JP4616724B2 - Manufacturing method of press mold - Google Patents

Description

  The present invention relates to a method for manufacturing a press mold used for press-molding a cement-based molding material to manufacture an exterior building material such as a roof tile.

  Although exterior building materials such as roof tiles are required to have water permeability, cement-based molded products generally cannot be said to have sufficiently high water resistance. Therefore, it has been studied to improve the water permeability of cement-based molded products, and by molding a cement-based molding material composed of a cement-containing inverse emulsion composition mainly composed of cement, water and oily substances, A method for producing a cement-based molded article having excellent water permeability has been proposed (see, for example, Patent Document 1).

  Cement-based molding materials composed of this cement-containing inverse emulsion composition have good fluidity during molding, so it is easy to press-mold into complex concavo-convex shapes, producing products with complex shapes It also has the advantage of being suitable for. However, on the other hand, the material is soft, and a molded product obtained by press molding has low shape retention and easily deforms. For this reason, curing cannot be performed by removing the molded product from the mold.

  Therefore, when molding the cement-based molding material 4 with a molding die composed of the upper die 5 and the lower die 1, press molding is performed between the upper die 5 and the lower die 1 to form a molded product 7. The molded product 7 is conveyed to the curing process while holding the molded product 7 thereon, and the molded product 7 is cured and cured. That is, first, as shown in FIG. 5 (a), the cement-based molding material 4 is supplied onto the molding surface 2 on the upper surface of the lower mold 1, and this lower mold 1 is placed under the upper mold 5 as shown in FIG. 5 (b). Then, the upper die 5 is moved downward and pressed between the molding surface 2 of the lower die 1 and the molding surface 11 of the lower surface of the upper die 5 as shown in FIG. To do. Next, the upper mold 5 is moved upward as shown in FIG. 5 (d) and the mold is opened, and the molded product 7 formed on the molding surface 2 on the upper surface is placed, and the lower mold 1 as shown in FIG. 5 (e). Is taken out from below the upper mold 5. Then, the lower mold 1 on which the molded product 7 is placed and held is conveyed to the curing process, and the molded product 7 is cured and cured while being held on the upper surface of the lower mold 1, and thereafter, as shown in FIG. Further, the cured product 6 can be taken out from the lower mold 1.

  However, in this case, curing is performed while the molded product 4 is placed on the lower mold 1, so a large number of lower molds 1 are required for one upper mold 5, and the cost of the expensive mold is extremely high. It will be expensive. For this reason, forming using the receiving tray 3 is performed.

  That is, the receiving tray 3 is formed of a plate material such as a metal plate in a shape along the molding surface 2 of the lower mold 1. First, a cement-based molding material is placed on the receiving tray 3 as shown in FIG. 4 is supplied, and the receiving tray 3 is placed on the molding surface 2 of the lower mold 1 set below the upper mold 5 as shown in FIG. Thereafter, the upper die 5 is moved downward and press-molded between the lower die 1 and the upper die 5 as shown in FIG. The cement-based molding material 4 is molded on the receiving tray 3, and the molded product 7 can be obtained on the receiving tray 3. Next, the upper die 5 is moved upward as shown in FIG. 3 (d) to open the die, and the receiving tray 3 is placed on the lower die 1 in a state where the molded product 7 formed on the upper surface is placed as shown in FIG. 3 (e). Remove from above. Then, the receiving tray 3 on which the molded product 7 is placed and held is conveyed to the curing process, and the molded product 7 is cured and cured while being held by the receiving tray 3, and thereafter the receiving tray 3 is received as shown in FIG. The cured product 7 is removed from the tray 3.

In this way, the molded product 7 is held on the receiving tray 3 and conveyed to the curing process while being shaped, so that the molded product 7 can be cured and cured without deformation or the like, Further, as the lower mold 1, it is only necessary to use a pair with the upper mold 5, so that the cost of an expensive mold is not increased.
JP 2003-252670 A

  The upper mold 5 and the lower mold 1 are designed based on the design drawing of the product 6 obtained by curing and curing the molded product 7. In the design drawing of the product 6, Based on the design of the molding surface 11 on the lower surface of the upper mold 5, the molding surface 2 on the upper surface of the lower mold 1 is designed based on the drawing on the back surface of the product 6. Is manufactured so as to conform to the shape and dimensions of the back surface of the product 6 by processing according to this design. On the other hand, the receiving tray 3 is also designed based on the drawing of the back surface of the product 6 in the design drawing of the product 6, and the receiving tray 3 is adapted to the shape and dimensions of the back surface of the product 6 according to this design. It has been produced.

  As described above, the molding surface 2 of the lower mold 1 and the receiving tray 3 are manufactured based on the drawings on the back surface of the product 6, respectively. 2 and the receiving tray 3 will each have a manufacturing error, and the manufacturing errors of both may cause a slight difference in the shape and dimensions of the molding surface 2 of the lower mold 1 and the receiving tray 3. In some cases, the receiving tray 3 cannot be placed in close contact with the molding surface 2 of the lower mold 1.

  If the receiving tray 3 is not in close contact with the molding surface 2 of the lower mold 1 and there is a gap between them, the cement-based molding material 4 is press-molded as shown in FIG. In doing so, a part of the cement-based molding material 4 enters the gap between the molding surface 2 of the lower mold 1 and the receiving tray 3 and partially enters the end of the molded product 7 as shown in FIG. Wraps around the back side of the receiving tray 3. Therefore, if the cement-based molding material 4 is cured and cured in a state where a part of the cement-based molding material 4 wraps around the back side of the receiving tray 3, the product 6 cannot be peeled off from the receiving tray 3, and the product 6 is taken out. May become impossible.

  The present invention has been made in view of the above points, and provides a mold manufacturing method capable of manufacturing a receiving tray and a lower mold so that the receiving tray can be brought into close contact with a molding surface of the lower mold. It is intended to do.

  The manufacturing method of the molding die according to claim 1 of the present invention is such that the receiving tray 3 is stacked on the molding surface 2 of the lower die 1, and the cement-based molding material 4 supplied to the surface of the receiving tray 3 is used as the lower die 1 and the upper die. When manufacturing a press mold for molding the molded product 7 by press molding with respect to 5, the shape and dimensions of the back surface of the product 6 based on the drawing of the back surface of the product 6 obtained from the design drawing of the product 6 First, a production drawing of the receiving tray 3 having the shape and dimensions of the front surface is prepared. Next, the receiving tray 3 is manufactured according to the manufacturing drawing of the receiving tray 3, and then the shape and dimensions of the back surface of the manufactured receiving tray 3 are manufactured. By scanning the three-dimensional data, the processing data of the molding surface 2 of the lower mold 1 suitable for the shape and dimensions of the back surface of the receiving tray 3 is obtained, and the molding surface 2 of the lower mold 1 is processed according to this processing data. To make the lower mold 1 The one in which the features.

  The invention of claim 2 is characterized in that, in claim 1, the cement-based molding material 4 is composed of a cement-containing inverse emulsion composition mainly composed of cement, water and an oily substance. .

  According to the present invention, since the molding surface 2 of the lower mold 1 is processed according to the processing data obtained by scanning the three-dimensional data of the shape and dimensions of the back surface of the manufactured receiving tray 3, The molding surface 2 of the lower mold 1 can be formed in a shape and size suitable for the back surface, and the receiving tray 3 can be in close contact with the molding surface 2 of the lower mold 1. Since the receiving tray 3 is manufactured based on the drawing of the back surface of the product 6 obtained from the design drawing of the product 6, the back surface shape of the molded product 7 is accurately formed by the receiving tray 3 as designed by the product 6. Is something that can be done.

  Hereinafter, the best mode for carrying out the present invention will be described.

  FIG. 1 is a flowchart showing the steps of the present invention, and the present invention will be described according to these steps.

  When manufacturing the product 6 as shown in FIG. 2A such as a roof tile, a design drawing in which the shape and dimensions of the product 6 are designed is created. First, a drawing 14 of the back surface 6a of the product 6 is created from the design drawing of the product 6 as shown in FIG. 2B in accordance with the shape and dimensions of the back surface (lower surface) 6a of the product 6. This drawing 14 is created so as to exactly match the shape / dimension of the back surface 6a of the product 6, and the shape / dimension of the front surface (upper surface) 6b of the product 6 is not particularly required to be created.

  Next, a production drawing 15 of the receiving tray 3 as shown in FIG. 2C is created based on the drawing 14 of the back surface 6a of the product 6. This production drawing 15 of the receiving tray 3 is prepared so that the shape and dimensions of the front surface (upper surface) 3 a of the receiving tray 3 exactly match the drawing 14 of the back surface 6 a of the product 6. The shape and dimensions of the back surface (lower surface) 3b need not be created.

  Then, according to the shape and dimensions described in FIG. 15, the receiving tray 3 as shown in FIG. The receiving tray 3 is manufactured such that the shape and size of the surface 3a thereof matches and matches the shape and size of the design drawing 15. The receiving tray 3 can be manufactured, for example, by pressing a metal plate having a uniform thickness. When the surface 3a of the receiving tray 3 is pressed so as to conform to the shape and dimensions of the manufacturing drawing 15, the receiving tray 3 is pressed. The shape and dimensions of the back surface 3b of the receiving tray 3 are in accordance with the shape and dimensions of the front surface 3a of the receiving tray 3. Accordingly, by manufacturing the receiving tray 3 by pressing the metal plate in this way, the receiving tray 3 to be used in a large number has the shape and dimensions of the front surface 3 a and the back surface 3 b in all the receiving trays 3. They can be formed to be the same.

  Next, three-dimensional data of the shape and dimensions of the back surface (lower surface) 3b of the receiving tray 3 manufactured in this way is taken. Acquisition of the three-dimensional data of the back surface 3b of the receiving tray 3 can be performed by performing a three-dimensional scan, and data suitable for the shape and dimensions of the back surface 3b of the receiving tray 3 can be obtained. Then, by fusing this data with CAD, machining data of the molding surface 2 of the lower mold 1 can be obtained. The NC machine is controlled by the CAD / CAM system according to this machining data, and the upper surface of the lower mold 1 is obtained. The lower die 1 can be manufactured by machining the surface of the lower die 1 as shown in FIG. 2 (e). Since the molding surface 2 of the lower mold 1 is manufactured in accordance with the three-dimensional data of the shape / dimension of the back surface 3b of the receiving tray 3, it has a shape that exactly matches and matches the shape / dimension of the back surface 3b of the receiving tray 3・ It is formed to dimensions.

  The molding surface 11 on the lower surface of the upper die 5 is manufactured so as to accurately follow the shape and dimensions of the surface (upper surface) 6b of the product 6 based on the design drawing of the product 6. The upper die 5 and the lower die 1. Using a molding die composed of the receiving tray 3, molding can be performed in the same manner as in FIG.

  That is, first, as shown in FIG. 3A, the cement-based molding material 4 is supplied onto the surface 3a of the receiving tray 3, and this receiving tray 3 is placed on the molding surface 2 of the lower mold 1 as shown in FIG. To be placed. At this time, since the shape and dimensions of the back surface 3b of the receiving tray 3 exactly match the shape and dimensions of the molding surface 2 of the lower mold 1, the receiving tray 3 can be brought into close contact with the molding surface 2 of the lower mold 1. it can. Next, the upper mold 5 is moved downward, press-molded between the lower mold 1 and the upper mold 5 as shown in FIG. 3C, and the cement-based molding material 4 is molded on the receiving tray 3 and molded. Product 7 is manufactured. At this time, since the receiving tray 3 is in close contact with the molding surface 2 of the lower mold 1, the cement-based molding material 4 does not enter between the receiving tray 3 and the lower mold 1. Further, since the front surface 3a of the receiving tray 3 is made to exactly match the shape / dimension of the back surface 6a of the product 6, it is molded into a shape / dimension that exactly matches the shape / dimension of the back surface 6a of the product 6. The product 7 can be molded.

  Thereafter, the upper mold 5 is moved upward as shown in FIG. 3D to open the mold, and the receiving tray 3 is placed on the lower mold in a state where the molded product 7 molded on the upper surface is placed as shown in FIG. Remove from the top of 1. Then, the receiving tray 3 on which the molded product 7 is placed and held is conveyed to the curing process, and the molded product 7 is cured and cured while being held by the receiving tray 3, and thereafter the receiving tray 3 is received as shown in FIG. The cured product 6 is removed from the tray 3. At this time, as described above, the receiving tray 3 is in close contact with the molding surface 2 of the lower mold 1 and the cement-based molding material 4 does not enter between the receiving tray 3 and the lower mold 1. The product 6 cannot be removed and the product 6 cannot be taken out.

  As described above, the present invention prevents the cement-based molding material 4 from entering between the receiving tray 3 and the lower mold 1 by bringing the receiving tray 3 into close contact with the molding surface 2 of the lower mold 1. Therefore, a particularly high effect can be obtained when the cement-based molding material 4 having good fluidity at the time of molding is molded. Hereinafter, what is suitable for use in the present invention will be described as the cement-based molding material 4 having good fluidity during molding.

  That is, the cement-based molding material 4 suitable for use in the present invention is composed of a cement-containing inverse emulsion composition mainly composed of cement, water, and an oily substance. In this composition, the ratio of cement to water can be arbitrarily set, but the weight ratio is generally preferably in the range of 0.3 to 2 water with respect to cement 1.

  The cement is not particularly limited, but can include Portland cement, fly ash cement, blast furnace cement, alumina cement, high alumina cement, silica fume, etc. Two or more types can be used in combination.

  The oily substance is for forming an inverse emulsion (W / O emulsion) with water, and is not particularly limited. Usually, a hydrophobic liquid substance is used, for example, toluene, xylene, kerosene, styrene. , Divinylbenzene, methyl methacrylate, trimethylolpropane trimethacrylate, unsaturated polyester resin, and the like. These can be used alone or in combination of two or more. The blending amount of the oily substance is preferably in the range of 5 to 10% by volume with respect to the total amount of water and solid content in the cement-containing inverse emulsion composition.

  In addition to the above components, an emulsifier is preferably added to the cement-containing inverse emulsion composition. The emulsifier is blended to impart stability to the inverse emulsion. Ionic surfactants, various anionic surfactants, cationic surfactants, and the like can be used. The blending amount of the emulsifier is preferably in the range of 1 to 3% by volume with respect to the total amount of water and solid content in the cement-containing inverse emulsion composition.

  An appropriate amount of a reinforcing material and various additives can be further blended in the cement-containing inverse emulsion composition. Examples of reinforcing materials include aggregates such as gravel, perlite, shirasu balloon, glass powder, and alumina silicate, synthetic fibers such as polypropylene fiber, acrylic fiber, vinylon fiber, and aramid fiber, and reinforcement such as carbon fiber, glass fiber, and pulp. Mention may be made of fibers.

It is a flowchart which shows each step of an example of embodiment of this invention. Each step of the above is shown, and (a) to (e) are schematic views respectively. Each process of a shaping | molding using a receiving tray is shown, (a) thru | or (f) is each schematic. It is the schematic which shows the state in which some cement-type molding materials wrap around to the back side of the receiving tray. Each process of the conventional shaping | molding is shown, (a) thru | or (f) is each schematic.

Explanation of symbols

1 Lower mold 2 Molding surface 3 Receiving tray 4 Cement-based molding material 5 Upper mold 6 Product 7 Molded product

Claims (2)

  A press mold for forming a molded product is manufactured by stacking a receiving tray on the molding surface of the lower mold and press molding the cement-based molding material supplied to the surface of the receiving tray between the lower mold and the upper mold. First, based on the drawing on the back side of the product obtained from the design drawing of the product, create a production drawing of the receiving tray that conforms to the shape and dimensions of the back side of the product, and then the production drawing of this receiving tray After manufacturing the receiving tray according to the above, by scanning the 3D data of the shape and dimensions of the back surface of the receiving tray, the processing data of the molding surface of the lower mold that matches the shape and dimensions of the back surface of the receiving tray is obtained. A method for manufacturing a press mold, comprising: obtaining a lower mold by processing the molding surface of the lower mold according to the processing data. The method for producing a press mold according to claim 1, wherein the cement-based molding material is composed of a cement-containing inverse emulsion composition containing cement, water and an oily substance as main components.

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