JP4005753B2 - Method of manufacturing mold body and inorganic cured body - Google Patents

Description

【００４８】
表１で本実施例の無機質硬化性組成物（パネル基材）を説明する。無機質粉体（Ａ）として、ＳｉＯ₂ −Ａｌ₂ Ｏ₃ 系無機質粉体であるメタカオリンを使用した。このメタカオリンは、エンゲルハード社製の商品名ＳａｔｉｎｔｏｎｅＳＰ−３３を三菱重工業社製ウルトラファインミル（ジルコニアボール直径１０ｍｍ使用、ボール充填率８５％、粉砕助剤としてトリエタノールアミン２５％、エタノール７５％の混合液をメタカオリンの０．６％添加）にて、３．３ｋＷ／ｋｇのエネルギーで、３時間処理したものである。
その他の粉体として無機質充填材と補強繊維と発泡剤とを加えた。
無機質充填材は、珪石粉とワラストナイトとを使用した。珪石粉は、住友セメント社製、ブレーン値５０００ｃｍ² ／ｇのものであり、ワラストナイトは、土屋カオリン社製の商品名ケモリットＡ−６０を使用した。
補強繊維は、ビニロン繊維であり、クラレ社製の商品名ＲＭ１８２×３を使用した。
また、発泡剤は、金属珪素粉末（Ｓｉ）を使用した。この金属珪素粉末は、２００メッシュ（目の開き７４μｍ）パス品である。
アルカリ金属珪酸塩水溶液（Ｂ）は、珪酸カリウム水溶液であり、ＳｉＯ₂ ／Ｋ₂ Ｏ＝１．４で濃度４５重量％のものを使用した。
この無機質反応性組成物で得られる無機質硬化体（パネル）は発泡体である。
【００４９】
型体は図１〜図１１に示す型体Ａ〜Ｋを使用した。型体Ａ〜Ｋの内寸は、それぞれ幅１０００ｍｍ，長さ２０００ｍｍ，深さ３０ｍｍである。
【００５０】
図１に示す実施例１の型体Ａは、鉄製の金属板部（支持体）３と、パネル基材（無機質硬化性組成物）５の表面を形成するＥＰＤＭゴム製の表面型１Ａと、型枠２Ａとから形成されている。表面型１Ａには、パネル基材５を硬化したパネル５ａの表面に凹凸模様を付与するために、凸部１１が設けられている。
また、型枠２Ａは、表面型１Ａの周端部に設けられパネル基材５の周端部を形成するＥＰＤＭゴム製の側面型２１Ａと鉄製のスペーサー２２Ａとから構成されている。この側面型２１Ａは、スペーサー２２Ａの内側面に設けられた逆テーパー状の突起と嵌合させることにより、スペーサー２２Ａに固着してある。
また、表面型１Ａは金属板部３の上に載置されており、表面型１Ａの周端部側面に当接するように側面型２１Ａが設けられている。
この表面型１Ａは側面型２１Ａの内周より若干大きくなされており、表面型１Ａを収縮させることにより型枠２Ａの中に設置してある。そのため、表面型１Ａと側面型２１Ａとの当接面は、互いのゴム弾性により塞がれている。
【００５１】
また、表面型１Ａと側面型２１Ａとスペーサー２２Ａと金属板部３は、それぞれ簡単に分離可能となされているので、型体Ａの清掃等のメンテナンスを各部材毎にできる。また、不具合の生じた部材だけを取り替えるだけで、型体Ａを有効に使用することができる。さらに、型体Ａの廃棄は、材質毎に分別して行うことができる。
【００５２】
無機質硬化性組成物５は、各原料をそれぞれオムニミキサーに投入して１５分間混合して調製した。
また、無機質硬化体（パネル）５ａは、型体Ａに無機質硬化性組成物５を充填して、蓋体４を型枠２Ａの上に載置固定し、生蒸気吹き出しで８５℃に温度調節した養生庫に設置し、５時間養生後取り出し、無機質硬化体であるパネル５ａを型体Ａから脱型し、８５℃で５時間空気乾燥して製造した。
このパネル５ａを品質評価した。品質評価としては、パネル５ａの外形寸法とバリの厚さを測定した。また、バリの発生部位及び発生方向を観察した。
以下パネル５ａの製造方法は同様なので、説明を省略する。
【００５３】
図２に示す実施例２の型体Ｂは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｂと、鉄製の側面型２１Ｂ（型枠２Ｂ）とから形成されている。表面型１Ｂの周縁部には、凸部１１の底部と同じ高さの側面型載置部２３Ｂが設けられている。側面型載置部２３Ｂの上に側面型２１Ｂが載置してあり、側面型２１Ｂは表面型１Ｂの中央部の加飾部の周端部側面に接するようになされている。また、表面型１Ｂは、金属板部３の上に載置されている。
【００５４】
図３に示す実施例３の型体Ｃは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｃと、鉄製の側面型２１Ｃ（型枠２Ｃ）とから形成されている。表面型１Ｃの周縁部には、凸部１１の頂部と同じ高さの側面型載置部２３Ｃが設けられ、側面型載置部２３Ｃの上に側面型２１Ｃが載置されている。また、表面型１Ｃは金属板部３の上に載置されている。
【００５５】
図４に示す実施例４の型体Ｄは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｄと、型枠２Ｄとから形成されている。表面型１Ｄの周縁部には、凸部１１の頂部と同じ高さの側面型載置部２３Ｄが設けられている。また、型枠２Ｄは側面枠２１Ｄとスペーサー２２Ｄとから構成されている。側面型２１Ｄは、スペーサー２２Ｄの内側面に設けられた逆テーパー状の突起と嵌合させることにより、スペーサー２２Ｄに固着してある。側面型２１Ｄは、側面載置部２３Ｄの上に載置されている。また、スペーサー２２Ｄは、金属板部３に載置され、表面型１Ｄの周端部側面に接して設けられている。また、表面型１Ｄは金属板部３の上に載置されている。
【００５６】
図５に示す実施例５の型体Ｅは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｅと、型枠２Ｅから形成されている。表面型１Ｅの周縁部には、凸部１１の頂部と同じ高さの側面型載置部２３Ｅが設けられている。また、型枠２Ｅは、ＥＰＤＭゴム製の側面型２１Ｅとスペーサー２２Ｅとから形成されており、側面型２１Ｅは、スペーサー２２Ｅ内側面に設けられた逆テーパー状の突起と嵌合させることにより、スペーサー２２Ｅに固着してある。型枠２Ｅは、側面型載置部２３Ｅの上に載置されている。表面型１Ｅは金属板部３の上に載置されている。
【００５７】
図６に示す実施例６の型体Ｆは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｆと、型枠２Ｆとから形成されている。表面型１Ｆの周縁部には、凸部１１の頂部と同じ高さの側面型載置部２３Ｅが設けられている。また、型枠２Ｆは、ＥＰＤＭゴム製の側面型２１Ｆと鉄製の外側周端部が下に向けた凸条となされたスペーサー２２Ｆとから形成されている。側面型２１Ｅは、スペーサー２２Ｆ内側面に設けられた逆テーパー状の突起と嵌合させることにより、スペーサー２２Ｆに固着してある。型枠２Ｆは、側面型載置部２３Ｆの上に載置されており、スペーサー２２Ｆの凸条は金属板部３の上に載置されている。また、表面型１Ｆは金属板部３の上に載置されている。
【００５８】
図７に示す実施例７の型体Ｇは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｇと、ＥＰＤＭゴム製の側面型２１Ｇと、スペーサー２２Ｇとから形成されている。表面型１Ｇと側面型２１Ｇとは一体的に形成されおり、金属板部３の上に載置され、かつ、表面型１Ｇの周端部側面に接してスペーサー２２Ｇが載置されている。側面枠２１Ｇとスペーサー２２Ｇとは当接するようになされており、型枠２Ｇを構成している。
【００５９】
図８に示す実施例８の型体Ｈは、金属板部３と、ＥＰＤＭゴム製の表面型１Ｈと側面型２１Ｈと、スペーサー２２Ｈとから形成されている。表面型１Ｈと側面型２１Ｈとは、一体的に形成されおり、金属板部３の上に載置され、かつ、表面型１Ｈの周端部側面に接してスペーサー２２Ｈが載置されている。また、側面型２１Ｈの外側周縁部上端には凹部が設けてあり、スペーサー２２Ｈの内側周縁部上端の凸部が嵌合するようになされており、型枠２Ｈを構成している。
【００６０】
図９に示す実施例９の型体Ｉは、金属製の箱状の外型３Ａと、ＰＥＴの発泡体製の表面型１Ｉと側面型２１Ｉとから形成されている。表面型１Ｉと側面型２１Ｉとは一体的に形成され、内型Ｉとなされている。内型Ｉは、外型３Ａの内面に接して設けられている。ここで、外型３Ａの側面がスペーサー２１Ｉとして機能するように形成されている。なお、この内型Ｉは、パネル５ａを製造する毎に新しいものに取り替えて使用した。
【００６１】
以上の実施例１〜９の型体Ａ〜Ｉと比較例２の型体Ｋは、それぞれ鉄製のスペーサー又は鉄製の側面型を使用している。そのため、それらの型体を使用して製造したパネル５ａの平面寸法は、初回に製造したものと終回（１００回目）に製造してものとで有為な差がなかった。それに対し、比較例１の型体Ｊは、パネル５ａの製造を繰り返す度に収縮し、初回と終回で製造したパネル５ａでは、長辺で５ｍｍ、短辺で３ｍｍの寸法変化が観測された。
また、実施例１〜９と比較例１，２におけるパネル５ａの厚さとパネル５ａのバリの厚さの評価結果を表２に示す。
【００６２】
【表２】

【００６３】
実施例１，４，６，７，８，９では、金属製のスペーサーを側面枠に備え、そのスペーサーを金属板部に当接させることにより、パネルが所定の厚さ３０ｍｍに近い寸法で製造できた。
また、表面型に側面型載置部を設けた実施例２，３，４，５，６では初回と終回とでバリの厚さの差は小さい。また、バリは、パネルの側面からパネルの表面に平行な方向に形成されるので、パネルの側面をやすり等で削ることによって、バリを簡単に取り去ることができた。つまり、パネルが効率よく製造できた。
上述の実施例に比較して、側面型載置部を設けず、側面型（型枠）が鉄製である比較例２では、初回から厚さの大きいバリが形成され、かつ、パネル５ａの製造を繰り返す毎にバリの厚さが大きくなった。また、バリがパネルの表側にあるため、凹凸加飾された表面を傷つけずにバリを取ることが困難であった。
それに対し、型枠の内側面にゴム弾性体の側面型を備えた実施例１では、比較例２に対し大きな改善効果が観測された。
また、側面型と表面型を一体的に形成した実施例７，８，９と比較例１では、バリの形成は見られなかった。
【００６５】
【発明の効果】
請求項１記載の発明の型体は、ゴム弾性体により形成された側面型の下面を表面型のゴム弾性体の表面に押圧することにより、表面型と側面型の当接面がゴム弾性体により塞がれ、液状の無機質硬化性組成物が当接面に侵入するのを防ぐことができるので、バリの発生を抑えることができる。
また、少量の無機質硬化性組成物が当接面に侵入してバリが形成されても、そのバリはパネルの側面からパネルの表面に平行な方向に形成されるので、パネルの側面をやすり等で削ることによって、バリを簡単に取り去ることができる。つまり、パネルの製造効率を高めることができる。
さらに、側面型がゴム弾性体で形成されているので、無機質硬化体の脱型を容易にできる。
また、表面型と側面型とは、当接しており分離することができるので、型体の清掃等のメンテナンスを各部材毎にできる。つまり、パネルの製造効率を高めることができる。さらに、不具合の発生した部材だけを廃棄することができる。
【００６６】
また、請求項２記載の発明の型体は、表面型が、中央部の凸部を有する加飾部と周縁部の側面型載置部とを備えており、その側面型載置部の高さが加飾部の凸部の頂部と同一高さ又は加飾部の凸部の頂部より高くなされている。
従って、少量の無機質硬化性組成物が当接面に侵入して形成されたバリは、無機質硬化体であるパネルの加飾面の最深部と同一高さ又は最深部より下でパネルの側面からパネルの表面に平行な方向に形成される。
従って、パネルの側面をやすり等で削ることによって、パネルの加飾面を傷める危険なしに、バリを簡単に取り去ることができる。つまり、パネルの製造効率を高めることができる。
【００６７】
また、請求項３記載の発明の型体は、パネル基材の寸法を規定するための剛体のスペーサーが側面型の外側に配設されて型枠となされているので、表面型の平面寸法と側面型の高さ寸法を所定の寸法に保ことができる。つまり、寸法精度のよいパネルを製造することができる。
【００６８】
また、請求項４記載の無機質硬化体の製造方法は、側面型にパネル基材の寸法を規定するための剛体のスペーサーが備えられた型枠を蓋体で押圧してパネル基材を所定の寸法にして加熱硬化する。従って、ゴム弾性体で形成された表面型及び側面型に熱が加わっても、表面型の平面寸法と側面型の高さ寸法を所定の厚さに保ことができ、無機硬化体であるパネルを所定の寸法で製造することができる。
【００７１】
また、請求項５記載の発明の無機質硬化体の製造方法は、無機質硬化性組成物がＳｉＯ₂ ―Ａｌ₂ Ｏ₃ 系無機質粉体（Ａ）と、この無機質粉体と反応するアルカリ金属珪酸塩水溶液（Ｂ）とを混合したものである。従って、寸法精度や品質に優れたパネルを簡単に製造することができる。
【００７２】
また、請求項６記載の発明の無機質硬化体の製造方法は、前記無機質硬化性組成物がＳｉＯ₂ ―Ａｌ₂ Ｏ₃ 系無機質粉体（Ａ）１００重量部に対して、アルカリ金属珪酸塩０．２〜４５０重量部、水３５〜１５００重量部を含む。従って、寸法精度や品質に優れたパネルを短時間に製造することができる。
【図面の簡単な説明】
【図１】本発明の型体の断面図である。
【図２】本発明の他の型体の断面図である。
【図３】本発明の型体の断面図である。
【図４】本発明の他の型体の断面図である。
【図５】本発明の他の型体の断面図である。
【図６】本発明の型体の断面図である。
【図７】本発明の他の型体の断面図である。
【図８】本発明の型体の断面図である。
【図９】本発明の他の型体の断面図である。
【図１０】従来の型体の断面図である。
【図１１】従来の型体の断面図である。
【符号の説明】
Ａ〜Ｋ 型体
１Ａ〜１Ｋ 表面型
１１ 凸部
２Ａ〜２Ｋ 型枠
２１Ａ〜２１Ｋ 側面型
２１Ａ，２１Ｄ〜２１Ｈ スペーサー
２２Ｂ〜２２Ｄ，２２Ｅ，２２Ｆ 側面型載置部
３ 金属板部（支持体）
４ 蓋体
５ パネル基材（無機質硬化性組成物）
５ａ パネル（無機質硬化体）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for an inorganic curable composition used for manufacturing an inorganic cured body used for building materials and the like, and a method for manufacturing an inorganic cured body.
[0002]
[Prior art]
Conventionally, cement and water, or SiO₂―Al₂O_ThreeA mold body is filled with an inorganic curable composition that is a mixture of an inorganic powder and a liquid that reacts with the powder, such as an aqueous inorganic powder and an alkali metal silicate aqueous solution, and is heated and cured to obtain an inorganic cured body. Methods are generally known.
For example, SiO₂―Al₂O_ThreeAn inorganic curable composition, which is a mixture of inorganic inorganic powder and an aqueous alkali metal silicate solution, is filled into a mold and heated and cured from the periphery of the mold with a heat medium, such as air heating or steam heating. A technique for manufacturing a body is disclosed in Japanese Patent Laid-Open No. 11-58342.
[0003]
In the above-described technique, the mold body filled with the inorganic curable composition is, as shown in FIG. 11, an EPDM rubber or the like that forms the surface of the metal plate portion 3 and the panel substrate 5 made of the inorganic curable composition. The surface mold 1K made of rubber and the metal side mold 21K which is provided at the peripheral end portion of the surface mold 1K and forms the peripheral end portion of the panel base 5 are formed.
[0004]
The surface mold 1K is placed on the metal plate portion 3, and a side mold 21K (form frame 2K) is provided in contact with the side surface of the peripheral end of the surface mold 1K. Further, the surface mold 1K is provided with a convex portion 11 in order to give a concavo-convex pattern to the surface of the panel 5a obtained by curing the panel base material 5. If there is a gap between the peripheral end side surface of the surface mold 1K and the inner surface of the side mold 21K, the panel base material 5 enters the gap. As a result, burrs are formed at the peripheral edge of the panel 5a obtained by curing the panel base material 5, and post-processing of the panel 5a is required.
In order not to generate a gap between the side end side surface of the surface mold 1K and the inner surface of the side mold 21K, the surface mold 1K requires accurate dimensional accuracy, and the manufacturing cost of the surface mold 1K is high. It was.
[0005]
The rubber is used after being crosslinked with a crosslinking agent such as sulfur in order to obtain necessary physical properties such as heat resistance. Since a part of this cross-linking agent remains after the cross-linking reaction, when the rubber surface mold 1K is repeatedly used, the cross-linking reaction proceeds and the surface mold 1K contracts, and the side surface of the side surface of the surface mold 1K. And a gap is generated between the inner surface of the side mold 21K. Due to this gap, a burr was formed at the peripheral end of the panel 5a, and post-processing of the panel 5a was necessary.
[0006]
Further, in the mold body J in which the surface mold 1J and the side mold 21J (mold frame 2J) are integrally molded with rubber as shown in FIG. There was a problem that the body J contracted and the size of the panel 5a became smaller. Further, since the mold J cannot be separated into the surface mold 1J and the side mold 21J, it is necessary to discard the entire mold J when a problem occurs.
[0007]
[Problems to be solved by the invention]
The present invention has been made in view of the above-described problems, and even if a panel made of an inorganic cured body is repeatedly manufactured by filling a panel with a panel base material made of an inorganic curable composition and then heat-curing it. There is no change in panel dimensions, no inconvenient burrs are formed on the panel, a mold body excellent in panel productivity and mold body disposal, and a method for producing an inorganic cured body using the mold body It is intended to provide.
[0008]
[Means for Solving the Problems]
  In order to achieve the above object, the invention according to claim 1 is a mold body filled with a panel substrate made of an inorganic curable composition, and the mold body is a rubber elastic body that forms the surface of the panel substrate. A surface mold comprising: a peripheral surface of the panel base material provided at a peripheral edge of the surface mold;SideWith a surface mold,ThatSurface typeSurface ofAnd said side moldUnderside ofAnd abutThe side mold is formed of a rubber elastic body.It is a mold characterized by
[0009]
Examples of the rubber elastic body of the present invention include soft synthetic resins, rubbers such as natural rubber and synthetic rubber, and foams such as synthetic resins and rubber.
Examples of the synthetic resin include polyethylene, polypropylene, polyester, polyethylene terephthalate (PET), fluororesin, vinyl chloride resin, acrylic resin, epoxy resin, phenol resin, urea resin, polycarbonate, and copolymers thereof.
Examples of the rubber include silicone rubber, EPDM rubber, natural rubber, isoprene rubber, neoprene rubber, chloroprene rubber, butadiene rubber, styrene butadiene rubber, acrylonitrile butadiene rubber, and fluorine rubber.
As the foam of synthetic resin or rubber, foamed polyethylene, foamed polypropylene, foamed polystyrene, foamed polyester, foamed EPDM rubber or the like is suitable. The specific gravity of these foams is preferably 0.2 or more from the viewpoint of strength.
[0010]
In addition, it is preferable to provide a support having a flat surface made of metal or synthetic resin under the surface mold because the surface mold of the rubber elastic body can be prevented from being deformed. The surface mold and the support may be fixed by adhesion, adhesion, or the like, or may be easily separable only by contacting.
[0011]
The mold body of the present invention may be provided with a lid body that covers the surface mold. Further, the panel substrate may be filled in the space formed by the surface mold, the side mold, and the lid so that the panel substrate can be cured by holding the mold at an arbitrary angle.
[0014]
  The invention according to claim 2 is the invention according to claim 1, wherein the surface mold includes a decorative portion having a convex portion at a central portion and a side surface type placement portion at a peripheral portion, and the side surface type placement. The height of the partThe same height as the top of the convex part of the decorative part orIt is a type | mold body made | formed higher than the top part of the convex part of the said decoration part.
[0015]
Here, the side surface type mounting part may be an inclined surface, and the height of the side surface type mounting part is the innermost height of the side surface type mounting part.
[0016]
  Also,Claim 3The described inventionClaim 1 or 2A rigid spacer for defining the dimensions of the panel substrate is the side surface typeArranged outsideIt is a mold characterized by being a formwork.
[0017]
The spacer in the present invention is preferably formed of a metal such as iron, stainless steel, or aluminum because it has high strength and is relatively inexpensive.
Further, it can be formed of a synthetic resin. In particular, it is preferable to use a thermosetting resin reinforced with glass fiber or carbon fiber because it has heat resistance and is easy to form integrally.
The side surface mold and the spacer of the present invention may be fixed by adhesion, adhesion, etc., may be fitted with a fitting portion and a fitting receiving portion, or may simply be in contact with each other. You may just be there.
[0018]
  Also,Claim 4The described invention relates to a panel substrate made of an inorganic curable composition.Claim 3A method for producing an inorganic cured body that fills and heats the described mold body, wherein the mold body is provided with a lid, and the mold body is pressed by the lid to set a thickness of the panel base material to a predetermined value. It is a method for producing an inorganic cured body characterized by heat-curing to a size.
[0023]
  Also,Claim 5The described inventionClaim 4In the inorganic curable composition is SiO₂ ―Al₂ O_Three It is a method for producing an inorganic cured body, characterized in that the inorganic inorganic powder (A) is mixed with an aqueous alkali metal silicate solution (B) that reacts with the inorganic powder.
[0024]
  Also,Claim 6The described inventionClaim 4In the inorganic curable composition is SiO₂ ―Al₂ O_Three It is a manufacturing method of the inorganic hardened | cured material characterized by including alkali metal silicate 0.2-450 weight part and water 35-1500 weight part with respect to 100 weight part of a system inorganic powder (A).
[0025]
As the inorganic powder (A) used in the present invention, SiO₂5 to 85% by weight and Al₂O_Three90 to 10% by weight is preferably used. Examples of such powders include fly ash, metakaolin, kaolin, mullite, corundum, and dust when producing alumina-based abrasives, pulverized and fired bauxite, etc., but are limited to these if the composition and particle size are appropriate. It is not something. In addition, since what can be obtained easily contains impurities, SiO₂And Al₂O_ThreeIs not 100% by weight, but the total may be 100% by synthesis. In addition, these powders may be used as they are, but in order to activate them, methods such as thermal spraying treatment, pulverization classification, and action of mechanical energy may be used.
[0026]
As a thermal spraying method, a thermal spraying technique applied to a ceramic coating is applied. The thermal spraying technique is preferably such that the material powder is melted at a temperature of 2000 to 16000 ° C. and sprayed at a speed of 30 to 800 m / second, such as a plasma spraying method, a high energy gas spraying method, and an arc spraying method. Is possible. The specific surface area of the obtained powder is 0.1 to 100 m.²/ G is preferred.
[0027]
Any known method can be adopted as a method for pulverization and classification. That is, examples of the pulverization method include a jet mill, a roll mill, a ball mill, and the like. Examples of the classification method include methods such as sieving, specific gravity, wind force, and wet sedimentation. These means may be used in combination.
[0028]
As a method of applying mechanical energy, a ball medium mill, a medium stirring mill, a roller mill or the like is used, and the mechanical energy to be applied is preferably 0.5 kwh / kg to 30 kwh / kg. When the mechanical energy is small, it is difficult to activate the powder, and when the mechanical energy is large, the load on the apparatus is large.
[0029]
The fly ash may be fired as necessary. If the firing temperature is too low, black color of fly ash remains and coloring with a pigment or the like becomes difficult, and if it is too high, the reactivity with the alkali metal silicate becomes low, so that the temperature is preferably 400 ° C to 1000 ° C.
[0030]
The alkali metal silicate aqueous solution [liquid (B)] used in the present invention is M₂O · nSiO₂A salt represented by (one or more metals selected from M = K, Na, Li), and if the value of n is too small, a dense inorganic cured product cannot be obtained. Since it raises and mixing becomes difficult, 0.05-8 are preferable, More preferably, it is 0.5-2.5.
[0031]
In the present invention, a foaming agent may be added as necessary in order to make the inorganic cured body into a foam. As foaming agents, peroxides (hydrogen peroxide, sodium peroxide, potassium peroxide, sodium perborate, etc.), metal powders (Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Al, Ga) , Sn, Si, ferrosilicon) or the like. If the amount of the foaming agent is too much, the foaming gas becomes excessive and bubbles are broken, and a good foam cannot be obtained. If the amount is too small, the expansion ratio is too small and the meaning of the foam is lost. Is preferred. When hydrogen peroxide is used as a foaming agent, it is preferably used as an aqueous solution for safety and stable foaming. When metal powder is used, the particle size is preferably 200 μm or less in order to obtain stable foaming.
[0032]
In the present invention, a foaming aid may be added as necessary in order to make foaming uniform. The foaming aid is not particularly limited as long as it causes foaming uniformly, and examples thereof include fatty acid metal salts such as zinc stearate, calcium stearate, and zinc palmitate, porous powders such as silica gel, zeolite, activated carbon, and alumina powder. can give. These may be used alone or in combination of two or more.
If the amount of the foaming aid is too large, the viscosity of the inorganic curable composition is increased and good foaming cannot be obtained. Therefore, the amount is preferably 10 parts by weight or less with respect to 100 parts by weight of the inorganic powder (A).
[0033]
In this invention, in order to improve the intensity | strength etc. of an inorganic hardening body, an inorganic filler may be added as needed. The inorganic filler is not particularly limited as long as it does not dissolve in water and does not react with the alkali metal silicate. For example, silica sand, river sand, zircon sand, crystalline alumina, rock powder, volcanic ash, silica flour, silica fume, Examples thereof include mixed cements such as bentonite and blast furnace slag, natural minerals such as sepiolite, wollastonite and mica, calcium carbonate, diatomaceous earth and the like. These may be added alone or in combination of two or more.
If the average particle size is too small, the inorganic filler will increase the viscosity of the composition and deteriorate the moldability of the inorganic curable composition. If it is too large, a uniform inorganic cured product cannot be obtained. 1000 μm is preferred. Since the intensity | strength of the inorganic hardened | cured material obtained will fall when there is too much quantity of an inorganic filler, 700 weight part or less is preferable with respect to 100 weight part of said inorganic powder (A).
[0034]
In the present invention, reinforcing fibers may be added as necessary to reinforce the inorganic cured body. Any reinforcing fiber can be used according to the performance to be imparted to the inorganic cured body. For example, vinylon fiber, polyamide fiber, polyester fiber, polypropylene fiber, carbon fiber, aramid fiber, glass fiber, potassium titanate fiber, steel fiber and the like can be used.
[0035]
If the fiber diameter of the reinforcing fiber is too thin, it re-aggregates during mixing, and fiber balls are easily formed by entanglement, and the strength of the finally obtained inorganic cured body does not improve. If it is too thick or too short, the reinforcing effect such as improvement in tensile strength is small. Moreover, when too long, the dispersibility and orientation of a fiber will fall and the intensity | strength of an inorganic hardening body will not be improved. Therefore, a fiber diameter of 1 to 500 μm and a fiber length of 1 to 15 mm are preferable. Since the dispersibility of the fibers decreases as the amount of the reinforcing fibers added increases, the amount is preferably 10 parts by weight or less with respect to 100 parts by weight of the inorganic powder (A).
[0036]
Furthermore, for the purpose of reducing the weight of the inorganic cured body, silica foam, pearlite, fly ash balloon, shirasu balloon, glass balloon, foamed clay foam, etc., foam of synthetic resin such as phenol resin, urethane resin, polyolefin, A polyvinylidene chloride balloon, a polyacryl balloon, etc. may be added.
These may be added alone or in combination of two or more.
Further, if necessary, alumina cement, γ-alumina, sprayed alumina, alkali metal aluminate or aluminum hydroxide may be added.
[0038]
[Action]
  Claim 1The mold of the invention comprises a surface mold made of a rubber elastic body that forms the surface of the panel base material, and a side face mold that is provided at the peripheral edge portion of the surface mold to form the peripheral edge portion of the panel base material, The surface of the surface mold and the bottom of the side moldThe side mold is formed of a rubber elastic body.ing. Therefore, The side formed by rubber elastic bodySurface typeThe underside ofSurface-type rubber elasticityDepending on the surface of the bodyBy pressing, the contact surface of the surface mold and the side moldIsIt can be blocked by the elastic body and prevent the liquid inorganic curable composition from entering the contact surface. Even if a small amount of the inorganic curable composition enters the contact surface to form burrs, the burrs are formed in a direction parallel to the panel surface from the side surface of the panel.
  Further, since the surface mold and the side mold are in contact with each other and can be separated, maintenance such as cleaning of the mold body can be performed for each member. Furthermore, only the member in which the defect has occurred can be discarded.
In addition, since the side surface mold is formed of a rubber elastic body, the inorganic cured body can be easily removed.
[0039]
  In the mold of the invention described in claim 2, the surface mold includes a decorative part having a convex part at the center part and a side surface type mounting part at the peripheral part, and the height of the side surface type mounting part is high. SagaThe same height as the top of the convex part of the decorative part orIt is made higher than the top of the convex part of the decoration part.
  Accordingly, the burr formed by a small amount of the inorganic curable composition entering the contact surface is the deepest part of the decorative surface of the panel, which is an inorganic cured body.The same height or deepest partBelow, it is formed in a direction parallel to the surface of the panel from the side surface of the panel.
[0040]
  Also,Claim 3In the mold of the invention, the rigid spacer for defining the dimensions of the panel substrate is a side mold.Arranged outsideIt is a formwork. Therefore, even when heat is applied to the surface mold or side mold formed of the rubber elastic body during curing, the planar dimension of the surface mold and the height dimension of the side mold can be maintained at predetermined dimensions.
[0041]
  Also,Claim 4In the method for producing an inorganic cured body, a side frame is pressed with a lid provided with a rigid spacer for defining the dimensions of the panel substrate, and the panel substrate is heated and cured to a predetermined dimension. . Therefore, the surface mold made of rubber elastic bodyas well asEven if heat is applied to the side mold, the planar dimension of the surface mold and the height dimension of the side mold can be maintained at a predetermined thickness, and a panel that is an inorganic cured body can be manufactured with a predetermined dimension.
[0044]
  Also,Claim 5In the method for producing an inorganic cured body of the invention, the inorganic curable composition is made of SiO.₂ ―Al₂ O_Three A system inorganic powder (A) and an alkali metal silicate aqueous solution (B) that reacts with the inorganic powder are mixed. Therefore, a panel having excellent dimensional accuracy and quality can be easily manufactured.
[0045]
  Also,Claim 6In the method for producing an inorganic cured body of the invention, the inorganic curable composition is made of SiO.₂ ―Al₂ O_Three It contains 0.2 to 450 parts by weight of alkali metal silicate and 35 to 1500 parts by weight of water with respect to 100 parts by weight of the inorganic inorganic powder (A). Therefore, a panel having excellent dimensional accuracy and quality can be manufactured in a short time.
[0046]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in more detail with reference to examples.
First, Table 1 shows the composition of the inorganic curable composition. Table 2 describes Examples 1 to 8 and Comparative Examples 1 and 2. 1 to 9 are longitudinal sectional views of molds used in Examples, and FIGS. 10 and 11 are comparative examples.
[0047]
[Table 1]

[0048]
Table 1 describes the inorganic curable composition (panel substrate) of this example. As inorganic powder (A), SiO₂-Al₂O_ThreeMetakaolin, a mineral inorganic powder, was used. This metakaolin is a mixture of Engelhard's trade name Satintone SP-33 made by Mitsubishi Heavy Industries, Ltd. The solution was treated with an energy of 3.3 kW / kg for 3 hours using 0.6% of metakaolin.
As other powders, an inorganic filler, a reinforcing fiber, and a foaming agent were added.
As the inorganic filler, quartzite powder and wollastonite were used. Silica stone powder, manufactured by Sumitomo Cement Co., Ltd., Brain value 5000cm²As for Wollastonite, the trade name Chemolit A-60 manufactured by Tsuchiya Kaolin Co., Ltd. was used.
The reinforcing fiber is a vinylon fiber, and a trade name RM182 × 3 manufactured by Kuraray Co., Ltd. was used.
Moreover, the metal silicon powder (Si) was used for the foaming agent. This metal silicon powder is a 200-mesh (opening 74 μm) pass product.
The alkali metal silicate aqueous solution (B) is a potassium silicate aqueous solution, and SiO₂/ K₂O = 1.4 and a concentration of 45% by weight were used.
The inorganic cured body (panel) obtained with this inorganic reactive composition is a foam.
[0049]
Molds A to K shown in FIGS. 1 to 11 were used as molds. The internal dimensions of the molds A to K are 1000 mm in width, 2000 mm in length, and 30 mm in depth, respectively.
[0050]
A mold body A of Example 1 shown in FIG. 1 includes an iron metal plate portion (support) 3 and a surface mold 1A made of EPDM rubber that forms the surface of a panel substrate (inorganic curable composition) 5. It is formed from the mold 2A. The surface mold 1A is provided with a convex portion 11 in order to give an uneven pattern to the surface of the panel 5a obtained by curing the panel base material 5.
The mold 2A is composed of a side mold 21A made of EPDM rubber and an iron spacer 22A which is provided at the peripheral end of the surface mold 1A and forms the peripheral end of the panel base material 5. The side surface mold 21A is fixed to the spacer 22A by fitting with a reverse-tapered protrusion provided on the inner surface of the spacer 22A.
Further, the surface mold 1A is placed on the metal plate portion 3, and a side surface mold 21A is provided so as to contact the side surface of the peripheral end of the surface mold 1A.
The surface mold 1A is slightly larger than the inner periphery of the side mold 21A, and is installed in the mold 2A by contracting the surface mold 1A. Therefore, the contact surface between the surface mold 1A and the side mold 21A is closed by the mutual rubber elasticity.
[0051]
Further, since the surface mold 1A, the side mold 21A, the spacer 22A, and the metal plate portion 3 can be easily separated from each other, maintenance such as cleaning of the mold A can be performed for each member. In addition, the mold body A can be used effectively only by replacing only the member in which a problem has occurred. Further, the mold body A can be discarded separately for each material.
[0052]
The inorganic curable composition 5 was prepared by putting each raw material into an omni mixer and mixing for 15 minutes.
The inorganic cured body (panel) 5a is filled with the inorganic curable composition 5 in the mold body A, the lid body 4 is placed and fixed on the mold 2A, and the temperature is adjusted to 85 ° C. by blowing live steam. The panel 5a, which is an inorganic hardened body, was removed from the mold A and was air-dried at 85 ° C. for 5 hours for production.
The panel 5a was quality evaluated. For quality evaluation, the outer dimensions of the panel 5a and the thickness of the burr were measured. Moreover, the generation | occurrence | production site | part and generation direction of a burr | flash were observed.
Hereinafter, the manufacturing method of the panel 5a is the same, and the description thereof is omitted.
[0053]
2 is formed of a metal plate portion 3, a surface mold 1B made of EPDM rubber, and a side face mold 21B (mold 2B) made of iron. A side surface mold placement portion 23B having the same height as the bottom of the convex portion 11 is provided on the peripheral edge of the surface die 1B. The side surface mold 21B is mounted on the side surface mold mounting portion 23B, and the side surface mold 21B is in contact with the side surface of the peripheral end of the decorative portion at the center of the surface mold 1B. Further, the surface mold 1 </ b> B is placed on the metal plate portion 3.
[0054]
The mold body C of Example 3 shown in FIG. 3 is formed of a metal plate portion 3, a surface mold 1C made of EPDM rubber, and an iron side face mold 21C (form frame 2C). A side surface mold placement portion 23C having the same height as the top of the convex portion 11 is provided at the peripheral edge of the surface die 1C, and the side surface die 21C is placed on the side surface mold placement portion 23C. Further, the surface mold 1 </ b> C is placed on the metal plate portion 3.
[0055]
A mold body D of Example 4 shown in FIG. 4 is formed of a metal plate portion 3, a surface mold 1D made of EPDM rubber, and a mold frame 2D. A side surface mold placement portion 23 </ b> D having the same height as the top of the convex portion 11 is provided at the peripheral edge of the surface die 1 </ b> D. The mold 2D is composed of a side frame 21D and a spacer 22D. The side surface mold 21D is fixed to the spacer 22D by fitting with a reverse-tapered protrusion provided on the inner surface of the spacer 22D. The side surface mold 21D is placed on the side surface placing portion 23D. The spacer 22D is placed on the metal plate portion 3 and is provided in contact with the side surface of the peripheral end portion of the surface mold 1D. The surface mold 1D is placed on the metal plate portion 3.
[0056]
A mold body E of Example 5 shown in FIG. 5 is formed of a metal plate portion 3, a surface mold 1E made of EPDM rubber, and a mold frame 2E. A side surface mold placing portion 23E having the same height as the top of the convex portion 11 is provided at the peripheral edge of the surface die 1E. Further, the mold 2E is formed of a side mold 21E made of EPDM rubber and a spacer 22E. The side mold 21E is fitted with a reverse taper-shaped protrusion provided on the inner surface of the spacer 22E. It is fixed to 22E. The mold 2E is placed on the side surface mold placement portion 23E. The surface mold 1E is placed on the metal plate portion 3.
[0057]
A mold body F of Example 6 shown in FIG. 6 is formed of a metal plate portion 3, a surface mold 1F made of EPDM rubber, and a mold frame 2F. A side surface mold placement portion 23 </ b> E having the same height as the top of the convex portion 11 is provided at the peripheral edge portion of the surface die 1 </ b> F. The mold 2F is formed of a side surface mold 21F made of EPDM rubber and a spacer 22F made of ridges with an outer peripheral edge of iron facing downward. The side surface mold 21E is fixed to the spacer 22F by fitting with a reverse taper-shaped protrusion provided on the inner surface of the spacer 22F. The mold frame 2 </ b> F is placed on the side surface mold placing portion 23 </ b> F, and the protrusions of the spacer 22 </ b> F are placed on the metal plate portion 3. The surface mold 1F is placed on the metal plate portion 3.
[0058]
A mold body G of Example 7 shown in FIG. 7 is formed of a metal plate portion 3, a surface mold 1G made of EPDM rubber, a side mold 21G made of EPDM rubber, and a spacer 22G. The surface mold 1G and the side mold 21G are integrally formed, and are placed on the metal plate portion 3, and a spacer 22G is placed in contact with the side surface of the peripheral end of the surface mold 1G. The side frame 21G and the spacer 22G are in contact with each other, and form the mold 2G.
[0059]
A mold body H of Example 8 shown in FIG. 8 is formed of a metal plate portion 3, a surface mold 1H made of EPDM rubber, a side mold 21H, and a spacer 22H. The surface mold 1H and the side mold 21H are integrally formed, and are placed on the metal plate portion 3, and a spacer 22H is placed in contact with the side surface of the peripheral end of the surface mold 1H. Further, a concave portion is provided at the upper end of the outer peripheral edge portion of the side surface mold 21H, and a convex portion at the upper end of the inner peripheral edge portion of the spacer 22H is fitted to form the mold 2H.
[0060]
A mold body I of Example 9 shown in FIG. 9 is formed of a metal box-shaped outer mold 3A, a PET foam surface mold 1I, and a side mold 21I. The surface mold 1I and the side mold 21I are integrally formed as an inner mold I. The inner mold I is provided in contact with the inner surface of the outer mold 3A. Here, the side surface of the outer mold 3A is formed to function as the spacer 21I. The inner mold I was replaced with a new one every time the panel 5a was manufactured.
[0061]
The mold bodies A to I in Examples 1 to 9 and the mold body K in Comparative Example 2 use iron spacers or iron side molds, respectively. Therefore, the planar dimensions of the panel 5a manufactured using these molds were not significantly different from those manufactured for the first time and those manufactured for the first time (100th time). In contrast, the mold J of Comparative Example 1 contracted each time the production of the panel 5a was repeated, and in the panel 5a produced in the first and last time, a dimensional change of 5 mm on the long side and 3 mm on the short side was observed. .
Table 2 shows the evaluation results of the thickness of the panel 5a and the thickness of the burr of the panel 5a in Examples 1 to 9 and Comparative Examples 1 and 2.
[0062]
[Table 2]

[0063]
In Examples 1, 4, 6, 7, 8, and 9, a metal spacer is provided on the side frame, and the panel is manufactured in a size close to a predetermined thickness of 30 mm by contacting the spacer with the metal plate portion. did it.
Further, in Examples 2, 3, 4, 5, and 6 in which the surface mold is provided on the surface mold, the difference in burr thickness is small between the first time and the last time. Further, since the burr is formed in a direction parallel to the panel surface from the side surface of the panel, the burr can be easily removed by shaving the side surface of the panel with a file or the like. In other words, the panel could be manufactured efficiently.
Compared to the above-described embodiment, in Comparative Example 2 in which the side surface mold placement portion is not provided and the side surface mold (formwork) is made of iron, a burr having a large thickness is formed from the first time, and the panel 5a is manufactured Each time, the thickness of the burr increased. Further, since the burr is on the front side of the panel, it is difficult to remove the burr without damaging the unevenly decorated surface.
On the other hand, in Example 1 in which the side surface mold of the rubber elastic body was provided on the inner side surface of the mold, a large improvement effect was observed with respect to Comparative Example 2.
Further, in Examples 7, 8, and 9 and Comparative Example 1 in which the side surface mold and the surface mold were integrally formed, no burr was formed.
[0065]
【The invention's effect】
  Claim 1The type of inventionFormed by rubber elastic bodySide typeThe underside ofSurface-type rubber elastic bodyOn the surfaceBy pressing, the contact surface of the surface mold and the side moldIsSince it is blocked by the elastic body and the liquid inorganic curable composition can be prevented from entering the contact surface, the occurrence of burrs can be suppressed.
  Even if a small amount of the inorganic curable composition enters the contact surface to form burrs, the burrs are formed in the direction parallel to the panel surface from the side surface of the panel, The burr can be easily removed by shaving with. That is, the manufacturing efficiency of the panel can be increased.
Furthermore, since the side surface mold is formed of a rubber elastic body, it is possible to easily remove the inorganic cured body.
  Further, since the surface mold and the side mold are in contact with each other and can be separated, maintenance such as cleaning of the mold body can be performed for each member. That is, the manufacturing efficiency of the panel can be increased. Furthermore, only the member in which the defect has occurred can be discarded.
[0066]
  In the mold of the invention described in claim 2, the surface mold includes a decorative part having a convex part at the center part and a side surface type mounting part at the peripheral part, and the height of the side surface type mounting part is high. SagaThe same height as the top of the convex part of the decorative part orIt is made higher than the top of the convex part of the decoration part.
  Accordingly, the burr formed by a small amount of the inorganic curable composition entering the contact surface is the deepest part of the decorative surface of the panel, which is an inorganic cured body.The same height or deepest partBelow, it is formed in a direction parallel to the surface of the panel from the side surface of the panel.
  Therefore, by removing the side surface of the panel with a file or the like, the burr can be easily removed without damaging the decorative surface of the panel. That is, the manufacturing efficiency of the panel can be increased.
[0067]
  Also,Claim 3In the mold of the present invention, a rigid spacer for defining the dimensions of the panel substrate is provided.Arranged outside the side moldSince it is a mold frame, the planar dimension of the surface mold and the height dimension of the side mold can be maintained at predetermined dimensions. That is, a panel with good dimensional accuracy can be manufactured.
[0068]
  Also,Claim 4In the method for producing an inorganic cured body, a side frame is pressed with a lid provided with a rigid spacer for defining the dimensions of the panel substrate, and the panel substrate is heated and cured to a predetermined dimension. . Therefore, the surface mold made of rubber elastic bodyas well asEven if heat is applied to the side mold, the planar dimension of the surface mold and the height dimension of the side mold can be maintained at a predetermined thickness, and a panel which is an inorganic cured body can be manufactured with a predetermined dimension.
[0071]
  Also,Claim 5In the method for producing an inorganic cured body of the invention, the inorganic curable composition is made of SiO.₂ ―Al₂ O_Three A system inorganic powder (A) and an alkali metal silicate aqueous solution (B) that reacts with the inorganic powder are mixed. Therefore, a panel having excellent dimensional accuracy and quality can be easily manufactured.
[0072]
  Also,Claim 6In the method for producing an inorganic cured body of the invention, the inorganic curable composition is made of SiO.₂ ―Al₂ O_Three It contains 0.2 to 450 parts by weight of alkali metal silicate and 35 to 1500 parts by weight of water with respect to 100 parts by weight of the inorganic system powder (A). Therefore, a panel having excellent dimensional accuracy and quality can be manufactured in a short time.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a mold according to the present invention.
FIG. 2 is a cross-sectional view of another mold according to the present invention.
FIG. 3 is a cross-sectional view of a mold according to the present invention.
FIG. 4 is a cross-sectional view of another mold according to the present invention.
FIG. 5 is a cross-sectional view of another mold according to the present invention.
FIG. 6 is a cross-sectional view of a mold according to the present invention.
FIG. 7 is a cross-sectional view of another mold according to the present invention.
FIG. 8 is a cross-sectional view of a mold according to the present invention.
FIG. 9 is a cross-sectional view of another mold according to the present invention.
FIG. 10 is a cross-sectional view of a conventional mold.
FIG. 11 is a cross-sectional view of a conventional mold.
[Explanation of symbols]
A to K type
1A ~ 1K surface type
11 Convex
2A ~ 2K formwork
21A-21K Side type
21A, 21D-21H Spacer
22B-22D, 22E, 22F Side surface type mounting part
3 Metal plate (support)
4 lid
5 Panel substrate (inorganic curable composition)
5a Panel (Inorganic hardened body)

Claims (6)

A mold body filled with a panel base material made of an inorganic curable composition, the mold body being provided on a surface mold made of a rubber elastic body that forms the surface of the panel base material, and a peripheral portion of the surface mold A side surface mold that forms a peripheral edge of the panel base material, the surface of the surface mold abuts the lower surface of the side surface mold, and the side surface mold is formed of a rubber elastic body. The type body. The surface mold includes a decorative part having a convex part at the center part and a side surface type mounting part at the peripheral part, and the height of the side surface type mounting part is the top of the convex part of the decorative part; The mold according to claim 1, wherein the mold body has the same height or is higher than the top of the convex portion. The mold body according to claim 1 or 2, wherein a rigid spacer for defining a dimension of the panel base material is disposed outside the side mold to form a mold frame. A method for producing an inorganic cured body in which a panel base material comprising an inorganic curable composition is filled in a mold body according to claim 3 and heated, wherein the mold body is provided with a lid, and the lid body includes the lid body. A method for producing an inorganic cured body, comprising pressing a mold to heat and cure the panel base material with a predetermined thickness. The inorganic curable composition is a mixture of a SiO ₂ —Al ₂ O ₃ inorganic powder (A) and an alkali metal silicate aqueous solution (B) that reacts with the inorganic powder. The manufacturing method of the inorganic hardening body of Claim 4 . The inorganic curable composition contains 0.2 to 450 parts by weight of alkali metal silicate and 35 to 1500 parts by weight of water with respect to 100 parts by weight of SiO ₂ —Al ₂ O ₃ based inorganic powder (A). The manufacturing method of the inorganic hardening body of Claim 4 characterized by the above-mentioned.

Images