JP7088658B2 - Substrate manufacturing method - Google Patents

Description

The present invention relates to a method for producing a base material.

Patent Document 1 discloses a conventional method for producing a base material. In the method for producing a base material described in Patent Document 1, an uneven pattern is formed by pressing a molding surface of a pressing device against the surface of a slurry-like plate-like body.

Japanese Patent No. 2854228

By the way, when the molded surface is pressed against the surface of the plate-shaped body, the material of the plate-shaped body is pushed away by the convex portion of the molded surface, and a concave portion is formed in the portion. However, if the height of the convex portion of the molded surface is higher than a certain height, the amount of movement of the material of the plate-shaped body when the molded surface is pressed against the surface of the plate-shaped body becomes large, and the material becomes It may be torn and crack-like molding defects (hereinafter, also referred to as "nest") may occur on the surface of the plate-like body.

The present invention has been made in view of the above circumstances, and an object thereof is to suppress the occurrence of crack-like molding defects on the surface of the base material regardless of the depth of the recesses of the base material. The present invention is to provide a method for producing a possible base material.

One aspect of the method for manufacturing a base material according to the present invention is a method for manufacturing a base material having recesses formed on the surface thereof, and is a preforming step of forming a preliminary recess shallower than the recesses on the surface of the uncured base material. It is characterized by comprising a main molding step of pressing the position of the preliminary recess to form the recess.

According to the method for producing a base material of the present invention, it is possible to suppress the occurrence of crack-like molding defects on the surface of the base material regardless of the depth of the recesses of the base material.

FIG. 1 is a front view of a base material molded by the method for producing a base material according to an embodiment of the present invention. FIG. 2A is a schematic plan view of a molding apparatus used in the above-mentioned method for manufacturing a base material. FIG. 2B is a cross-sectional view taken along the line AA of FIG. 2A. FIG. 3A is a cross-sectional view illustrating the same preforming process. FIG. 3B is an enlarged view of a portion A of FIG. 3A. FIG. 4A is a cross-sectional view immediately before the upper die of the press die is lowered in the main molding step of the same. FIG. 4B is a cross-sectional view showing a state in which the upper die of the press die is lowered in the main molding step of the same. FIG. 4C is an enlarged view of a portion B of FIG. 4B. FIG. 4D is a cross-sectional view of a press mold opened in the same molding process. 5A to 5C are cross-sectional views of a modified example of the spare recess.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

The method for producing the base material 1 of the present embodiment is a method of molding the base material 1 of the ceramic siding from the molding material. As shown in FIG. 1, the base material 1 of the present embodiment is a plate-like body having a rectangular shape (including a square) when viewed from the front. The base material 1 referred to in the present embodiment means a plate-like body before coloring or undercoating in the process of manufacturing the siding material.

The base material 1 includes a plurality of joints 11 (horizontal joints), a plurality of recesses 12 (vertical joints) orthogonal to the joints 11, and a decorative surface 13 partitioned by the recesses 12 and the joints 11. ing. Each joint 11 extends parallel to the longitudinal direction of the base material 1 and is continuous over the entire length of the base material 1 in the longitudinal direction. The plurality of joints 11 are formed at intervals in the vertical direction, and are formed in parallel with each other. Each recess 12 extends in a direction intersecting the joint 11 and specifically extends in a direction orthogonal to the joint 11. The recess 12 is formed over substantially the entire length of the base material 1 in the width direction.

The decorative surfaces 13 of the present embodiment are all formed at the same height and are formed on the same surface.

The base material 1 of the present embodiment is molded by using the molding apparatus 3 shown in FIG. The method for producing the base material 1 of the present embodiment includes an extrusion molding step of molding the uncured base material 2 by an extruder 4, and a pre-molding step of forming a preliminary recess 22 on the surface of the uncured base material 2 by a roll 5. The cutting process is provided by the cutting device 6, and the main forming process is provided by the press die 7.

Here, the uncured base material 2 refers to a base material 1 having a certain shape and before being cured. The uncured base material 2 in the present embodiment is an extruded product molded by the extruder 4.

In the extrusion molding step, the molding material is extruded by the extrusion device 4 to form the uncured base material 2. The extruder 4 includes an extruder 41 that extrudes a molding material, and an extrusion die 42 that forms the molding material extruded by the extruder 41 into a constant shape.

The molding material is, for example, a hydraulic material containing cement, reinforcing fibers, a water reducing material and water. Cement is, for example, one or more materials selected from the group consisting of Portland cement, blast furnace cement, and alumina cement. Reinforcing fibers include, for example, one or more fibers selected from the group consisting of pulp fibers, vinylon fibers, polypropylene fibers, glass fibers, aramid fibers, carbon fibers. The length of the reinforcing fiber is preferably in the range of, for example, 1 to 10 mm, and more preferably in the range of 4 to 8 mm.

The extruder 41 supplies the molding material to the extrusion die 42 while kneading the molding material. The extruder 41 has an input port 411, and the molding material is supplied from the input port 411. The molding material charged from the charging port 411 is sent to the extrusion die 42 while being kneaded by the auger screw 412.

The extrusion die 42 is a die for molding a molding material supplied by the extruder 41. The extruded die has, for example, a mouthpiece 421 having a substantially rectangular opening, whereby a flat plate-shaped uncured base material 2 can be formed. Further, as shown in FIG. 2B, a plurality of molding protrusions 422 protruding downward are formed on the inner upper surface of the base 421. The molding protrusion 422 forms a concave groove 21 over the entire length in the longitudinal direction (extrusion direction) of the uncured base material 2 on the surface (upper surface) of the uncured base material 2. The concave groove 21 is a through joint 11 in the base material 1. In the molding material extruded from the extruded die 42, the longitudinal direction of the reinforcing fibers is oriented along the extrusion direction.

The preforming step is a step of forming a preliminary recess 22 on the surface of the uncured base material 2. The pre-molding step of the present embodiment is performed after the extrusion molding step. In the preforming step of the present embodiment, as shown in FIG. 3A, a preliminary recess 22 is formed on the surface of the uncured base material 2 by the roll 5.

The preliminary recess 22 is a recess formed on the surface of the uncured base material 2 shallower than the recess 12 (vertical joint) of the base material 1. By forming the preliminary recess 22 before forming the recess 12 in the subsequent main molding step, it is possible to suppress the amount of movement of the molding material when forming the recess 12 in the main molding step.

The preliminary recess 22 extends in a direction intersecting the concave groove 21 formed in the uncured base material 2, and specifically, a direction orthogonal to the longitudinal direction of the concave groove 21 (that is, a width direction of the base material 1). ). The spare recess 22 is formed at a position corresponding to the recess 12 in the base material 1.

Here, FIG. 3B shows an enlarged view of the spare recess 22. Further, in FIG. 3B, the concave portion 12 is shown by an imaginary line (dashed-dotted line). As shown in FIG. 3B, the spare recess 22 has a pair of side surfaces 221 and a bottom surface 222 in cross section. The pair of side surfaces 221 face each other. Further, the bottom surface 222 is formed on the inner side of the side surface 221. The bottom surface 222 is located on the surface side of the base material 1 in the thickness direction with respect to the bottom surface 122 of the recess 12. In the preliminary recess 22 of the present embodiment, the pair of side surfaces 221 and the bottom surface 222 both form a curved surface and are continuous. Therefore, the spare recess 22 is formed in an arc shape in cross section. In the present embodiment, the cross-sectional shape of the preliminary recess 22 is formed by an arc having a central angle of less than 180 °. The preliminary recess 22 does not have to have an arc-shaped cross section as a whole, and a part of the preliminary recess 22 may have an arc-shaped cross section as shown in a modification described later.

The width of the spare recess 22 is formed to be smaller than the width of the recess 12 of the base material 1. The preliminary recess 22 is formed so that the width becomes narrower as it approaches the bottom surface 222 (toward the center side in the thickness direction of the uncured base material 2). The side surface 221 and the bottom surface 222 of the spare recess 22 are formed so as to fit inside the recess 12 of the base material 1.

Further, in the spare recess 22, the angle α formed by the tangent plane P at the end of the spare recess 22 on the opening side and the main surface (here, the upper surface) of the surface of the base material 1 is at the end of the recess 12 on the opening side. It is preferably smaller than the angle β formed by the tangent plane and the main surface.

The "tangent plane" here means a plane formed by a collection of tangents at any point on the plane. Therefore, in the embodiment, the tangent plane at the end of the recess 12 on the opening side coincides with the side surface 121 of the recess 12. Further, the term "end" as used herein means not only one point at the end but also a certain range including the end.

Such a spare recess 22 is formed by the roll 5 as shown in FIG. 3A. The roll 5 repeatedly forms the preliminary recess 22 in the longitudinal direction of the uncured base material 2 with respect to the uncured base material 2 moving on the conveyor 31. The rotation axis 51 of the roll 5 extends in a direction orthogonal to the transport direction of the conveyor 31 (that is, the extrusion direction from the extrusion die 42) on a plane parallel to the transport surface of the conveyor 31. On the outer peripheral surface of the roll 5, a plurality of convex shapes (hereinafter, this convex shape is referred to as "protrusion portion 52") for forming the spare concave portion 22 are formed. The rotation speed of the roll 5 is controlled by, for example, a servomotor which is a drive source. The rotation speed of the roll 5 is controlled by a control device (not shown) so as to be synchronized with the transfer speed of the conveyor 31.

The control device controls the drive of the roll 5, the conveyor 31, the cutting device 6, the extruder 41 and the like. The control device is composed of, for example, a computer whose main component is a microprocessor. The control device controls, for example, the extrusion speed of the uncured substrate 2 by controlling the extruder 41, controls the conveyor 31 and the roll 5 to be synchronized, and controls the conveyor 31 and the cutting device 6. Under control, the uncured substrate 2 can be cut to a desired size.

The cutting step is a step of cutting the uncured base material 2 to a certain size. The cutting step is performed after the preforming step. In the cutting step, the cutting device 6 cuts the uncured base material 2 on which the preliminary recess 22 is formed along a plane orthogonal to the transport direction. The cutting device 6 is controlled by a control device, and determines a cutting point based on, for example, the transport distance of the conveyor 31.

In this molding step, after the cutting step (that is, after the pre-molding step), the recess 12 is formed in the uncured base material 2 by placing a mold at a position corresponding to the preliminary recess 22. That is, in this molding step, the position of the preliminary recess 22 is pressed to form the recess 12. The main molding step of the present embodiment is performed using the press mold 7.

The press mold 7 forms the uncured base material 2 into the same shape as the base material 1 by closing the mold with respect to the uncured base material 2. As shown in FIG. 4A, the press mold 7 includes a mold body 71 having an upper mold 72 and a lower mold 76, a press machine 78 that can be raised and lowered, and a base 77 for attaching the mold body 71 to the press machine 78. ing.

The mold body 71 is a portion that forms the outer shape of the uncured base material 2 between the upper mold 72 and the lower mold 76. The upper mold 72 of the mold body 71 has a molding portion 73 that forms a pattern and a recess 12 on the surface (upper surface) of the uncured base material 2, and the uncured base material 2 is located on the outer periphery of the molding portion 73 and is constant. It is provided with an outer peripheral portion 75 formed to a thickness. The outer peripheral portion 75 can be elastically deformed in the moving direction (vertical direction) of the press mold 7.

The lower surface of the molding portion 73 is a molding surface 74. The molded surface 74 is pressed against the surface of the uncured base material 2 to form a pattern and a recess 12 on the surface of the uncured base material 2. The molding surface 74 includes a plurality of convex shapes (hereinafter, this convex shape is referred to as “convex portion 741”) forming the concave portion 12 and a pressing surface 742 forming a pattern on the surface corresponding to the decorative surface 13. There is.

The pressing surface 742 is provided with a suction portion (not shown) for sucking the uncured base material 2. The suction portion is configured, for example, by connecting a tube to each of a plurality of through holes formed along the convex portion 741 on the pressing surface 742 and connecting a pump to the tube. When the molding surface 74 of the press mold 7 is pressed against the uncured base material 2, the suction portion strongly presses the uncured base material 2 against the pressing surface 742 by sucking a part of the molding material from the through hole. You can guess. As a result, the pattern can be clearly formed on the decorative surface 13, and the corner portion between the concave portion 12 and the decorative surface 13 can be clearly formed.

The convex portion 741 is placed at a position corresponding to the preliminary concave portion 22 to form the concave portion 12 on the surface of the uncured base material 2. The convex portion 741 protrudes downward (in the pushing direction of the press mold 7) from the pressing surface 742. As shown in FIGS. 4B and 4C, the convex portion 741 is formed to be narrower toward the tip, and is formed in a trapezoidal cross section. The width of the tip surface of the convex portion 741 is formed to be smaller than the width (opening width) of the preliminary concave portion 22. Further, the width of the base portion of the convex portion 741 is formed so as to be equal to or larger than the width (opening width) of the preliminary concave portion 22.

These plurality of convex portions 741 are formed at regular intervals in the longitudinal direction of the uncured base material 2 (the transport direction of the uncured base material 2). Since the plurality of protrusions 741 are formed at positions corresponding to the spare recesses 22, they are formed at the same pitch as the spare recesses 22.

The press die 7 having such a configuration operates as follows in the main molding step. As shown in FIG. 4A, when the uncured base material 2 is conveyed to a predetermined position of the lower die 76 with respect to the press die 7 by the conveyor 31, the upper die 72 is lowered.

Here, the predetermined position of the uncured base material 2 with respect to the press mold 7 is a position where the spare recess 22 is located inside the recess 12 when the press mold 7 is closed, as shown in FIG. 4C. Refers to a relationship. Therefore, not only when the center in the width direction of the preliminary recess 22 of the uncured base material 2 and the center in the width direction of the convex portion 741 coincide with each other in the pushing direction of the press die 7, these centers are slightly aligned with each other. It may be shifted to.

When the press mold 7 is lowered, as shown in FIG. 4B, the tip of the convex portion 741 enters the preliminary concave portion 22 of the uncured base material 2, and the convex portion 741 is pressed from above the preliminary concave portion 22. After that, the pressing surface 742 is pressed against the surface of the uncured base material 2 corresponding to the decorative surface 13, and the outer peripheral portion 75 hits the lower mold 76, so that the press mold 7 is closed.

Next, as shown in FIG. 4D, the upper mold 72 is raised and the uncured base material 2 is removed from the press mold 7 to obtain the uncured base material 2 on which the decorative surface 13 and the recess 12 are formed. .. After that, the base material 1 can be formed by, for example, autoclaving and curing the uncured base material 2.

The alignment of the convex portion 741 of the press mold 7 and the preliminary concave portion 22 of the uncured base material 2 is performed, for example, as follows. A sensor 8 for detecting the depth of the preliminary recess 22 of the uncured base material 2 is arranged on the upstream side of the press mold 7 in the transport direction. The sensor 8 is composed of, for example, a distance measuring sensor. The sensor 8 detects the depth of the spare recess 22 and outputs the detected signal to the control device.

Based on this detection signal, the control device determines at which position on the conveyor 31 the detected spare recess 22 is located. After that, the control device moves the uncured base material 2 so that the preliminary recess 22 is located below the corresponding convex portion 741.

As a result, the preliminary concave portion 22 and the convex portion 741 can be aligned with each other. Further, according to this positioning method, even if there are many different depths of the spare recess 22, the spare recess 22 and the convex portion 741 can be accurately positioned. The position of the specific spare recess 22 may be determined by performing image recognition using a camera as the sensor 8.

As described above, in the method of manufacturing the base material 1 of the present embodiment, the preliminary recess 22 shallower than the recess 12 is formed by the pre-molding step, and then the recess 12 is formed by the main molding step. Therefore, the amount of movement of the material during molding of the recess 12 can be reduced as compared with the case where the recess 12 is formed without forming the spare recess 22. Even in the main molding step of the present embodiment, nests (air bubbles) may be generated immediately after molding of the recess 12, but the nests are small and small because the amount of movement of the material is small. Therefore, the nest formed immediately after the molding of the recess 12 is restored by the molding material and disappears.

[Modification example]
The preliminary recess 22 of the above embodiment is formed in an arc shape in cross section, but may have a shape as shown in FIGS. 5A to 5C, for example. In the drawing, the concave portion 12 is represented by a two-dot chain line.

As shown in FIG. 5A, the preliminary recess 22 of one modification is formed in a cross-sectional trapezoidal shape similar to the shape of the recess 12. In order to form the preliminary concave portion 22, the protrusion 52 forming the preliminary concave portion 22 may be formed to have a similar shape to the convex portion 741 forming the concave portion 12 and to be smaller than the convex portion 741 forming the concave portion 12. In this case, it is assumed that the convex portion 741 and the protruding portion 52 have the same shape.

As shown in FIG. 5B, the spare recess 22 of one modification has a pair of side surfaces 221 of the spare recess 22 having a curved surface and a bottom surface 222 having a flat surface. That is, at least a part of the preliminary recess 22 according to this modification is formed in an arc shape in cross section. The spare recess 22 may be formed with the bottom surface 222 having a curved surface and the side surface 221 having a flat surface. In this case, the protrusion 52 forming the spare concave portion 22 and the convex portion 741 forming the concave portion 12 have different shapes.

As shown in FIG. 5C, the preliminary recess 22 of one modification is a V-shaped groove. The side surface 221 of the spare recess 22 has a looser inclination angle than the side surface 121 of the recess 12. That is, the angle of the side surface 221 of the preliminary recess 22 with respect to the surface is formed to be smaller than the angle of the side surface 121 of the recess 12 with respect to the surface. In this case, the protrusion 52 forming the spare concave portion 22 and the convex portion 741 forming the concave portion 12 have different shapes.

Further, in the spare recess 22 of this modification, the angle between the tangent plane at the end of the spare recess 22 on the opening side and the main surface (here, the upper surface) of the surface of the base material 1 is the end of the recess 12 on the opening side. It is smaller than the angle between the tangent plane and the main surface of the part. In this modification, the tangent plane and the side surface of the spare recess 22 coincide with each other. The term "end" as used herein means not only one point at the end but also a certain range including the end.

〔application〕
The uncured base material 2 of the above embodiment was formed by the extrusion molding step, but the uncured base material 2 does not have to be formed by the extrusion molding step.

The recess 12 of the base material 1 extends in a direction orthogonal to the longitudinal direction of the uncured base material 2, but may be inclined with respect to the longitudinal direction of the uncured base material 2, for example. That is, the longitudinal direction of the recess 12 may intersect with the longitudinal direction of the uncured base material 2.

The preliminary recess 22 of the above embodiment is continuously formed, but may be intermittent. That is, the spare recess 22 does not necessarily have to be continuous as long as it is formed at a position corresponding to the recess 12.

Further, the cross-sectional shape of the preliminary recess 22 of the above embodiment is formed in an arc having a central angle of less than 180 °, but may be an arc having a central angle of 180 °.

The decorative surfaces 13 of the above embodiment are all formed on the same surface. Therefore, when the molded surface 74 comes into contact with the portion of the uncured base material 2 corresponding to the decorative surface 13, the same pressure is applied over the entire surface of the decorative surface 13. Therefore, in the above embodiment, the amount of movement of the material during molding is smaller than in the case where the heights of the decorative surfaces 13 are different from each other, and the generation of nests can be further suppressed, which is preferable.

According to the method for manufacturing the base material 1 of the above embodiment, the occurrence of nests can be suppressed without being limited to the inclination angle of the side surface 121 of the recess 12 with respect to the decorative surface 13, but the inclination angle of the side surface 121 of the recess 12 is 60 ° or less. (That is, looser than 60 °), the formation of nests can be further suppressed.

According to the method for producing the base material 1 of the above embodiment, the generation of nests in the recesses 12 can be suppressed, but if the nests formed in the recesses 12 are conspicuous, they may be formed on the surface of the recesses 12 at the time of painting. By adding a pattern, the nest can be made inconspicuous. In particular, by making the pattern of the concave portion 12 painted the same as the pattern painted on the decorative surface 13, the nest can be made more inconspicuous.

The recess 12 of the above embodiment is a so-called box joint-shaped recess 12, but the method of manufacturing the base material 1 of the above embodiment can be applied to the V joint-shaped recess 12. Therefore, the recess 12 is not limited to the box joint shape.

In the above embodiment, the pre-molding step is performed only once before the main molding step, but for example, two or more pre-molding steps may be included.

Although the preliminary recess 22 of the above embodiment is formed by the roll 5, a press die may be used.

The preliminary recess 22 of the above embodiment is applied only to the vertical joints, but may be applied to the vertical joints and the horizontal joints. That is, in the present molding step, the joints 11 and the like extending in the longitudinal direction of the base material 1 may be formed.

In addition, the configuration of the above embodiment can be appropriately redesigned as long as it does not deviate from the gist of the present invention.

〔effect〕
The method for producing the base material 1 of the above-described embodiment (including the modified example) described above has the following features. That is, the method for manufacturing the base material 1 is the method for manufacturing the base material 1 that forms the recess 12 on the surface of the base material 1. The method for manufacturing the base material 1 includes a pre-molding step of forming a preliminary recess 22 shallower than the recess 12 on the surface of the uncured base material 2, and a main molding step of pressing the position of the preliminary recess 22 to form the recess 12. To prepare for. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the first aspect.

According to the method for manufacturing the base material 1 according to the first aspect, the recess 12 can be formed on the uncured base material 2 after the preliminary recess 22 is formed, so that even if the recess 12 is deep, the recess 12 can be formed. The amount of movement of the material when the mold is pressed can be reduced. As a result, it is possible to suppress the formation of nests on the base material 1.

Moreover, in the molding only in the main molding process without the conventional pre-molding step, the material in the portion corresponding to the decorative surface 13 also moves significantly due to the large movement of the material in the portion corresponding to the recess 12, and as a result, the base material 1 A sink mark is generated on the back surface of the surface corresponding to the decorative surface 13. On the other hand, in the manufacturing method of the above embodiment, the material movement of the portion corresponding to the recess 12 in the main molding step is small, and the material movement of the portion corresponding to the decorative surface 13 is also small. As a result, the sink mark on the back surface is suppressed.

Further, the method for producing the base material 1 of the above embodiment (including a modification) has the following additional characteristics in addition to the characteristics of the method for producing the base material 1 of the first aspect. That is, in the method for manufacturing the base material 1, the width of the spare recess 22 is smaller than the width of the recess 12. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the second aspect.

According to the method for manufacturing the base material 1 according to the second aspect, in the base material 1, a part of the spare recess 22 is not exposed on the inner surface of the recess 12, and the appearance of the base material 1 is prevented from being spoiled. be able to.

Further, the method for producing the base material 1 of the above embodiment (including a modification) has the following additional characteristics in addition to the characteristics of the method for producing the base material 1 of the second aspect. That is, in the method for manufacturing the base material 1, the spare recess 22 has a side surface 221 and a bottom surface 222. At least one of the side surface 221 and the bottom surface 222 is a curved surface. That is, at least a part of the spare recess 22 has an arcuate cross section. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the third aspect.

According to the method for producing the base material 1 according to the third aspect, in the molding of the preliminary recess 22, shearing force is less likely to be generated when the mold is pressed, and the generation of nests can be suppressed. As a result, even when the recess 12 is formed in the main molding step, the generation of nests can be suppressed.

Further, the method for producing the base material 1 of the above embodiment (including a modification) has the following additional characteristics in addition to the characteristics of the method for producing the base material 1 according to the third aspect. That is, in the method for manufacturing the base material 1, the spare recess 22 is formed in an arc shape in cross section. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the fourth aspect.

According to the method for producing the base material 1 according to the fourth aspect, the generation of nests can be further suppressed in the molding of the preliminary recess 22.

Further, the method for producing the base material 1 of the above-mentioned modification has the following additional characteristics in addition to the characteristics of the method for producing the base material 1 of the second aspect. That is, in the method for manufacturing the base material 1, each of the spare recess 22 and the recess 12 has a pair of side surfaces 221, 121. The angle of the side surface 221 of the preliminary recess with respect to the surface is smaller than the angle of the side surface 121 of the recess 12 with respect to the surface. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the fifth aspect.

According to the method for producing the base material 1 according to the fifth aspect, the generation of nests can be suppressed in the molding of the preliminary recess 22.

Further, the method for producing the base material 1 of the above embodiment (including the modified example) has the following additional features in addition to the features of the method for manufacturing the base material 1 according to any one of the first to fifth aspects. Have. That is, in the method for producing the base material 1, the uncured base material 2 contains fibers. Hereinafter, the method for molding the base material 1 having this feature is referred to as a method for producing the base material 1 according to the sixth aspect.

Normally, nests are likely to occur when the molding material contains fibers, but according to the method for producing the base material 1 according to the sixth aspect, the formation of nests can be suppressed while increasing the strength of the base material 1 by the fibers.

Further, the method for producing the base material 1 of the above embodiment (including the modified example) has the following additional features in addition to the features of the method for manufacturing the base material 1 according to any one of the first to sixth aspects. Have. That is, the method for producing the base material 1 further includes an extrusion molding step. The extrusion molding step is performed before the premolding step, and the uncured base material 2 is molded by extruding the molding material from the extrusion die 42. The recess 12 extends in a direction intersecting the longitudinal direction of the uncured base material 2 formed in the extrusion molding step (in the above embodiment, the recess 12 extends in the width direction of the base material 1). The base material 1 manufactured here has a rectangular shape. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the seventh aspect.

According to the method for manufacturing the base material 1 according to the seventh aspect, the cross-sectional shape orthogonal to the longitudinal direction of the base material 1 is adjusted by changing the shape of the extrusion die 42 in the extrusion molding step according to the pattern. Therefore, the shape can be made in consideration of the amount of flow of the material in the main molding process.

Further, the method for producing the base material 1 of the above embodiment (including the modification) has the following additional characteristics in addition to the characteristics of the method for producing the base material 1 according to the seventh aspect. That is, in the method for manufacturing the base material 1, the uncured base material 2 includes a concave groove 21 formed over the entire length in the longitudinal direction of the uncured base material 2. The concave groove 21 is formed by the extrusion die 42 in the extrusion molding process. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the eighth aspect.

According to the method for manufacturing the base material 1 according to the eighth aspect, the through joints 11 extending in the longitudinal direction of the base material 1 are formed by extrusion molding, and the vertical joints extending in the direction orthogonal to the longitudinal direction of the base material 1 are formed. Can be molded in this molding step.

Further, the method for producing the base material 1 of the above embodiment (including the modification) has the following additional features in addition to the characteristics of the method for producing the base material 1 according to any one of the first to eighth aspects. Have. That is, in the method for manufacturing the base material 1, the convex shape in which the preliminary recess 22 is formed in the pre-molding step and the convex mold in which the recess 12 is formed in the main molding step are different in shape. Hereinafter, the method for producing the base material 1 having this feature is referred to as the method for producing the base material 1 according to the ninth aspect.

According to the method for producing the base material 1 according to the ninth aspect, for example, in the pre-molding step, the roll 5 having a convex shape is used, and in the main molding step, a convex mold having a shape different from the convex shape of the roll 5 is used. A flat press mold 7 having the above can be used.

1 Base material 12 Recesses 2 Uncured base material 22 Preliminary recess α Angle between the tangent plane at the end of the preliminary recess and the main surface of the surface of the base material β Angle between the tangent plane at the end of the recess and the main surface

Claims (3)

A method for manufacturing a base material having recesses formed on its surface.
A pre-molding step of forming a preliminary recess shallower than the recess on the surface of the uncured substrate, and
Main molding to form the recess by pressing the position of the preliminary recess using a press mold that forms the uncured substrate into the same shape as the substrate by closing the mold with respect to the uncured substrate. With the process ,
The width of the preliminary recess is smaller than the width of the recess.
The angle formed by the tangent plane at the end of the preliminary recess and the main surface of the surface of the base material is smaller than the angle formed by the tangent plane at the end of the recess and the main surface.
Manufacturing method of base material. The method for manufacturing a base material according to claim 1 , wherein at least a part of the preliminary recess has an arcuate cross section . The base material has a rectangular shape,
The method for manufacturing a base material according to claim 1 or 2 , wherein the recess extends in the width direction of the base material .

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