern forming mold to which the stretchable material is attached. The decorative pattern is formed by pressing, and then the mold is opened to cure the molded body inside or outside the mold.

[0008]

[Function] When the pattern forming mold material attached to the decorative surface side of the upper mold is pressed against the molded body to form a decorative pattern on the molded body, the stretchable material fits into the pattern forming mold material and forms. The decorative pattern is formed on the molded body while being in close contact with the surface of the body.

When the mold is opened, the molded body and the pattern forming mold are released from the mold by instantaneous contraction of the stretchable material.

[0010] As described above, since the stretchable material exists between the pattern forming mold and the molded body at the time of shaping, the molded body does not adhere to the pattern forming mold at the time of opening the mold.

As a result, the shaped article is not damaged.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a method for producing a molded article made of a hydraulic inorganic material according to the present invention will be described below with reference to the drawings showing an embodiment.

FIG. 1 is a front view schematically showing the overall structure of a press forming apparatus used in the method of manufacturing a molded body made of a hydraulic inorganic material according to the present invention, and FIG. 2 shows a tray and a molded body installed in the same apparatus. FIG. 3 is a front view showing a state of the apparatus, FIG. 3 is a front view showing an initial state of press forming before a pattern forming mold material attached to an upper pressing plate of the apparatus is in close contact with a molded body, and FIG. FIG. 5 is a front view showing a state in which the forming die material is in close contact with the molded body and performing press forming. FIG. 5 is a front view showing a state in which the pressing by the upper mold of the apparatus is released and the pressing plate is opened.
7 is a front view showing a state in which the pressing of the upper mold is completely released, and FIG.
Is a side sectional view schematically showing the configuration of an extrusion molding apparatus for extruding a molded body on a tray, FIG. 8 is a perspective view showing a tray and a molded body placed on this tray, and FIG. It is a partial perspective view shown.

In the method for producing a molded article made of a hydraulic inorganic substance according to the present invention, a decorative pattern 1d is decorated and formed on an extruded molded article 1 made of an uncured hydraulic inorganic substance.

That is, the stretched stretchable material 4 is attached to the pattern forming mold 3 attached to the decorative surface side of the upper mold 2, and the uncured molded body 1 is replaced with the stretchable material 4.
Is pressed by the pattern forming mold member 3 provided with
Is subjected to decorative shaping, and then the mold is opened to cure the molded body 1 inside or outside the mold.

The upper die 2 comprises a first upper die 21 and a second upper die 22, and the spring 5 is interposed between the first upper die 21 and the second upper die 22.

Further, pressing portions 21a and 21b are provided to project downward from the first upper mold 21, and these pressing portions 21a and 21b are provided.
21 b is penetrated by the second upper mold 22.

A pressing portion 22a also projects downward at the center of the second upper die 22, and one end of each of the pressing plates 6 and 6 is pivotally attached to the pressing portion 22a.

The other ends of the pressing plates 6 and 6 are attached to pressing portions 21a and 21b of the first upper die 21 via links 7 and 7, respectively.

The links 7, 7 are provided with play by long holes so that the pressing plates 6, 6 can move up and down.

The pressing plates 6, 6 are normally opened as shown in FIG. 1 by the urging force of the spring 5 interposed between the first upper die 21 and the second upper die 22. ing.

A pattern forming die 3 is attached to the decorative surface side (lower surface side) of these press plates 6 and 6.

Further, the stretchable material 4 is attached to the pattern forming mold 3 in a stretched state as described above.

The pattern forming mold member 3 is made of a flexible pattern sheet, and is formed of rubber or synthetic resin.

The rubber material has a rubber hardness of 50 or more.

The synthetic resin is made of a material having a Barcol hardness of 40 or less.

The stretchable material 4 is made of a material having air permeability, and has a property of being stretched when pulled and returned to its original state when loosened.

As the elastic material 4, a woven fabric or a sheet material of a mesh material having a thickness of 5 mm or less is suitable.

For example, there is a material using a spandex obtained by knitting and processing a polyurethane fiber and a nylon fiber, an acrylic fiber, a polyester fiber or the like which expands and contracts in a loop shape.

[0030] This is preferably a fabric generally used for swimwear, socks or pantyhose.

Examples of the woven fabric include Leica manufactured by Asahi Kasei Corporation, Spandex manufactured by Toray Industries, Inc. and Spandex manufactured by Unitika Ltd.

Reference numeral 8 denotes a lower mold. The lower mold 8 has a central projecting portion 8a and projecting portions 8b, 8b at both ends. A tray 9 is placed on the projecting portion 8a. Is done.

The uncured molded body 1 extruded from the extrusion molding apparatus 30 shown in FIG. 7 is placed on the tray 9.

This compact 1 is cut for each tray 9.

Next, the press forming step of forming the decorative pattern 1d on the compact 1 by the press forming apparatus will be described.

First, as shown in FIG. 2, the tray 9 and the uncured molded body 1 are placed on the chevron-shaped projection 8a of the lower die 8 of the press molding apparatus.

In this state, the upper mold 2 is pressed.

Then, the second upper mold 22 is moved to the projection 8 of the lower mold 8.
At b and 8b, the second upper mold 22 stops as shown in FIG.

When the pressing is further continued, the distance between the first upper die 21 and the second upper die 22 is reduced against the urging force of the spring 5, and the open pressing plates 6, 6 are closed.

Then, as shown in FIG. 4, the pattern forming mold member 3 of the portion attached to the pressing plates 6, 6 has the upper slope 1 a,
At approximately the same time, the pattern forming mold member 3 of the portion attached to the pressing portion 22a of the second upper mold 22 closely adheres to the upper flat surface 1c of the uncured molded body 1.

As described above, the pattern forming mold member 3 is in a state of substantially covering the upper flat surface 1c and the upper slopes 1a, 1b of the uncured molded body 1.

At this time, the pressing force from the pressing portion 22a of the second upper mold 22 acts on the upper flat surface 1c of the uncured molded body 1, and the pressing surfaces 6a and 6b press the upper slopes 1a and 1b. The pressing force acts on the upper surfaces 1a, 1b, and 1c from different directions.

The uncured molded body 1 is decorated via a stretchable material 4 attached to the pattern forming mold member 3 and each of the upper surfaces 1a, 1 of the uncured molded body 1 is decorated.
The corners of b, 1c, that is, the borders, are also decorated without interruption of the decorative pattern.

After that, when the pressing of the upper mold 22 is released, the pressing plates 6 and 6 are opened again as shown in FIGS. 5 and 6, and the tray 9 placed on the chevron-shaped projection 8a of the lower mold 8 is opened. An uncured molded article 1 having a decorative pattern formed thereon is obtained.

As described above, by applying a pressing force to each of the upper surfaces 1a, 1b, 1c of the uncured molded body 1 having a plurality of bent surfaces in one pressing step, each of the upper surfaces 1a, 1b, 1c of the molded body 1 is pressed.
The decorative pattern 1d can be formed reliably and efficiently by uniformly pressing the entirety of a, 1b, and 1c.

As shown in FIG. 8, the molded article 1 in the uncured state is cured and cured together with the tray 9 and then removed from the tray 9 to form a long corner accessory with a decorative pattern 1d.

As shown in FIG. 9, the corner long part composed of the molded body 1 thus obtained has a decorative pattern 1d.
Are formed continuously at the corners of the panel 11 on which the pattern 11 is formed.

In the above-described embodiment, the manufacturing process of the long corner part formed by three bent surfaces has been described as an example. However, the present invention is not limited to this, and for example, it is possible to use two bent surfaces. The present invention can also be applied to the formed L-shaped corner accessory.

Next, an example in which the present invention is actually implemented will be described.

As the stretchable material 4, Leica AP61110 which is a spandex manufactured by Asahi Kasei Kogyo Co., Ltd. was used.

The pattern forming mold member 3 had a shape corresponding to the shape of the outer corner of the outer wall. The pattern was a ceramic tile-like uneven pattern, and the material was urethane rubber having a rubber hardness of 95.

Table 1 shows the composition of the raw materials for forming the molded body 1 composed of the building corner part.

[0053]

[Table 1]

Then, press molding was performed using the press molding apparatus shown in FIG. 1 as shown in FIGS.

First, based on the composition shown in Table 1, other raw materials except for water were charged in an Erich mixer manufactured by Nippon Erich Co., Ltd., and were dry-mixed at 880 rpm for 3 minutes. Mix for 2 minutes and remove.

This was kneaded with a kneader manufactured by Miyazaki Iron Works Co., Ltd., and the mixture was charged into a vacuum extruder, extruded and formed to a thickness of 15 mm, a size of both sides of 145 mm, and a length of 2800.
Thus, an uncured molded body 1 made of a corner material having a thickness of 1 mm was obtained.

In the state where the uncured molded body 1 thus extruded and molded into a substantially product shape is placed on the tray 9, the angled projection 8a of the lower die 8 of the press molding apparatus shown in FIG. And press-formed using a hydraulic press by the steps shown in FIGS. 2 to 6.

In this press molding, the surface pressure is 10 kg / cm.
After pressing with ² for 10 seconds, the mold was opened, and the uncured molded body 1 on which the decorative pattern 1d was decorated and formed was taken out together with the tray 9.

Thereafter, while the molded body 1 was placed on the tray 9, steam curing was performed in an atmosphere of 60 ° C. for 8 hours, and then the mold was removed.

As a result, a molded body 1 whose surface was decorated was obtained.

The molded body 1 made of the corner material was molded by interlocking the extrusion molding and the press molding by the method described above.
Even if the stretchable material 4 is not damaged, and the molded body 1 does not adhere to the mold surface even if no release agent is used on the decorative surface of the molded body 1, the tiles can be uniformly decorated with a tiled tone. Could be done.

As a comparative example, a stretchable material 4
Was press-formed in the same manner as described above, without providing the same.

As a result, the surface of the uncured molded body 1 adhered to the pattern forming mold member 3 and normal molding could not be performed.

[0064]

As described above, according to the present invention, the entire upper surface of the molded body can be pressed evenly during press molding, so that the molding having a deep uneven pattern, joint pattern, or undercut portion can be performed. The effect of being able to perform the decorative shaping work of the body reliably and efficiently is achieved.

[Brief description of the drawings]

FIG. 1 is a front view schematically showing an overall configuration of a press molding apparatus used in a method for producing a molded article made of a hydraulic inorganic material according to the present invention.

FIG. 2 is a front view showing a state where a tray and a molded body are installed in the apparatus.

FIG. 3 is a front view showing an initial state of press forming before a pattern forming mold attached to an upper pressing plate of the same device comes into close contact with a molded body.

FIG. 4 is a front view showing a state in which a pattern forming mold of the apparatus is in close contact with a molded body and performing press molding.

FIG. 5 is a front view showing a state where the pressing by the upper mold of the same device is released and the pressing plate is opened.

FIG. 6 is a front view showing a state in which the pressing of the upper mold is completely released.

FIG. 7 is a side sectional view schematically showing the configuration of an extrusion molding apparatus for extruding a molded body on a tray.

FIG. 8 is a perspective view showing a tray and a molded body placed on the tray.

FIG. 9 is a partial perspective view showing a construction example of a molded body.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Molded body 1d Decorative pattern 2 Upper mold 3 Pattern forming mold material 4 Elastic material

Claims (1)

(57) [Claims] 1. A method for manufacturing a molded body comprising a molded body made of an extruded uncured hydraulic inorganic material and decorating and shaping a decorative pattern, the method comprising the steps of: A stretched stretchable material is attached to the mold material, and the uncured molded body is pressed with a pattern-forming mold material provided with the stretchable material to decorate and shape the decorative pattern. A method for producing a molded body made of a hydraulic inorganic material, comprising opening and curing the molded body in or out of a mold.