JP3497118B2 - Mold for ceramic building board and method for manufacturing ceramic building board using the mold - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a ceramic building board mold and a method for manufacturing a ceramic building board using the mold.

[0002]

2. Description of the Related Art Ceramic walls are used to fasten the outer wall of a building. In recent years, the types of ceramic building boards have also diversified, and for example, building board 3 shown in FIG.
0A, which is relatively small and thick (for example, 35
Building boards with high formability that show the feeling of masonry of natural stone are also on the market. As a method of manufacturing such a building board, cement, sand, reinforcement is put into a mold equipped with a cavity having a bottom surface and a peripheral surface shape along the shape of the surface and the peripheral surface of the ceramic building board to be obtained. A so-called cast molding method into a mold is often used, in which a raw material obtained by mixing a fiber material and the like is poured and cured. According to this molding method, various surface uneven patterns can be formed, and therefore, there is an advantage that an outer wall material having high moldability can be manufactured.

A process for manufacturing a building board by the above-mentioned casting method will be described with reference to FIG. First, raw materials such as cement and sand are mixed (301), supplied to a hopper (302), and injected from the hopper into the mold (303). At this time, preferably, a mold release agent is applied to the entire inner surface of the mold (304), and further, a transfer pigment is applied (305). After the raw material is supplied, the mold is vibrated to promote the wraparound of the raw material (306), and the material is left in that state for about 24 hours to wait for the raw material to cure (307). After curing, a demolding operation is performed (308) to obtain a building board. The obtained building board is preferably laid down for about 2 weeks to be naturally dried (3
09), the conventional clear coating or the like is applied (310), and the product is obtained (311).

[0004]

In the case of manufacturing a ceramic building board which is relatively small and has a large thickness by the casting method, it is necessary to use a mold having a large cavity depth. In this case, the demolding work must be carefully performed so as not to damage the molding shape of the material filled deep inside. Also, since such ceramic building boards are used as wall coverings for buildings, it is necessary to manufacture a large number of them, so it is necessary to select a durable material that is easy to demold. There is.

Therefore, a mold is made of a material having both strength and deformability, such as urethane rubber or silicone rubber,
When the poured raw material is cured, the mold itself is deformed by peeling or peeling the mold by hand to remove the mold. In that case, even if the deformability is required for demolding, it is necessary to have the shape retention property required for the molding die. Therefore, at present, the rubber hardness is 50.
Relatively hard urethane rubber or silicon rubber of about 70 degrees is used as a mold material.

However, a material having a rubber hardness of about 50 to 70 degrees is poor in deformability, and in the case of a simple rectangular ceramic construction board, even if it is relatively easy to remove from the mold, the projected corner and the fitted corner. In the case of a ceramic building board with a complicated planar shape such that and are mixed, it is virtually impossible to demold by deforming the mold, and at present, a ceramic building board with such a complicated shape is It cannot be made by this method. In addition, since the deformability is small, considering the certainty of die cutting, there is a limit to the depth and shape of the unevenness formed on the bottom surface of the cavity, which is the surface pattern of the ceramic building board to be molded, and there is a deep pattern. Also, ceramic building boards with a dovetail-shaped pattern on the surface are not formed. Furthermore, since elastic materials such as urethane rubber and silicone rubber generally tend to have a large strain over time, and when used for a long period of time, the product accuracy is reduced,
There is also the inconvenience that the effective use period of the mold is limited.

Japanese Unexamined Patent Publication (Kokai) No. 9-262816 describes a concrete panel molding frame using a design mold made of a resin or rubber having a design surface formed by cutting on a predetermined surface. By using such a design mold, it becomes easy to mold molded products having various surface patterns. However, this design type is used by adhering it inside the outer frame body for shape retention with an adhesive, and since no special consideration is given to demolding the molded product, ease of demolding,
Considering the certainty, there are limits to the depth and shape of the irregularities that can be formed in the design type.

The present invention has been made in view of the above circumstances, and it is a mold made of an elastic material such as urethane rubber or silicon rubber, but has a problem of facilitating demolding and a complicated structure. It is possible to simultaneously satisfy both the problems of molding ceramic building boards with various shapes and surface patterns,
Moreover, it is an object of the present invention to provide a mold for a ceramic building board and a method for manufacturing a ceramic building board using the mold, which can minimize the deterioration of the accuracy of the product due to the distortion of the mold.

[0009]

The ceramic building board mold according to the present invention for solving the above-mentioned problems is made of an elastic material as a whole, and the surface of the ceramic building board to be obtained is obtained. And a mold body having a cavity having a bottom surface along the shape of the peripheral surface and a peripheral surface shape on the inner surface, and a groove formed along the peripheral surface of the cavity partially or along the entire circumference. And a shape-retaining frame that can be inserted into and removed from the groove formed in the mold body. Preferably, in the ceramic-type building board mold, the mold body is made of urethane rubber or silicon rubber, more preferably urethane rubber or silicone rubber having a rubber hardness of 20 to 40 degrees, and the shape retaining frame is made of a metal material. Made by.

In the ceramic building board die according to the present invention, the contour and surface pattern of the ceramic building board to be formed are given by the die body, but the shape retention of the die body does not depend on the rigidity of the die body, but separately. It is secured by the shape retention frame provided. Therefore, even if the mold body is made of a highly deformable material, it does not significantly affect the accuracy of the ceramic-type building board to be molded. Due to the large deformability of the mold, even if the peripheral surface of the cavity has a complicated shape in which the outer corner and the inner corner are mixed, by deforming the mold body, the molded product can be easily removed. Can be molded. Therefore, it is possible to form a ceramic building board that is small and has a large thickness, but has a complicated planar shape.

Further, since the mold body can be made of a highly deformable material, even if a deep recess or a groove having a dovetail cross section is formed on the bottom surface of the cavity, it is easy to remove the mold from the recess. Therefore, a ceramic building board having a deep pattern or a dovetail-shaped cross section on its surface can be easily formed.

The material of the mold body is optional as long as it is resistant to the raw material of the ceramic building board and has the required elasticity, but an elastic material such as urethane rubber or silicone rubber is particularly preferable. Further, as described above, in the present invention, since the mold material does not require high hardness, urethane rubber or silicone rubber having a rubber hardness of 20 to 40 degrees which is easily deformed may be used. In general, a material having a low rubber hardness has a large change in strain amount over time, but by using a shape-retaining frame, product accuracy can be maintained even when used for a long period of time.

Depending on the size and shape of the mold body or the material thereof, the peripheral wall itself of the mold body may partially have the required shape retention property. In that case, it is not necessary to form the "groove" in a portion having such shape retention property, and the groove should be formed only partially (a portion where deformation is expected during molding) along the peripheral surface. You may However, even in that case, since a portion such as a tattooed portion or a projected corner portion of the die main body is likely to be distorted or deformed, it is desirable to form a groove and insert a shape retention frame to perform molding.

In manufacturing a building board using the building board mold according to the present invention, the ceramic material is poured into the cavity with the shape-retaining frame inserted in the groove of the mold body, and the ceramic material is After hardening, the shape retaining frame is extracted, and the hardened ceramic building board is released from the mold while deforming the mold body.

In a preferred embodiment, the shape retention frame integrally includes a top plate capable of covering the open surface of the cavity. As a result, during the primary hardening of mortar and cement, the water necessary for the hydration reaction of the cement can be allowed to harden while maintaining a sufficient wet state, so that the quality of the building board is stable. can do. In this case, at the time of manufacturing the building board, after pouring the ceramic material into the cavity of the mold body, the shape retaining frame may be inserted into the groove of the mold body. An opening for pouring may be formed in advance, and after pouring, the opening may be closed by an appropriate means.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing an example of a ceramic-type building board mold according to the present invention, showing a state in which a building body of a building board mold and a shape retaining frame are separated. By using this building board mold 1, a building board 30 having the shape shown in FIG. 2 is molded.

As shown in a perspective view in FIG. 2, the building board 3
0 has a thickness of D, a short side has a length of 2L, and a long side has a length of 4L. It has a planar shape in which the protruding corner and the entering corner are complicatedly mixed. In addition, the surface 31 of the building board 30 is provided with a concavo-convex pattern for expressing the masonry feeling of natural stone, and the concavo-convex pattern has a depth as shown in a partially enlarged sectional view of FIG. Recessed portion 33 of 20 mm or more
It also includes a recess 34 having a dovetail cross section. According to the present invention, even a building board having such a complicated plan view shape and having a complicated uneven pattern formed on the surface thereof can be easily cast-molded.

As shown in FIG. 1, a building board mold 1 comprises a rubber mold 10 as a mold body and a metal frame 20 as a shape-retaining frame. FIG. 1 shows a state where the rubber mold 10 and the metal frame 20 are separated, and FIG. 4 is a sectional view taken along the line IV-IV in FIG. 1, showing a state where the metal frame 20 is attached to the rubber mold 10. It shows with. The rubber mold 10 has a rubber hardness of 20 to 40 degrees.
Made from high-grade urethane rubber, it is highly deformable,
Even when a building board having a complicated shape and surface pattern is formed, the mold can be easily removed. Gold frame 20
Is made of metallic material such as stainless steel, and does not easily deform even when heat or pressure is applied.

The rubber form 10 is a building board 30 to be obtained.
Cavity 13 having a shape of a bottom surface 11 and a peripheral surface 12 along the shapes of the surface 31 and the peripheral surface 32 of the inner surface, and having a generally convex shape in plan view (the depth D1 is the thickness D of the building board 30
Deeper) and a groove 14 formed along the peripheral surface 12 in the cavity 13.

In the present invention, as described above, the rubber mold 10 is made of a highly deformable material. Since the shape of the building board 30 to be molded is determined by the shape of the cavity 13 of the rubber mold 10, the raw material mortar 40
When the resin is cured in the cavity 13, the rubber mold 10
Need to be transformed.

Therefore, at the time of molding, the metal frame 20 is inserted into the groove 14 of the rubber mold 10 prior to the pouring of the mortar 40. Since the rigidity of the rubber mold 10 is secured by the metal frame 20 and the deformation of the cavity is prevented, the rubber mold 10 is not deformed by the pouring of the mortar 40, and is not deformed even during curing and curing. .
The metal frame 20 is removed when the cured building board is released from the mold. As a result, the rubber mold 10 can be easily deformed, and the mold can be smoothly removed.

Next, a manufacturing process of a building board using the building board mold 1 will be described with reference to FIG. In the method for manufacturing a ceramic building board according to the present invention, in addition to the conventional building board manufacturing process described above with reference to FIG. 3, “insert shape retaining frame” (501) and “shape retaining frame” are used. Remove "(50
The two steps of 9) are performed. Describing the manufacturing process step by step, first, the step of "inserting a shape retention frame", that is, the step of inserting the metal frame 20 into the rubber mold 10 is performed (501). Next, the same process as the conventional manufacturing process is sequentially performed, and the raw material of the building board is the cavity 1
In the state of being supplied to No. 3, wait for the raw material to cure (502-5
08). FIG. 4 is a sectional view in this state. here,
"Remove the shape retention frame," that is, replace the metal frame 20 with the rubber mold 10
The process of extracting from is performed (509). Then, the building board 30 is demolded while gradually bending the rubber form 10 outward from the end (510). After that, the conventional manufacturing process is performed to obtain a product (511 to 513).

Another embodiment of the shape retaining frame for a building board according to the present invention is shown in FIG. FIG. 7 is a sectional view taken along line VII-VII in FIG. 6 showing a state where the shape retaining frame of this embodiment is inserted into the mold body. For the mold body, the same rubber mold frame 10 as described above with reference to FIG. 1 is used. In this form, the metal frame 50 serving as a shape-retaining frame
Is composed of a side surface portion 51 and a top plate 52, and the side surface portion 51 to be inserted into the groove 14 of the rubber mold 10 has a shape along the groove 14, and the top plate 52 extends along the upper edge of the side surface portion 51. Are integrally formed. The side surface portion 51 of the metal frame 50 is attached to the rubber mold 10
When it is inserted into the groove 14, the cavity 13 of the rubber mold 10 is closed. Therefore, when hardening the mortar which is the raw material of the building board in the cavity 13, the water in the mortar necessary for the hydration reaction is prevented from escaping to the outside of the cavity 13, and the hardening is performed while maintaining a sufficiently wet state. You can As a result, without being affected by the external environment,
It is possible to obtain a building board that is always uniform and of high quality.

When the metal frame 50 with such a top plate 52 is used, the side surface portion 51 of the metal frame 50 is inserted into the groove 14 of the rubber mold 10.
The mortar cannot be poured into the cavity 13 because the cavity 13 of the rubber mold 10 is sealed when the is inserted. Therefore, in the building board manufacturing process in this case, as shown in FIG.
After 03), the shape retaining frame is inserted (806) into the mold body. The other steps are the same as the manufacturing steps in the case of using the metal frame 20 without the top plate described above with reference to FIG.

Incidentally, the manufacturing process of inserting the shape-retaining frame into the mold body after injecting the building board raw material into the mold as described above can be adopted when the shape-retaining frame 20 without the top plate is used. is there. However, considering the easiness of the work process, it is better to adopt the manufacturing process in which the building board raw material is poured into the mold with the shape-retaining frame inserted in the mold body as described above with reference to FIG. Good. However, whichever manufacturing process is used,
The quality of the obtained building boards is the same.

FIG. 9 shows an example in which a wall surface is constructed by the building board manufactured in this way. In addition to the building board 30 having the shape described above, building boards of various shapes, such as a cross-shaped building board 60 and an H-shaped building board 61, are manufactured, and they are combined, as shown in the figure. A variety of wall surfaces are created. In this case, since these building boards are designed so that the length of each side is an integral multiple of a certain length L, building boards having different shapes can be easily combined and arranged. In addition, even at the stage of planning how to arrange the building boards on the entire wall surface, by allocating building boards of various shapes on the grid G having an equal interval L on the design drawing,
The wall surface can be easily planned.

FIG. 10 and FIG. 11 show another embodiment in which the wall surface is made of a building board manufactured by using the building board mold according to the present invention. In this embodiment, building boards 70 and 71 having a curved shape are used, and the wall surface is constituted by only one kind of building board. Even in the case where the wall surface is composed of one type of building board as described above, since the degree of freedom of the shape of the building board is high, it is possible to express an unprecedented wall surface design.

The groove 14 is not necessarily formed along the entire circumference of the peripheral surface 12 of the cavity 13, but may be formed partially. Also, the rubber mold 1
The outer contour shape of 0 is not particularly limited as long as it does not hinder the demolding of the building board.

[0029]

EFFECTS OF THE INVENTION A building board mold according to the present invention and a method of manufacturing a ceramic building board using the mold are a mold made of an elastic and flexible material such as urethane rubber or silicon rubber. While using, it is possible to satisfy both the problem of facilitating demolding and the problem of molding ceramic-type building boards with complicated shapes and surface patterns at the same time, and reducing the accuracy of the product due to mold distortion. It can be reduced as much as possible.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a building board mold according to the present invention.

FIG. 2 is a perspective view of a building board made using the building board mold shown in FIG.

FIG. 3 is a diagram showing an uneven surface pattern of the building board shown in FIG.
III-III line partial enlarged sectional view of FIG.

FIG. 4 is a sectional view taken along line IV-IV of the building board mold shown in FIG. 1.

FIG. 5 is a flowchart illustrating a manufacturing process of a building board using the building board mold according to the present invention.

FIG. 6 is a perspective view showing another embodiment of a shape retaining frame for a building board according to the present invention.

7 is a cross-sectional view taken along the line VII-VII of FIG. 6, showing a state in which the shape retention frame shown in FIG. 6 is inserted into the mold body.

FIG. 8 is a flow diagram illustrating a manufacturing process of a building board when the shape retention frame shown in FIG. 6 is used.

FIG. 9 is an elevational view showing an example in which a wall surface is constituted by a building board manufactured using a building board mold according to the present invention.

FIG. 10 is an elevational view showing another embodiment in which a wall surface is constituted by a building board manufactured using the building board mold according to the present invention.

FIG. 11 is an elevational view showing still another embodiment in which a wall surface is constituted by a building board manufactured using the building board mold according to the present invention.

FIG. 12 is a front side perspective view showing an example of a ceramic building board.

FIG. 13 is a flowchart illustrating a manufacturing process of a ceramic building board.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Building board mold, 10 ... Rubber form, 11 ... Bottom, 12 ...
Peripheral surface, 13 ... Cavity, 14 ... Groove, 15 ... Upper part, 2
0 ... Gold frame

Claims (3)

(57) [Claims] 1. A rubber hardness of 20 to 40 degrees, which is made of urethane rubber or silicon rubber, and has a bottom surface and a peripheral surface shape along the shape of the surface and the peripheral surface of the ceramic building board to be obtained. A mold body having a cavity provided on the inner surface and a groove formed along the entire circumference so as to be along the peripheral surface of the cavity, and insertable into and removable from the groove formed in the mold body. Hokatachiwaku, Do from the Ri, the Hokatachiwaku is
Integrated top plate that can cover the open surface of the cavity
The type for the ceramic building board that is prepared for. 2. The ceramic building board mold according to claim 1, wherein the shape retaining frame is made of a metal material. 3. The ceramic building plate mold according to claim 1 , wherein the ceramic material is poured into the cavity of the mold body, and then the shape retaining frame is inserted into the groove of the mold body. ,
After the ceramic material is cured in that state, the shape-retaining frame is extracted, and the cured ceramic building board is demolded while deforming the mold body, thereby manufacturing the ceramic building board.