JP4956462B2 - Manufacturing method of outer wall material - Google Patents

Description

  The present invention relates to a method for manufacturing an outer wall surface material, in which a foamable raw material is cast into a molding die composed of a lower mold and an upper mold to mold an outer wall surface material.

  Conventionally, as a method for producing an outer wall surface material, many methods for forming an outer wall surface material by casting a foamable raw material into a forming die composed of a lower die and an upper die have been practiced.

For example, as a prior art of the present applicant, Patent Document 1 discloses an outer sheet having a uniform strength by sandwiching a sheet having gas permeability in an out-of-plane direction and an in-plane direction between a lower mold and an upper mold. A method by which a wall material can be manufactured is disclosed.
JP 2006-35678 A

  However, in the above-described conventional method for manufacturing an outer wall surface material, since the back surface of the formed outer wall surface material is a flat surface, if the adhesive is adhered to the outer wall base surface as it is, the adhesive strength is not uniform due to unevenness of the adhesive. There was a problem.

  As a countermeasure, a separate foot is provided on the back surface of the outer wall material, and the adhesive is applied to the groove between the back foot with a substantially constant thickness so that the adhesive strength is uniform. However, in this case, there is a problem that it takes time and is uneconomical.

  Then, this invention aims at providing the manufacturing method of the outer wall surface material which can manufacture the outer wall surface material which can be adhere | attached economically with uniform adhesive strength to an outer wall base surface.

  In order to achieve the above object, the outer wall surface material manufacturing method of the present invention is a method for manufacturing an outer wall surface material in which a foamable raw material is cast into a molding die composed of a lower mold and an upper mold. The upper surface in which a plurality of recesses for forming a back foot having a substantially constant depth are formed on a flat surface on the lower die and the lower surface, the inner surface of which is the shape of the surface and side surfaces of the outer wall surface material. A mold is used, the required foamable raw material is poured into the lower mold, the upper mold is set, the foamable raw material is foam-cured, removed, and the outer wall surface is removed. A material is formed.

  Here, when the required foamable raw material is cast into the lower mold and the upper mold is set, the gas permeability is in the out-of-plane direction and in-plane direction between the lower mold and the upper mold. It is preferable to sandwich a sheet having

  The plurality of recesses for forming the back foot of the upper mold may have substantially the same shape and are formed at substantially constant intervals.

  Such a manufacturing method of the outer wall surface material of the present invention is a molding die for forming a plurality of back feet having a substantially constant depth in a plane on the lower surface and the lower surface in which the inner surface has the shape of the surface and side surface of the outer wall surface material. Using an upper mold with a recess, cast the required foamable raw material into the lower mold, set the upper mold, foam and cure the foamable raw material, and then remove the mold from the outer wall. Since it is configured to mold the material, the outer wall material to be manufactured is integrally molded with a plurality of recesses for molding the back foot of the upper mold, so that it is economically formed. In addition, it is possible to manufacture an outer wall surface material that can be bonded to the outer wall base surface with uniform adhesive strength.

  Here, when a required foamable raw material is poured into the lower mold and the upper mold is set, a sheet having gas permeability in the out-of-plane direction and the in-plane direction is sandwiched between the lower mold and the upper mold. In this case, in the foaming step, unnecessary gas including air inside the mold is efficiently removed from the end of the sheet, so that a high-quality outer wall material having uniform strength can be manufactured.

  Further, when the plurality of recesses for forming the back foot of the upper mold have substantially the same shape and are formed at substantially constant intervals, the back foot on the back surface of the manufactured outer wall surface material is substantially the same. Since it is shaped and has a substantially constant interval, when the adhesive is applied to the back surface of the outer wall material, the amount of the adhesive per unit area becomes substantially constant, making the adhesive strength more uniform on the outer wall base surface. An outer wall material that can be bonded can be manufactured.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

  As shown in FIG. 1, the manufacturing method of the outer wall surface material of the present embodiment includes a lower die 2 having a shape of the surface and side surfaces of the outer wall surface material on which the inner surface 2 a is formed, and a lower surface as the mold 1. Further, an upper die 3 having a plurality of recesses 3a,.

  Here, the lower mold 2 is made of silicon rubber, and the upper mold 3 is made of FRP (fiber reinforced plastic).

  However, the materials of the lower mold 2 and the upper mold 3 are not limited to these, and those having a durability that can be reused over and over are relatively soft so that the molded outer wall surface material can be easily demolded. Preferably used.

  Then, as shown in FIGS. 2 and 3, a necessary amount of foamable raw material 4 in consideration of expansion due to foaming is cast into the lower mold 2.

  Here, as the foamable raw material 4, a mixture of metakaolin, potassium silicate, silica sand, waranite, vinylon, zinc stearate, lead and an inorganic pigment is used.

  Zinc stearate serves as a foaming agent, and this mixture is made foamable.

  However, the foamable raw material 4 is not limited to this, and may be a foamable material that can form the outer wall surface material.

  Subsequently, as shown in FIG. 4, the upper die 3 is set by sandwiching a sheet 5 having gas permeability in the out-of-plane direction and the in-plane direction at the upper portion of the lower die 2.

  Here, House 5 (registered trademark) manufactured by Sakai Chemical Industry Co., Ltd. is used for the sheet 5.

  However, the sheet 5 is not limited to this, and is durable or heated to have gas permeability in the out-of-plane direction and the in-plane direction, and to withstand the pressurization due to the expansion of the foamable raw material 4 during foam curing. Those having heat resistance that can withstand heat resistance are preferably used.

  Subsequently, in the state shown in FIG. 4, when heated for about 30 minutes at a temperature of about 90 ° C. from the outside of the mold 1 by a hot plate press (not shown), as shown in FIG. The raw material 4 is expanded by foaming and further cured to be molded into the shape of the inner surface of the mold 1.

  Finally, as shown in FIG. 6, by removing the lower mold 2 and the upper mold 3 and the sheet 5 (thickness 0.25 mm) from the foamed raw material 4 formed by curing, The outer wall surface material 6 is manufactured.

Further, the plurality of recesses 3a for forming the back foot of the upper mold 3 have the same spherical hole shape (depth 0.50 mm, φ 8.00 mm) one by one. Are formed at a constant interval ( 20.00 mm).

  Therefore, as shown in FIG. 7, each of the back surfaces of the manufactured outer wall surface material 6 has the same spherical shape (height 0.50 mm, φ8.00 mm) and the distance between them. Are integrally formed with back legs 6a,... At a constant interval (20.00 mm).

  Next, the effect of the manufacturing method of the outer wall surface material of this Embodiment is demonstrated.

  Such a manufacturing method of the outer wall surface material of the present invention includes a lower die 2 having a shape of the surface and side surface of the outer wall surface material 6 on which the inner side surface 2a is manufactured, and a substantially constant depth on the lower surface as the molding die 1. The upper mold 3 is formed by casting the required foamable raw material 4 into the lower mold 2 using the upper mold 3 formed with the recesses 3a,. The foamable raw material 4 is foam-cured and then demolded to form the outer wall surface material 6.

  Therefore, the back wall 6a,... Having a substantially constant height is integrally formed on the manufactured outer wall surface material 6 by the plurality of recesses 3a,. Thus, the outer wall surface material 6 that can be bonded to the outer wall base surface with uniform adhesive strength can be manufactured economically.

  Here, when the required foamable raw material 4 is cast on the lower mold 2 and the upper mold 3 is set, the gas permeability is in the out-of-plane direction and in-plane direction between the lower mold 2 and the upper mold 3. In the foaming step, unnecessary gas including air inside the mold 1 is efficiently removed from the end of the sheet 5 in the foaming process. Can be manufactured.

  Further, since the plurality of recesses 3a for forming the back foot of the upper mold 3 have substantially the same shape and are formed at substantially constant intervals, the back surface of the manufactured outer wall surface material 6 is The back legs 6a,... Have substantially the same shape, and have a substantially constant interval.

  Therefore, when the adhesive is applied to the back surface of the outer wall surface material 6, the amount of the adhesive per unit area becomes substantially constant, and the outer wall surface material 6 that can be bonded to the outer wall base surface with more uniform adhesive strength is manufactured. it can.

  Although the best embodiment of the present invention has been described in detail with reference to the drawings, the specific configuration is not limited to this embodiment, and design changes that do not depart from the gist of the present invention are possible. Are included in the present invention.

  For example, the shape of the recesses 3a for forming the back foot of the upper mold 3 is not limited to the same spherical hole shape one by one.

  In short, the shape of the recesses 3a for forming the back foot is substantially the same as the back foot of the outer wall surface material 6 to be manufactured, and has a substantially constant interval, and is adhered to the back surface of the outer wall surface material 6. Any shape can be used as long as the amount of the adhesive per unit area becomes substantially constant when the agent is applied, and the adhesive strength can be made uniform with the base surface of the outer wall.

It is a longitudinal cross-sectional view which shows schematic structure of the shaping | molding die used for the manufacturing method of the outer wall surface material of the best embodiment of this invention. It is a longitudinal cross-sectional view which shows the process in the middle of casting the foamable raw material in a lower mold | type. It is a longitudinal cross-sectional view which shows the process which casted the foamable raw material in a lower mold | type. It is a longitudinal cross-sectional view which shows the process which set the upper mold | type to the lower mold | type. It is a longitudinal cross-sectional view which shows the state which the foamable raw material expanded and hardened | cured by foaming. It is a front view which shows the manufactured outer wall surface material. It is a top view which shows the back surface of the manufactured outer wall surface material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mold 2 Lower mold 2a Inner side surface 3 Lower mold 3a Recess molding 4 Back foaming raw material 5 Sheet 6 Outer wall surface material 6a Back foot

Claims (3)

A method for producing an outer wall surface material, in which a foamable raw material is poured into a molding die composed of a lower mold and an upper mold to mold an outer wall surface material,
The molding die is composed of the lower die in which the inner side surface has the shape of the surface and side surfaces of the outer wall surface material, and the upper die in which a plurality of recesses for molding a back foot having a substantially constant depth are formed on the bottom surface. Use
After the required foamable raw material is poured into the lower mold, the upper mold is set, the foamable raw material is foam-cured, then demolded, and the outer wall surface material is formed. A method for producing an outer wall material.   A sheet having gas permeability in an out-of-plane direction and an in-plane direction between the lower mold and the upper mold when the foamable raw material required for the lower mold is cast and the upper mold is set. The method for producing an outer wall surface material according to claim 1, wherein:   The manufacturing method of the outer wall surface material according to claim 1, wherein the plurality of recesses for forming the back foot of the upper mold have substantially the same shape and are formed at substantially constant intervals. Method.