JPH0470097B2 - - Google Patents

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a tool for molding an article by applying pressure to a basic material, particularly a plate or sheet material, such as a tool for a vacuum forming press machine or Regarding types.

BACKGROUND OF THE INVENTION Pressing tools typically include a female die or die and a male die, but if the article to be molded has a complex shape, the tool parts may also have a correspondingly complex shape. is necessary. Furthermore, such tool parts need to be made of a material with mechanical properties capable of retaining their geometry and transmitting the required pressure to the sample. Conventionally, press tools are made of steel, and the molded surfaces of the tools are finished by various machining processes, such as milling, grinding, polishing, etc.

(Problem to be solved by the invention) It is also known to use a model to mold the working surface of a press tool into a desired shape. Although this molding process is simple in principle, it is often with difficulties. Obtaining precisely shaped surfaces with foundry melts (cast iron, glass, ceramics), which become liquid at high temperatures and solidify into hard, durable materials, results in excessive thermal volume changes during solidification. On the other hand, most of the casting materials that can be molded at room temperature and harden or set at room temperature either lack their mechanical strength (gypsum, Bakelite) or have poor health or Causes environmental problems (epoxy).

SUMMARY OF THE INVENTION According to the present invention, novel, extremely strong and dense materials, in particular
DK79/00047 (Japanese Patent No. 1419493, Special Publication No. 1983)
-59182), and international patent application PCT/
The cement-bonded materials disclosed in DK81/00048 (Japanese Patent Publication No. 57-500645) and others (the disclosure of which is also referred to herein) are surprisingly suitable for tools for molding articles by press. It has been found that it is suitable for this purpose and has characteristics and performance that have been desired but not yet available. These materials are hereinafter referred to as "DSP materials" in this specification and claims. this
DSP materials exhibit far superior casting ability compared to ordinary cement-based materials and are therefore extremely easy to mold. Besides, DSP
The material has a compressive strength of 4% compared to ordinary cement-based products.
Compressive strengths up to ~6 times higher can be achieved, and in special embodiments, the yield stress of iron (approximately
260MPa) and exhibits far superior casting ability than ordinary cement-based materials. The surface structure of the model to which the material is applied is reproduced with great precision. Therefore, if cast precisely, even a fingerprint can be accurately reproduced. In addition to providing the external dimensional limits required for these tools, DSP materials can also be used to incorporate cement-based materials into other components, for example in the form of rods, fibers, etc., to impart sturdiness to the material in a very simple manner. can be mixed inside. It is also very easy to incorporate thin pipes or small channels into the material to introduce liquid or gaseous bodies into or out of the molding zone, and even in materials with high hardness such as steel or hard metal bodies. Components may also be incorporated into zones subject to particularly high loads during the press molding process.

High quality molding tools are often expensive to manufacture and are therefore usually only economical when molding a large number of products. Often there is a demand for the production of a small number of products and in such cases this new, high quality, cement-based DSP product is cheap, quick and easy to prepare tooling and requires special means. It offers promising possibilities as it does not require

Thus, according to the invention, there is provided a tool for molding a product from a base material, the molding tool itself having at least one molded surface, and at least a portion of the tool comprising the molded surface. is composed of a cured product of the following hydraulic composite material, and this hydraulic composite material comprises inorganic solid particles A (hereinafter referred to as "particles A") having a particle size of 50 Å to 0.5 μm. ) and solid particles B (hereinafter referred to as "particles B") containing cement having a particle size of 0.5 to 100 μm and at least one order larger than particles A.
, a surface-active dispersant, compact-shaped solid particles with dimensions of 100 μm to 0.1 m (hereinafter referred to as "particles C"), and water, and the amount of particles A is such that particles B and C are the above-mentioned composite. An amount that is less than or equal to the amount that can fill the void between particles B and C when they are densely packed in a material without being substantially deformed, in contact with each other, and with substantially no bridging phenomenon. and the amount of water is such that the particles B and C are densely packed as specified in the above composite material and the tightly packed particles B and C are dissolved in the surface active dispersant below.
The amount of surface-active dispersant is the amount that just fills the voids formed between particles A, B, and particle C when particles A are uniformly distributed in the voids between them. is sufficient to achieve a dense packing of particles B and C as specified above and a uniform distribution of particles A as specified above, and particle C has a strength greater than that of ordinary sand and stone for ordinary concrete. Specifically, the following criteria: When evaluating particles of a material whose size ratio of maximum to minimum particle size does not substantially exceed 4, at a solids loading rate of 0.70, 30 MPa or more, and at a solids loading rate of 0.75, 50 MPa As described above, at a solid filling rate of 0.80, at least one of the following is required: a die pressure of 90 MPa or more, a Mohs hardness of more than 7 (related to the minerals that make up the particles C), and a Knoop indentation hardness of more than 800 (related to the minerals that make up the particles C). It has the strength to meet the requirements.

In the above, strictly speaking, the amount of water should satisfy the above definition with the surface-active dispersant dissolved, but the amount of surface-active dispersant is
Since the amounts are extremely small compared to the amounts of B, C and water, the increase or decrease in volume due to water dissolving the surface active dispersant can be practically ignored. Therefore, when determining the amount of water in the composite material used in the present invention, the influence of the surface active dispersant can be ignored in calculations.

Similarly, according to the invention, the hydraulic composite material is cast into a mold whose shape is shaped at least in part by means of a model of the product to be produced by a molding tool, and then cured. A method for manufacturing a molded tool is also provided, characterized in that it forms at least a molded surface of the tool.

The hydraulic material in one preferred embodiment comprises an additional component (component D) having at least one dimension that is at least one order of magnitude larger than the particles A.

In the molding tool of the present invention, the molding surface of the tool for molding a base material into a product is constructed using a cured product of a hydraulic composite material. The entire tool may be made from hydraulic composite material, but at least the molding surface for molding is made from hydraulic composite material.

(Description of the principle of the invention) DSP (Densified Systems) in the present invention
containing homogeneously arranged ultrafine
Particles) material or hydraulic composite material, the constituent particles A (e.g. silica dust),
The explanation will be as follows, taking into account the particles B (eg, Portland cement) and the surface active dispersant (super plasticizer). First, as shown in Figure 17 A and B, the particles B (Portland cement) are densely packed and the particles B
If particles A (silica dust), which are finer than particles B (Portland cement), are distributed in the voids between particles (Portland cement), the solid filling rate (density) of the system will improve, and the compressive strength will also improve. That is clear. Previous attempts have been made to achieve this kind of dense packing, including the use of surface-active dispersants, ultrafine particles, and low water ratios, but none of them actually achieved the desired results. filling was never realized.

In contrast, in the present invention, the above-mentioned ideal packing is achieved by using a larger amount of surface-active dispersant (superplasticizer) than previously thought, and by reducing the amount of water used to achieve the above ideal packing. B (Portland cement) and uniformly distributed particles A
This is achieved by specifying the amount of silica dust that just fills the voids between the particles. Since the particles A are so fine that they actually exist as aggregated secondary particles, an extremely large amount of surface-active dispersant is required to uniformly disperse them as primary particles due to their surface area. Furthermore, it seems difficult to obtain the plastic or fluid consistency necessary for workability at the beginning of mixing, so if a large amount of water is used, a dense packing may not be obtained in the end.

This results in a dense packing of particles B (Portland cement), made possible by the use of very large amounts of surface-active dispersants and very small amounts of water, and particles A (silica) evenly distributed in the interstices between them. Observation of the fracture surface of a hardened product obtained by using ordinary sand or stone, which is used in conventional Portland cement, as an aggregate and a matrix of a system of Instead of avoiding rocks and rocks and sinking into the matrix, the process progressed by breaking the aggregate. What this means is that the breaking strength and adhesion to aggregate of the DSP material obtained by the above principle are greater than the breaking strength of ordinary sand and ordinary stone. This kind of thing is impossible with conventional Portland cement systems.

Furthermore, this hydraulic composite material (DSP material)
When applied to a model as a material with a plastic or fluid consistency and cured, it has been found to have the property of reproducing the surface structure of the model with extreme precision, and even human fingerprints and the grooves of a record can be reproduced accurately. did. This is because shrinkage during curing can be ignored due to the presence of ultrafine particles (silica dust) and the absence of unnecessary water.

Two surprising properties of this hydraulic composite material (DSP material) (therefore, this composite material should no longer be considered as a new composite material belonging to a different category from conventional cement materials) By using aggregate with a higher hardness than ordinary sand or ordinary stone used in conventional cement-based products, the compressive strength of the hardened product is lower than that of ordinary cement-based products. The strength can be as high as 4 to 6 times, and in special embodiments, it has been able to match the yield stress of iron. Therefore, if it has this high compressive strength and the property that it can be easily molded into complex and precise shapes (this hydraulic composite material can be cast molded like ordinary cement-based materials), it will be possible to Steel forming tools (bending and drawing molds, etc.)
An inexpensive molding tool is provided that is particularly useful for molding small to medium number of products.

Manufacturing tools or molds used for press working of iron plates, etc. by cast molding of cement-based hydraulic composite materials instead of machining steel is a new and previously unanticipated technology. Yes, and its usefulness is extremely high.

Here, in the present invention, the dense packing of the cured product obtained by the hydraulic composite material consists of particles A, particles B,
In defining the amounts of particles C, surface-active dispersant, and water themselves, as already defined, and reference can be made to FIG. In other words, particles B and C are in a state of being densely packed with each other in substantial contact with each other without any cross-linking phenomenon, and in other words, particles B and C exert a cohesive force to form secondary particles. It is obtained by densely packing particles B and C in a state that is completely nullified by a surface-active dispersant. At this time, the particles physically entangle each other to form a bridge, forming an aggregate of particles. In order to express that no abnormal cavities are formed inside the particles, it is stipulated that the particles "substantially contact" but there is no "bridging phenomenon." Another way of expressing this is that "the particles Assuming that the particles have a geometrically similar shape and are large enough that the fixing surface force does not work significantly, the filling obtained by applying gentle mechanical vibration to the system of large particles and the substantial "filling similar to"
That's what it means.

On the other hand, when the particles A are packed, they are uniformly dispersed in the voids formed between the densely packed particles B and C. Particle A is characterized in that it does not locally aggregate itself to form secondary particles, but is uniformly distributed in the voids as primary particles,
Particles A are not necessarily tightly packed.

For details of this dense packing, please refer to
Reference should be made to Publication No. 59182, but for reference, the close packing of particles achieved in hydraulic composites cannot be expressed in specific quantities, but is practical and useful. One such technique is as follows. That is, although the particle system of the composite material of the present invention consists of particles A and particles B and C, the degree of filling of this particle system can be expressed by the degree of filling of particles B and C. The degree of filling of particles B and C is actually determined as follows. In other words, a system is created in which the voids between particles are completely filled with liquid and the particles are packed (distributed) as densely as possible by removing the effect on the particle surface using methods such as using a surface-active dispersant. Create it. It is easy to determine the packing ratio of particles from this system. In this case, the liquid does not need to be water, and the surface active dispersant is not particularly limited. For example, according to such an experiment by the present inventor using a specific commercially available cement, a cement filling factor of 0.60 was obtained.
The filling rate of the particles B and C obtained by removing only the surface restraining force of the particles B and C and densely packing the particles B and C is defined as the reference density. The dense packing obtained with hydraulic composites then generally occurs when the composite contains less than 10% by volume of particles A (based on the total volume of particles A + particles B, C), at least at least 10% by volume of particles A. 80%, preferably 90%, more preferably 95
% density of particles B and C, and the composite material has a density of 10 to 20
% particles A by volume, at least 75%, preferably 85%, more preferably 90% of the reference density
The density of particles B and C is 20, and the density of the composite material is 20
It is possible to have a density of particles B, C of at least 70%, preferably 80%, even more preferably 85% of the reference density, if more than % by volume of particles A are present. Note that as the amount of particles A added increases, the density of the densely packed particles B and C obtained by the composite material of the present invention is slightly diluted, but as mentioned earlier, It should be noted that, since the density of particles A increases with the amount of particles A added, the degree of particle packing of the entire composite is not so diluted, but is sufficiently dense. be.

In any case, the present invention is a molding tool constructed using such a densely packed structure of particles A, B, and C, the special hardness of particles C, and this hydraulic composite material. It is characterized by

(Detailed Description of the Invention) Examples of particles A, B, C and component D are
It is described in Japanese Patent Publication No. 59182 and Japanese Patent Publication No. 57-500645 (However, in Japanese Patent Publication No. 57-500645, component D of the present invention is referred to as component C).

Particle B is a particle that hardens by partial dissolution in a liquid, chemical reaction in the molten state, and precipitation of the reaction product. In particular, particle B is an inorganic binder containing cement. Often at least 20% by weight of Particle B is Portland cement. It is preferred that at least 50% by weight of the particles B are Portland cement, and in particular it is preferred that the particles B consist essentially of Portland cement particles. In addition to this, the particles B may also include particles selected from fine sand, flyash, and fine powder.

Particle A is also a particle that hardens by partial dissolution in a liquid, a chemical reaction in the solution, and precipitation of the formed reactants, and in particular exhibits substantially lower reactivity than particle B or substantially Particles that do not show reactivity. Typically, particles A are inorganic materials of the type described in the above-mentioned patent publications, such as "silica dust", which typically ranges from 50 Å to 0.5 μm, typically is 200
It is a material containing SiO ₂ that has a particle size of Å to 0.5 μm and is produced as a by-product when producing metal silicides, such as ferrous silicide, in an electric furnace. The specific surface area of silica dust is 50,000 to 2,000,000 cm ² /g, especially
It is 250000cm ² /g.

The particles A may, for example, comprise flyash, in particular finely ground flyash to a specific surface area (Blaine) of at least 5000 cm ² /g, especially at least 7000 cm ² /g, and often 10000 cm ² /g.

Particles A usually occupy 0.1 to 50%, preferably 5 to 50%, and more preferably 10 to 30% by volume of the total amount of particles A and B. In most cases, the most effective strength properties are obtained when particles A and B are closely packed together.

The amount of silica dust to ensure dense packing of the silica dust particles largely depends on the particle size distribution of the silica dust and the wide voids that exist between the densely packed particles B. Therefore, a well-classified Portland cement containing 30% fine spherical flyash particles, when densely packed, will have much finer particles for silica dust than a corresponding densely packed cement with particles of the same size. leaving a void. When Particle B is a system mainly composed of Portland cement, silica dust is densely packed in an amount of 15 to 50% based on the volume of Particle A+Particle B. A similar idea can be applied to other types of particles A,
This also applies to systems containing B.

A typical example of particles D is quartz sand.
One feature of the present invention is that a sand-like material (particles C) is used that has superior strength to sand-like materials used in ordinary concrete. (Typically, the sand used in ordinary concrete consists of ordinary rocks such as granite, gnice, sandstone, flint, and limestone, which contain minerals such as quartz, feldspar, mica, calcium carbonate, and silicic acid.) Component D may thus be sand or stone.

Various comparative tests are used to evaluate whether the special sand stone material (particle C) is stronger than the ordinary concrete sand stone material. For example: 1. Measurement of hardness 2. Measurement of the crushing strength of single particles 3. Hardness of the minerals constituting the sandstone material 4. Measurement of the resistance to powder compaction 5. Abrasion test 6. Grinding test 7. Measurement of the strength of composite materials containing particles High strength and An example of particle C with high hardness is 85
There are refractory grades of bauxite and silicon carbide containing % Al ₂ O ₃ (corundum). Both materials have significantly higher hardness than the minerals found in normal sand and stone. Therefore, both corundum and silicon carbide have a Mohs hardness of 9, while aluminum oxide (corundum) has a Knoop indentation hardness of 1635~
1680, while silicon carbide is reported to have a hardness of 2130 to 2140, while Mohs hardness is 7, which is one of the hardest minerals in sandstone used for ordinary concrete.
Knoop indentation hardness is 710-790. (George S. Bradey and Henry Earl Kloser, Materials Handbook, 11th edition, McGraw-Hill Publishers)
(George S. Brady and Henry R. Clauser,
Material Handbook, 11th ed., MeGraw−
Hill Book Company) The high strength of these materials has been demonstrated in powder compaction tests and tests using mortar and concrete containing a silica-cement binder using the materials as sandstone to compare with regular concrete sandstone. It was shown that.

Many materials other than the two mentioned above can of course also be used as strong sandstone materials (particles C). Typical materials include materials with a Mohs hardness of 7 or higher, such as yellow jade, lawsonite, diamond, corundum, fenasite, spinel, beryl, chlorophyll,
Turmorin, granite, andalusite, staurolite, zircon, boron carbide, and tungsten carbide are used.

The criterion of hardness may, of course, be expressed by the Knoop indentation, indicating that minerals with values above that of quartz (710-790) are stronger compared to the materials that make up ordinary concrete sandstone. It is considered a material.

Particles C are thus strong natural minerals, artificial minerals and alloys, in particular materials whose strength of the particles corresponds to at least one of the following criteria:

1. International patent application (for particles of material in which the particle size ratio between the largest and smallest particles does not substantially exceed 4)
When evaluated by the method described in PCT/DK81/00048 (Special Publication No. 57-500645), the filling degree is 30 MPa or more at a filling degree of 0.70.
50MPa or more at 0.75, filling degree 0.80
Die pressure above 90MPa, preferably filling degree 0.70
At 45MPa or more, at filling degree 0.75
70MPa or more, die pressure of 120MPa or more at filling degree 0.80 2 (regarding minerals that make up the particles) 7 or more,
Preferably a Mohs hardness of 8 or more, 3 (regarding the minerals that make up the particles) 800 or more,
Preferably Knoop indentation hardness of 1500 or more In the above, die pressure etc. are measured by the following method.

Die pressure: Individual sand and stone fraction samples are compressed in a uniaxial die press. The compression device consists of a cylindrical die cylinder open at both ends and two cylindrical pistons (16-23 mm diameter depending on the powder).
Coarsely pour in the dry ingredients. Constant compression speed (e.g. 5
mm/min) to a compression pressure of 350 MPa, and then move the piston in the opposite direction to release the pressure. Plot the force/transfer curve during this compression/release and use it as a function of the degree of compaction (the ratio of the volume of the particles themselves to the volume of the total powder mass, i.e. (1 - porosity)). Can measure pressure MPa.

Mohs hardness: Determined by comparing the hardness with the following materials known as the Mohs hardness standard.

1: Talc. 2: Mineral salt or gypsum. 3: Limestone.
4: Fluorite. 5: Apatite. 6: Feldspar. 7: Quartz.
8: Topaz. 9: Corundum. Ten:
diamond.

The test method is to find the softest material of the above that can scratch the test piece. The hardness of the test object is intermediate between the scratched material and the next softer material.

Knoop hardness: 25-3600g depending on specimen size
by the penetration of the diamond apex angle to create a diamond indentation with a diagonal length ratio of 7:1 by applying a load of . The hardness value is the ratio of the load to the projected area of the indentation. This measurement method is specified in ASTME 384.

Particles C, as opposed to the usual sand stone used with cement matrices, are
DK81/00048 (Special Publication No. 57-500645)/
03170, European patent application 81103363.8 and Danish patent application 1957/81 (Japanese Patent Publication No. 57-500645), it has the same level of strength as the DSP matrix itself,
Increases the strength of tools made with DSP materials. Particle C is 10 to 90% of the total volume of particles A, B, and C.
It is often used in a volume %, preferably 30 to 80 volume %, particularly preferably 50 to 70 volume %. particle C
It is also desirable in many cases to be substantially densely packed.

The DSC matrix further contains metal fibers including steel fibers, mineral fibers, glass fibers, asbestos fibers, heat-resistant fibers, carbon fibers, and plastic fibers such as polypropylene fibers, polyethylene fibers, nylon fibers, Kevlar fibers, and other aromatic fibers. selected from the group including inorganic non-metallic whiskers such as graphite and Al ₂ O ₃ whiskers, wollastonite, asbestos, other inorganic synthetic or naturally occurring inorganic fibers, metallic whiskers such as iron whiskers, and mica. It may also contain embedded fibers and/or plate-shaped modifiers. If the DSP matrix is made by conventional mixing and casting techniques, the fibers (or threads or rovings) are usually cut fibers (or threads or rovings).
It is typically used in an amount of 1 to 5% by volume when the aspect ratio is 100 or more, and up to 5 to 10% by volume when the aspect ratio is 10 to 100. For example, steel fibers with a thickness of 0.1 to 1 mm
Larger amounts of cut fibers can be incorporated by techniques that combine large and small fibers, such as by using in combination with 10 μm glass fibers.

Cut steel fibers, especially steel fibers with a length of 5 mm to 50 mm, especially steel fibers with a length of 10 mm to 30 mm, e.g. 10 to 15 mm steel fibers or
Steel fibers of 20-30 mm or mixtures thereof with a thickness of 0.2-1 mm, for example 0.3-0.6 mm, have been found to be suitable. The steel fibers may also have special geometries that facilitate anchoring in the material, such as depressions in the surface or in order to obtain maximum anchoring effect in the matrix. It may also have a hook-like or other protrusion.

Additional component D which is advantageously mixed into the product of the invention
Examples include reinforced steel bars or metal bars containing rods. Inclusion of additional component D in the material is useful for optimum strength and stiffness or for other purposes to obtain close packing of the additional component. Easily deformable (free-flowing) matrices permit much more concentrated loading of additional components than is obtainable with known techniques.

Fiber blending in particular is of great interest because of the unique performance of DSP matrices with respect to anchor fibers. The type and morphology of the fibers will depend on the field of use of the tool; as a general rule, the larger the size of the tool, the longer and thicker the fibers are preferred.

Particularly when the tool of the invention is of large size, it is preferably reinforced by reinforcing steel such as bars, rods, wires, fibers, etc. The shaping of the material is done under very gentle conditions so that the reinforcing component retains its geometrical nature during the casting process.

According to one embodiment, the DSP matrix (located in particular at the working surface area of the forming tool) contains additional solid material within the voids of the structure formed by particles A and B. The additional solid material can be selected from the group consisting of organic polymers such as polymethyl methacrylate or polystyrene, low melting point metals and inorganic metalloids such as sulfur.

As mentioned above, the DSP material can be cast by mixing Particle A, Particle B, water, and a surfactant dispersant, optionally with Particle C, optionally additional component D, and Particle A. , liquid, surface-active dispersant, optionally particles B, particles C and/or additional component D, are mechanically mixed together into a viscous plastic material, and then, if necessary or desired, particles of type B, C, D and/or components are mixed into the resulting material by mechanical means to give the desired component distribution, and then optionally particles C and/or additional component D. The resulting material is cast under low stress while adding . to provide at least a portion of said molded surface.

The forces associated with forming the material typically include the force of gravity acting on the material, or inertial force acting on the material, or contact force, or Simultaneous action of two or more of the above forces This is probably due to stress.

In particular, this force is an oscillating force with a frequency between 0.1 Hz and 10 ⁶ Hz, including those of the type mentioned above, or combinations of such oscillatory forces with non-oscillatory forces of the type mentioned above. There is a match.

If Particle A is silica dust and Particle B is Portland cement, the liquid is water and the dispersant is described in International Patent Application PCT/DK79/00047.
(Special Publication No. 60-59182) or international patent application
PCT/DK81/00048 (Special Publication No. 57-500645)
Typical are concrete superplasticizers of the type discussed in .

The surfactant dispersant is used in an amount sufficient to cause the liquid to plasticize the material under low stress, usually less than 5 kg/cm ² , preferably less than 100 g/cm ² .

Any type of dispersant, especially concrete superplasticizer, is useful for the purposes of this invention because in sufficient quantities it will disperse the system under low stress. The concrete superplasticizer used in the examples is an alkali or alkaline earth metal salt, in particular a highly condensed naphthalene sulfonic acid/fluor, in which more than 70% by weight consists of molecules containing 7 or more naphthalene nuclei. Sodium or calcium salt of maldehyde condensate. This type of commercially available product is “Mighty”
(Mighty) and is manufactured by Kao Soap Co., Ltd. in Tokyo, Japan. In the DSP material containing silica dust based on Portland cement according to the invention, this type of concrete superplasticizer is 1 to 4% by weight, especially 2% by weight, based on the total weight of Portland cement and silica dust.
It is used in high proportions of ~4% by weight.

Another type of concrete superplasticizer useful for the purposes of the present invention is shown in Example 2 of International Patent Application PCT/DK81/00048.

The DSP material for manufacturing the tools of the invention is packaged and shipped as a dry powder, and water is added at the work site. In this case, the dispersant is introduced into the composite material in dry form. This type of composite material is precisely metered and mixed by the manufacturer so that the end user can add a predetermined amount of liquid, e.g.
DK79/00047 (Special Publication No. 59182 of 1982) and International Patent Application PCT/DK81/00048 (Special Publication of Publication No. 1982-59182)
The remaining mixing may be carried out as planned as described in Example 11 of Publication No. 500645).

The weight ratio between water and Portland cement plus other particles B plus silica dust in the cement-silica dust based DSP material is typically between 0.12 and 0.3, preferably between 0.12 and 0.20. The patent applications mentioned above disclose several important variations and embodiments for making useful DSP materials.
In embodiments where the composite material is premixed or molded under high stress, the water/powder ratio may be, e.g.
It may be as low as 0.08 to 0.13. Thus, for example, casting may be carried out under molding pressures of up to 100 kg/cm ² and, in special cases, even higher pressures, by extrusion or by rolling.

Casting is accomplished by spraying, painting, brushing, injection, or applying a layer of material onto a support surface and molding the material to form at least a portion of the molded surface portion.

Casting can also be done by centrifugal force.

If the DSP matrix contains additional solid material within the voids of the structure formed by particles A and B, this solid material partially or completely infiltrates the solidified DSP material with liquid and then and by solidifying the liquid to form a solid substance, such as by cooling or polymerization. The liquid typically exhibits at least one of the following properties: Capable of leaking the internal surface of the construct formed from particles A and B Containing molecules with dimensions at least one order of magnitude smaller than particles A Cooling or Upon solidification by polymerization, leaving behind substantially the same volume of solid material as the liquid. The efficiency of infiltration by a liquid is evaluated by one or more of the following measurements:

drying the particles or parts thereof to be saturated; applying a vacuum to the particles or parts thereof to be infiltrated prior to the infiltration process; and applying external pressure to the infiltration liquid after contacting the particles with the infiltration liquid. .

Other concrete-like materials that are useful for the tools of the present invention, or particularly for surfaces thereof, that are subject to excessive stress include cement-polymer based materials (CP materials and DSPP materials).

UK Patent Application 7905965, Publication 21018737A, European Patent Application 80301908, Publication 0.021681, and European Patent Application 80301909, Publication 0.021684A1 are based on very high concentration and very dense mixture components typically used in high stress fields. It discloses the production of samples of substantially higher quality than conventional cement-based products, primarily using a much thicker polymer solution than the concentrated polymer solution combined with the same Portland cement. Such materials are useful materials for use as concrete-like materials according to the present invention. Particularly useful embodiments of such materials include those that are combined with fibers of the type mentioned above, particularly during mixing under high stress and/or whose viscosity is reduced prior to casting, such as by dilution with a polymer solution or water. There are materials that have been reduced by processing to values suitable for casting or molding. A particularly interesting polymer-containing material is the DSP material mentioned above, which also includes a polymeric binder. (Such materials can be designated as DSPP materials: Densified Systems containing a polymer and uniformly dispersed ultrafine particles.
containing Polymer and homogeneously
The organic polymers for the CP or DSPP materials are, for example, the same polymers as those described in the above mentioned UK Patent Application 7905965 (Publication 2018737A), i.e. the water-dispersible polymers more or less related to the following group: mixture of polymers related to one or more of the groups)
Includes: References 1) Kirk-Othma, Encyclopedia of Chemical Technology, (Kirk-
Othmer, Encyclopedia of Chemical
Latex defined in Technology, ) 7, pages 676/716 Reference 1), 17, pages 391-410 or Reference 3)
Ale El Merza: “Water-soluble polymers.
Developments since 1978, Chemical Technology Review No. 181, Noise Data Corporation, Park Ridge, New Jersey,
USA1981 pages 1-596 (Yale L. Meltzer:
“Water−Soluble Polymer.Development
since 1978”，Chemical Technology Review
No.181, Noyes Data Corporation, Park
Ridge, New Jersey, ) or reference 2) Pea Ullman, 12,530~
According to a special embodiment of the resin derivatives defined on page 536 (P. Ullmann), the polymers may be selected from the special group: cement dispersants, known as concrete superplasticizers, such as sulfonated naphthalenes, or Medium molecular weight polymers such as melamine-formaldehyde condensates or alkali or alkaline earth metal salts of their underlying acids, or high molecular weight polymers thereof. Additionally, amide derivatives of these polymers may also be used.

A feature common to the aforementioned polymer groups is that these polymers have the ability to form a film by dehydrating and/or crosslinking an aqueous dispersion.

Typical polymer concentrations in aqueous systems used to make cement-polymer-containing matrices range from 1 to 60%. The amount of aqueous system (water+polymer) used to prepare the material is in the range of about 10 to about 70% by volume, particularly in the range of about 20 to about 50% by volume, based on the total composition.

The ratio of polymer (solid) to cement depends on several factors such as the desired strength of the material, the exact nature of the polymer, the type and particle size of the cement, and the presence of other particles filling the voids between the cement particles. You can decide accordingly. However, the volume ratio of polymer to cement in the matrix used in the materials of the invention is typically in the range between 0.1 and 35% by volume (although it may also be between 0 and 40% by volume), and often 2 and 35% by volume. Between 10% by volume.

In special cases, matrix-containing Special care is taken to achieve an effective distribution of the components of the matrix, such as by high-pressure molding or shaping the product from the material; all these methods are described in European Patent Application No. 80301909.
(Publication Publication No. 0021682A1) serves to provide a material having a pore distribution with a small pore ratio and a particular maximum proportion of pores of a particular maximum size for the matrix. Other methods that can be used to impart special properties to matrices, for example with respect to tensile strength in bending, include European Patent Application No. 80301908 (Publication No.
There is the use of special interval grading systems such as those disclosed in 0021681A1).

A very special type of matrix with high strength, especially high tensile strength in bending, suitable for the tools of the invention often does not contain polymers, but has cement as a substantial binding component and special treatments, i.e. very Careful grinding to form a colloid of highly distributed cement hydrate in a homogeneous material or a matrix containing materials that form a shear-affected matrix during the early stages of cement hydration. be. Such materials can be made by adding water to cement and subjecting it to high shear and grinding until some degree of hydration occurs.

The cements used in these matrices of the invention are typically low temperature cements, low alkali sulfate resistant cements, gypsum, calcined gypsum, calcium sulfate, high alumina cements, magnesium oxide cements, zinc oxide cements and portland cements such as silicon oxide cement types (identified in U.S. Pat. No. 4,154,717), fluoroaluminosilicate glasses and other dental types such as glass ionic cements and other types of cements that supply ions capable of cross-linking polymers. It is a portland cement that includes deformation.

Overall, some of the drying mechanisms of these matrices used in the present invention are similar to those used in the present invention. Holiday, Chemistry and Industry, December 1972, No. 2
Pages 921-929 (L.Holiday, Chemistry and
Industry, 2nd December, 1972), 2, such as calcium ions or silicon ions,
This can be said to be due to ionically cross-linking with the negative position of the polymer by 3 or other polyvalent cations (cations).

One group of polymers of particular interest with respect to ionic "crosslinking" of polymers are acrylic acid-based polymers and other polymers with carboxylic acids or derivatives thereof crosslinked to the backbone of the polymer. Examples of these materials include Paul Gee. Written by Paul G. Stecher Park Ridge, New Jersey
Ridge, New Jersey, USA) Noyes Data Corporation
“New Dental Materials” published in 1980
Materials), pages 115-145. Most of these polymers fall into the above group, ie, water-soluble resins. Particularly interesting materials of this type include materials in which carboxy groups have been changed to amide groups. In a basic environment, the amide groups are dissociated by alkaline hydrolysis and the carboxy groups are available for cross-linking with cations, especially ions liberated from the inorganic part of the matrix material. Polymers that are acidic and can be crosslinked in the presence of bases are known in dental technology. For purposes of this application, these polymers are typically too reactive and react too quickly to mold the composition after mixing. However, with proper use of the inorganic components of the matrix, it is possible to release acidic groups, for example by using inorganic materials that release cations very slowly and the reaction is limited by limited availability of cations. It becomes possible to utilize these polymers that have These materials may be plaster of paris or fluoroaluminosilicate glass. In this regard, Portland cement is said to release several types of ions, including (primarily) calcium ions, aluminum ions, silicon ions, magnesium ions, and iron ions.

CP or DSPP materials are used in the tools of the invention in the same way as DSP materials, or CP, DSPP materials are
For example, it is applied as a tape or sheet to the surface area of the tool that is exposed to the greatest stress.

References to DSP materials from now on should also be understood to refer to CP or DSPP materials modified to be suitable for the same purpose.

In the present invention, a cement-based cast material for a tool is designed with respect to its specific composition depending on the requirements combined with the specific application and desired performance of the tool in question.

For tools used under high temperature conditions, it is especially important to include structures and fibers with good thermal conductivity, such as metal components or metal fibers.

To design materials for male and female press tool parts for molding from substantially planar materials, the thickness of the plate or sheet, the yield strength of the plate or sheet material, the bursting strength of the plate or sheet material, etc. , and the radius of curvature must be taken into account. The strength required of the material for male and female tools is the strength of the sheet or panel to be formed divided by the strength of the tool material multiplied by the thickness of the sheet or panel material divided by the radius of curvature. in proportion to
The constants here depend on these parameters according to an equation stating that they are determined by the direction of pressure and the coefficient of friction between the molded plate and the male and female tools. (The characteristics of the above formula are related to the conditions during molding, that is, molding temperature, molding speed, etc.) As will become clear from the explanation with reference to the drawings, the exact There are several ways in which it is possible to take advantage of the unique properties of the new cement-based materials to obtain tools: The model can be made from an exact mold of the product to be molded, or from a suitable material such as fiberglass/polyester. It may be prepared by either casting of the material.

1 The male mold may be cast directly onto the model. After curing, the model is removed and the male tool is provided with a layer thickness corresponding to the thickness of the plate to be pressed. (Typically,
A wax sheet is used as the thick layer. )
The female tool is then cast onto the male tool covered with a thick layer. After curing, the female and male tools are separated and the thick layer is removed. (Only one side model of the desired product is used in this technique.) 2. The male part is cast as described in 1). The model remains on the male part during curing, after which the female tool is cast directly onto the model as described in 1).

In this technique, a model is used that contains exact copies of both sides of the product to be made.

3. Male and female tools are cast simultaneously around a model placed in a two-part cast box as described in connection with FIG.

In all cases of 1) to 3), it is preferable to spray a mold release agent such as graphite onto the surface of the model prior to casting.

In the tools of the invention, the material comprising the DSP material may be reinforced by conventional strengthening principles such as arranging steel bars or the like in a manner suitable to resist tensile stresses. Micro-reinforcement against micro-cracks and local stresses can be obtained with the various types of fibers mentioned above. These reinforcing fibers need not be uniformly distributed in the matrix, but it may be advantageous to concentrate them on surfaces or other parts of the tool which are exposed to particularly high stresses during use.

As mentioned above, the tool of the invention is reinforced by conventional reinforcement principles. The nature and extent of the reinforcement can be calculated in advance on that basis, taking into account which parts or cross-sections of the tool of the invention are particularly exposed to stress. Reinforcement is accomplished by placing one or more members of steel or other metal within the tool such that at least one surface thereof is exposed to and forms part of the molded surface portion of the final tool. Including. Advantageously, such exposed reinforcing metal members are arranged to form raised edges or other protrusions of the final tool that are subject to excessive stress during use of the tool.

The surface portion of the reinforcing tool member to be exposed is molded to be exactly complementary to the corresponding surface of the molding. Preferably, these exposed metal surface portions are finished by grinding and/or polishing.

The reinforcing metal member is then placed within a molding partially defined by the model such that the exposed surface portion of the reinforcing member is in contact with a corresponding surface portion of the model. Once all reinforcement structures are placed in the molding, the DSP material is cast as described above.

(Effects of the invention, industrial applications) However, one feature is that the DSP material is extremely easy to repair or later strengthen parts that are found to be exposed to high stresses during use of the tool. I can do it. In the case of such repairs, it is also possible to incorporate, for example, special types of DSP materials or particularly hard components, such as hard metals or steel materials or CP materials, especially in the areas where the greatest stresses occur during use of the tool. Or it may be combined with DSPP material or its tape.

While the DSP material used in the present invention is easy to cast and therefore exhibits optimal properties, allowing economic tooling to be obtained even for small production volumes, the material also exhibits optimal properties with respect to its surface properties. be. Depending on the quality of the model, the materials used in the invention may have a polished metal or smooth plastic-like surface, in other words a surface ideal for forming tools and with minimal friction with the product being formed. Obtainable. It is surprising that these special surface requirements were found to be practically met by cement-based materials. Therefore, for example, under the conditions reported in Example 1, it was possible to draw a 0.9 mm thick steel plate with a radius of curvature of 3 mm without using any special means.

Due to the ease of manufacture of the high quality tools of the present invention, the present invention has the advantage of being able to form by drawing or bending with much higher performance and precision than previously possible. Whereas high-quality, long-life tools for this purpose would normally require being made of steel using many techniques that are very expensive, the tools of the present invention can be made quickly and inexpensively, and This faithfully reproduces the surface of the material, allowing for the inexpensive production of automotive spare parts and structural elements that are not mass-produced on such a large scale as to justify the preparation of steel tooling, for example. Moreover, because the tool of the invention has a unique surface quality, these advantages are achieved without degrading the quality of the product.

Therefore, the main types of products made by using the tool of the invention include products made from metal sheet or panel materials, such as hulls or shells of ships, agricultural machinery, aircraft and other transportation vehicles. , transportation machinery, especially automobile body parts, and in particular repair of automobile body parts or parts of car body parts such as hoods, fenders or parts thereof, doors or parts thereof, floor panels or parts thereof, front parts or parts thereof, etc. There are parts. The sheet or panel material used to make these products is processed from the continuous sheet or panel material by mechanical, electrical, acoustic, or electromagnetic means, such as a wire cutting machine,
Blanks cut by laser cutting or the like, sawing, punching, wire cutting are suitable.

Since the economical production possibilities of the inventive tool can enjoy all the advantages of reinforcing technology even in large sizes, the present invention applies its precise drawing/bending technology to e.g. ship hulls, buildings, large containers, and It can be applied to new application fields such as the manufacture of large structures such as parts and reaction vessels. The tools of the present invention may be made entirely of new cement-based materials, or may incorporate more or less thick surface areas of these materials into other structures, including older drawing/bending tools for forming that are already obsolete. By application, it is made to have sufficient strength for the purpose.

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an open-topped container 10 made of a material of sufficient strength, such as wood or steel, for example. A moldable material 11, such as a molding resin, for example for making foamed polyurethane or polystyrene, is placed in a container 10 in a plastic state, and a model 12 of the product to be molded is shown in FIG. It is placed in the moldable composition 11 with its concave side facing up. Once the material 11 has hardened, a support frame 13 is placed on the upper edge of the container 10, as shown in FIG. A release layer such as Aite is applied thereon, and the side wall of one mold is constituted by a frame 13. A reinforcement 14, such as a steel rod, is placed within the frame 13. A cement-based DSP cast material 15 of the type described above is placed in an open-topped mold, optionally with vibration of the mold, until the upper surface of the cast material is substantially level with the upper edge of the frame 13. Injected. When the cement-based DSP material dries,
The frame 13 with the finished male tool 16 is removed from the mold as shown in FIG. The male tool 16 is then coated with a layer 17 of plastic material, such as a sheet of wax, of a thickness corresponding to the thickness of the plate or sheet material to be formed by the tool.
covered by. As shown in FIG. 4, a frame 18 with a reinforcing material 14 is placed on the upper edge of the frame 13,
This again creates an open mold with an open top, the bottom of which is constituted by the wax-coated surface of the male part 16. As with the male part described above, the female part 19 is cast within this mold. All edges of the molding that extend beyond the contour of the model are hidden with a suitable material, such as wax, to a thickness preferably greater than the thickness of the stock to be molded in the final tool assembly.

As illustrated in FIGS. 5 and 6, the male and female tool parts are mounted in a press, such as a hydraulic press, and the blank 20 is introduced therebetween and shaped into the shape of the mold 12 by drawing. Molded. In the mold shown in FIG.
Inlet 2 into two mold chambers 24, 25 for simultaneous casting of male and female tool parts on opposite sides of 2.
A double molding is carried out in which the cast material is introduced through 2 and 23. In this case the model 12 corresponds on both sides to the desired product to be manufactured.

As shown in FIG.
A reinforcing steel member 14a may be included having a surface portion placed in contact with the reinforcing steel member 14a. These surface portions are exactly complementary to the engagement surfaces of model 12 and steel member 14a. Steel member 14
Preferably, a is connected to other parts 14 of the reinforcement, for example by wires or rods (not shown) welded thereto. In the completed male and female tool parts, the exposed surface portions of the steel member 14a are located at areas where the tool parts will be exposed to unusually high stresses in use, i.e., on molded surfaces such as the protruding edges of the tool. form part of Incorporating reinforcing elements such as steel or other metal reinforcing elements 14a on high stress surfaces of the tool will substantially extend the useful life of the tool.

Figures 11 and 12 show a dish-shaped product such as an automobile lamp body made of thermoplastic flat sheet or plate 27.
This is a schematic illustration of vacuum forming using a cast mold or die 28 using a cement-based cast material of the type described above. The mold 28 is made by casting a cement-based material onto the exterior surface of the model as described above. The mold 28 has a cavity 29 open at the top, which communicates with a vacuum source (not shown) via a vacuum conduit 31 with an intake passage 30 and a valve 32 provided in the bottom wall of the mold 28. are doing.

The thermoplastic sheet or plate 27 is sandwiched between a flange 33 formed on the upper edge of the mold 28 and a gripping member 34 containing electrical heating means 35 which are supplied with electrical power through electrical wires 36. When the thermoplastic plate 27 is clamped between the flange 33 and the gripping member 34 and heated by the latter, the cavity 29 is connected to a vacuum source by opening the valve 32, thereby The heated thermoplastic plate is suctioned into intimate engagement with the inner wall of the cavity 29 to form the product 26. When the finished product has cooled sufficiently, it is removed from the mold.
To facilitate cooling of the molded article, mold 28 may include internal passageways (not shown) for circulating a coolant, such as water.

13 and 14 illustrate the manufacture of the lower tool part 37 of a pressing tool used for pressing corrugated sheets 38 made of fiber cement material. The tool part 37 is cast in a mold formed by a bottom part 39 and a peripheral frame part 40 with a cement-based cast material 15 of the type described above. The bottom part 39 includes a lower layer 41 made of a moldable material such as resin and having a wavy upper surface.
and a corrugated steel plate 42 having a complementary shape to the upper surface of the layer 41. A number of closely-aligned rubber tapes or bands 43 are attached to the upper surface of the steel plate 42 by a suitable adhesive so as to extend transversely, preferably at right angles to the corrugation direction of the plate 42.

When the rubber tapes 43 are arranged so as to be mutually located over the entire upper surface of the steel plate 42, the frame part 40 is placed on the upper surface of the bottom part 39 as shown in FIG. The frame part 40 includes a number of suction tubes 44 extending along the top of each corrugation of a corrugated steel plate 42. These suction tubes are supported by laterally extending support bars 45 whose ends are connected to the frame part 40.

The cast material 15 is placed in a mold with an open top.
The cast material is poured, with the mold being vibrated if desired, until the top surface of the cast material is substantially level with the top edge of the frame part 40. Once the material 15 has dried, the frame 40 with the resulting lower tool part 37 is removed from the bottom part 39. The tool part 37 forms a corrugated upper surface with a number of closely aligned laterally extending grooves 46 formed by rubber tape 43, which grooves are used as drainage grooves.
Therefore, the upper surface of the lower tool part 37 is
7 is covered with a perforated corrugated steel plate 47 having a shape complementary to the corrugations of the top surface of 7, and which steel plate 47 is preferably covered by a corrugated wire mesh (not shown) made of bronze, for example. .

FIG. 16 shows a complete press tool mounted on a mechanical or hydraulic press. The tool comprises a lower tool part 37 which may be stationary and an upper tool part 48 fixed to a vertically movable part 49 of the press. The upper tool part 48 can be constructed in the same manner as described above with respect to the lower tool part. However, the upper tool part has a laterally extending drainage groove 46.
The perforated corrugated steel plate 47 may also be made without perforated corrugated steel plate 5.
May be replaced with 0. In the lower position of the upper tool part 48, a corrugated closed space is defined between the corrugated plates 47 and 50. Preformed corrugated plates or panels 38 made of wet fiber cement material are attached to upper and lower tool parts 48 and 3.
7, the plate or panel 3
The density of 8 increases considerably, while the water drains out of the holes in the steel plate 47 and flows down into the underlying drainage grooves 46, and furthermore the water flows down below these grooves located in the valleys of the corrugated surface of the lower tool part 37. collected into parts. Therefore, suction pipes 44 are connected to these groove parts via connection holes or pipes 51, which suction pipes 44 allow water to be sucked out of the cavity defined between the upper and lower tool parts and to remove the fiber cement material. It is connected to a pump or vacuum source (not shown) so that it can be compressed.

Example 1 The materials used in this example were: Cement: low alkali sulfate resistant Portland cement Silica dust: finely divided spherical SiO ₂ rich dust.
Specific surface area (determined by BET technique) approx.
250000 cm ² /g, corresponding to an average particle size of 0.1μ. Density 2.22 g/cm ³ Bauxite: Refractory grade roasted bauxite, 85% Al ₂ O ₃ , density 3.32 g/cm ³ , particle size 0-4 mm Mighty: So-called concrete super plasticizer, typically 7 pieces or more A highly condensed naphthalene sulfonic acid/formaldehyde condensate consisting of 70% or more of the molecules containing the above naphthalene nucleus. Density approximately 1.6g/cm ³ . Solid powder, aqueous solution (42% by weight, 58% by weight water) (Aalborg Portland-Cement-Fabrik, Denmark)
under the trademark Cem-Mix. ) Steel fiber: diameter 0.4mm, length 12mm each and
24mm. Cut with a blunt instrument so that the fiber ends show slight deformation to promote the anchoring effect of the cement-based matrix.

Water: ordinary tap water Preparation of tools for manufacturing the edges of automobile fenders A cement-based cast material was made with the following composition.

Cement 720Kg Silica Dust 144Kg Bauxite 1800Kg Mighty Powder 15Kg Steel Fiber 12mm 60Kg Steel Fiber 24mm 40Kg Water 180Kg Cement, silica dust, Mighty and bauxite are mixed in a paddle mixer until a homogeneous mixture is obtained and the mixture is packed in 25Kg bags. packaged in. Mixing was continued until a plastic viscous fluid was obtained (approximately 10 minutes). The steel fibers were then gradually introduced into the mixture in amounts corresponding to the listed composition.

The resulting soft fluid mixture was cast into the molds shown in FIGS. 2 and 8. In the mold a glass fiber-epoxy model 12 of the fender part, approximately 5 cm deep, is placed in a polyurethane foam in a box 10 measuring approximately 80 cm x 60 cm, forming the bottom surface, and in a frame 13. A reinforcement consisting of 1 cm steel rods was installed. The mold was vibrated by an air hammer. The mold was filled with cast material to the highest possible level to or just above the edge of the steel frame 13. The exposed surfaces of the cast material were then covered with plastic film to prevent water from evaporating therefrom. The cast material was left to solidify at room temperature for about 24 hours and then held at about 30-35°C for about 48 hours. The frame was then flipped over and the polyurethane and fiberglass-epoxy models were removed, thus exposing the surface of the dried cement bonded material. On the surface of the dried cement-bonded material,
A 0.9 mm wax film was placed and made to follow the surface contour exactly. Another frame with a 1 cm steel rod reinforcement is placed on top of the male tool part and the female tool part is made of the same material as before, as shown in Figure 4.
It was cast in the same way as before. The female part was dried in the same manner as described above without being removed from the male part.

Both the male and female tool parts were mounted in a 200 ton hydraulic press, and the fender parts corresponding to the model were made from rough cold rolled 1403 steel with a thickness of 0.9 mm. The squeezing pressure was 50 tons. The compaction time was about 30 seconds per blank, but it would be possible to obtain a compaction time of about 2-3 seconds using a high speed hydraulic press. The minimum radius of curvature obtained in this case was 3 mm. In this way, approx.
1000 units were molded.

Example 2 A corrugated plate or panel made by conventional methods was subjected to a compaction process with a tool of the type shown in FIG. The overall dimensions of the lower tool part are 735×
It was 1100 x 140mm. The lower tool part has a diameter of 25
It was equipped with four suction tubes 44 of 10 mm in diameter, while the connecting hole 51 had a diameter of 10 mm. Tool parts 37 and 4
No. 8 was cast with the same DSP material and in the same manner as described in Example 1. The width and depth of the drain are 10mm and 8mm respectively.
mm, and the groove spacing was 15 mm. The lower tool part 37 was covered with a 2 mm thick perforated, corrugated steel plate, the diameter of the holes was 2 mm, and the distance between the holes was approximately 8-10 mm. This perforated steel plate was covered with a corrugated wire mesh made of bronze and covered with an upper tool part 48 and a solid corrugated steel plate 50.

Wet corrugated plates or panels made from various fiber cement mixtures were made on a conventional Magnani-machine. Each of these corrugated fiber cement panels is placed on the wire mesh of the lower tool part 37 and then compressed between the tool parts for 2 seconds at a pressure varying from 34 to 63 Kg/ ^cm2 , thereby compressing the plate or panel. The specific gravity increased by 8-14%.

Traditional hatschek machine (Hatschek-
Another wet corrugated fiber cement plate or panel made by a press machine was compacted by the press tool just described. Each fiber cement panel was subjected to a pressure of 100 Kg/cm ² for 45 seconds, thereby increasing the specific gravity of the panel by 45%. In the latter case, the surface area of the lower tool part 37 defined between adjacent drainage grooves 46 was exposed to an average pressure of approximately 167 kg/cm ² . However, the tool parts functioned perfectly without any cracks or other deterioration.

[Brief explanation of drawings]

The invention will be explained in detail with reference to the drawings. 1 and 2 are schematic explanations of the method of casting male tool parts, FIG. 3 is a schematic cross-sectional view showing the tool parts made by the method of FIGS. 1 and 2, and FIG. A schematic illustration of a female tool part or die cast corresponding to the male tool part shown in FIG. 3, FIGS. 5 and 6 including the male and female parts in two different working positions. A schematic illustration of a press or drawing tool; FIGS. 7 and 8 are perspective views further illustrating the process of casting a male part; and FIG. FIG. 10 is a cross-sectional view of a mold in which cooperating male and female tool parts can be cast simultaneously; FIGS. FIGS. 13 and 14 are illustrations of the method for forming the lower tooling part used to make corrugated sheet metal; FIG. the lower tool part placed thereon;
The figure is a partially sectional side view of a completed tool for pressing corrugated sheets made of fiber-cement material.

Claims (1)

[Scope of Claims] 1. A tool for molding a product from a basic material, the molding tool itself having at least one molded surface, and at least the portion of the tool that includes the molded surface. A tool comprising a cured product of the following hydraulic composite material. The hydraulic composite material includes inorganic solid particles A (hereinafter referred to as "particles A") having a particle size of 50 Å to 0.5 μm, and solid particles B (hereinafter referred to as "particles A") having a particle size of 0.5 to 100 μm and containing cement that is at least one order larger than the particles A. (hereinafter referred to as "particle B"), a surface active dispersant, and a 100μ
It consists of compact-shaped solid particles with dimensions of m to 0.1 m (hereinafter referred to as "particles C") and water, and the amount of particles A is such that particles B and C are substantially deformed into the composite material. The amount of water is less than or equal to the amount that can fill the void between particles B and C when the particles B and C are tightly packed in a state where they are in substantial contact with each other without substantial cross-linking phenomenon, and The amount is such that when the following surface-active dispersant is dissolved, particles B and C are densely packed in the composite material as specified above, and particles A are filled in the voids between the tightly packed particles B and C. The amount of the surface-active dispersant is such that when uniformly distributed, it just fills the voids formed between particles A, B, and particle C, and the amount of surface-active dispersant is such that when the composite material is mixed, particles B and C as specified above are mixed. The amount is sufficient to achieve a dense packing of C and a uniform distribution of particles A as defined above, and the particles C have a strength greater than that of ordinary sand and stone for ordinary concrete. 2. The tool according to claim 1, wherein the strength of the particles C satisfies at least one of the following criteria. When evaluating particles of a material in which the size ratio of the maximum and minimum particle diameters does not substantially exceed 4, the die pressure is 30 MPa or more at a solids filling rate of 0.70, 50 MPa or more at a solids filling rate of 0.75, and 90 MPa or more at a solids filling rate of 0.80. , a Mohs hardness of more than 7 (for the minerals that make up particle C), a Knoop indentation hardness of more than 800 (for the minerals that make up particle C). 3. Tool according to claim 1 or 2, wherein the composite material further comprises an additional component D having at least one dimension that is at least one order of magnitude larger than the particles A. 4 Particles C are densely packed, and dense packing means that the particles are geometrically similar in shape to the particles and have a particle size so large that the adhesion surface force does not work significantly. 4. A tool according to claim 1, 2 or 3, wherein the filling is substantially similar to that obtained by applying mechanical vibration. 5. Any one of claims 1 to 4, wherein the particles A are densely packed, or the cohesive single structure A is formed of such densely packed particles.
Tools listed in section. 6. The tool according to any one of claims 1 to 5, wherein the matrix contains a dispersant. 7. The tool according to any one of claims 1 to 6, which contains additional component D which is a solid component. 8. The tool of claim 7, wherein the additional component D is selected from the group consisting of compact shaped components, plate shaped components and elongated shaped components. 9 Additional component D is sand; stone; metal bars and rods, including steel bars or rods, metal fibers such as steel fibers, plastic fibers, Kevlar fibers,
glass fiber, asbestos fiber, cellulose fiber,
Claim 6: Whiskers selected from the group consisting of mineral fibers, heat-resistant fibers, fibers including carbon fibers, inorganic non-metallic whiskers such as graphite and Al ₂ O ₃ whiskers, and metallic whiskers such as iron whiskers.
The tool described in item 8 or item 8. 10. The tool according to any one of claims 8 to 9, wherein the additional component D is densely packed. 11. A tool according to any one of claims 1 to 10, wherein the particles B comprise at least 50% by weight of Portland cement particles. 12. Tool according to claim 11, wherein the particles B additionally include particles selected from fine sand, flyash and fine powder. 13. Claims 1 to 1, wherein the particles A are silica dust having a specific surface area of 50,000 to 2,000,000 cm ² /g.
The tool according to any one of item 2. 14. A tool according to any one of claims 1 to 13, wherein the particles C consist of one or more of the following components: Topaz, lawsonite, diamond, corundum, fenasite, spinel, beryl, chrysolite, tarmoline, granite, andalusite, staurolite zircon, boron carbide, tungsten carbide. 15. The tool according to any one of claims 1 to 14, wherein the particles C are made of refractory grade bauxite. 16 Particle C is 10 of the total volume of particles A, B and C
16. A tool according to any one of claims 1 to 15, wherein the tool is present in an amount of ~90% by volume. 17. Claims 1 to 16, wherein the composite material additionally comprises reinforcing steel as bars or rods.
The tool described in any one of paragraphs. 18. Tool according to any one of claims 1 to 17, wherein the matrix additionally comprises a polymer. 19. A method for manufacturing a tool having at least one molded surface for molding a product from a basic material by means of the molding surface, the method comprising: Inorganic solid particles A (hereinafter referred to as "particles A"), cement-containing solid particles B (hereinafter referred to as "particles B") having a particle size of 0.5 to 100 μm and at least one order larger than particles A, and a surface active dispersion. and compact solid particles with dimensions of 100 μm to 0.1 m (hereinafter referred to as “particles C”).
and water, and the amount of particles A is such that particles B and C are in close contact with each other without being substantially deformed in the composite material and with substantially no bridging phenomenon. The amount of water is less than the amount that can be theoretically filled into the void between particles B and C when the particles are filled into the composite material. When particles B and C are densely packed as specified above and particles A are uniformly distributed in the gaps between the tightly packed particles B and C, a particle is formed between particles A, B and particle C. and the amount of surface-active dispersant is such that the composite material is mixed to achieve a dense packing of particles B and C as defined above and a uniform distribution of particles A as defined above. and the particles C have a strength greater than that of ordinary sand and stone for ordinary concrete. A method for manufacturing a molding tool, characterized in that at least the molding surface of the molding tool is formed by casting in a mold in which a part of the shape has been formed and curing. 20. The method according to claim 19, wherein the strength of the particles C satisfies at least one of the following criteria. When evaluating particles of a material in which the size ratio of the maximum and minimum particle diameters does not substantially exceed 4, the die pressure is 30 MPa or more at a solids filling rate of 0.70, 50 MPa or more at a solids filling rate of 0.75, and 90 MPa or more at a solids filling rate of 0.80. , a Mohs hardness of more than 7 (for the minerals that make up particle C), a Knoop indentation hardness of more than 800 (for the minerals that make up particle C). 21. The composite material further comprises an additional component D having at least one dimension at least one order of magnitude larger than particles A, and the amount of particles A is such that particles B, C and D are When the particles B, C, and D are densely packed into the composite material without being substantially deformed, in substantial contact with each other, and with substantially no bridging phenomenon, the voids between the particles B, C, and D are filled. The amount of water is less than the amount that can be theoretically filled, and the amount of water is less than the amount that can be filled theoretically.
is formed between particles A, B, C, and D when the particles are densely packed as defined above and particles A are uniformly distributed in the voids between the tightly packed particles B, C, and D. The amount of surface-active dispersant is just enough to fill the voids, and the amount of surface-active dispersant is such that when the composite material is mixed, there is a dense packing of particles B, C and D as defined above and a uniform distribution of particles A as defined above. 21. The method of claim 19 or 20, wherein the amount is sufficient to achieve.