JP4914974B2 - Cement-based molded body manufacturing method and molding apparatus - Google Patents

Description

  The present invention relates to a method and apparatus for manufacturing a cement-based molded body, and more particularly, to manufacture a cement-based cured body used for an exterior building board or the like, by molding a cement-based material and forming a cement-based molded body having a desired shape. The present invention is directed to a method for molding and manufacturing a body and a molding apparatus used in such a method.

A technique using a cement hardened plate as an outer wall material of a building is known. If the outer wall surface is constructed by arranging hardened cement plates, it is easier to construct an outer wall that is more productive, has better quality performance, and has a higher appearance design than the outer wall surface that is constructed by mortar or concrete construction on site.
The cement hardened plate is made by adding fibers and resins and other materials to hydraulic materials such as cement as necessary, and then pouring water into the mold and extruding the molding material. It is manufactured by molding into a desired outer shape and drying and curing naturally or forced curing by steam curing or the like. If a concavo-convex pattern is formed on the mold surface of the mold, it is possible to produce a cement-hardened plate with a high design property having a concavo-convex pattern on the surface.

As a method of manufacturing a cement hardened plate having a concavo-convex pattern on its surface, a technology is used in which a cement material is formed into a flat plate shape, a concavo-convex pattern is formed on the surface of this flexible cement molded plate, and then cured and cured. Are known. For forming the concavo-convex pattern, the embossing roll having the concavo-convex pattern may be rolled while being pressed against the surface of the cement-molded plate, or a press die having the concavo-convex pattern may be pressed.
However, when the surface of the cement-molded plate is bent or curved, it becomes difficult to form the uneven pattern. Specifically, when forming a concavo-convex pattern on each of the two bent surfaces, for example, it is necessary to press a press die from a direction orthogonal to each surface and then open the mold separately in the orthogonal direction. In addition, the structure of the press molding apparatus becomes very complicated.

Patent Document 1 proposes a technique for forming a concavo-convex pattern on a plurality of surfaces or curved surfaces intersecting at different angles of a cement-molded plate. Specifically, a concavo-convex pattern is formed on the surface of a flat extruded product with an embossing roll, a concave groove for folding is cut out on the back surface, and then the extruded product is bent with a convex ridge for bending to obtain a predetermined three-dimensional shape. A concave-convex pattern is formed on the bent surface or curved surface of the extruded product.
JP-A-5-131422

In the technique of Patent Document 1 described above, a bending recess must be processed on the back surface of an extrusion-molded product on which an uneven pattern is formed. It is difficult to turn over the extruded product in a soft state, and it is difficult to process the back surface while the extruded product is supported flat.
If the extruded product is bent at the location of the folding groove, the folding groove is closed, but a break still remains at the position of the folding groove. This cut portion tends to be weak in strength.
Furthermore, when forming a concavo-convex pattern with an embossing roll, it is easy to form a groove-like or protruding line-like concavo-convex pattern continuous in the longitudinal direction, but it is difficult to form irregularities intermittent in the longitudinal direction. Since the cylindrical surface of the embossing roll rolls on the horizontal surface of the extruded product, the uneven surface is formed on the surface of the extruded product. It is difficult to avoid the upper end being chipped or distorted.

  An object of the present invention is to make it possible to easily manufacture a cement-based molded body having a clear concavo-convex pattern on a bent surface or a curved surface, which is difficult to obtain with the above-described prior art.

A method for producing a cement-based molded body according to the present invention is a method for molding a cement-based material, and manufacturing a cement-based molded body having an uneven design on the surface, wherein the cement-based material is extruded, A step (a) for obtaining a preform having a convex shape, a movable molding die configured by combining a plurality of split molds, each mold having a mold surface corresponding to the uneven design, and a fixed mold Between the step (b) of obtaining a cement-based molded body having a concavo-convex design on the surface of the convex by pressing the preform, and separating the divided molds of the movable mold from each other, of the split type, look including the step (c) for mold opening in the direction normal to the surface of the cement-based molded body that faces, in the step (b) and (c), the preform is placed Fixed mold and said fixed mold A movable mold that is arranged to face each other and is configured by combining a plurality of divided molds, each of which has a mold surface corresponding to the uneven design, and that is opened and closed with respect to the fixed mold, and the fixed A molding apparatus is used, which is disposed in a molding die and includes a mold opening actuator that contacts each of the divided molds and pushes in a mold opening direction for each of the movable molds .

[Cement-based materials]
The same materials, blending, and manufacturing techniques as those of ordinary cement-based cured products can be applied to the cement-based material that is the main material of the cement-based molded body.
Those containing a W / O emulsion of oily substance and water and cement are preferred. A polymerizable oily substance is preferable as the oily substance.
Specifically, for example, techniques described in JP-A-5-246747 and JP-A-2002-47040 can be suitably employed.
<Cement>
It is a material that determines basic mechanical strength and other properties of hardened cementitious materials. Normal cement material can be used. Examples thereof include Portland cement, fly ash cement, blast furnace cement, and alumina cement. Multiple types of cement can be used in combination.

10 to 40% by volume can be blended in the cement-based material (in the total amount of the cement-based material including water). Preferably, it is 15-30 volume%.
<Polymerizable oily substance>
Among oily substances capable of forming a W / O emulsion with water, polymerizable substances are used. The polymerizable oily substance is polymerized by a polymerization reaction in the curing and curing process, and constructs a skeleton structure of a cement-based cured body together with cement that is hydrated and cured. When the skeletal structure of the cement-based cured body is well constructed, dimensional shrinkage associated with curing is less likely to occur.
As an oily substance, a hydrophobic liquid substance tends to form a W / O emulsion with water.

As specific examples of the polymerizable oily substance, those having a polymerizable double bond (vinyl monomer) such as styrene, divinylbenzene, methyl methacrylate, trimethylolpropane trimethacrylate, and unsaturated polyester resin are useful. The polymerization reaction of the oily substance having a polymerizable double bond and the hydration reaction of the cement proceed favorably at the same time, and the skeleton structure of the above-mentioned cement-based cured body is favorably formed.
The polymer of the oily substance, together with the cement, constructs a skeleton structure of a cement-based hardened body and determines basic characteristics. It functions to improve the physical properties and surface properties of hardened cementitious materials. Usually, 4 to 10% by volume can be blended in the cement-based material, although it varies depending on the use and required performance of the cement-based cured body and the type of oily substance to be used. Preferably, it is 5-7 volume%.

In order to accelerate the polymerization reaction of the polymerizable oily substance, a polymerization initiator composed of an organic peroxide, a persulfate or the like can be used in combination with the polymerizable oily substance.
<W / O emulsion>
The W / O emulsion is also called a water-in-oil emulsion and is a state in which fine water particles are dispersed in a continuous phase of an oily substance.
By mixing water and a polymerizable oily substance so as to constitute such a W / O emulsion, and stirring and mixing, the target W / O emulsion can be obtained.
As the oily substance, an oily substance other than the polymerizable oily substance described above can be blended. In addition to water, other liquid or solid particles may be added. The cement can be dispersed in the W / O emulsion as fine solid particles.

After preparing the W / O emulsion, other materials such as cement can be mixed, or the emulsification treatment can be performed in a state where other materials are mixed in addition to water and oily substances.
<Emulsifier>
In order to promote the formation of the W / O emulsion, it is effective to add an emulsifier.
As the emulsifier, an emulsifier used in a usual emulsion technique can be used. A material that is effective for forming a W / O emulsion of an oily substance and water, hardly adversely affects the molding and curing of the cementitious material, and does not impair the quality performance of the cemented cured body is preferable.

Specific examples of emulsifiers include nonionic surfactants such as sorbitan sesquiolate, glycerol monostearate, sorbitan monooleate, diethylene glycol monostearate, sorbitan monostearate, diglycerol monooleate, various anionic surfactants, cations And surface active agents.
The amount of emulsifier used varies depending on the blending ratio and required performance of the oily substance and water, but can usually be set in the range of 1 to 3% by volume with respect to the total amount of water and solid content in the cementitious material.
<Reinforcing material>
It is useful for improving physical properties such as mechanical strength of a cement-based cured body.

Various reinforcing materials used in the production of ordinary cement-based hardened bodies can be used. Specifically, there is a material known as a so-called cement aggregate. There are materials known as reinforcing fibers. Examples of the reinforcing fiber include synthetic fibers such as polypropylene fiber, acrylic fiber, vinylon fiber, and aramid fiber, carbon fiber, glass fiber, and pulp. Inorganic particles such as gravel, perlite, shirasu balloon, glass powder, and alumina silicate are also used. There are also porous or hollow inorganic particles.
These reinforcing materials can be blended at about 0.5 to 10% by volume with respect to the total amount of the cementitious material.

<Other materials>
Additive materials used in the production of ordinary cement-based hardeners can be combined. For example, a coloring agent etc. are mentioned.
<Preparation of cement-based material>
Basically, the materials constituting the cement-based material described above may be uniformly stirred and mixed. Each material may be stirred and mixed at the same time, or a part of the materials may be stirred and mixed, and then the remaining materials may be added and further stirred and mixed.
It is desirable to set production equipment and production conditions so that a W / O emulsion of water and an oily substance is formed satisfactorily.

As a stirring device, a dissolver, a screw line mixer, an ultrasonic homogenizer, a colloid mill, a planetary mixer, a static mixer, a nauter mixer, a ribbon blender, a tumble mixer, a paddle mixer, and the like can be used.
It is effective to knead a material whose viscosity is increased by adding cement or a reinforcing material to the W / O emulsion with a kneading apparatus. As the continuous kneading apparatus, a continuous kneader, a twin screw extruder, or the like can be used.
(Extrusion molding)
An extrusion technique for ordinary cementitious materials is applied.

By extruding the cement-based material supplied to the extrusion molding device from the extrusion die, a preform corresponding to the die shape of the extrusion die can be obtained. By performing extrusion molding on a conveyor or performing extrusion molding while moving an extrusion die, a continuous preform can be obtained. By performing extrusion molding of cement-based material intermittently or by cutting a continuous extrusion molded product obtained by continuous extrusion molding into predetermined dimensions, a preform with a predetermined dimension and shape can be obtained. .
The preform formed by extrusion is still in a deformable plastic state. In order to facilitate the handling of the preform, a support base or a floor plate that supports the preform can be used. If the preform is handled in such a state that it is placed on such a support base or laying board, the preform can be prevented from being deformed or deformed.

[Shape structure of preformed body]
As for the shape of the preform, the surface for forming an uneven design later has a convex shape. The convex shape means that the entire surface is not a uniform flat surface but has a protruding convex shape.
Specifically, there is a form in which a plurality of flat surfaces protrude in an intersecting manner with an angle. If the inner angle between the surfaces is less than 180 °, it will be convex. Usually, the inner angle is set to 45 to 135 °. For example, a bent plate-shaped preform that has a cross-sectional “L” shape and is continuous in the length direction may be used. In this case, the “L” shape obtained by rotating the “L” shape by 45 ° so that the corners face upward constitutes a convex shape.

A circular arc surface obtained by cutting a part of the cylinder is also convex. In the case of an arc surface, in the cross-sectional shape, the radius of curvature of the arc can be set to 7.5 to 2000 cm, and the opening angle from the center of the arc to both side edges of the arc surface can be set to 5 to 180 °. The curved surface protruding beyond the arc is convex. In some cases, a curved surface and a curved surface, or a curved surface and a flat surface intersect to form a convex shape. The left and right shapes may be the same or different with respect to the convex vertex or the central axis.
In the case of a cement-based molded body applied to a building exterior board or the like, the preformed body often has a plate shape having a constant thickness as a whole. In this case, if the front surface is convex, the back surface has the same concave shape. Specifically, a bent plate having an “L” cross section, a cylindrical curved plate, and the like have substantially the same front and back shapes. In the case of such a plate-like cement-based molded body, the thickness can be set in the range of 1 to 7.5 cm. Furthermore, in the case of a preform having a columnar shape or a rod shape, the back surface may not be concave even if the surface is convex. The front surface is convex and the back surface is flat, or both the front and back surfaces are convex.

Of the preformed body, the surface on which the uneven design is later formed is usually a flat surface or a smooth curved surface. However, another uneven shape can be provided as long as it can be formed by extrusion. For example, if irregularities are provided in the inner shape of the extrusion die, the extruded preform can be provided with concave grooves and ridges that are continuous in the length direction.
〔Press molding〕
Basically, a press molding technique that is used for manufacturing a normal cement-based molded body is applied.
The press molding apparatus usually includes a pair of molds and a press mechanism that applies a press pressure to the molds. Of the pair of molds, one mold is a fixed mold that is fixed, and the other mold is a movable mold that is disposed to face the fixed mold and performs a mold opening and closing operation. The mold surface of the movable mold is provided with a concavo-convex shape corresponding to the concavo-convex shape to be press-molded on the cement-based molded body. In a general press molding apparatus, a fixed mold and a movable mold are arranged up and down, a fixed mold is disposed below, and a movable mold is disposed above. There is also a horizontal type device in which a fixed mold and a movable mold are arranged in the horizontal direction.

The movable mold can improve the mold separation of the cement-based molded body by ejecting pressurized air from the mold surface. A concave-convex structure for positioning each other can be provided on the mold-matching surface of the movable mold and the fixed mold.
The press pressure for pressing the movable mold against the fixed mold varies depending on the material composition of the preform and the required performance of the cement-based cured body to be finally produced. It can be set in the range of 0 MPa. If the pressing pressure is too low, it is difficult to sufficiently form the uneven design.
The mold surface of the movable mold has an uneven shape corresponding to the uneven design to be press-formed on the preform. The mold surface of the fixed mold is made to correspond to the shape on the side of the preform that does not have the uneven design. Although the concave / convex shape for forming the preform can be provided on the mold surface of the fixed mold, it is difficult to mold a complex concave / convex shape such as the concave / convex design of the movable mold.

When the preform is placed on the mold surface of the fixed mold, the surface on which the concavo-convex design is formed faces the movable mold so as to face the movable molded body at an inclination angle that is as gentle as possible. Set the orientation of the preform. If the convex surface that molds the concavo-convex design is arranged symmetrically with respect to the apex or central axis of the convex shape, it is easy to mold the concavo-convex design with a movable mold, and the mold can be opened smoothly. . There is also an advantage that the split structure of the split mold can be simplified and the operation mechanism of the mold opening is also simplified.
An uneven design corresponding to the mold surface shape of the movable mold is formed on the surface of the cement-based molded body obtained after press molding.

[Uneven design]
The uneven design formed on the surface of the cement-based molded body is not particularly limited as long as it can be formed by press molding.
The shape formed when extruding the preform is not included in the uneven design formed by press molding, but the shape formed by press molding is combined with the shape of the preform to form the uneven design. There is also a case.
As an uneven design, for example, there is one in which a large number of convex portions or concave portions having the same geometric shape are arranged in a predetermined pattern. If the convex portions are rectangular in a plane and are arranged at intervals in the vertical and horizontal directions, an external appearance design such as a tile finish surface or a brick finish surface is exhibited, which is useful for a building exterior board. The convex part can be made into a shape with fine irregularities such as natural rocks, stones, and bricks. An uneven shape representing a picture, a character, a symbol, or the like may be used. The uneven design does not simply represent the appearance design. For example, a concavo-convex structure for attaching another member to the cement-based cured body, a concave groove for wiring, or the like can be provided as a part of the concavo-convex design.

(Split type)
The movable mold is composed of a plurality of divided molds.
The division structure of the movable mold is set according to the shape structure of the preform, the arrangement structure of the uneven design, and the like. Specifically, when the movable mold is opened after press molding, the divided molds are separated so that the separated molds can be opened in the direction normal to the surface of the cement-based molded body facing each other. To do. Thus, when the movable mold is opened, each of the divided molds faces each other so that the uneven design formed on the cement-based molded body is not distorted or damaged by the movement of the movable mold. The mold can be opened in an appropriate direction with respect to the uneven design.

In addition, the mold opening direction or path of each divided type is set in a direction away from each other without crossing each other. When the mold opening directions of a plurality of split molds intersect, it is difficult to open the split molds simultaneously without interfering with each other.
When the surface which shape | molds an uneven | corrugated design among a preforming body contains the several plane which mutually cross | intersects, a movable shaping | molding die can be divided | segmented into the division type | mold corresponding to each plane. In the preform with the above-mentioned “L” cross section, the left and right surfaces around the corners or ridge lines can be configured separately from each other. If the left and right split molds are opened in the normal direction with respect to the left and right surfaces, they move away from each other, so that interference and collision can be avoided.

In the case where the surface on which the uneven design is molded is a curved surface, it is possible to provide a split mold that divides and shapes the curved surface into a certain angle range. Divided design of movable mold so that the surface of the preform formed by the mold surface of the split mold is substantially flat, slightly curved or curved near the plane. It is desirable to do. If the convex curved surface is constituted by a plurality of divided molds in the circumferential direction, each divided mold is opened in the normal direction of the curved surface at that portion and can be moved away from each other.
In the press molding operation, the movable mold is closed and the split mold is integrally coupled until the press pressure is applied. It is no different from normal movable molds.

The split mold is provided with fastening means for coupling to each other. For example, fastening with a bolt, a band, an engagement fitting, or the like is possible. In order to accurately position the divided molds, a positioning uneven structure can be provided. The split-type fastening structure and positioning structure need to be a structure that enables split-type separation and mold opening operations.
The split mold can be provided with a concavo-convex structure that performs positioning with the fixed mold when the mold is closed. In this case as well, a structure that can be separated from the fixed mold by movement during the mold opening operation of the split mold is employed.
In order to facilitate the separation of the split mold or the mold opening operation, a metal structure such as a hanging ring or a lifting handle can be provided on the outer surface of the split mold. It is desirable to set the arrangement and structure of the metal fitting structure so that it can be handled both in the state of the movable molding die assembled with the split die and in the individual state of being divided individually.

[Open mold]
The mold opening operation of the movable mold includes separation of a plurality of divided molds and individual mold opening operation of each divided mold.
The individual mold opening operation of each divided mold can be performed manually, but usually, the mold opening can be performed accurately in an appropriate direction by performing mechanically.
As the split mold opening mechanism, the fixed mold may be provided with a mold opening actuator that contacts each split mold and pushes in the mold opening direction for each split mold of the movable mold.
The mold opening actuator can include a piston cylinder mechanism, a slider mechanism, a toggle mechanism, a cam mechanism, and the like driven by hydraulic pressure, pneumatic pressure, electromagnetic force, or the like.

The body part of the mold opening actuator is attached to the fixed mold. Usually, if it is provided at both ends in the length direction of the fixed mold, it is difficult to interfere with press molding. If the actuating member of the mold opening actuator is not fixed to the split mold but abuts against a part of the split mold to push the split mold, the mold is separated from the fixed mold after opening the mold. Easy to remove.
The operating amount of the mold opening actuator is sufficient to be a short distance such that the mold surface of the split mold is separated from the uneven design formed on the cement-based molded body. Usually, it is sufficient that the split mold can be pushed to about 20 to 30 mm.

  In the case where the split mold faces the flat surface portion of the convex surface of the preform, the split mold may be opened in the direction of the normal line that stands in the vertical direction from the surface. When the facing part of the split mold is a curved surface, if the curved surface is a simple cylindrical surface, the normal direction at the center position of the cylindrical surface can be set as the mold opening direction. When the curved surface is a complicated curved surface, the direction in which the normal direction of each position is averaged or the direction in which the deviation from the normal direction at each position is the smallest is set as the normal direction for opening the split mold. be able to. The mold opening actuator should just arrange | position the operating direction of the operating member in parallel with the said normal line direction. Even if it is not a mathematically strict normal line direction, it may be a direction substantially close to the normal line direction as long as there is no significant adverse effect on the uneven design formed on the cement-based molded body.

[Curing curing]
A cement-based cured body is obtained by curing the cement-based molded body.
Basically, a curing and curing apparatus and curing and curing conditions in a normal cement-based cured body manufacturing technique are applied. For example, steam curing, autoclave curing, etc. are adopted.
The curing conditions vary depending on the blending of cementitious materials and the performance required of the cementitious hardened body, but are usually set at 40 to 100 ° C. for 20 to 48 hours. During the curing process, the temperature can be changed stepwise or continuously.
When the cement-based molded body is transferred from the press molding process to the curing and curing process, the molding shape in the extrusion molding and press molding can be prevented from collapsing if the cement-based molded body is supported by the above-described floor plate or the like. Curing and curing can also be performed with the cement-based molded body placed on a fixed mold in press molding.

The method for producing a cement-based molded body according to the present invention is obtained by obtaining a preform having a convex surface by extrusion and then fixing the preform with a movable mold having a mold surface corresponding to the uneven design. By press molding with a molding die, a cement-based molded body having an uneven design on the surface is molded.
At this time, the movable mold is configured by combining a plurality of divided molds, and when the mold is opened, each divided mold is separated from each other, and each divided mold is normal to the surface of the facing preform. By opening the mold in the direction, it is possible to obtain a cement-based molded article having an irregular design with an exact shape as designed without distorting or scraping a part of the concave-convex design formed on the surface of the cement-based molded article. Can be easily obtained.

  Cement-based cured products obtained by curing and curing cement-based molded bodies can show beautiful irregular designs when used for building exterior materials, etc., and improve the exterior design of buildings Can do.

2-7 performs manufacture of the cement-type molded object 10 shown in FIG.
[Cement-based molded body]
As shown in FIG. 1, the cement-based molded body 10 is a strip-shaped member having a bent plate shape with a cross section of an approximately “L” shape. The left and right surfaces that are orthogonal to the outside intersect each other at an angle of 90 °. Rectangular trapezoidal convex portions 14 are arranged on the respective surfaces at intervals in the vertical and horizontal directions. Between each convex part 14, the lattice groove-shaped recessed part 12 exists. Convex part 14 and concave part 12 constitute an uneven design.
In addition, since the cement-type molded object 10 may deform | transform until it hardens, you have to avoid putting the cement-type molded object 10 in the state shown in FIG. 1 independently. Usually, a supporting plate or a stand is disposed on the back side of the cement-based molded body 10.

The cement-based molded body 10 is cured and cured to become a cement-based cured body, and is used for construction of an outer wall of a building. Among the buildings, for example, it is constructed at the corner where the outer wall surfaces in two directions intersect. The outer surface of the pillar can also be configured. It is also applied to the eaves, rooftop and other corners.
The cement-based molded body 10 having such a shape structure is manufactured through the following steps.
(Extrusion molding)
As shown in FIG. 2, the cement-based material is extruded from an extrusion die 22 of the extrusion-molding apparatus 20 containing the cement-based material. The cross-sectional shape of the extrusion die 22 is set to an L shape corresponding to the cross-sectional shape of the cement-based molded body 10.

The support 24 arranged in front of the extrusion die 22 has an L-shaped cross section. The left and right surfaces constituting the L shape are inclined at 45 ° with respect to the vertical direction. The ridgeline at the corner where the left and right surfaces intersect protrudes upward. A floor plate 26 having a bent plate shape having the same L-shaped cross section is disposed on the L-shaped section of the support base 24. The floor plate 26 is made of, for example, a thin steel plate having a thickness of 0.22 mm.
The preform 16 extruded from the extrusion die 22 onto the floor plate 26 has a bent plate shape having an L-shaped cross section. For example, in the cross-sectional shape, the thickness is 30 mm, the left and right side length is 16 cm, and the total length is 320 cm. Although the preform 16 immediately after extrusion is soft and easily deformed, the cross-sectional shape does not collapse or deform because the preform 16 remains in an L-shaped cross-section and is supported by contacting the floor plate 26 and the support base 24 having the same shape. The upward surface of the preform 16 is an inclined surface inclined at 45 ° to the left and right, and the entire surface is flat and has no irregularities.

〔Press molding〕
As shown in FIG. 3, the preform 16 is fed into a press forming apparatus including a pair of upper and lower forming dies 30 and 40 while being supported by the floor plate 26.
<Molding equipment>
The lower mold 30 is a fixed mold, and the upper mold 40 is a movable mold. Among them, the movable mold 40 is configured by combining a pair of left and right split molds 40a and 40b.
The mold surface 32 formed on the upper surface of the fixed mold 30 has a convex shape corresponding to the lower surface shape of the floor plate 26. It has an inclined surface inclined at an angle of 45 ° with respect to the vertical direction from the center to the left and right. The floor plate 26 is disposed in a stable state in close contact with the mold surface 32.

In the movable mold 40 in which the divided molds 40 a and 40 b are combined, the mold surface 42 formed on the lower surface corresponds to the shape of the upper surface side of the cement-based molded body 10. It is a mountain shape inclined at 45 ° to the left and right. Convex and concave shapes corresponding to the convex portions 14 and the concave portions 12 of the cement-based molded body 10 are provided on the left and right surfaces, respectively.
Near the outer periphery of the fixed mold 30 and the movable mold 40, there are provided an engaging convex part 34 and an engaging concave part 44 that engage with each other. When the movable mold 40 is closed to the fixed mold 30, both are positioned. Both the left and right side surfaces of the engaging convex portion 34 and the engaging concave portion 44 are 45 ° inclined surfaces.

The contact surfaces of the left and right split dies 40a and 40b constituting the movable mold 40 are a combination of an engaging convex portion 46 protruding in the horizontal direction from the vertical surface and an engaging concave portion 47 recessed in the horizontal direction. Has been placed. The division molds 40a and 40b are aligned with each other. The side surfaces of the engaging convex portion 46 and the engaging concave portion 47 are also inclined surfaces of 45 ° like the engaging convex portion 34 and the engaging concave portion 44.
Although not shown in the drawings, the split dies 40a and 40b are provided with handles and hanging metal fittings that serve as clues for lifting, hanging, and moving.
The left and right split dies 40a, 40b are integrally coupled to each other by fastening means (not shown) at the start of press molding, and are handled as an integrated movable molding die 40. As the fastening means, bolt fastening is adopted.

<Press molding>
As shown in FIG. 4, the support plate 62 and the lifting plate 60 are placed in a state where the movable forming die 40 is placed on the floor plate 26 and the preform 16 placed on the mold surface 32 of the fixed forming die 30. It is installed in a press device consisting of
When the elevator 60 is lowered, the movable mold 40 is pressed against the fixed mold 30. By applying a pressing pressure to the elevator plate 60, the preform 16 is press-molded. The press pressure can be set to 0.5 MPa, for example.
With the movable mold 40 abutting against the fixed mold 30 and the engagement convex part 34 and the engagement concave part 44 being engaged, the mold surface of the movable mold 40 is placed on the flat surface of the preform 16. The concavo-convex shape in 42 is transferred, and the cement-based molded body 10 having the desired concavo-convex design is formed.

<Opening mold: Separation of split mold>
As shown in FIG. 5, the movable mold 40 is opened from the fixed mold 30. At this time, the split molds 40a and 40b of the movable mold 40 are separated and moved in different directions.
Specifically, first, the fastening of the split dies 40a and 40b is released. Thereafter, the left and right split dies 40a and 40b are separated to the left and right so as to be lifted in the normal direction orthogonal to the left and right surfaces of the cement-based molded body 10, that is, in a diagonal 45 ° direction. Since the convex portions 14 and the concave portions 12 formed on the cement-based molded body 10 and the mold surfaces of the split molds 40a and 40b are separated from each other in the normal direction, the mold release can be performed smoothly. Done. The corners of the convex portions 14 and the concave portions 12 of the cement-based molded body 10 are not chipped or distorted.

Both the engaging convex portion 34 and the engaging concave portion 44 that have positioned the fixed mold 30 and the movable mold 40 are smoothly disengaged along the inclined side surface of 45 °. Similarly, the engaging convex portion 46 and the engaging concave portion 47 that have engaged the split dies 40a and 40b are also smoothly separated along the inclined side surface of 45 °. In addition, the contact surfaces of the fixed mold 30 and the movable mold 40 are both composed of 45 ° inclined surfaces and a horizontal plane so that the split molds 40a and 40b can be smoothly moved obliquely upward, and slide each other. It can be moved.
For the above-described split molds 40a and 40b to move obliquely upward, a distance to the extent that the mold surface 42 is separated from the cement-based molded body 10, for example, 20 mm is sufficient. It is not necessary to completely separate the split molds 40a and 40b from the fixed mold 30.

<Split type mold opening mechanism>
FIG. 6 shows a mechanism for performing the mold opening operation of the split molds 40a and 40b obliquely upward.
A pair of mold opening actuators 50, 50 are installed at the end of the fixed mold 30 in the length direction. In the mold opening actuator 50, the operating shaft 52 moves forward and backward by hydraulic pressure or pneumatic pressure. Each of the pair of mold opening actuators 50 and 50 advances and retracts the operating shaft 52 in a direction of 45 ° obliquely upward 45 ° from the center of the fixed mold 30. This is the mold opening direction of the split molds 40a and 40b.

A patch plate 48 is fixed to each of the split dies 40a and 40b. The tip of the operating shaft 52 of the mold opening actuator 50 abuts against the contact plate 48 and pushes and moves the split molds 40 a and 40 b through the contact plate 48.
Since the mold opening actuator 50 is not joined to the contact plate 48, the split molds 40a and 40b can be separated from the fixed mold 30 when the split molds 40a and 40b are removed.
<Opening mold: Removal of split mold>
As shown in FIG. 7, the divided dies 40 a and 40 b that have already been separated and separated from the cement-based molded body 10 are respectively lifted upward, completely separated from the fixed mold 30, and from above the cement-based molded body 10. Remove.

The cement-based molded body 10 can be removed from the fixed mold 30 together with the floor plate 26 and sent to the next step. It can also be transported while being placed on the fixed mold 30.
The separated molds 40a and 40b that have been removed can be assembled with the movable molding die 40 that are integrally coupled by engaging the engagement convex portion 46 and the engagement concave portion 47 again and fastening them with bolts or the like. The assembled movable mold 40 is used for the next press molding process.
[Curing curing]
The cement-based molded body 10 is fed into the curing treatment room together with the floor plate 26. If it is kept at a predetermined atmosphere and temperature in the curing treatment chamber, the cement-based molded body 10 is cured and a cement-based cured body is obtained.

[Another embodiment]
The embodiment shown in FIG. 8 is basically a technique common to the above embodiment, but the molding shape of the cement-based molded body 10 is different. The difference will be mainly described.
The preform 16 is extruded into a circular arc plate shape in cross section. Accordingly, the floor plate 26 also has a cross-sectional arc plate shape. The mold surfaces 32 and 42 of the fixed mold 30 and the movable mold 40 are also formed in a cross-sectional arc plate shape.
The preform 16 and the floor plate 26 are disposed in the fixed mold 30. The arc shape forms a convex shape upward. The movable molding die 40 is closed, and press molding is performed by a press device including the support plate 62 and the lift plate 60 as in the above embodiment.

In the mold opening operation, the split molds 40a and 40b are separated from each other, and then moved left and right obliquely upward 45 °. In this case, since the surface of the cement-type molded object 10 is a circular arc surface, the exact normal direction changes with places. However, on the left and right semicircular arc surfaces in contact with the left and right split dies 40a and 40b on the surface of the cement-based molded body 10, the average normal direction is obliquely upward close to 45 °. Therefore, if the split molds 40a and 40b are opened in the direction of 45 ° diagonally upward and leftward, it is possible to sufficiently prevent the shapes of the convex portions 14 and the concave portions 12 of the cement-based molded body 10 from being broken or distorted. .
About the left and right semicircular arc surfaces, the mold opening direction of the split molds 40a and 40b, and the mold surface 32 of the fixed mold 30 and the movable mold 40, so as to coincide with the normal direction at the center in the circumferential direction. If the shape of 42, the inclination angle of the side surfaces of the engaging uneven portions 34, 44, 46, and 47 are designed, smoother mold opening is possible.

  In the above embodiment, the movable mold 40 can be configured by three divided molds of left, middle and right. The mold opening direction of the split mold may be set to 45 ° left, right above, and 45 ° right.

  The manufacturing method of the cement-type molded object concerning this invention can be utilized for manufacture of the exterior board used for the outer wall finishing of a building, for example. An exterior plate having a bent plate shape or a curved plate shape and having a clear concavo-convex design on the surface can be manufactured with high productivity.

The perspective view of the cement-type molded object obtained by embodiment of this invention Side view (a) and sectional view (b) showing the extrusion process Sectional view showing the state before press forming Sectional view showing the stage during press forming Sectional view showing the stage of separation and mold opening of split mold Front view showing split type separation mechanism Sectional view showing the stage of removing the split mold Sectional drawing of the press molding stage which shows another embodiment

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Cement-type molded object 12 Concave part 14 Convex part 16 Preliminary molded object 20 Extrusion apparatus 26 Base plate 30 Fixed shaping | molding die 32 Mold surface 40 Movable shaping | molding die 40a, 40b Divided die 42 Concavity and convexity surface 48 Applicator plate 50 Mold opening actuator 60 Lifting board 62 Support board

Claims (3)

A method for producing a cement-based molded body having a concavo-convex design on a surface by molding a cement-based material,
A step (a) of obtaining a preform having a convex surface by extruding the cement-based material, and a mold surface corresponding to the uneven design in each divided mold. A step (b) of obtaining a cement-based molded body having a concavo-convex design on the surface of the convex shape by press-molding the preformed body between a movable molding die having a fixed mold and the movable molding die; each split mold are separated from each other, each of the split type, look including the step (c) for mold opening in the direction normal to the surface of the cement-base molded article are facing,
In the steps (b) and (c), a fixed mold in which the preform is disposed, and a fixed mold that is disposed to face the fixed mold, and a plurality of divided molds are combined. A mold surface corresponding to the concave and convex design, a movable mold that is opened and closed with respect to the fixed mold, and a fixed mold that is disposed on the fixed mold. Using a molding apparatus provided with a mold opening actuator that contacts and pushes in the mold opening direction,
A method for producing a cement-based molded article. In the step (a) , as the preform , a preform having a cross-sectional “L” shape and two surfaces intersecting a convex shape is extruded, and the step (b) The step (b-1) of disposing the two convex surfaces to the left and right in a posture inclined to the left and right, and the preform for the preform formed in the fixed mold movable mold that combines the left and right split type corresponding to the inclined surfaces of the left and right of the body, and a step (b-2) forming said irregularities design on the surface of the preform, in the step (c), the left and right divided type, you mold opening in the direction normal to the inclined surface of the cement-based molded body, each of the split mold is facing, method for producing cement-based molded article according to 請 Motomeko 1. 3. The method for producing a cement-based molded body according to claim 1 or 2, wherein the press-molding apparatus is used for the steps (b) and (c), the stationary mold in which the preform is disposed, and the fixing A movable mold that is arranged opposite to the mold and is configured by combining a plurality of divided molds, each of which has a mold surface corresponding to the uneven design, and is opened and closed with respect to the fixed mold; An apparatus for molding a cement-based molded body , comprising: a mold opening actuator arranged in the fixed mold and for each divided mold of the movable mold, and abutting on each divided mold and pushing in the mold opening direction.

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