JP7240288B2 - Forming mold, press molding method for inorganic building board, and inorganic building board - Google Patents

Description

TECHNICAL FIELD The present invention relates to a mold, a press molding method for an inorganic building board, and an inorganic building board. More specifically, the present invention relates to a mold for press-molding an inorganic building board, a method of press-molding an inorganic building board, and an inorganic building board.

Patent Literature 1 describes inorganic building boards used for exterior wall materials, roof materials, and the like. Inorganic building boards are produced by press-molding a green sheet whose main component is a hydraulic material such as a cement-based material with a mold, curing it by curing to form a hardened board, and coating the surface of the hardened board with a water-based paint or the like. Manufactured by forming

JP 2016-175256 A

In inorganic building boards such as those described above, it has been desired to make it difficult for the texture and design of the surface to be impaired.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a molding die, a method for press-molding an inorganic building board, and an inorganic building board that are capable of making it difficult for the texture and design of the surface to be impaired. do.

A forming die according to an aspect of the present invention is a forming die for press-molding an inorganic building board provided with bottom joints extending to an end face while a green sheet is restrained on all four sides. It has a convex portion forming the bottom joint. The convex portion includes a reference surface on the bottom surface of the bottom joint, and a bulging portion provided at the end of the bottom joint and bulging toward the surface side of the inorganic building board from the reference surface in the bottom joint. and has a shape to mold.

A press molding method for an inorganic building board according to one aspect of the present invention uses the mold described above. A step of forming the bottom joints on the green sheet by press-molding the green sheet containing an inorganic material as a main component while restraining the four circumferences of the green sheet.

An inorganic building board according to one aspect of the present invention includes a bottom joint extending to an end face. The bottom surface of the bottom joint has a reference surface and a bulging portion that is provided at the end of the bottom joint and bulges from the reference surface to the surface side in the bottom joint.

According to the present invention, the moldability of the inorganic material is improved, and the texture and design of the surface are less likely to be impaired.

FIG. 1A is a perspective view showing a part of Embodiment 1 of the inorganic building board according to the present invention. FIG. 1B is a cross-sectional view of the XZ plane of the bottom joint portion in FIG. 1A. FIG. 2A is a sectional view showing a part of one embodiment of the press molding method according to the present invention. FIG. 2B is a cross-sectional view showing one embodiment of the mold according to the present invention. FIG. 3A is a perspective view showing a part of Embodiment 2 of the inorganic building board according to the present invention. FIG. 3B is a cross-sectional view of the XZ plane of the bottom joint portion in FIG. 3A. FIG. 4A is a perspective view showing a part of Embodiment 3 of the inorganic building board according to the present invention. FIG. 4B is a cross-sectional view of the XZ plane of the bottom joint portion in FIG. 4A. 5A to 5C are XZ-plane cross-sectional views showing modifications of the inorganic building board according to the present invention.

(Embodiment 1)
<Inorganic building board>
FIG. 1A shows an inorganic building board 1 of this embodiment. This inorganic building board 1 is used as a wall board for buildings such as houses and buildings. In particular, the inorganic building board 1 is used as an exterior wall board that constitutes the exterior wall of a building.

The inorganic building board 1 is formed with a bottom joint 2 by press-molding a flat base material made of an uncured inorganic material. The uncured inorganic material is, for example, a moldable material containing a hydraulic component such as cement, aggregate such as silica or silica powder, reinforcing fiber such as pulp or synthetic fiber, and water.

The inorganic building board 1 is formed in a square shape or a rectangular shape in plan view. Further, the inorganic building board 1 is formed in a substantially plate shape. A plan view means that the inorganic building board 1 is viewed from the surface 11 in a direction parallel to the thickness direction Z of the inorganic building board 1 . The surface 11 of the inorganic building board 1 is a surface facing outward (a surface facing away from the base) when the inorganic building board 1 is constructed.

An inorganic building board 1 has an uneven surface, and has a plurality of bottom joints 2 and a plurality of protrusions 6 . The bottom joint 2 is formed to extend in one of the directions orthogonal to the thickness direction Z. As shown in FIG. The direction in which the bottom joint 2 extends is defined as the X direction. An inorganic building board 1 has a plurality of bottom joints 2 . The plurality of bottom joints 2 are arranged in a direction perpendicular to the X direction and the thickness direction Z. As shown in FIG. The direction in which the plurality of bottom joints 2 are arranged is defined as the Y direction. In addition, below, a Z direction may be called "height direction."

The bottom joint 2 is open to the surface 11 and the end face 12 of the inorganic building board 1 . That is, the bottom joint 2 has a surface opening 21 opening to the surface 11 of the inorganic building board 1 and an end surface opening 22 opening to the end surface 12 of the inorganic building board 1 . The surface opening 21 is formed over the entire length of the inorganic building board 1 in the X direction. The end face opening 22 includes an end face opening 221 on one side of the bottom joint 2 in the X direction and an end face opening on the other side of the bottom joint 2 in the X direction. One end face opening 221 opens to one end face 121 of the inorganic building board 1 in the X direction. The other end face opening is open to the other end face of the inorganic building board 1 in the X direction.

A surface portion 111 is formed between the surface openings 21 adjacent in the Y direction. The surface portion 111 constitutes the surface of the inorganic building board 1 other than the surface opening portion 21 .

The bottom joint 2 has a bottom surface 5 and side surfaces 55 . The bottom surface 5 is formed at a position facing the surface opening 21 . The side surfaces 55 are formed to protrude toward the surface 11 from both ends of the bottom surface 5 aligned in the Y direction. The Y-direction dimension of the bottom surface 5 is smaller than the Y-direction dimension of the surface opening 21 . Therefore, the side surfaces 55 are inclined so that the distance between the two side surfaces 55 facing each other in the Y direction increases as the surface 11 is approached.

The bottom surface 5 has a reference surface 51 and an inclined portion 52 . The dimension in the Z direction (the position in the height direction) of the bottom joint 2 on the reference plane 51 is constant. On the other hand, the Z-direction dimension of the bottom joint 2 in the inclined portion 52 is formed so as to become shallower as it approaches the one end surface 121 . That is, the bottom surface 5 has an inclined portion 52 that is inclined from the reference surface 51 toward the surface 11 as the one end surface 121 is approached. The inclined portion 52 reaches one end surface 121 of the inorganic building board 1 .

The inclined portion 52 further has a flat portion 53 . The dimension of the bottom joint 2 in the flat portion 53 in the Z direction is constant. The inclined portion 52 and the flat portion 53 are surfaces formed closer to one end surface 121 of the inorganic building board 1 than the reference surface 51 is. That is, the inclined portion 52 and the flat portion 53 are formed closer to one end face opening 221 of the bottom joint 2 than the reference plane 51 is. The flat portion 53 is formed at a portion near one end surface 121 of the inclined portion 52 . That is, the flat portion 53 is formed at a portion of the inclined portion 52 near one end face opening 221 . Therefore, the inclined portion 52 reaches one end surface 121 of the inorganic building board 1 at the portion of the flat portion 53 . The bottom surface 5 is formed continuously from the reference surface 51 to the inclined portion 52 (including the flat portion 53), but the inclined portion 52 has a constant gradient with respect to the reference surface 51 except for the flat portion 53. are doing. In this specification, the term "constant" does not mean constant in a strict sense, but is a concept that includes substantially constant.

A bulging portion 50 is formed at the end of the inorganic building board 1 in the X direction. The surface of the bulging portion 50 has an inclined portion 52 (including a flat portion 53). The thickness of the bulging portion 50 is greater than the thickness of the inorganic building board 1 at the portion of the reference surface 51 . The thickness of the bulging portion 50 is smaller than the thickness of the inorganic building board 1 at the surface portion 111 . Therefore, the inclined portion 52 (including the flat portion 53) is located above the reference plane 51 and below the surface portion 111 in the Z direction. That is, the bulging portion 50 is a portion provided at the end of the bottom joint 2 and bulging toward the surface 11 of the inorganic building board 1 from the reference surface 51 in the bottom joint 2 .

The inorganic building board 1 constitutes an outer wall by being attached to a wall foundation. In this case, a plurality of inorganic building boards 1 can be arranged vertically and horizontally. A gap is provided between the end faces 12 of the adjacent inorganic building boards 1 to form a joint. This joint is filled with a sealing material to improve the waterproofness of the outer wall.

<Regarding the manufacturing method of the inorganic building board>
The inorganic building board 1 as described above can be manufactured by press-molding a green sheet 100 with a molding die 200, as shown in FIG. 2A.

The green sheet 100 can be formed by molding an uncured inorganic material into a sheet shape. The uncured inorganic material is a moldable material containing hydraulic components such as cement, aggregates such as silica and silica powder, reinforcing fibers such as pulp and synthetic fibers, and water. The green sheet 100 is obtained by molding the uncured inorganic material into a sheet by extrusion molding, papermaking, casting, or the like. Incidentally, the inorganic material is contained in a ratio of, for example, 20 to 75 parts by mass of cement, 20 to 60 parts by mass of aggregate, and 5 to 20 parts by mass of reinforcing fiber. It can contain about double the amount of water.

A mold for press molding can be used as the mold 200 . The mold 200 includes a surface mold (upper mold) 201 and a back surface mold (lower mold) 202 . One surface (lower surface) of the surface die 201 is formed as a molding surface, and a convex portion 300 for molding a molding groove portion 310 is provided on the surface 101 of the green sheet 100 . The molded groove portion 310 becomes the bottom joint 2 by hardening the green sheet 100 after molding. The back surface mold 202 has a flat surface (upper surface) on which the green sheet 100 is placed.

A plurality of protrusions 300 are provided on the molding surface of the surface mold 201 . The convex portion 300 is shaped and arranged so that the formed groove portion 310 corresponding to the bottom joint 2 extending in the X direction can be formed in the green sheet 100 . The tip end surface (lower end surface) 30 of the projection 300 forms the bottom surface of the groove 310 , and the side surface 31 of the projection 300 forms the side surface of the groove 310 . The bottom surface of the formed groove portion 310 is formed corresponding to the bottom surface 5 of the bottom joint 2 . The side surface of the formed groove portion 310 is formed corresponding to the side surface 55 of the bottom joint 2 .

In molding the green sheet 100 using the mold 200, the green sheet 100 is set on the back surface mold 202, and the surface mold 201 is brought close to the green sheet 100 from above. The molding surface of the mold 201 is pressed (pressed). As a result, the convex portion 300 bites into the surface 101 of the green sheet 100 and the forming groove portion 310 is formed in the green sheet 100 . The forming groove portion 310 is open to the front surface 101 and the end surface 102 of the green sheet 100 . The pressing pressure can be, for example, 0.01 MPa to 0.3 MPa.

Here, the green sheet 100 is press-molded with its four circumferences restrained. That is, in order to prevent the shape of the green sheet 100 from collapsing due to the pressure during press molding, the green sheet 100 is restrained so as to surround the four circumferences thereof. A rectangular frame 400 in a plan view can be used to restrain the four circumferences of the green sheet 100 , and the green sheet 100 is placed inside the frame 400 during press molding. The frame portion 400 is formed so as to protrude from the lower surface of the surface mold 201 (the surface on the side of the rear surface mold 202), and in a state where the molding surface of the surface mold 201 is pressed against the surface of the green sheet 100, the green sheet 100 is pressed on the four sides. Constrain by enclosing from

The bottom surface of the formed groove portion 310 includes a portion corresponding to the reference surface 51 of the bottom surface 5 of the bottom joint 2, a portion corresponding to the inclined portion 52 of the bottom surface 5 of the bottom joint 2, and a flat portion 53 of the bottom surface 5 of the bottom joint 2. Corresponding parts are molded. Therefore, the tip surface 30 of the convex portion 300 includes a reference surface forming portion 301 for forming a portion corresponding to the reference surface 51 of the bottom surface 5 and an inclined portion for forming a portion corresponding to the inclined portion 52 of the bottom surface 5. It has a molding portion 302 and a flat portion molding portion 303 for molding a portion corresponding to the flat portion 53 of the bottom surface 5 .

In the inclined portion forming portion 302 , the projecting dimension of the convex portion 300 gradually decreases so that the depth of the forming groove portion 310 becomes shallower as it approaches the end surface 102 of the green sheet 100 . Further, the flat portion molding portion 303 is provided at a position corresponding to the bottom surface at the X-direction end portion of the molding groove portion 310 of the convex portion 300 . Therefore, even if the inorganic material constituting the green sheet 100 is pressed by the convex portion 300 during press molding, it is likely to flow toward the inclined portion forming portion 302 and the flat portion forming portion 303, thereby improving formability and improving the inorganic building board. The texture and design of the inorganic building board 1 are hardly damaged, and chipping and chipping at the ends of the inorganic building board 1 are reduced. The green sheet 100 is sandwiched between the sloped portion forming portion 302 and the flat portion forming portion 303 and the back surface mold 202 to form a portion corresponding to the bulging portion 50 .

After forming the forming grooves 310 in the green sheet 100 as described above, the green sheet 100 is removed from the mold, and the formed green sheet 100 is cured by steam curing, autoclave curing, or the like. After that, the inorganic building board 1 having the bottom joint 2 formed by the molded groove portion 310 is formed by applying surface coating or the like.

(Embodiment 2)
The inorganic building board 1 according to the present embodiment differs from the inorganic building board 1 according to the first embodiment in the configuration of the inclined portion 52 . In the following, configurations similar to those of the first embodiment are denoted by common reference numerals, and descriptions thereof are omitted as appropriate.

In the inorganic building board 1 according to this embodiment, as shown in FIG. 3, the inclined portion 52 does not have the flat portion 53. The bottom surface 5 has an inclined portion 52 that is inclined from the reference surface 51 toward the surface 11 as it approaches the one end surface 121 . and reaches one end face 121 of the inorganic building board 1 .

In the inorganic building board 1 according to this embodiment, the inclined portion 52 is provided at the end portion of the bottom joint 2 . The inclined portion 52 is inclined from the reference surface 51 toward the surface 11 toward the end surface 12 . Therefore, the lower opening edge of the end face opening 221 of the bottom joint 2 is formed with the inclined portion 52 .

(Embodiment 3)
The inorganic building board 1 according to this embodiment differs from the inorganic building boards 1 according to the first and second embodiments in the structure of the end surface 12 . In the following, configurations similar to those of Embodiment 1 or 2 are denoted by common reference numerals, and descriptions thereof are omitted as appropriate.

In this embodiment, as shown in FIG. 4, the end surface 12 (one end surface 121) has a slope 131. As shown in FIG. The slope 131 is formed in such a shape that the corner of the end face 12 on the surface 11 side is chamfered. The slope 131 is formed as a surface of the surface portion 111 on the side of the end surface 12 . The end surface 12 is composed of a slope 131 and a vertical surface 132 below the slope 131 in the Z direction. The slope 131 slopes outward from the surface portion 111 of the inorganic building board 1 . The slope 131 is also inclined with respect to the vertical plane 132 . The slopes 131 are positioned between adjacent end face openings 221 .

(Modification)
Embodiments 1-3 are but one of various embodiments of the present invention. Embodiments 1 to 3 can be modified in various ways according to design and the like, as long as the object of the present invention can be achieved.

In the above description, the gradient of the inclined portion 52 excluding the flat portion 53 is constant with respect to the reference plane 51, but the present invention is not limited to this. The slope of the inclined portion 52 may change from the reference surface 51 to the end surface 12 . In FIG. 5A, the inclined portion 52 is formed on a surface curved concavely toward the surface 11 side. In FIG. 5B, the inclined portion 52 is formed on a surface curved convexly toward the surface 11 side. In FIG. 5C, a convex curved surface having a radius of curvature smaller than that in FIG.

In the above, the inorganic building board 1 is explained as a wall material, but it is not limited to this, and the inorganic building board 1 may be, for example, a ceiling board or a roof board.

Although the case where the wall plate is an outer wall plate has been described above, it may be an inner wall plate that forms the inner wall of the room.

In the above description, the inorganic building board 1 is a ceramic siding material, but the inorganic building board 1 may be, for example, a lightweight cellular concrete panel (ALC panel), a tile, or the like.

On the surface 11 of the inorganic building board 1 (including the bottom surface 5 and the side surface 55 of the bottom joint 2), for example, a fine uneven pattern (embossed or satin finished) may be formed.

In the above description, the inclined portion 52 and the flat portion 53 are formed corresponding to all of the plurality of bottom joints 2, but this is not the only option. A portion 53 may be formed.

In the above description, the inclined portion 52 and the flat portion 53 are formed corresponding to one end of the bottom joint 2, but the present invention is not limited to this, and the inclined portions corresponding to both ends of the bottom joint 2 52 and flat portion 53 may be formed.

Although the case where all of the plurality of bottom joints 2 extend in one direction (the X direction) has been described above, the present invention is not limited to this. 2. In the above description, the bottom joint 2 is formed over the entire length in the X direction, but the present invention is not limited to this. good.

Although all of the plurality of bottom joints 2 are open to the end face 12 of the inorganic building board 1 in the above description, the present invention is not limited to this. good.

In the press molding method described above, a suction effect may be applied to the green sheet 100 through the surface mold 201 . This makes it easier to bring the green sheet 100 into close contact with the molding surface of the surface mold 201, thereby improving moldability. In particular, when manufacturing the inorganic building board 1 with deeply carved bottom joints 2, the texture (surface properties) of the inorganic building board 1 is improved.

In the press molding method described above, the green sheet 100 may be molded while the mold 200 is vibrated. As a result, the fluidity of the inorganic material forming the green sheet 100 is improved, and the moldability is improved. In particular, when manufacturing the inorganic building board 1 with deep bottom joints 2, the formation (surface property) of the inorganic building board 1 is improved.

(summary)
As described above, the molding die 200 according to the first aspect is a molding die for press-molding the inorganic building board 1 having the bottom joint 2 extending to the end face 12 in a state in which the green sheet 100 is constrained on all four sides. 200. It has a convex portion 300 forming the bottom joint 2 . The convex portion 300 is provided on the bottom surface 5 of the bottom joint 2, the reference surface 51, and the end portion of the bottom joint 2, and protrudes from the reference surface 51 to the surface 11 side of the inorganic building board 1 in the bottom joint 2. It has a shape that molds the bulging portion 50 .

According to this aspect, since the bulging portion 50 is formed at the end of the bottom joint 2 and bulges toward the surface 11 side of the inorganic building board 1 from the reference surface 51 in the bottom joint, green The fluidity of the inorganic material forming the sheet 100 to the end portion of the bottom joint 2 is improved, and the moldability is improved. Therefore, the texture and design of the surface 11 of the inorganic building board 1 are less likely to be impaired.

In the first aspect, the forming die 200 according to the second aspect has a slanted portion 52 on the bulging portion 50 that is inclined toward the surface 11 side of the inorganic building board 1 as the end face 12 is approached. It has a shape to mold.

According to this aspect, the fluidity of the inorganic material forming the green sheet 100 to the end portion of the bottom joint 2 is improved, and the moldability is improved. Therefore, the texture and design of the surface 11 of the inorganic building board 1 are less likely to be impaired.

In the second aspect, the mold 200 according to the third aspect has a shape in which the convex portion 300 further molds a flat portion 53 whose surface is substantially parallel to the reference plane 51 on the side of the end surface 12 of the inclined portion 52. have.

According to this aspect, the fluidity of the inorganic material forming the green sheet 100 to the end portion of the bottom joint 2 is improved, and the moldability is improved. Therefore, the texture and design of the surface 11 of the inorganic building board 1 are less likely to be impaired.

The press molding method for the inorganic building board 1 according to the fourth aspect uses any one of the first to third molds 200 . It includes a step of forming bottom joints 2 on the green sheet 100 by press-molding the green sheet 100 whose main component is an inorganic material while restraining the four circumferences of the green sheet 100 .

According to this aspect, the fluidity of the inorganic material forming the green sheet 100 to the end portion of the bottom joint 2 is improved, and the moldability is improved. Therefore, the texture and design of the surface 11 of the inorganic building board 1 are less likely to be impaired.

An inorganic building board 1 according to the fifth aspect includes a bottom joint 2 reaching an end face 12 . The bottom surface 5 of the bottom joint 2 has a reference surface 51 and a bulging portion 50 that is provided at the end of the bottom joint 2 and bulges toward the surface 11 from the reference surface 51 in the bottom joint 2 .

According to this aspect, the appearance of the bottom joint 2 can be changed by the bulging portion 50, and the design can be easily improved.

In the inorganic building board 1 according to the sixth aspect, in the fifth aspect, the bulging portion 50 has an inclined portion 52 inclined from the reference surface 51 toward the end surface 12 toward the surface 11 side.

According to this aspect, the appearance of the bottom joint 2 can be changed by the inclined portion 52, and it is easy to improve the design.

In the inorganic building board 1 according to the seventh aspect, in the sixth aspect, the inclined portion 52 further has a flat portion 53 whose surface is substantially parallel to the reference plane 51 on the side of the end surface 12 .

According to this aspect, the appearance of the bottom joint 2 can be changed by the flat portion 53, and it is easy to improve the design.

REFERENCE SIGNS LIST 1 inorganic building board 11 surface 12 end surface 2 bottom joint 5 bottom surface 50 bulging portion 51 reference surface 52 inclined portion 53 flat portion 100 green sheet 200 mold 300 convex portion

Claims (7)

A mold for press-molding an inorganic building board having bottom joints extending to the end face while restraining the four circumferences of the green sheet,
Having a convex portion for forming the bottom joint,
The convex portion includes a reference surface on the bottom surface of the bottom joint, and a bulging portion provided at the end of the bottom joint and bulging toward the surface side of the inorganic building board from the reference surface in the bottom joint. and having a shape that molds
molding mold. The convex portion has a shape that forms an inclined portion that inclines toward the surface side of the inorganic building board as it approaches the end face.
The mold of Claim 1. The convex portion has a shape in which a flat portion whose surface is substantially parallel to the reference plane is further formed on the end surface side of the inclined portion.
The mold of Claim 2. A step of forming the bottom joint on the green sheet by press-molding the green sheet containing an inorganic material as a main component with the four circumferences restrained using the mold according to any one of claims 1 to 3. include,
A press molding method for inorganic building boards. Equipped with a bottom joint that reaches the end face,
The bottom surface of the bottom joint is
a reference surface;
a bulging portion that is provided at the end of the bottom joint and bulges toward the surface side from the reference surface in the bottom joint,
Inorganic building board. The bulging portion has an inclined portion that inclines from the reference surface toward the end surface side toward the surface side,
The inorganic building board according to claim 5. The inclined portion further has a flat portion on the end face side, the surface of which is substantially parallel to the reference plane,
The inorganic building board according to claim 6.

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