JP3229147B2 - Method of manufacturing press plate for building board and method of manufacturing building board - 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 of manufacturing a press plate for a building board mainly used for manufacturing a cement board mixed with a wood reinforcing material, and a method of manufacturing a building board using the press template. It is.

[0002]

BACKGROUND OF THE INVENTION This type of building board is formed by adding about 20 to 40% by weight of water to a molding material, which is a mixture mainly composed of a wood reinforcing material and a cement-based hydraulic material, and then spraying it on a press template. It is desirable that the mat be formed by a dry method or a semi-dry method in which a press template is further placed on the mat, pressed and cured. What is necessary is that such a dry method or a semi-dry method enables continuous mass production of building boards, and a deep three-dimensional pattern on the surface of the building boards by forming a negative uneven pattern on the mold surface of the press mold plate. This is because a positive concavo-convex pattern can be formed. The above-mentioned building board is fixed to the frame of the building with fasteners such as nails and screws. At this time, the slip is used to determine the position at which the nails or screws are driven or when the nails or screws are driven. Requires a lot of trouble.

[0003]

2. Description of the Related Art Conventionally, a molding material for a cement plate is kneaded with water and extruded into a plate-like shape, and a mark roller having a plurality of mark pins disposed on a peripheral surface thereof is brought into contact with the surface to form a mark. Thus, there has been proposed a method of manufacturing a cement board having a screwing mark for preventing slippage at a predetermined location (Japanese Patent Laid-Open No. 2-112905).

[0004]

The above-mentioned conventional method can be applied only to a cement board formed by extrusion molding, and a molded article formed by extrusion molding produces a cement board having a deep three-dimensional uneven pattern since the structure is dense. Is difficult to do,
In addition, the mark roller is used only to form a screwed mark and does not form an uneven pattern.To form an uneven pattern, a separate emboss roller must be used, which increases the number of processes. Productivity is reduced. Furthermore, if the uneven pattern is formed by the embossing roller before the marking by the mark roller, the uneven pattern may be deformed at the time of marking. The mark may be deformed.

[0005]

According to the present invention, as a means for solving the above-mentioned conventional problems, a pin recess (4) of a matrix (1) having a pin recess (4) at a predetermined position on a mold surface (2) is provided. 4) Pin to
After setting (6), an FRP layer (7) is formed by hand lay-up on the mold surface (2) of the matrix (1), and the FRP layer is formed.
After curing (7), the matrix (1) is released and the FRP
The present invention provides a method of manufacturing a press template (18) for a building board in which the pin (6) is transplanted to the hardened layer (7A) side, and further provides a press template (18) in which the pin (6) is transplanted at a predetermined position. On the mold surface (12), a molding material M mainly composed of a wood reinforcing material and a cement-based hydraulic material is sprayed to form a mat, the mat is cured by pressing, and the press mold plate (18) is cured. An object of the present invention is to provide a method for manufacturing a building board (24) that forms a fastening recess (22) at a predetermined location by a pin and then removes the mold. The present invention will be described in detail below.

[0006] The matrix material used in the present invention includes glass fiber, carbon fiber, ceramic fiber, diallyl phthalate resin reinforced with rock wool, unsaturated polyester resin, styrene resin, urea resin, melamine resin, phenol resin and the like. Synthetic resin (FRP), or inorganic materials such as ceramics, gypsum, and silicates. Desirable materials include unsaturated polyester or styrene-unsaturated polyester containing glass fiber and gypsum. , Hand lay-up, injection molding,
Alternatively, it is manufactured by cutting or the like. The matrix has a positive mold surface corresponding to the surface shape of the target building board, and if desired, the mold surface has a positive uneven pattern, and a pin recess is formed at a predetermined position. .

[0007] A pin is set in the pin recess of the mother die, a mold release agent is applied to the mold surface, and then an FRP layer is formed on the mold surface by hand lay-up. That is, the same reinforcing fibers as the matrix material are laid on the mold surface of the matrix as it is or as a nonwoven fabric or a knitted fabric, and the above synthetic resin mixed with a curing agent is applied and impregnated thereon, and then further impregnated if desired. The reinforcing fiber is laid as it is or as a nonwoven fabric or a knitted fabric, and the above synthetic resin mixed with the same curing agent is applied and impregnated thereon, and this procedure is repeated a predetermined number of times to form an FRP layer having a predetermined thickness. Form. Then, or a mold plate coated with a release agent on the mold surface is placed on the FRP layer and pressed slightly, and the FRP layer is cured in that state. The curing of the FRP layer is usually performed at room temperature, but may be performed if desired. When the mold and the template are used after the FRP layer is cured, when the template is released, the pins set on the mold are transplanted to the FRP layer side, and thus, at predetermined positions. A press template with the pins implanted is manufactured.

In order to manufacture the building board of the present invention using the above-mentioned press template, a dry or semi-dry method is desirably applied, but it goes without saying that a wet method is also applied. In the dry or semi-dry method, a mat is formed by spraying a molding material mainly composed of a wood reinforcing material and a cement-based hydraulic material on the press template. Examples of the wood reinforcing material used in the molding material include pulp, wood fiber, wood wool, wood chips, wood flour, and the like. Examples of the cement-based hydraulic material include portland cement, jet cement, blast furnace slag cement, and fly ash. There is one kind or a mixture of two or more kinds of cement, alumina cement and the like. Other than the above components, for example, silica stone powder, silica powder, silica fume, shirasu balloon, perlite, mica, diatomaceous earth, dolomite, gypsum, wollastonite, fly ash, blast furnace slag, coal ash, glass powder, siliceous clay,
Aggregates such as alumina, bentonite, calcium carbonate, magnesium carbonate, polyester fiber, polyamide fiber,
Synthetic fiber such as acrylic fiber, acetate fiber, polyethylene fiber and polypropylene fiber, natural fiber such as cotton, wool, coconut fiber, bamboo fiber and hemp fiber, inorganic fiber such as glass fiber, carbon fiber, ceramic fiber and rock wool Fiber reinforcement, calcium chloride, magnesium chloride, magnesium hydroxide, aluminum sulfate, sodium aluminate,
A cement hardening accelerator such as water glass and a water repellent such as wax, paraffin, and silicon may be added. Further, a crushed scrap of a cement board mainly composed of cements and reinforcing fibers may be added. In the above molding material, the wood reinforcing material is usually added in an amount of about 15 to 30% by weight,
In the semi-dry method, water is further added, and the water content of the molding material is adjusted so as to be usually about 30 to 50% by weight.

The hydrated molding material is sprayed on the press mold plate. In the continuous production process, a large number of the press mold plates are arranged on a conveyor, and when the molding material passes through the spraying position of the molding material. Then, the molding material is sprayed on the press plate with a predetermined thickness, and a mat is formed. At this time, the molding material may be selected by wind from one direction. In this case, when the pressing die plate conveying direction and the ventilation direction are opposite, the mat formed on the pressing die plate has a structure in which the bottom (front side) is fine and the top (back side) is rough, When the plate conveying direction and the ventilation direction are the same, the opposite is true, and the lower part has a rough structure and the upper part has a fine structure.

[0010] On the mat formed on the press template in this manner, a flat plate-type press template is further placed, or the mat is stacked together with a several-stage press die and pressed together. Then, the mat is cured. The pressing condition in this case is 2 to 4 MPa, preferably 2.5 to
The curing condition is usually 3.5 MPa, under the conditions of a temperature of 50 to 80 ° C. and a humidity of 90 to 95% RH for 7 to 15 hours.
During the pressing and curing, a tightening recess is formed in the mat contact surface of the press mold plate by a pin on the mold surface of the press mold plate.
Then, after the press curing and curing, if the press mold plate is released, a building board having a fastening recess at a predetermined location is manufactured.

In the wet method, a molding material similar to that used in the dry method or semi-dry method is used, and the molding material is dispersed in water to form a slurry having a solid content of usually about 7 to 15% by weight. The slurry is allowed to flow on a porous body such as a felt or a net and sucked and dehydrated to form a wet mat.
Then, the press mold plate of the present invention is pressed against the surface of the mat to cure in this state, and the mat is cured. Curing conditions may be the same as the above-mentioned dry method or semi-dry method. During the curing, a tightening recess is formed on the mating surface of the mat by the pins of the mold surface of the press mold plate. After curing and curing, if the press mold plate is removed, a building board having a fastening recess at a predetermined location is manufactured.

[0012]

In the present invention, an FRP layer (7) is formed by hand lay-up on a mold surface (2) of a matrix (1) in which a pin (6) is set in a pin recess (4). Since the matrix (1) is released after the curing of (7), the pins (6) are transplanted to the FRP cured layer (7A) side to form the fastening recesses (22) of the building board (24). A press die plate (18) in which pins (6) are formed at predetermined positions on a die surface (2) is easily manufactured. In the dry method or the semi-dry method, the molding material M is sprayed on the press template (18) to form a mat (8), and the mat (8) is formed.
(8) is pressed and cured to produce a building board (24), and in the wet method, the press mold plate (18) is pressed against the surface of the papermaking mat and the mat is cured and cured in this state. Board (2
Since 4) is manufactured, a fastening recess (22) is formed at a predetermined position of the building board (24) by the pin (6) of the press template (18).

[0013]

【Example】

[Example 1] (Manufacture of press template) A gypsum master mold (1) as shown in Fig. 1 by casting a gypsum slurry in a predetermined mold and curing and drying it.
To manufacture. A predetermined positive uneven pattern (3) is formed on the mold surface (2) of the gypsum matrix (1), and a pin recess is formed at a predetermined position.
(4) is formed. As shown in FIG. 2, a release agent (5) is applied to the mold surface (2) of the gypsum matrix (1), and a pin (6) is set in the pin recess (4). The pin (6) is
(6A) and a groove (6B) formed in the root of the main body (6A). In order to support the pin (6) in the pin recess (4), a filler such as sand (4A) or clay, calcium carbonate, stone powder, ceramic powder, or glass powder is used.
(4) is filled.

In this way, the pin (6) is set and the mold surface is set.
An FRP layer (7) is formed by hand lay-up on the matrix (1) on which the release agent (5) is applied to (2) as shown in FIG. That is, a glass fiber mat (8) is laid on the mold surface (2), and a styrene-unsaturated polyester mixture (9) mixed with a curing agent is applied and impregnated on the glass fiber mat (8). ), And the styrene-unsaturated polyester mixture (9) is applied and impregnated thereon, and this procedure is repeated to form an FRP layer (7) having a predetermined thickness. On the FRP layer (7), a template (11) having a release agent (10) applied on its surface is placed, and slightly pressed.
The layer (7) is cured at room temperature. When the FRP layer (7) is hardened, it is further cured by heating at 100 ° C. for 5 hours to complete the hardening almost completely. Thereafter, the matrix (1) and the mold plate (11) are removed from the FRP hardened layer (7A). .

In this way, a press die plate body (12) comprising the FRP hardened layer (7A) shown in FIGS. 4 to 6 is manufactured.
On the mold surface (13) of the press mold plate body (12), a negative concavo-convex pattern (14) corresponding to the positive concavo-convex pattern (3) of the gypsum matrix (1) is formed. A pin (6) implanted from the gypsum matrix (1) is protruded, and guide ribs (15) are formed vertically and horizontally. The guide rib (15) is for forming a guide groove for positioning at the time of cutting in a building board to be manufactured. Adhesive (16) is applied to the press plate body (12)
The metal plate (17) is backed by the final press die plate
(18) is manufactured, and as the adhesive (16), a rubber-based adhesive or an elastomer adhesive is used in consideration of a difference in thermal expansion coefficient between the press die plate body (12) and the metal plate (17). It is desirable to use an elastic adhesive such as an agent. In the press die plate (18), a press die plate body (12) composed of an FRP hardened layer (7A)
Since the groove (6B) of the pin (6) bites into the inside, the mounting strength of the pin (6) is extremely large.

[Example 2] (Manufacture of a building board) A molding material having the following composition is sprayed on the mold surface (13) of the press mold plate (18) manufactured in Example 1 to form a mat. Portland cement 60 parts by weight Wood chips 25 マ グ ネ シ ウ ム Magnesium chloride 1.2 パ ラ Paraffinic waterproofing agent 1.0 〃 Water 40 平板 Place a flat press template on a formed mat and press it with a pressure of 3 MPa. Well humidity 90% R
H, curing at 70 ° C. for 10 hours. The portland cement contained in the mat is hydrated and hardened by the above curing, and after curing, if the press template (18) and the flat press template are removed from the mold, an architectural plate original as shown in FIG. 7 ( 19) is manufactured. A positive concave / convex pattern (21) corresponding to the negative concave / convex pattern (14) of the mold surface (13) of the press template (18) is formed on the surface (20) of the building plate precursor (19), and Pin (6) in place
, And a guide groove (23) is formed by the guide rib (15). The original building board (19)
Is trimmed and cut to a predetermined size.However, when the sensor of the cutter positioning device falls into the guide groove (23) of the building board body (19), the positioning of the cutter for cutting the building board body (19) is performed. Is performed.

In this manner, a building board (24) having a fastening recess (22) formed at a predetermined position on the surface shown in FIGS. 8 and 9 is manufactured. The building board (24) is as shown in FIG. A nail (25) or a screw (26) as shown in FIG. 9 is used to fix the nail to the building frame. When the tip of a nail (25) or a screw (26) is inserted into the fastening recess (22), the nail (25) or the screw (26) can be easily slipped without slipping. The building board
Driven or screwed into (24).

[0018]

Thus, in the present invention, a press template for a building board having pins protruding at predetermined locations on a mold surface can be easily manufactured. In order to manufacture a building board using the press template of the present invention, any of a wet method, a dry method or a semi-dry method is applied, and particularly, if a dry method or a semi-dry method is applied, the surface of the building board is applied. It is possible to form a deep three-dimensional uneven pattern, and a fastening recess is formed in the surface of the building board by the pins of the press template, so that the building board is fixed to the building frame. The work of fastening nails and screws becomes extremely easy.

[Brief description of the drawings]

 1 to 9 show an embodiment of the present invention.

FIG. 1 is a partial sectional view of a matrix.

FIG. 2 is a partial cross-sectional view of a matrix in a pin mounted state.

FIG. 3 is a partial cross-sectional view of a master block in a state in which an FRP layer is formed.

FIG. 4 is a plan view of a press die.

FIG. 5 is a sectional view taken along line AA in FIG.

FIG. 6 is a sectional view taken along line BB in FIG. 4;

FIG. 7 is a perspective view of an original building plate.

FIG. 8 is a partial cross-sectional view illustrating nailing of a building board.

FIG. 9 is a partial cross-sectional view illustrating screwing of a building board.

[Explanation of symbols]

 1 Master mold 2 Mold surface 4 Pin recess 6 Pin 7 FRP layer 7A FRP hardened layer 18 Press template 19 Building board original body 20 Surface 22 Fastening recess 24 Building board 25 Nail 26 Screw

Continuation of the front page (56) References JP-A-57-150513 (JP, A) JP-A-2-112905 (JP, A) JP-A-6-315922 (JP, A) JP-A-48-62817 (JP) , A) Japanese Utility Model 2-19503 (JP, U) Japanese Utility Model Application 57-24011 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 7/00 B28B 3/02 B29C 70/30

Claims (4)

(57) [Claims] An FRP layer is formed by hand lay-up on a mold surface of a mother die having a pin recess at a predetermined position on a mold surface, and setting a pin in the pin recess. A method for manufacturing a press template for a building board, comprising: releasing the matrix after curing, and implanting the pin on the FRP cured layer side. 2. The method according to claim 1, wherein said matrix is made of synthetic resin or gypsum. 3. A mat by spraying a molding material mainly composed of a wood reinforcing material and a cement-based hydraulic material on a mold surface of a press mold plate in which pins are implanted at predetermined locations according to claim 1 or 2. Forming the mat, pressing and hardening the mat, forming a fastening recess at a predetermined position by a pin of the press mold plate, and then removing the mold. 4. The surface of a paper-making mat formed by press-molding a press-type plate according to claim 1 or 2 in which pins are implanted at predetermined locations using a molding material mainly composed of a wood reinforcing material and a cement-based hydraulic material. And curing the papermaking mat in that state, forming a fastening recess at a predetermined location with a pin of the press mold plate, and then removing the mold from the mold.