JPH05200717A - Method and apparatus for producing inorganic building material - Google Patents

Abstract

PURPOSE:To produce an inorg. building material having decorative patterns provided thereto by shaping certain decorative patterns on the surface of an uncured inorg. molded object in an extrusion molding process without using a release agent. CONSTITUTION:An unhardened inorg. molded object 9 is extruded from the mold 2 provided to the leading end of an extruder 1 and an emboss decorating device 5 rotating in synchronous relation to the emission speed of the unhardened inorg. molded object 9 is brought into contact with the surface of the unhardened inorg. molded object 9 through an expansible member 6 to shape decorative patterns.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing an inorganic building material which forms a decorative pattern on the surface in an extrusion molding process.

[0002]

2. Description of the Related Art Heretofore, a method of manufacturing an inorganic building material has been widely used in which an uneven pattern or the like is formed on the surface in the extrusion molding process.

For example, when an uneven pattern is formed on the surface along the extrusion direction, unevenness is provided on the inner surface of the top die of the molding die, and the inorganic kneaded material is extruded from this top die to form the uneven pattern on the surface. Has been adopted. However, according to this method, only a simple uneven pattern along the extrusion direction can be formed on the surface.

Further, as a method of forming a concavo-convex pattern on the surface in a direction not along the extrusion direction, for example, Japanese Patent Publication No. 58-38.
As described in Japanese Patent No. 085, a method has been proposed in which an endless strip having an uneven pattern on the outer surface is made to face a core body of an extrusion molding die and is rotated in synchronization with the extrusion speed.

[0005]

However, according to this method, it is possible to form a relatively simple uneven pattern on the surface, but it is impossible to form a complicated wood grain pattern or a design pattern. There is a problem. As the cause, in the inorganic composition for the uncured inorganic molded body that forms a concave-convex pattern on the surface in the extrusion molding process, uniform flow characteristics in the die die and the uncured inorganic molded body extruded collapses. In order to prevent the shape retention, a fine aggregate used for imparting an appropriate shape retention property and a water retention admixture such as methyl cellulose are blended. For this reason, the uncured inorganic molded body is likely to adhere to the surface of the endless strip having an uneven pattern, and it is difficult to form a reliable uneven pattern on the surface.

Therefore, in this method, in order to reliably form an uneven pattern on the surface of the uncured inorganic molded body, it is necessary to manufacture the endless belt while continuously applying a release agent. However, there is a problem that this release agent adversely affects the coating film performance of the paint used in the subsequent step.

The present invention solves the above-mentioned conventional problems, and forms a reliable decorative pattern on the surface of an uncured inorganic molding without using a release agent in the extrusion molding process. Accordingly, it is an object of the present invention to provide a method and an apparatus for manufacturing an inorganic building material capable of manufacturing an inorganic building material having a decorative pattern with a good appearance on the surface.

[0008]

The method for producing an inorganic building material of the present invention is a method for producing an inorganic building material, which comprises curing and curing after decorating a decorative pattern on the surface of an uncured inorganic molded body in an extrusion molding process. , The uncured inorganic molded body is extruded from the molding die provided at the tip of the extrusion device, and the surface of the uncured inorganic molded body is rotated at the surface speed synchronized with the discharge speed at the upper end of the molding die. This is a method of shaping a decorative pattern by bringing the body into contact with the elastic member.

In the present invention, first, an inorganic molding raw material is supplied to an extruder to extrude an uncured inorganic molded body from a molding die. Then, at the time of extrusion, from the upper end of the upper molding land of the molding die, a rotating body whose surface speed rotates in synchronization with the discharge speed of the uncured inorganic molded body is stretched over the elastic body. Through, to contact the surface of the uncured inorganic molded body to form a decorative pattern on the surface.

At the time of shaping the decorative pattern, the elastic member is the uncured inorganic molded body of the rotating body at the portion of the surface of the uncured inorganic molded body where the rotating body is most pressed through the elastic member. The decorative pattern is formed in a state of being deformed by the pressing force of, and as the rotating body rotates from that part to the part near the surface of the uncured inorganic molded body, it gradually recovers, and the rotating body When the pressing force disappears, the elastic member recovers from the decorative pattern formed on the surface of the uncured inorganic molded body due to the resilience of the elastic member, so that the material of the uncured inorganic molded body may adhere to the elastic member. Even without using a release agent, a reliable decorative pattern can be formed, and an inorganic building material having a decorative pattern with a good appearance on the surface can be manufactured.

As a result, the material of the uncured inorganic molded body does not adhere to the stretchable member without using a release agent, and the decorative pattern can be reliably formed. The uncured inorganic molded body whose surface has a decorative pattern is
For example, by receiving on a tray, cutting each tray, and curing and curing this together with the tray, an inorganic building material having a decorative pattern with a good appearance on the surface can be obtained.

In the present invention, the inorganic molding raw material comprises a hydraulic inorganic substance, water and a water-soluble polymer substance,
A composition to which reinforcing fibers, an inorganic lightweight aggregate and the like are added, if necessary, is used.

As the hydraulic inorganic substance, any inorganic substance which shows a hardening property when kneaded with water can be used without any particular limitation. For example, ordinary Portland cement, special Portland cement, alumina cement,
Examples include plain cement such as roman cement, acid-resistant cement, fire-resistant cement, special cement such as water glass cement, and air-hardening cement such as gypsum, lime, and magnesia cement. Especially, in terms of strength and water resistance, Portland cement Alumina cement is preferably used.

The amount of water added is preferably 20 to 100 parts by weight with respect to 100 parts by weight of the hydraulic inorganic substance. If the amount added is less than 20 parts by weight, the hydraulic inorganic substance will tend to be insufficiently hardened. On the contrary, if the amount added exceeds 100 parts by weight, the mechanical strength of the resulting molded article will decrease. Tend to do.

As the water-soluble polymer substance, it is dissolved in water to give viscosity, and the fluidity of the composition comprising the hydraulic inorganic substance and water is improved to improve the shapeability, and the cement is used. It can be used without particular limitation as long as it is a polymer substance that absorbs excess water in the cured body and can serve as a binder that fills the voids between the cement particles, for example, methyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, Examples thereof include cellulose ethers such as carboxymethyl cellulose and hydroxypropyl methyl cellulose, polyvinyl alcohol, polyacrylic acid and the like.

As the reinforcing fiber, any reinforcing fiber can be used depending on the performance desired to be imparted to the molded body.
Examples thereof include synthetic fibers such as vinylon, polyamide, polyester, polypropylene, carbon, aramid, acrylic, and rayon, glass fibers, potassium titanate, inorganic fibers such as steel, pulp, and the like. In particular, when synthetic fibers are used, the flexibility is remarkably improved, so that they are preferably used.

The reinforcing fiber has a thickness of 0.1 to 40 denier,
Those having a length of 1 to 15 mm are preferably used. The thickness is
If it is less than 0.1 denier, it tends to be re-aggregated during mixing, forming fiber balls easily due to entanglement, and making it difficult to further improve the strength of the resulting molded article.
On the other hand, when it exceeds 40 denier, the reinforcing effect such as improvement in tensile strength of the obtained molded article tends to be small.
Further, when the length is less than 1 mm, the reinforcing effect such as improvement in tensile strength tends to be small, and conversely, when the length is more than 15 mm, the dispersibility and orientation of the fibers tend to be deteriorated. There is.

The reinforcing fiber is added in an amount of the hydraulic inorganic substance 10
20 parts by weight or less is preferable with respect to 0 parts by weight. If the amount added exceeds 20 parts by weight, the dispersibility of the fibers tends to decrease.

The inorganic filler is not particularly limited as long as it does not dissolve in water, does not inhibit the curing reaction of the hydraulic inorganic substance, and does not significantly inhibit the action of the composition material used in combination. For example, silica sand, aggregates for semet mortar such as river sand, fly ash, silica flour, silica fume, bentonite, mixture material for mixed cement such as blast furnace slag, natural minerals such as sepiolite, wollastonite and mica, calcium carbonate , Diatomaceous earth and the like. For the purpose of further reducing the weight, silica natural balloons, perlite, fly ash balloons, shirasu balloons, glass balloons, inorganic natural foams such as foaming firing viscosity may be used. These may be used alone or in combination of two or more kinds.

The inorganic filler has an average particle size of 0.03 to 50.
Those having a thickness of 0 μm are preferably used. If it is less than 0.03 μm, the strength of the resulting molded article tends to decrease, and conversely, if it exceeds 500 μm, the particles of the inorganic filler are difficult to disperse and the impact strength tends to decrease. ..

The addition amount of the inorganic filler is the hydraulic inorganic substance 1
It is preferably 200 parts by weight or less with respect to 00 parts by weight. If the amount added exceeds 200 parts by weight, the strength of the obtained molded article tends to decrease.

In the apparatus for producing an inorganic building material of the present invention, a molding die is provided at the tip of an extruding device for extruding an uncured inorganic molding, and a rotating body is provided above the tip of the molding die, and an outer peripheral surface thereof is provided. A stretchable member is stretched, and the outer peripheral surface of the rotating body comes into contact with the surface of the uncured inorganic molded body discharged from the molding die through the stretchable member, and synchronized with the discharge speed of the uncured inorganic molded body. It is capable of rotating at a surface speed of

FIG. 1 is an example of an apparatus for manufacturing an inorganic building material according to the present invention. In FIG. 1, reference numeral 1 is an extruder, and a hollow molding die 2 is provided at a molding discharge port at the tip of the extruder 1. The hollow molding die 2 is provided with a molding land 3 and a core 4 for molding the hollow portion. The upper molding land 31 of the molding land 3 is shortened by cutting out the front end side, and the front surface of the front end portion is a concave arc surface.

The embossed decorative roll 5 is provided in the notched portion on the tip side of the upper molding land 31. An engraved pattern AB for forming a decorative pattern on the surface of the uncured inorganic molded body is provided on the outer peripheral surface thereof. The embossed decorative roll 5 is rotatable by a driving means (not shown) such that its surface speed is synchronized with the discharge speed of the uncured inorganic molded body discharged from the hollow molding die 2.
The lower end of the upper molding land 31 can be appropriately adjusted so as to be located on the extension line of the lower surface of the upper molding land 31 or slightly below the extension line.

A turn roll 7 is provided above the embossed decorative roll 5. An endless belt-shaped elastic member 6 is hung between the embossed decorative roll 5 and the turn roll 7, and is adjusted by a tension roll 8 to have an appropriate tension. It is stretched around the embossed decorative roll 5 and the turn roll 7 by rotation.

In the present invention, the rotating body may be, for example, an embossed decorative roll having an embossed pattern such as an uneven pattern or an engraved pattern on the outer peripheral surface thereof, or a belt-shaped rotating body, such as a roll having a solid or satin outer peripheral surface or a belt-shaped rotating body. Etc. can be used.

In the present invention, the elastic member is breathable, has the property of expanding when pulled and returning to its original state when loosened, and is a sheet-like material such as a woven cloth or mesh material having a thickness of 5 mm or less. It can be preferably used.

Specific examples of the stretchable member include, for example, spandex cloth (generally, swimwear, socks, panties, etc.) that is made of stretchable polyurethane fibers and nylon or acrylic fibers / polyester fibers, etc. As a woven fabric used for stockings and the like, for example, a product name “Leuca” manufactured by Asahi Kasei Co., Ltd.) is preferably used.

Various decorative patterns can be provided on the surface of the inorganic building material by various combinations of the surface condition of the outer peripheral surface of the rotating body and the elastic member. For example, as the rotating body, when using an embossed decorative roll or a belt-shaped rotating body provided with an embossed pattern such as an uneven pattern or an engraved pattern on the outer peripheral surface thereof, a satin pattern using a fiber that expands and contracts as an elastic member or To produce an inorganic building material having a profound decorative pattern with a texture of the fabric such as the texture of the fabric and the texture of the fabric in addition to the embossed pattern on the surface of the rotating body by using the fabric of the floral pattern. You can

When a roll or a belt-shaped rotary member having an outer peripheral surface which is solid or satin is used as the rotary member, a stretchable silk fabric or a flower pattern embroidery cloth is used. Although it is flat, it is possible to manufacture an inorganic building material having a silky tofu texture or a decorative pattern with a floral texture on the entire surface.

In the present invention, examples of the inorganic building material include an inorganic building board containing cement, an inorganic aggregate or the like as a main component, and an L-shaped inorganic building corner accessory such as a corner material with a raised corner. Be done.

[0032]

The method for producing an inorganic building material according to the present invention is such that an uncured inorganic molded body is extruded from a molding die provided at the tip of an extrusion device, and the uncured inorganic molded body has a surface on the tip of the molding die. When a decorative pattern is formed by contacting a rotating body that rotates at a surface speed synchronized with the discharge speed through an elastic member, the surface of the uncured inorganic molded body is formed when the decorative pattern is formed. In the part where the rotating body is most pressed through the elastic member, the elastic member shapes the decorative pattern in a state of being deformed by the pressing force applied to the uncured inorganic molded body of the rotating body, and from that part. The uncured inorganic molded body gradually recovers as it rotates from the surface of the uncured inorganic molded body to the part near the surface of the uncured inorganic molded body. Remove from the decorative pattern formed on the surface of the Therefore, the material of the uncured inorganic molded body does not adhere to the stretchable member or the rotating body, and even without using a mold release agent, a reliable decorative pattern is formed and the surface is decorated with a good appearance. It is possible to manufacture a patterned inorganic building material.

In the apparatus for producing an inorganic building material of the present invention, a molding die is provided at the tip of an extrusion device for extruding an uncured inorganic molding, and a rotating body is provided above the tip of the molding die, and the outer peripheral surface is provided on the outer surface of the body. A stretchable member is stretched, and the outer peripheral surface of the rotating body comes into contact with the surface of the uncured inorganic molded body discharged from the molding die through the stretchable member, and synchronized with the discharge speed of the uncured inorganic molded body. The uncured inorganic molded material does not adhere to the stretchable member or the rotating body because it can be rotated at a surface speed that ensures a reliable decorative pattern without using a release agent. It can be used as an apparatus for manufacturing an inorganic building material, which is shaped and provided with a decorative pattern having a good appearance on the surface.

[0034]

【Example】Example Manufacture of raw materials for molding Portland Cement (ordinary port made by Onoda Cement
Land cement) 100 parts by weight, silica powder (Sumitomo Cement)
Made by the company, specific gravity 1.11, average particle size 5.7 μm) 50 weight
Part, fly ash (manufactured by KANDENKA CORPORATION, specific gravity 2.2, comparison table
Area 3400 cm ²/ G) 40 parts by weight, shirasu balloon
(Taken Industry Co., Ltd., specific gravity 0.08, average particle size 150 μm)
10 parts by weight, polypropylene fiber as reinforcing fiber (tether
Manufactured by CK: product name "Taflight", average length 9 mm) 3
Parts by weight, methyl cellulose (manufactured by Shin-Etsu Chemical Co., Ltd .: trade name “9
0SH ") 2 parts by weight, pulp (manufactured by Kojinsha:" Cell top "
HS106 ") and 2 parts by weight of the Erich mixer (Japan
3) at a rotation speed of 880 rpm.
After dry blending for 55 minutes, add 55 parts by weight of water,
The mixture was mixed for 2 minutes at the same rotation number.

The mixture was kneaded from an Erich mixer, using a kneader having a barrel diameter of 100φ (Miyazaki Tekko Co., Ltd.). Manufacturing of Inorganic Building Material A method of manufacturing the inorganic building material shown in FIG. 3 will be described with reference to FIG.

A vacuum extruder was used as the extruder 1, and the kneaded product obtained above was supplied to this, and the hollow plate-shaped uncured inorganic molded body 9 was continuously extruded from the hollow molding die 2. As the elastic member 6, a plain spandex cloth (manufactured by Roika Corporation: trade name "AP61110") is used, and as the embossed decorative roll 5, a stack-like engraving pattern AB is provided on the surface thereof.
Using the one provided with, at the tip of the hollow molding die 2,
A decorative pattern A′B ′ was formed on the upper surface of the uncured inorganic molded body 9 by the embossed decorative roll 5 via the elastic member 6. When shaping a decorative pattern, an uncured inorganic molded body 9
The material of the embossed decorative roll 5 through the elastic member 6
The decorative pattern A′B ′ could be shaped reliably without adhering to the surface.

The uncured inorganic molded body 9 having a decorative pattern on its upper surface was received by a tray, cut into each tray, and steam curing was performed together with the tray in an atmosphere of 60 ° C. for 8 hours.
By removing from the mold, as shown in FIG. 3, a surface having a decorative pattern A′B ′, thickness 15 mm, width 250 mm, length 3
Fifty m hollow plates 10 were obtained.

As a result, the spandex cloth was not damaged at all. Further, it was possible to obtain the hollow plate 10 on which the decorative pattern A'B 'in a stack-like shape having a reliable and good appearance was formed.

Comparative Example A hollow plate was manufactured in the same manner as in Example except that the elastic member 6 was not used.

As a result, when shaping the decorative pattern, the material of the uncured inorganic molded body adheres to the surface of the embossed decorative roll, and a hollow plate having the decorative pattern formed on the surface is obtained. I couldn't.

[0041]

[Effect] Since the method for producing an inorganic building material of the present invention is configured as described above, the material of the uncured inorganic molded body adheres to the stretchable member and the rotating body when shaping the decorative pattern. Without using a release agent, it is possible to reliably form a decorative pattern and manufacture an inorganic building material having a decorative pattern on its surface.

Since the apparatus for manufacturing an inorganic building material of the present invention is configured as described above, when shaping a decorative pattern,
It can be provided as an apparatus for manufacturing an inorganic building material in which a reliable decorative pattern is formed without adhering the material of the uncured inorganic molded body to the stretchable member or the rotating body and the surface is provided with the decorative pattern.

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of an apparatus for manufacturing an inorganic building material of the present invention.

FIG. 2 is a cross-sectional view illustrating an example of a method for manufacturing an inorganic building material of the present invention.

FIG. 3 is a perspective view showing an example of an inorganic building material obtained by the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Extruder 2 Hollow molding die 3 Molding land 4 Core 5 Embossing decorative roll 6 Elastic member 7 Turn roll 8 Tension roll 9 Unhardened inorganic molding 10 Hollow plate 31 Upper molding land AB Engraving pattern A'B 'addition Decorative pattern

Claims (2)

[Claims] 1. In a method for producing an inorganic building material in which a decorative pattern is formed on the surface of an uncured inorganic molded body in an extrusion molding process, and then cured by curing, it is uncured from a molding die provided at the tip of an extrusion device. The inorganic molded body is extruded, and the surface of the uncured inorganic molded body is brought into contact with a rotating body that rotates at a surface speed that is synchronized with the discharge speed at the top of the tip of the molding die through a stretchable member to give a decorative pattern. A method for manufacturing an inorganic building material, which comprises shaping. 2. A molding die is provided at the tip of an extruding device for extruding an uncured inorganic molding, and the tip of the molding die has an upper part,
A rotating body is provided, and an elastic member is stretched on the outer peripheral surface of the rotating body. The rotating body is in contact with the outer peripheral surface of the uncured inorganic molded body discharged from the molding die through the elastic member.
An apparatus for producing an inorganic building material, which is capable of rotating at a surface speed that is synchronized with a discharge speed of an uncured inorganic molded body.