JPH0691624A - Manufacture of decorative mat for molding concrete plate and molding tool used for manufacture - Google Patents

Abstract

PURPOSE:To release a molded decorative mat without moving a bottom force and also without accumulating tailings of a releasant on the surface of a projected and recessed pattern transfer layer by blowing a pressurized fluid off the surface of projected and recessed pattern transfer layer formed on a bottom force before releasing. CONSTITUTION:A molding tool consists of a top force 2 and a bottom force 1, and the bottom force 1 composed of a bottom face section, a frame section for encircling the bottom face section by a proper space and forming a molding recess and a porous recessed and projected pattern transfer layer formed on the bottom face of the molding recess, while the top force 2 is composed of a cover material for the molding recess and provided with pressurized fluid force feeding section for force feeding the pressurized fluid into the recessed and projected pattern transfer layer and blowing the fluid off the surface of the recessed and projected pattern transfer layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative mat for molding concrete boards and a molding die used for the method.

[0002]

2. Description of the Related Art Generally, in order to transfer an uneven pattern onto a surface of a concrete board, a decorative mat having an uneven pattern corresponding to the uneven pattern is used, and the concrete material is in contact with the uneven pattern surface. It is cast. The upper mold 2 as shown in FIG. 6 is used for manufacturing such a makeup mat.
A molding die including 5 and the lower die 26 is used. The upper mold 25 is made of a flat iron plate, and the lower mold 26 is a flat iron bottom plate 26a.
And an iron frame 26b partially attached (movable or slidable) to the bottom plate 26a, and an uneven pattern transfer layer on the surface (an uneven pattern transfer layer similar to the uneven pattern to be formed on a concrete plate) A metal mold (for example, a casting mold, an aluminum mold, an iron mold, etc.) on which is formed 26c,
Alternatively, it is made of a resin type (for example, epoxy resin type, silicon resin type, etc.) 26c.

A cosmetic mat is manufactured in the following manner using the above molding die. That is, first, a mold release agent is applied to the surface of the uneven pattern transfer layer formed on the mold 26c of the lower mold 26, and then a foaming resin liquid such as a urethane foam resin is injected into the lower mold 26, and then plywood is applied from above. 27 is set and the plywood 27 is used to prevent bubbles from escaping. After that, the upper and lower molds 25 and 26 are closed. In that state, the foamed resin liquid is heated at a temperature of 40 to 60 ° C. to foam,
Then it is cured and then demolded. This allows
A decorative mat having a surface with an uneven pattern is obtained.

[0004]

However, in the above method, the wax component in the release agent melted at the time of heating is pressed by the foaming pressure of the foaming resin liquid to the surface of the uneven pattern transfer layer of the lower mold. The uneven pattern is gradually changed by being attached and accumulated. Therefore, in order to remove the slag caused by the wax component in the release agent, a solvent is applied to the surface of the uneven pattern transfer layer and scraped off with a metal brush. In addition to damaging the surface of the pattern transfer layer, if a resin mold is used as the mold 26c, the resin mold 26c will swell with the solvent. Moreover, since the foamed resin liquid is pressed from above by the plywood 27 to suppress escape of bubbles, the upper surface of the molded body (decorative mat) is located below the upper end surface of the lower mold 26 in the lower mold 26. Therefore, the decorative mat cannot be demolded only by opening the upper mold 25 and removing the plywood 27.
Therefore, a part of the iron frame 26b of the lower mold 26 is attached to the bottom plate 26.
Disadvantage that the mold cannot be released unless it is moved with respect to a to form a gap in the side surface and compressed air is blown to the contact portion between the surface of the uneven pattern transfer layer and the decorative mat using this gap. There is.

The present invention has been made in view of the above circumstances, and molding is performed without depositing the release agent residue on the surface of the uneven pattern transfer layer formed on the lower mold and without moving the lower mold. It is an object of the present invention to provide a method for producing a decorative mat for concrete plate molding capable of demolding the formed decorative mat and a molding die used for the method.

[0006]

In order to achieve the above object, the present invention comprises an upper die and a lower die, the lower die having a bottom portion and a bottom portion surrounded by an appropriate width for molding. A step of preparing a forming die comprising a frame portion for forming a recess and a porous uneven pattern transfer layer provided on the bottom surface of the forming recess, the upper die comprising a lid material for the forming recess; , A step of molding a decorative mat for concrete board molding by injecting a foamed resin liquid into the molding recess of the lower mold and then closing the upper and lower molds to foam and cure the foamed resin liquid, and when releasing the decorative mat A method for producing a decorative mat for concrete plate molding, which comprises a step of pressurizing a pressurized fluid into the uneven pattern transfer layer to blow it out from the surface of the uneven pattern transfer layer and demold the decorative mat, is defined as a first summary. It has a mold and a lower mold, and the lower mold has a bottom part and an appropriate width for the bottom part. A frame portion to create a go-between for molding recess,
It comprises a porous uneven pattern transfer layer provided on the bottom surface of the molding recess, the upper mold comprises a lid of the molding recess, pressurizing a pressurized fluid into the uneven pattern transfer layer. A second aspect is a mold having a pressurizing fluid press-fitting portion that is blown out from the surface of the uneven pattern transfer layer.

[0007]

That is, the method of the present invention comprises an upper die and a lower die, wherein the lower die has a bottom portion, a frame portion which surrounds the bottom portion with an appropriate width to form a forming recess, and A mold is used which is composed of a porous uneven pattern transfer layer provided on the bottom surface of the molding recess, and whose upper mold is a lid material for the molding recess. Then, first, after injecting the foamed resin liquid into the molding recess of the lower mold, for example, a bubble escape preventing plate-like body is disposed in the upper opening of the molding recess. Then, the upper and lower molds are closed, and in that state, the foamed resin liquid is heated to foam and then cured. As a result, the decorative mat for concrete plate molding having the uneven pattern formed by the transfer of the uneven pattern transfer layer is formed on the surface. When the decorative mat thus formed is released from the mold, a pressurized fluid such as pressurized air is pressed into the uneven pattern transfer layer and blown out from the surface of the uneven pattern transfer layer. As a result, the decorative mat is released from the surface of the uneven pattern transfer layer. At the time of this mold release, it becomes possible to grasp the above-mentioned makeup mat in a floating state by hand and take it out from the inside of the lower mold, without moving the iron frame of the lower mold as in the conventional example, and the makeup mat. Can be demolded. Moreover, by blowing compressed air from the surface of the uneven pattern transfer layer, the wax component of the release agent that melts during heating and adheres to the uneven pattern surface is blown away and does not accumulate on the surface of the uneven pattern transfer layer. . Therefore, there is no need to perform a cleaning operation using a solvent and a metal brush as in the conventional example, and the problem of damaging or swelling the surface of the uneven pattern transfer layer does not occur.

Next, the present invention will be described in detail based on examples.

[0009]

FIG. 1 shows one embodiment of the lower frame of the molding die of the present invention. In the figure, reference numeral 1 denotes a lower mold, and the lower mold 1 is a flat iron bottom plate 1a, an iron frame 1b which can be fitted and fixed in a fitting groove 1c formed in the bottom plate 1a, and the bottom plate 1a and the iron frame. 1b, the gypsum layer 6, the epoxy resin plate 5, the polyethylene sheet 4, which are sequentially arranged from the side of the bottom plate 1a, the foamed resin layer 3 with continuous pores having an uneven pattern formed on the surface, and It is composed of a polyethylene sheet 4 and an air passage 7 formed between the foamed resin layer 3.

The lower mold 1 as described above is manufactured as follows. That is, first, the foamed resin layer 3 with continuous pores
In order to provide the above, as shown in FIG. 2, a foam layer forming lower mold 20 having an uneven pattern (an uneven pattern in which the unevenness is opposite to the uneven pattern to be formed on the concrete plate) is formed,
The uneven pattern is arranged in an upward direction, and one end of the iron frame 1b of the lower mold 1 is fitted and fixed in the groove 20a of the lower mold 20 for foam layer formation. After that, the lower mold 20 for molding the foam layer
A mold release agent is applied to the surface on which the uneven pattern is formed, and then the epoxy resin liquid is poured into the iron frame 1b. Next, a mold release agent is applied to the mold surface of the foam layer forming upper mold 21 to form the foam layer forming upper mold 21.
Is set on the other end of the iron frame 1b. In this state, the epoxy resin liquid is heated to foam and then cured. During the curing, when the foamed epoxy resin liquid is in a semi-cured state, the foam layer molding upper mold 21 is removed,
As shown in FIG. 3, a series of vertical and horizontal grooves 7a are formed on the surface of the epoxy resin liquid in a semi-cured state. This groove 7a
The one end 7b is connected to the first through hole 12 formed in one side wall of the iron frame 1b, and the other end 7c is connected to the second through hole 13 formed in the other side wall of the iron frame 1b. When the curing is completed, a foamed resin layer 3 having continuous pores is obtained, in which a concavo-convex pattern (a concavo-convex pattern similar to the concavo-convex pattern applied to the concrete plate) is formed on one side surface and grooves 7a are formed on the other side surface. The polyethylene sheet 4 is attached to the other side surface of the foamed resin layer 3 (the side surface where the groove 7a is formed), and the other side surface a
An air passage 7 formed between the groove 7a and the polyethylene sheet 4 is provided in the. Then, an epoxy resin plate 5 for back-up is adhered onto the polyethylene sheet 4. At this time, a space is left between the epoxy resin plate 5 and the upper end surface of the iron frame 1b. Then, the fitting groove 1c of the bottom plate 1a of the lower mold 1 is fitted and fixed to the other end of the iron frame 1b, and gypsum is injected into the space through the injection hole 11 formed in the bottom plate 1a and cured. . After that, the foam layer forming lower die 20 is removed. As a result, the lower mold 1 as shown in FIG. 1 is manufactured.

Using the lower mold 1 and the flat plate-shaped upper mold 2 described above, a decorative mat with an uneven pattern is manufactured as follows. That is, first, as shown in FIG. 4, the lower mold 1 is set upward and set on the four support legs 14 (only two front legs are shown in the drawing). An air inflow pipe 9 provided with an on-off valve 9a is connected to a first through hole 12 formed in one side wall of the lower mold 1, and the pipe 9 is connected to a compressed air pressure source (not shown), The air outflow pipe 10 is connected to the second through hole 13 formed in the other side wall. At this time, the open / close valve 9a is closed. Then, lower mold 1
The mold release agent is applied to the uneven surface of the foamed resin layer 3 of
A polyurethane resin liquid is poured into the inside, and a plywood 8 for preventing bubbles from escaping from above is set. In that state, a hydraulic cylinder (not shown) is driven to lower the pressing tool 15 and lower the upper mold 2 attached to the lower end of the pressing tool 15,
The upper and lower molds 1 and 2 are closed by engaging the engagement part (not shown) of the upper mold 2 with the engaged part (not shown) of the lower mold 1. After that, by heating means (not shown) at a temperature of 40 to 60 ° C. for 5
It is held for 10 minutes to foam, and after the foaming process, it is cured at room temperature for a certain time (for example, about 1 hour).

In such a process, among the generated bubbles (cells), the cells in the vicinity of the uneven pattern forming surface of the foamed resin layer 3 and the mold surface are compressed by the foaming pressure and are crushed (disappeared). The cells in the vicinity of the mold surface are more likely to be crushed because they are compressed in the expanded state by heating.
On the other hand, the cells on the inner side of the surface of the foamed resin layer 3 which is closer to the uneven pattern forming surface and the mold surface are not affected by the pressure during foaming so much, and the cells remain without disappearing. as a result,
As shown in FIG. 5, in the decorative matte 22, a dense solid portion that can be said to be substantially free of cells, that is, the integral skin layer 23 and the porous portion 24 to be the internal foamed resin layer are formed. Come to do. In such a foam molding step, in order to efficiently form a good integral skin layer 23, it is effective to increase the foaming pressure to keep the foaming ratio of the raw material low.
The foaming pressure is in the range of 0.5 to ⁵ kg / cm ² , preferably 1 to ² kg / cm ² .

After the above curing is completed, the pressing tool 15 is raised to open the upper mold 2 and remove the plywood 8. Then,
The on-off valve 9a is opened, compressed air is supplied from the compressed air pressure source to the air passage 7 provided in the foamed resin layer 3, and is blown out from the uneven surface of the foamed resin layer 3 through the continuous pores of the foamed resin layer 3. . Due to the momentum of the compressed air, the makeup mat floats away from the uneven surface and rises a little above the upper end surface of the lower mold 1, then grasps it by hand and lifts it out of the lower mold 1. . The decorative mat with the uneven pattern thus obtained is used for forming a concrete board with the uneven pattern.

According to this structure, the makeup mat can be separated from the uneven pattern surface by the force of the compressed air blown from the uneven pattern surface of the foamed resin layer 3 formed on the lower mold 1, and the lower mold 1 has It can be easily demolded by letting it rise above the upper end surface. Moreover, the compressed air blows off the wax of the release agent adhering to the uneven pattern surface, leaving almost no residue on the uneven pattern surface, and does not accumulate as a slag.

[0015]

INDUSTRIAL APPLICABILITY As described above, according to the present invention, when the molded decorative mat is released from the mold, the concave-convex pattern transfer layer of the lower mold is pressed with a pressurized fluid such as pressurized air to transfer the concave-convex pattern. Blow off from the surface of the layer. As a result, the makeup mat can be released from the surface of the uneven pattern transfer layer, and at the time of this release, the makeup mat in a raised state can be grasped by hand and taken out from the lower mold. Therefore, the makeup mat can be removed from the mold without moving the lower iron frame as in the conventional example. Moreover, by blowing compressed air from the surface of the uneven pattern transfer layer, the wax component of the release agent that melts during heating and adheres to the uneven pattern surface is blown away and does not accumulate on the surface of the uneven pattern transfer layer. . Therefore, there is no need to perform a cleaning operation using a solvent and a metal brush as in the conventional example, and the problem of damaging or swelling the surface of the uneven pattern transfer layer does not occur.

[0016]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a lower mold of a molding die of the present invention.

FIG. 2 is an explanatory diagram showing a method for molding the lower mold.

FIG. 3 is a plan view of the lower mold during molding.

FIG. 4 is an explanatory view showing a process of producing a decorative mat using the above molding die.

FIG. 5 is a cross-sectional view of the makeup mat.

FIG. 6 is a cross-sectional view showing a conventional example.

[Explanation of symbols]

 1 Lower mold 2 Upper mold 3 Foamed resin layer 7 Air passage

Claims (2)

[Claims] 1. A lower mold comprising an upper mold and a lower mold, the lower mold having a bottom part, a frame part surrounding the bottom part with an appropriate width to form a molding recess, and a bottom part of the molding recess. And a step of preparing a molding die which is composed of a porous uneven pattern transfer layer provided in the upper mold and the upper die is a lid material of the molding recess, and a foaming resin liquid is injected into the molding recess of the lower mold. After that, the upper and lower molds are closed to foam and cure the foamed resin liquid to form a decorative mat for concrete board molding, and when the decorative mat is removed from the uneven pattern, a pressurized fluid is pressed into the transfer layer to form an uneven pattern. A method for producing a decorative mat for forming a concrete board, comprising a step of blowing out from the surface of the transfer layer to release the decorative mat. 2. A lower mold comprising an upper mold and a lower mold, the lower mold having a bottom part, a frame part surrounding the bottom part with an appropriate width to form a molding recess, and a bottom part of the molding recess. And a porous concave-convex pattern transfer layer provided in the upper mold, and the upper mold is formed of a lid material for the molding recess, and a pressurized fluid is pressed into the concave-convex pattern transfer layer and blown out from the surface of the concave-convex pattern transfer layer. A molding die having a pressurizing fluid press-fitting section for allowing the pressurizing fluid to press.