JP7136562B2 - Irregular base material and its manufacturing method - Google Patents

Irregular base material and its manufacturing method Download PDF

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JP7136562B2
JP7136562B2 JP2018014138A JP2018014138A JP7136562B2 JP 7136562 B2 JP7136562 B2 JP 7136562B2 JP 2018014138 A JP2018014138 A JP 2018014138A JP 2018014138 A JP2018014138 A JP 2018014138A JP 7136562 B2 JP7136562 B2 JP 7136562B2
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recess
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uneven
concave
base material
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JP2019130741A (en
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優 小島
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KMEW Co Ltd
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Kubota Matsushitadenko Exterior Works Ltd
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Description

本発明は、凹凸基材及びその製造方法に関する。詳しくは、外壁材などの建材として使用可能な凹凸基材及びその製造方法に関する。 TECHNICAL FIELD The present invention relates to an uneven base material and a method for manufacturing the same. More specifically, it relates to an uneven base material that can be used as a building material such as an exterior wall material, and a method for producing the same.

従来、未硬化の水硬性材料からなる平板状のセメント板の表面に凹凸型を押し付けて成形し、表面に凹凸柄を有する凹凸基材を製造することが行われている。この場合、成形時に、凹凸型の方にセメント板を真空吸引することにより、凹凸をシャープに形成することが行われている(例えば、特許文献1参照)。 Conventionally, a concave-convex base material having a concave-convex pattern on the surface is produced by pressing a concave-convex mold against the surface of a flat cement board made of an uncured hydraulic material. In this case, during molding, the cement plate is vacuum-sucked toward the concave-convex mold to form sharp concavities and convexities (see, for example, Patent Document 1).

特開2002-103319号公報JP-A-2002-103319

しかし、柄深さ(凹凸の高低差)の大きい凹凸柄の場合、成形時の水硬性材料の移動変位が大きくなり、凹部の底面と側面との角部に亀裂が生じやすいという問題があった。 However, in the case of a concave-convex pattern with a large handle depth (difference in the height of the concave-convex pattern), there is a problem that the displacement of the hydraulic material increases during molding, and cracks are likely to occur at the corners of the bottom and side surfaces of the recess. .

本発明は上記の点に鑑みてなされたものであり、凹部の底面と側面との角部に亀裂が生じにくい凹凸基材及びその製造方法を提供することを目的とする。 The present invention has been made in view of the above points, and an object of the present invention is to provide an uneven substrate in which cracks are less likely to occur at the corners of the bottom and side surfaces of recesses, and to provide a method for manufacturing the same.

本発明に係る凹凸基材は、表面に凹凸柄が形成された凹凸基材であって、平坦な底面と、前記底面から立ち上がる側面とを備えて前記凹凸柄を構成する凹部が形成され、細長い凸条に形成されて前記凹凸柄を構成する凸部には傾斜凹部が設けられており、前記傾斜凹部は、該凸部の短手方向一方側に前記凹部の前記底面に向かって下り傾斜した底面を備え、前記凹部の前記底面と前記側面との間の角部が曲面状に形成され、前記凹部の前記底面の前記傾斜凹部に対応する位置にのみ、シボが形成されている。 The uneven base material according to the present invention is an uneven base material having an uneven pattern formed on its surface, and is provided with a flat bottom surface and a side surface rising from the bottom surface, forming a concave portion that constitutes the uneven pattern. A sloping recess is provided on the protruding portion that is formed as a protruding line and constitutes the uneven pattern, and the sloping recess is inclined downward toward the bottom surface of the recess on one side in the short direction of the protruding portion. A corner portion between the bottom surface and the side surface of the recess is formed in a curved surface shape, and grains are formed only at positions corresponding to the inclined recesses on the bottom surface of the recess .

本発明に係る凹凸基材の製造方法は、未硬化の水硬性材料からなる無機質板の表面に凹凸型を押圧することにより、前記凹凸基材を製造する方法であって、前記凹凸型は、前記底面及び前記底面から立ち上がる前記側面を備える前記凹部を形成するための成形凸部と、前記凸部を形成するための成形凹部と、前記傾斜凹部を形成するための成形傾斜凸部とを有し、前記成形凸部の頂面と側面との間の角部が曲面状に形成され、前記凸部は、細長い凸条に形成され、前記凹部の前記底面の前記傾斜凹部に対応する位置にのみ、シボが形成されるA method for producing an uneven base material according to the present invention is a method for producing an uneven base material by pressing an uneven mold against the surface of an inorganic plate made of an uncured hydraulic material, wherein the uneven mold comprises: a molding projection for forming the recess having the bottom surface and the side surface rising from the bottom surface ; a molding recess for forming the projection; and a molding inclined projection for forming the inclined recess. The corner between the top surface and the side surface of the molded projection is formed into a curved surface , and the projection is formed as an elongated projection at a position corresponding to the inclined recess on the bottom surface of the recess. Grain is formed only when

本発明では、成形時に未硬化の水硬性材料が流れやすくなって、凹部の底面と側面との角部に亀裂が生じにくい。 In the present invention, the uncured hydraulic material easily flows during molding, and cracks are less likely to occur at the corners of the bottom and side surfaces of the recess.

図1Aは、本発明に係る凹凸基材の一実施の形態を示す正面図である。図1Bは、本発明に係る凹凸基材の一実施の形態を示す斜視図である。FIG. 1A is a front view showing an embodiment of an uneven base material according to the present invention. FIG. 1B is a perspective view showing one embodiment of the uneven base material according to the present invention. 図2Aは、本発明に係る凹凸基材の一実施の形態の一部を示す断面図である。図2Bは、本発明に係る凹凸基材の一実施の形態の角部を示す拡大断面図である。FIG. 2A is a cross-sectional view showing part of an embodiment of an uneven base material according to the present invention. FIG. 2B is an enlarged cross-sectional view showing corners of an embodiment of the uneven base material according to the present invention. 図3は、本発明に係る凹凸基材の製造方法の一実施の形態を示す断面図である。FIG. 3 is a cross-sectional view showing an embodiment of the method for producing an uneven base material according to the present invention.

以下、本発明を実施するための形態を説明する。 DETAILED DESCRIPTION OF THE INVENTION Embodiments for carrying out the present invention will be described below.

[凹凸基材]
本実施の形態の凹凸基材100は、図1A及び図1Bに示すように、表面に凹凸柄を有している。凹凸柄は複数の凹部10と複数の凸部20とを備えて形成されている。各凹部10及び各凸部20は凹凸基材100の長手方向に延びるように形成されている。また凹部10と凸部20は凹凸基材100の短手方向に交互に並んで形成されている。なお、以下では、凹凸基材100の長手方向及び短手方向をそれぞれ単に「長手方向」、「短手方向」と称する。
[Uneven base material]
As shown in FIGS. 1A and 1B, the uneven base material 100 of the present embodiment has an uneven pattern on its surface. The uneven pattern is formed with a plurality of recesses 10 and a plurality of protrusions 20 . Each concave portion 10 and each convex portion 20 are formed to extend in the longitudinal direction of the uneven substrate 100 . In addition, the concave portions 10 and the convex portions 20 are alternately arranged in the lateral direction of the concave-convex substrate 100 . In addition, below, the longitudinal direction and the lateral direction of the uneven|corrugated base material 100 are only called "longitudinal direction" and "lateral direction", respectively.

さらに凸部20には複数の傾斜凹部30が設けられている。長手方向に細長い凸条の凸部20は、複数の平面視略矩形状の凸部分40と、傾斜凹部30と、によって構成されている。傾斜凹部30は、短手方向一方側に底面11に向かって下り傾斜した底面31と、この底面31の長手方向両側端から凹凸基材100の表側に立ち上がる一対の側面32と、を備えている。そして、底面31の底面11側端部から側面32に亘って角度が急峻となっており、ほぼ垂直になっている。そうして、凸部分40の傾斜凹部30側の角部が急峻となっている。 Further, the convex portion 20 is provided with a plurality of inclined concave portions 30 . The convex portion 20 elongated in the longitudinal direction is composed of a plurality of substantially rectangular convex portions 40 in plan view and the inclined concave portion 30 . The inclined concave portion 30 has a bottom surface 31 inclined downward toward the bottom surface 11 on one side in the width direction, and a pair of side surfaces 32 rising from both longitudinal direction ends of the bottom surface 31 toward the front side of the uneven base material 100 . . The angle is steep from the end of the bottom surface 31 on the side of the bottom surface 11 to the side surface 32, and the bottom surface 31 is almost vertical. Thus, the corner portion of the convex portion 40 on the inclined concave portion 30 side is steep.

また、凹凸基材100の表面には、一対の傾斜凹部30a、30bが隣接した部分がある。この場合、一方の傾斜凹部30aの底面31aが短手方向一方側に下り傾斜している一方、他方の傾斜凹部30bの底面31bが短手方向他方側に下り傾斜している。これら両傾斜凹部30a、30bの境界には、一方の傾斜凹部30aの底面31aから立ち上がる側面32aと、他方の傾斜凹部30bの底面31bから立ち上がる側面32bと、が形成されており、それぞれ、凸部20の短手方向中央まで形成されている。 Further, the surface of the uneven base material 100 has a portion where the pair of inclined recesses 30a and 30b are adjacent to each other. In this case, the bottom surface 31a of one of the inclined recesses 30a is inclined downward to one side in the short direction, while the bottom surface 31b of the other inclined recess portion 30b is inclined downward to the other side in the short direction. A side surface 32a rising from the bottom surface 31a of one of the inclined recesses 30a and a side surface 32b rising from the bottom surface 31b of the other inclined recess 30b are formed at the boundary between the two inclined recesses 30a and 30b. 20 is formed up to the center in the transverse direction.

図2Aに示すように、凹部10は平坦な底面11とその両側から立ち上がる側面12とを備えて形成されている。そして、凹部10の底面11にはシボ13が形成されている。シボ13は底面11の全面にわたって形成されていても良いし、底面11の一部に設けてもよい。特に、底面11の傾斜凹部30に対応する位置においては、成形時の水硬性材料の流れが複雑になるため、底面11に亀裂が生じやすいが、シボ13を形成することにより亀裂を目立ちにくくすることができる。シボ13の形状や大きさは特に限定されないが、例えば、直径0.3mm以上1.0mm以下の微細な多数の突起で形成することができる。 As shown in FIG. 2A, the recess 10 is formed with a flat bottom surface 11 and side surfaces 12 rising from both sides thereof. A texture 13 is formed on the bottom surface 11 of the recess 10 . The texture 13 may be formed over the entire bottom surface 11 or may be provided on a portion of the bottom surface 11 . In particular, at positions corresponding to the inclined recesses 30 of the bottom surface 11, the flow of the hydraulic material during molding is complicated, so cracks are likely to occur in the bottom surface 11, but the formation of the grains 13 makes the cracks inconspicuous. be able to. The shape and size of the emboss 13 are not particularly limited, but for example, it can be formed of a large number of minute projections with a diameter of 0.3 mm or more and 1.0 mm or less.

また図2Bに示すように、凹部10の底面11と側面12との間の角部14は曲面状(凹曲面状)に形成されている。これにより、成形時の水硬性材料の流れがスムーズになって、角部14に亀裂が生じにくくなる。角部14は曲率半径が0.5mm以上1.5mm以下とすることができるが、これに限定されるものではない。曲面状の角部14は凹部10の長手方向の全長にわたって形成しても良いし、凹部10の長手方向の一部に形成しても良い。また凹部10の底面11と側面12とのなす角度θは、30°以上87°以下が好ましい。 Further, as shown in FIG. 2B, a corner portion 14 between the bottom surface 11 and the side surface 12 of the recess 10 is formed in a curved (concave) shape. As a result, the hydraulic material flows smoothly during molding, and cracks are less likely to occur at the corners 14 . The corner portion 14 can have a curvature radius of 0.5 mm or more and 1.5 mm or less, but is not limited to this. The curved corner portion 14 may be formed over the entire length of the recess 10 in the longitudinal direction, or may be formed in a part of the recess 10 in the longitudinal direction. Also, the angle θ between the bottom surface 11 and the side surface 12 of the concave portion 10 is preferably 30° or more and 87° or less.

[凹凸基材の製造方法]
凹凸基材100は、無機質板の表面に凹凸型を押圧することにより形成される。無機質板は未硬化の水硬性材料で形成されている。未硬化の水硬性材料は、セメントや骨材や補強繊維及び水などを含有する成形材料である。無機質板は未硬化の水硬性材料を押出成形法や抄造法などで板状に成形することにより形成される。無機質板はコア部とスキン部とを有して形成することができる。コア部は無機質板の中心部を形成する部分であり、スキン部は無機質板の表面を形成する部分である。従って、コア部の全面はスキン部によって覆われている。コア部の比重はスキン部の比重よりも小さく形成されている。例えば、コア部に気泡や空隙や中空孔などを設け、スキン部に気泡や空隙や中空孔などを設けないようにして、コア部の比重をスキン部の比重よりも小さくすることができる。従って、単位面積あたりの重量や強度をほとんど変えることがなく、無機質板を厚く形成することができ、この結果、表面に高低差の大きい(深い)凹凸柄を形成することが可能となる。例えば、単一の材料で形成された無機質板に6mmの凹部を形成できる場合、同じ厚みでコア部とスキン部とを備えた無機質板では9~12mmの凹部を形成することができる。
[Method for manufacturing uneven base material]
The uneven substrate 100 is formed by pressing an uneven mold against the surface of an inorganic plate. The inorganic board is made of an uncured hydraulic material. An uncured hydraulic material is a molding material containing cement, aggregates, reinforcing fibers, water, and the like. The inorganic board is formed by forming an uncured hydraulic material into a plate shape by an extrusion molding method, a papermaking method, or the like. The inorganic board can be formed to have a core portion and a skin portion. The core portion is a portion that forms the central portion of the inorganic board, and the skin portion is a portion that forms the surface of the inorganic board. Therefore, the entire surface of the core portion is covered with the skin portion. The specific gravity of the core portion is formed to be smaller than the specific gravity of the skin portion. For example, the specific gravity of the core portion can be made smaller than that of the skin portion by providing bubbles, voids, hollow holes, etc. in the core portion and not providing bubbles, voids, hollow holes, etc. in the skin portion. Therefore, it is possible to form a thick inorganic board without changing the weight or strength per unit area, and as a result, it is possible to form a (deep) uneven pattern with a large height difference on the surface. For example, if a 6 mm concave portion can be formed in an inorganic plate made of a single material, a 9 to 12 mm concave portion can be formed in an inorganic plate having a core portion and a skin portion with the same thickness.

図3に示すように、凹凸型200は、凹部10を形成するための成形凸部210と、凸部20を形成するための成形凹部220と、傾斜凹部30を形成するための成形傾斜凸部(図示省略)とを備えている。成形凸部210の頂面211は凹部10の底面11を成形する。従って、頂面211にはシボ13に対応する成形シボ213が設けられている。また成形凸部210の頂面211と側面212の角部214は凹部10の底面11と側面12との角部14を成形する。従って、頂面211と側面212の角部214は、底面11と側面12との角部14の曲面状に対応するような曲面状(凸曲面状)に形成されている。 As shown in FIG. 3, the concave-convex mold 200 includes a molding convex portion 210 for forming the concave portion 10, a molding concave portion 220 for forming the convex portion 20, and a forming inclined convex portion for forming the inclined concave portion 30. (not shown). The top surface 211 of the molding projection 210 molds the bottom surface 11 of the recess 10 . Therefore, the top surface 211 is provided with a molding texture 213 corresponding to the texture 13 . A corner 214 between the top surface 211 and the side surface 212 of the molded projection 210 forms the corner 14 between the bottom surface 11 and the side surface 12 of the recess 10 . Therefore, corners 214 between the top surface 211 and the side surfaces 212 are formed in a curved surface shape (convex curved surface shape) corresponding to the curved surface shape of the corner portions 14 between the bottom surface 11 and the side surfaces 12 .

そして、無機質板300の表面に凹凸型200を押圧することにより、平坦な無機質板300の表面に凹凸柄が形成される。このとき、凹凸型200を通じて無機質板300を真空吸引することにより、無機質板300が凹凸型200に密着しやすくなり、鮮明な(シャープな)凹凸柄が形成しやすくなる。このようにして凹凸柄を成形した後、脱型し、成形後の無機質板300を養生硬化することにより、凹凸基材100が形成される。 Then, by pressing the concave-convex mold 200 against the surface of the inorganic plate 300 , a concave-convex pattern is formed on the flat surface of the inorganic plate 300 . At this time, by vacuum-sucking the inorganic plate 300 through the concave-convex mold 200, the inorganic plate 300 is easily brought into close contact with the concave-convex mold 200, and a clear (sharp) concave-convex pattern is easily formed. After forming the uneven pattern in this manner, the molded inorganic plate 300 is removed from the mold, and the molded inorganic plate 300 is cured to form the uneven base material 100 .

[本実施形態の特徴]
本実施の形態の凹凸基材100は、水硬性材料の硬化物で形成され、表面に凹凸柄が形成された凹凸基材100である。凹凸基材100は、底面11と、底面11から立ち上がる側面12とを備えて凹部10が形成されている。底面11と側面12との間の角部14が曲面状に形成されている。
[Features of this embodiment]
The uneven base material 100 of the present embodiment is an uneven base material 100 formed of a cured product of a hydraulic material and having an uneven pattern formed on its surface. The concave-convex substrate 100 has a bottom surface 11 and side surfaces 12 rising from the bottom surface 11 to form concave portions 10 . A corner portion 14 between the bottom surface 11 and the side surface 12 is formed in a curved shape.

このような凹凸基材100は、成形時に未硬化の水硬性材料が流れやすくなって、凹部10の底面11と側面12との角部14に亀裂が生じにくい。 Such a concave-convex base material 100 facilitates flow of uncured hydraulic material during molding, and cracks are less likely to occur at the corners 14 between the bottom surface 11 and the side surface 12 of the concave portion 10 .

本実施の形態において、角部14は、曲率半径が0.5mm以上1.5mm以下であることが好ましい。 In the present embodiment, corner portion 14 preferably has a curvature radius of 0.5 mm or more and 1.5 mm or less.

このような凹凸基材100は、成形時に未硬化の水硬性材料がより流れやすくなって、凹部10の底面11と側面12との角部14に亀裂が生じにくい。 Such a concave-convex base material 100 makes it easier for the uncured hydraulic material to flow during molding, and cracks are less likely to occur at the corners 14 between the bottom surface 11 and the side surface 12 of the concave portion 10 .

本実施の形態の凹凸基材100の製造方法は、未硬化の水硬性材料からなる無機質板300の表面に凹凸型200を押圧することにより、表面に凹凸柄が形成された凹凸基材100を製造する方法である。凹凸型200は、底面11と、底面11から立ち上がる側面12とを備える凹部10を形成するための成形凸部210を有している。成形凸部210の頂面211と側面212との間の角部214が曲面状に形成されている。 In the method for manufacturing the uneven substrate 100 of the present embodiment, the uneven substrate 100 having the uneven pattern formed on the surface is produced by pressing the uneven mold 200 against the surface of the inorganic plate 300 made of an uncured hydraulic material. It is a method of manufacturing. The concave-convex mold 200 has a forming protrusion 210 for forming the concave portion 10 having the bottom surface 11 and the side surface 12 rising from the bottom surface 11 . A corner portion 214 between the top surface 211 and the side surface 212 of the molded convex portion 210 is curved.

このような凹凸基材100の製造方法は、成形時に未硬化の水硬性材料が成形凸部210の表面に沿ってスムーズに流れやすくなって、凹部10の底面11と側面12との角部14に亀裂が生じにくい。 In this method of manufacturing the uneven base material 100, the uncured hydraulic material easily flows along the surfaces of the molded protrusions 210 during molding, and the corners 14 between the bottom surface 11 and the side surfaces 12 of the recesses 10 are formed. Cracks are less likely to occur.

10 凹部
11 底面
12 側面
14 角部
100 凹凸基材
200 凹凸型
210 成形凸部
211 頂面
212 側面
214 角部
REFERENCE SIGNS LIST 10 concave portion 11 bottom surface 12 side surface 14 corner portion 100 uneven base material 200 uneven mold 210 molding convex portion 211 top surface 212 side surface 214 corner portion

Claims (3)

水硬性材料の硬化物で形成され、表面に凹凸柄が形成された凹凸基材であって、
底面と、前記底面から立ち上がる側面とを備えて前記凹凸柄を構成する凹部が形成され、
細長い凸条に形成されて前記凹凸柄を構成する凸部には傾斜凹部が設けられており、
前記傾斜凹部は、該凸部の短手方向一方側に前記凹部の前記底面に向かって下り傾斜した底面を備え、
前記凹部の前記底面と前記側面との間の角部が曲面状に形成され
前記凹部の前記底面の前記傾斜凹部に対応する位置にのみ、シボが形成されている
凹凸基材。
An uneven substrate formed of a cured product of a hydraulic material and having an uneven pattern formed on the surface,
A concave portion is formed which has a bottom surface and a side surface rising from the bottom surface and constitutes the concave-convex pattern,
A slender concave portion is provided in the convex portion that is formed as an elongated convex line and that constitutes the concave-convex pattern,
The inclined recess has a bottom surface that slopes downward toward the bottom surface of the recess on one side in the short direction of the projection,
a corner portion between the bottom surface and the side surface of the recess is formed into a curved surface ;
A texture is formed only at a position corresponding to the inclined recess on the bottom surface of the recess.
Concavo-convex base material.
請求項1において、
前記角部は、曲率半径が0.5mm以上1.5mm以下である
凹凸基材。
In claim 1,
The uneven base material, wherein the corners have a curvature radius of 0.5 mm or more and 1.5 mm or less.
未硬化の水硬性材料からなる無機質板の表面に凹凸型を押圧することにより、請求項1又は2に記載の凹凸基材を製造する方法であって、
前記凹凸型は、前記底面及び前記底面から立ち上がる前記側面を備える前記凹部を形成するための成形凸部と、前記凸部を形成するための成形凹部と、前記傾斜凹部を形成するための成形傾斜凸部と、を有し、
前記成形凸部の頂面と側面との間の角部が曲面状に形成され
前記凸部は、細長い凸条に形成され、
前記凹部の前記底面の前記傾斜凹部に対応する位置にのみ、シボが形成される
凹凸基材の製造方法。
3. A method for producing the uneven substrate according to claim 1 or 2 by pressing an uneven mold against the surface of an inorganic plate made of an uncured hydraulic material, comprising:
The concave-convex mold includes a molding projection for forming the recess having the bottom surface and the side surface rising from the bottom surface , a molding recess for forming the projection, and a molding slope for forming the inclined recess. having a convex portion ;
a corner portion between the top surface and the side surface of the molded convex portion is formed into a curved surface ;
The convex portion is formed as an elongated convex line,
A texture is formed only at a position corresponding to the inclined recess on the bottom surface of the recess.
A method for producing an uneven base material.
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JP2003013580A (en) 2001-07-02 2003-01-15 Nichiha Corp Construction plate
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