JPH0245124A - Manufacture of water-permeable sheet with patterns - Google Patents
Manufacture of water-permeable sheet with patternsInfo
- Publication number
- JPH0245124A JPH0245124A JP19589588A JP19589588A JPH0245124A JP H0245124 A JPH0245124 A JP H0245124A JP 19589588 A JP19589588 A JP 19589588A JP 19589588 A JP19589588 A JP 19589588A JP H0245124 A JPH0245124 A JP H0245124A
- Authority
- JP
- Japan
- Prior art keywords
- sheet
- water
- mold
- permeable sheet
- composite sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 6
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 19
- 238000007666 vacuum forming Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 239000002131 composite material Substances 0.000 abstract description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 8
- 238000000465 moulding Methods 0.000 abstract description 7
- 239000000463 material Substances 0.000 description 18
- 239000004567 concrete Substances 0.000 description 10
- 239000011148 porous material Substances 0.000 description 9
- 239000011381 foam concrete Substances 0.000 description 8
- 239000004744 fabric Substances 0.000 description 7
- 239000002344 surface layer Substances 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000011162 core material Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Panels For Use In Building Construction (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Producing Shaped Articles From Materials (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
この発明は軽量発泡コンクリート板等の表面に凹凸模様
を形成する際用いられる模様付透水性シートの製法に関
するものである。DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a water-permeable patterned sheet used for forming an uneven pattern on the surface of a lightweight foamed concrete plate or the like.
軽量発泡コンクリート板は、一般にプレハブ住宅の壁材
等として用いられている。この種の軽量発泡コンクリー
ト板２０は、芯材となる鉄筋２１をコンクリート部で包
含した構造になっており、第７図に示すように、コンク
リート部の内部に多数の気泡を有している。そして、こ
の気泡が通水路となるため、住宅に施工後、屋外側から
大気中の水分等が気泡を通って入り込み、芯体となって
いる鉄筋２１等を発錆させ、その発錆にもとづく鉄筋２
１の膨張によって、ひびが入るというような難点を有し
ている。このような問題を解決するため、第８図に示す
ように軽量発泡コンクリート板２０の外表面に塗料等の
塗膜２２を形成し、水分等の侵入を防止することが考え
られている。しかしながら、いちいち軽量発泡コンクリ
−１反２０の外表面に上記のような塗膜２２を形成する
ことは、工程が複雑になり、製品のコスト上昇の原因と
なる。Lightweight foamed concrete plates are generally used as wall materials for prefabricated houses. This type of lightweight foamed concrete board 20 has a structure in which a concrete portion contains reinforcing bars 21 serving as a core material, and as shown in FIG. 7, the concrete portion has a large number of air bubbles inside. Since these air bubbles become water passages, after construction is completed in a house, moisture from the atmosphere enters through the air bubbles from the outside, causing the reinforcing bars 21, etc. that form the core to rust. Rebar 2
The problem is that cracks form due to the expansion of 1. In order to solve this problem, it has been considered to form a coating film 22 of paint or the like on the outer surface of the lightweight foam concrete board 20 to prevent moisture from entering, as shown in FIG. However, forming the coating film 22 as described above on the outer surface of each 1-20 piece of lightweight foamed concrete complicates the process and causes an increase in the cost of the product.
そこで最近では、第９図に示すように、連通気孔を有す
る成形型２３にコンクリート材料を注型し、成形型２３
の下方から矢印のように吸引するに際して、成形型２３
の表面に帆布等の布材２５を載置し、この布材２５の微
細気孔によって布材２５に接する部分の密度を高めこの
部分を外壁側に使用するという技術が開発されている。Therefore, recently, as shown in FIG. 9, concrete material is poured into a mold 23 having communicating holes.
When suctioning from below in the direction of the arrow, the mold 23
A technique has been developed in which a cloth material 25 such as canvas is placed on the surface of the cloth material 25, and the density of the portion in contact with the cloth material 25 is increased by the fine pores of the cloth material 25, and this portion is used for the outer wall side.
ところが、上記のように布材２５等を用いて外表面層の
高密度化を図る場合、外表面が平坦であれば問題はない
が、外表面に凹凸模様を形成する場合には、布材２５が
模様の凹凸に沿わず凹凸模様部分でしわが生ずるため、
外表面に模様を有しかつその外表面層が緻密になってい
る模様付コンクリート板を製造することは不可能視され
ている。However, when trying to increase the density of the outer surface layer using the cloth material 25 etc. as described above, there is no problem as long as the outer surface is flat, but when forming an uneven pattern on the outer surface, the cloth material 25 etc. 25 does not follow the unevenness of the pattern and wrinkles occur in the uneven pattern area,
It has been considered impossible to produce a patterned concrete plate which has a pattern on its outer surface and whose outer surface layer is dense.
この発明者は、上記のような布材に代えて、微細気孔が
全体に分布形成されている熱可塑性樹脂シートからなる
透水性シートに凹凸模様を形成し、この模様付透水性シ
ートを成形型の成形用凹部内に両凹凸模様を合致させた
状態で敷設し、その模様付透水性シートが敷設された成
形用凹部内にコンクリート材料を注型すれば立体的な凹
凸模様を有する軽量コンクリート板が得られると着想し
一連の研究を重ねた。しかしながら、上記透水性シート
は、全体に微細孔が形成されているため、これを成形型
の型面の凹凸模様に合致するように正確に成形すること
は殆ど不可能であった。Instead of the above-mentioned cloth material, the inventor formed an uneven pattern on a water-permeable sheet made of a thermoplastic resin sheet in which fine pores are distributed throughout, and then molded the patterned water-permeable sheet into a mold. A lightweight concrete board with a three-dimensional uneven pattern can be obtained by laying the concave and convex patterns in a matching pattern in the forming concavity, and by pouring concrete material into the forming concave where the patterned water-permeable sheet is laid. I came up with the idea that this would be possible and conducted a series of studies. However, since micropores are formed throughout the water-permeable sheet, it is almost impossible to accurately mold it to match the uneven pattern of the surface of the mold.
この発明は、このような事情に鑑みなされたもので、所
定の凹凸模様を正確に形成しうる模様付透水性シートを
製造する方法の提供をその目的とする。The present invention was made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a patterned water-permeable sheet that can accurately form a predetermined uneven pattern.
この発明は、上記の目的を達成するため、型面に凹凸模
様を有する真空成形型の上記型面に、加熱軟化状態の熱
可塑性樹脂製透水性シートを密封対面させ、上記型面と
熱可塑性樹脂製透水性シートとに囲われた空間を真空吸
引する真空成形法において、上記熱可塑性樹脂製透水性
シートの型面と反対側の面に、上記透水性シートと略同
じ軟化点の熱可塑性樹脂製気体不透過性シートを重ね、
その状態で両シートを加熱軟化状態にして型面に対面さ
せ真空吸引するという構成をとる。In order to achieve the above-mentioned object, the present invention has a vacuum forming mold having an uneven pattern on the mold surface, and a water-permeable sheet made of a thermoplastic resin in a heat-softened state is brought into sealing contact with the mold surface of the vacuum molding mold. In a vacuum forming method in which a space surrounded by a water-permeable resin sheet is vacuum-suctioned, a thermoplastic resin having approximately the same softening point as the water-permeable sheet is placed on the surface opposite to the mold surface of the water-permeable thermoplastic resin sheet. Layering resin gas impermeable sheets,
In this state, both sheets are heated to a softened state, then placed facing the mold surface and vacuum-suctioned.
この発明者は、透水性シートに所定の凹凸模様を正確に
形成しうる方法の開発について一連の研究を重ねた結果
、真空成形法が好適であることをつきとめた。しかしな
がら、真空成形法によって透水性シートを成形しようと
する場合、透水性シートは、全体に微細孔が形成され気
体流通性を有しているため真空成形法にかけることがで
きない。そこで、さらに研究を重ねた結果、その透水性
シートと略同じ軟化点の気体不透過性の熱可塑性樹脂製
シートを上記透水性シートに重ねて複合シート化し、こ
れを真空成形にかけると、複合シート全体に正確な凹凸
模様が形成され、したがってその複合シートから熱可塑
性樹脂製気体不透過性シートを剥離すると、正確な凹凸
模様が転写形成された透水性シートが得られることを見
いだしこの発明に到達した。The inventor conducted a series of studies to develop a method for accurately forming a predetermined uneven pattern on a water-permeable sheet, and as a result, found that a vacuum forming method was suitable. However, when attempting to form a water-permeable sheet using a vacuum forming method, the water-permeable sheet cannot be subjected to the vacuum forming method because micropores are formed throughout the sheet and it has gas flowability. Therefore, as a result of further research, a gas-impermeable thermoplastic resin sheet with approximately the same softening point as the water-permeable sheet was layered on the water-permeable sheet to form a composite sheet, and when this was vacuum-formed, a composite sheet was created. It was discovered that an accurate uneven pattern is formed on the entire sheet, and therefore, when a gas-impermeable thermoplastic resin sheet is peeled from the composite sheet, a water-permeable sheet with an accurate uneven pattern transferred thereon can be obtained, and this invention is based on this discovery. Reached.
つぎに、実施例について説明する。Next, examples will be described.
第１図はこの発明に用いる熱可塑性樹脂製透水性シー）
１に、この透水性シート１と略等しい軟化点を有する熱
可塑性樹脂製気体不透過性シート２を重ね両シートの静
電気力を利用し複合シート３′化する状態を示している
。上記透水性シート１としては、ポリエチレン、ポリプ
ロピレン等の熱可塑性樹脂からなる厚み０．３〜２．０
ｍｍ、好適には０．５〜１．０ ｍｍのフィルム状シー
トが用いられる。また、気体不透過性のシート２として
も上記透水性シート１と略同じ材料が用いられる。この
場合、気体不透過性シート２は、上記透水性シート１と
略等しい軟化点を有するものが用いられる。Figure 1 shows a thermoplastic resin water-permeable sheet used in this invention)
1 shows a state in which a gas-impermeable thermoplastic resin sheet 2 having approximately the same softening point as the water-permeable sheet 1 is stacked to form a composite sheet 3' using the electrostatic force of both sheets. The water permeable sheet 1 is made of thermoplastic resin such as polyethylene or polypropylene and has a thickness of 0.3 to 2.0.
A film-like sheet having a diameter of 0.5 mm to 1.0 mm is used. Furthermore, substantially the same material as the water-permeable sheet 1 is used as the gas-impermeable sheet 2. In this case, the gas-impermeable sheet 2 used has approximately the same softening point as the water-permeable sheet 1.
ここで略等しい軟化点とは、両者の差が１０°Ｃ以下の
場合をいい、好適には２〜７°Ｃの範囲内である。成形
性の点で気体不透過性シート２の軟化点よりも透水性シ
ート１の軟化点の方が低いことが好ましい。そして、両
シートの組み合わせは、同種の材料であってもよいし異
種材料であってもよい。また、上記透水性シート１には
、１００メツシユ以下の微細な気孔が全面に分布形成さ
れており、この微細孔の分布成形によりフィルム状シー
トの全体が透水性を帯びている。ここで上記微細孔は、
加熱軟化により開孔しないことが重要であり、真空成形
に際しての加熱軟化処理により多少開孔しても結果的に
１００メツシユ以下の孔径になっていることが好適であ
る。通常は、上記微細孔が開孔しないような加熱軟化条
件が設定される。Here, substantially equal softening points refer to a case where the difference between the two is 10°C or less, preferably within the range of 2 to 7°C. From the viewpoint of moldability, it is preferable that the softening point of the water-permeable sheet 1 is lower than that of the gas-impermeable sheet 2. The combination of both sheets may be of the same type of material or of different types of materials. Furthermore, the water-permeable sheet 1 has fine pores of 100 meshes or less distributed over the entire surface, and the distribution of the fine pores makes the entire film-like sheet water-permeable. Here, the above micropores are
It is important that pores do not open due to heat softening, and even if some pores open due to heat softening during vacuum forming, it is preferable that the resulting pore diameter is 100 mesh or less. Usually, heating softening conditions are set such that the fine pores do not open.
この発明は、上記複合シート３′を第２図に示すような
真空成形型３１の型面に、透水性シート１を下側にした
状態で取りつけ、その状態で上方からヒーター３２で加
熱して全体を加熱軟化状態にする。３１ａは複合シート
３′の保持治具である。ついで、その状態から第３図に
示す矢印のように真空吸引して複合シート３′の全体を
真空成形型３１の型面の凹凸模様（凹凸模様は図示の都
合上省略しである。）に沿わせて熱変形させ成形する。In this invention, the above-mentioned composite sheet 3' is attached to the mold surface of a vacuum forming mold 31 as shown in FIG. Heat and soften the entire body. 31a is a holding jig for the composite sheet 3'. Then, from this state, the entire composite sheet 3' is vacuum-suctioned as shown by the arrow in FIG. It is then heat-deformed and molded.
つぎに、型を冷却して複合シート３′の全体を初期の硬
度に戻し、ついで第４図に矢印で示すように真空成形型
３１内に空気を吹き込み複合シート３′を成形させる。Next, the mold is cooled to return the entire composite sheet 3' to its initial hardness, and then air is blown into the vacuum mold 31 as shown by the arrow in FIG. 4 to form the composite sheet 3'.
このようにして複合シート３′の全体が真空成形され、
凹凸模様が転写形成される。つぎに、得られた複合シー
ト３′から気体不透過性シート２を剥離除去する。その
結果第５図に示すように、凹凸模様が転写形成された透
水性シート１が得られるようになる。この透水性シート
１は、自己保形性を有しており、転写形成された凹凸模
様は、その凹凸模様形状を保持する。In this way, the entire composite sheet 3' is vacuum formed,
An uneven pattern is transferred and formed. Next, the gas impermeable sheet 2 is peeled off and removed from the obtained composite sheet 3'. As a result, as shown in FIG. 5, a water-permeable sheet 1 having an uneven pattern transferred thereon can be obtained. This water-permeable sheet 1 has self-shape retention, and the transferred uneven pattern retains its shape.
なお、上記の実施例では、透水性シート１と気体不透過
性シート２との複合化は、シートを構成する熱可塑性樹
脂自体の静電気力によって行われているが、接着力の弱
い接着剤を使用し複合化するようにしても差し支えはな
い。In the above embodiment, the water-permeable sheet 1 and the gas-impermeable sheet 2 are combined using the electrostatic force of the thermoplastic resin itself that constitutes the sheet. There is no problem in using and compounding them.
このようにして得られた模様付透水性シート１は、第６
図に示すように透水性材料製４の成形型３の成形用凹部
３ａ内に、その成形用凹部３ａの転写用凹凸模様に透水
性シート１の凹凸模様を合致させた状態で着脱自在に敷
設され、その成形用凹部３ａに、発泡剤入りコンクリー
ト材料１１を注型し、成形するという用途に用いられる
。この注型成形の際、成形型３内において、コンクリー
ト材料１１は、真空吸引によって水分や空気を除去され
る。特に、透水性シート１に接した部分１１ａは、透水
性シート１の凹凸模様を転写されると同時に、水分や気
泡を他の部分よりも強く除去され高密度化される。この
ようにして成形された材料は、上記成形型３から成形さ
れ、養生硬化され、模様付軽量コンクリート板に形成さ
れる。第６図において、５．６は枠材、７は真空用吸引
用空間、８は桟材、９はボルト、１０は真空吸引ノズル
である。The patterned water permeable sheet 1 thus obtained is
As shown in the figure, the water-permeable sheet 1 is removably laid in the molding recess 3a of the mold 3 made of water-permeable material 4, with the projection-recess pattern of the water-permeable sheet 1 matching the transcription-recess pattern of the molding recess 3a. The concrete material 11 containing a foaming agent is poured into the molding recess 3a and used for molding. During this cast molding, moisture and air are removed from the concrete material 11 in the mold 3 by vacuum suction. Particularly, the portion 11a in contact with the water-permeable sheet 1 has the uneven pattern of the water-permeable sheet 1 transferred thereto, and at the same time, moisture and air bubbles are removed more strongly than other portions, thereby increasing the density. The material thus molded is molded from the mold 3, cured and cured to form a patterned lightweight concrete plate. In FIG. 6, 5.6 is a frame material, 7 is a vacuum suction space, 8 is a crosspiece, 9 is a bolt, and 10 is a vacuum suction nozzle.
このようにして得られるコンクリート板（図示せず）は
、内部に気泡が分布していて軽量化され、かつ表面層（
ｌｌａ＜第６図参照））が凹凸模様状に形成されている
と同時に、水分等の浸透を防止するよう高密度化されて
いる。The concrete plate (not shown) obtained in this way has air bubbles distributed inside and is lightweight, and the surface layer (
lla (see FIG. 6)) is formed in an uneven pattern, and at the same time is highly dense to prevent penetration of moisture and the like.
なお、上記模様付透水性シート１は使い捨てであるため
、その透水性シート１の微細孔が目づまりした時には、
直ちに交換して操業を継続することができる。In addition, since the patterned water permeable sheet 1 is disposable, when the micropores of the water permeable sheet 1 become clogged,
It can be replaced immediately and operations can continue.
以上のように、この発明は、熱可塑性樹脂製透水性シー
トを真空成形するに際し、そのシートと略同じ軟化点を
有する気体不透過性の熱可塑性樹脂製シートを重ねて複
合化し、その状態で真空成形に掛けるため、微細孔が分
布形成されていて本来的に真空成形に適さない透水性シ
ートに対しても、所定の凹凸模様を正確に形成しうるよ
うになる。As described above, when vacuum forming a water-permeable thermoplastic resin sheet, gas-impermeable thermoplastic resin sheets having approximately the same softening point as the sheet are layered to form a composite, and in that state, Because it is subjected to vacuum forming, it becomes possible to accurately form a predetermined uneven pattern even on a water-permeable sheet that is inherently unsuitable for vacuum forming because it has minute pores distributed in it.
第１図はこの発明に用いる透水性シートと気体不透過性
シートとの複合シート化の説明図、第２図、第３図、第
４図はその真空成形説明図、第５図はそれによって得ら
れた模様付透水性シートの断面図、第６図はその模様付
透水性シートを用いて軽量発泡コンクリート板を製造す
る説明図、第７図は従来の軽量発泡コンクリート板の断
面図、第８図はそれの表面に塗膜を形成した断面図、第
９図は外表面層が高密度化された従来の軽量発泡コンク
リート板の製造状態説明図である。
１・・・透水性シート ２・・・気体不透過性シート３
・・・複合シート
１・・・真空成形型
ａ・・・取
付治具Fig. 1 is an explanatory diagram of forming a composite sheet of a water-permeable sheet and a gas-impermeable sheet used in this invention, Figs. A cross-sectional view of the obtained patterned water-permeable sheet, FIG. 6 is an explanatory diagram of manufacturing a lightweight foamed concrete board using the patterned water-permeable sheet, and FIG. 7 is a cross-sectional view of a conventional lightweight foamed concrete board. FIG. 8 is a cross-sectional view showing a coating film formed on the surface of the same, and FIG. 9 is an explanatory diagram of the manufacturing state of a conventional lightweight foamed concrete plate having a high-density outer surface layer. 1... Water-permeable sheet 2... Gas-impermeable sheet 3
...Composite sheet 1...Vacuum forming mold a...Mounting jig
Claims (1)
、加熱軟化状態の熱可塑性樹脂製透水性シートを密封対
面させ、上記型面と熱可塑性樹脂製透水性シートとに囲
われた空間を真空吸引する真空成形法において、上記熱
可塑性樹脂製透水性シートの型面と反対側の面に、上記
透水性シートと略等しい軟化点を有する熱可塑性樹脂製
気体不透過性シートを重ね、その状態で両シートを加熱
軟化状態にして上記型面に対面させ真空吸引することを
特徴とする模様付透水性シートの製法。(1) A thermoplastic resin water-permeable sheet in a heat-softened state is placed in a sealing manner on the mold surface of a vacuum forming mold having an uneven pattern on the mold surface, and the thermoplastic resin water-permeable sheet is surrounded by the mold surface and the thermoplastic resin water-permeable sheet. In a vacuum forming method in which a space is vacuum-suctioned, a gas-impermeable thermoplastic resin sheet having a softening point approximately equal to that of the water-permeable sheet is placed on the surface opposite to the mold surface of the water-permeable thermoplastic resin sheet. A method for manufacturing a patterned water-permeable sheet, which comprises stacking the sheets, heating and softening both sheets in that state, facing the mold surface, and applying vacuum suction.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19589588A JPH0245124A (en) | 1988-08-04 | 1988-08-04 | Manufacture of water-permeable sheet with patterns |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19589588A JPH0245124A (en) | 1988-08-04 | 1988-08-04 | Manufacture of water-permeable sheet with patterns |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0245124A true JPH0245124A (en) | 1990-02-15 |
Family
ID=16348774
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19589588A Pending JPH0245124A (en) | 1988-08-04 | 1988-08-04 | Manufacture of water-permeable sheet with patterns |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0245124A (en) |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5729419A (en) * | 1980-07-31 | 1982-02-17 | Nissan Motor Co Ltd | Molding method of interior fitting |
| JPS57102307A (en) * | 1980-12-16 | 1982-06-25 | Mitsubishi Monsanto Chem Co | Production of perforated container made of synthetic resin |
-
1988
- 1988-08-04 JP JP19589588A patent/JPH0245124A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5729419A (en) * | 1980-07-31 | 1982-02-17 | Nissan Motor Co Ltd | Molding method of interior fitting |
| JPS57102307A (en) * | 1980-12-16 | 1982-06-25 | Mitsubishi Monsanto Chem Co | Production of perforated container made of synthetic resin |
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