JPH0776013A - Manufacture of roof tile - Google Patents

Abstract

PURPOSE:To provide a manufacturing method for simple roof tiles capable of affording diversified designs, surface decorations, and large-sized formed items by enabling formation even in a small quantity of water. CONSTITUTION:A hydraulic inorganic composite 2 is supplied into an extruder 1, and an uncured inorganic continuous formed body 4 is extruded by passing through a dies 3 mounted on the tip end of the extruder 1, and then the surface of the inorganic continuous extruded formed body 4 is cut in its side surface while giving decoration on the inorganic continuously extruded formed body 4 by means of a decoration roller 5 having irregular patterns on its surface and a cutting blade.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing roof tiles.

[0002]

2. Description of the Related Art Conventionally, as roof tiles, clay tiles such as Yuzu leaf tiles and Ibushi tiles have been well known and have been most often used. However, recently, quality clay has decreased,
It has become difficult to mass-produce products with good performance. Therefore, roof tiles using a so-called hydraulic inorganic cured material such as thick slate and cement roof tile have been produced.
These use a large amount of water relative to the amount of cement in order to improve the moldability, so it takes time for the dehydration and demolding steps, and it is difficult to increase the productivity, and the obtained cured product Was of low strength. Therefore, in order to enable molding even with a small amount of water, a method of extruding a hydraulic inorganic composition in a plate shape by an extrusion molding machine and subsequently press-molding it into a tile shape by a press machine (Japanese Patent Publication No. 57-1900).
No. 9, Japanese Patent Laid-Open No. 2-307852, etc.) have been proposed. However, in the above method, since press molding is performed by a pressing machine, in order to cope with various designs and surface decoration, it is necessary to prepare many kinds of molds, and
A high pressure is required to form a large molded product,
There were drawbacks such as shortening the life of the mold and increasing the size of the equipment.

The object of the present invention is to solve the above problems and to enable molding with a small amount of water.
An object of the present invention is to provide a simple roof tile manufacturing method capable of forming a variety of designs, surface decorations, and large molded products.

[0003]

An extrusion apparatus used in the present invention includes a portion parallel to an axial direction and a portion continuous in a circumferential direction, and has a cutting blade sharply protruding in a radial direction from an outer periphery, A cylindrical decorative roll having an uneven pattern formed on the outer peripheral surface and being rotatable is installed near a die outlet attached to the tip of the extruder.

The hydraulic inorganic composition used in the present invention comprises a hydraulic inorganic substance, water, and if necessary, reinforcing fiber, inorganic filler and the like.

The hydraulic inorganic substance used in the present invention is not particularly limited as long as it is an inorganic substance which shows a hardening property when kneaded with water. For example, ordinary portland cement, special portland cement, alumina cement, roman cement, etc. Cement, acid resistant cement, fire resistant cement,
Examples include special cements such as water glass cement, and air-hardening cements such as gypsum, lime, and magnesia cement. Particularly, in terms of strength and water resistance, Portland cement and alumina cement are preferably used. These may be used alone or in combination of two or more.

When the amount of water used in the present invention is small, the hydraulic inorganic substance is not sufficiently cured, and
The dispersibility of the composition decreases, and when it increases, the strength of the finally obtained cured product decreases, so 15 to 100 parts by weight is preferable to 100 parts by weight of the hydraulic inorganic substance.

In the present invention, a water-soluble polymer substance may be added if necessary. The water-soluble polymer substance,
It dissolves in water to give viscosity, enhances the fluidity of the composition obtained from the hydraulic inorganic substance and water to improve the shapeability, and absorbs excess water in the cement hardened product to cement. Polymeric substances that can serve as a binder for filling voids between particles are preferable, and examples thereof include cellulose ethers such as methyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, hydroxypropyl methyl cellulose, polyvinyl alcohol, polyacrylic acid, and lignin sulfonate. can give. When the amount of the water-soluble polymer substance added decreases, the fluidity of the composition decreases, and when the amount of the water-soluble polymer substance increases, the water resistance of the finally obtained cured product decreases, so 1 part by weight relative to 100 parts by weight of the hydraulic inorganic substance is added. The following are preferred.

In the present invention, an inorganic filler may be added if necessary. The inorganic filler is preferably one that does not dissolve in water, does not inhibit the hardening reaction of the hydraulic inorganic substance, and does not significantly inhibit the action of any constituent material used in the production method of the present invention, such as silica sand and river sand. Cement mortar aggregates, fly ash, silica flour, silica fume, bentonite, blast furnace slag, and other mixed cement admixtures, sepiolite, wollastonite, natural minerals such as mica, calcium carbonate, and diatomaceous earth. For the purpose of further reducing the weight, inorganic natural foams such as silica balloons, perlite, fly ash balloons, shirasu balloons, glass balloons and foamed and baked clay may be added. These may be added alone or in combination of two or more.

When the average particle size of the above-mentioned inorganic filler is small, the strength of the finally obtained cured product is low, and when it is large, the particles of the inorganic filler are difficult to disperse, so that the impact strength is low. 0.03 to 500 μm is preferable. The amount of the above-mentioned inorganic filler is preferably 200 parts by weight or less with respect to 100 parts by weight of the hydraulic inorganic substance, because the strength of the finally obtained cured product decreases as the added amount increases.

In the present invention, reinforcing fibers may be further added if necessary. As the reinforcing fiber, any one can be used according to the performance desired to be imparted to the molded product, and examples thereof include vinylon fiber, polyamide fiber, polyester fiber, polypropylene fiber, carbon fiber, aramid fiber, glass fiber, potassium titanate fiber, and steel fiber. Can be used.
The fiber diameter of the reinforcing fiber is reaggregated at the time of mixing when it becomes thin, fiber balls are easily formed by entanglement, the strength of the finally obtained cured product is not further improved, and when it becomes thick or short, the tensile strength is increased. Since the reinforcing effect such as improvement is small and the dispersibility and orientation of the fiber are reduced when it is long, the fiber diameter is preferably 0.1 to 40 denier and the fiber length is 1 to 15 mm. Since the dispersibility of the fibers decreases as the amount of the reinforcing fibers added increases, the hydraulic inorganic substance 1
20 parts by weight or less is preferable with respect to 00 parts by weight.

The manufacturing method of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic front view showing an example of the manufacturing method of the present invention. FIG. 2 is a schematic plan view showing an example of the manufacturing method of the present invention.

A die 3 is attached to the tip of the extruder 1, and a cylindrical decorative roll 5 is installed near the exit of the die 3. The decorative roll 5 is rotatable, and an uneven pattern 6 is formed on the outer peripheral surface thereof, and a cutting blade 7 is provided. The cutting blade 7 includes a portion 71 that is parallel to the axial direction and a portion 72 that is continuous in the circumferential direction, and projects sharply in the radial direction from the outer circumference.

The material of the cutting blade 7 is generally steel, but other metals, synthetic resins, ceramics or the like may be used. The tip of the cutting blade 7 is preferably provided with a taper of 2 to 5 ° in order to surely cut the inorganic plate-shaped continuous extrusion molded body 4. If the thickness of the cutting blade 7 is thin, the blade is likely to be chipped, and if it is thick, it becomes difficult to cut, so 0.5 to 5 mm is preferable. In the present invention, first, the hydraulic inorganic composition 2 is supplied to the extruder 1. The hydraulic inorganic composition 2 supplied to the extruder 1 is a die 3
And is extruded to obtain an uncured inorganic plate-shaped continuous extrusion molded body 4. When the extrusion speed is low, it becomes difficult to cut while decorating the surface of the inorganic plate-shaped continuous extrusion-molded product 4, and when it is high, the concavo-convex pattern 6 of the decorating roll 5 is not clearly transferred, so 5 to 500 mm / sec is preferable. .

A cutting blade is obtained by pressing the obtained inorganic plate-shaped continuous extruded product 4 while rotating the decorated roll 5 in the transport direction of the inorganic plate-shaped continuously extruded product 4 by the decorative roll 5. The inorganic plate-shaped continuous extrusion-molded body 4 is cut by 7 and an uneven pattern corresponding to the uneven pattern 6 of the decorative roll is provided on the surface, and the roof tile 8 is obtained. The pressing force when the inorganic continuous extruded body 4 is cut by the cutting blade 7 varies depending on the hardness of the inorganic plate-shaped continuous extruded body 4, but if it is too high, there is a problem that the uneven pattern is damaged. / Cm ² is preferred.

The roof tile of the present invention can be cured by using a conventional curing method, for example, by heating at the same time as decoration. In addition, although the obtained cured product may be naturally cured over time,
When a hydraulic inorganic substance such as Portland cement, which has a slow curing reaction, is used, the curing reaction is promoted by performing curing by a conventionally known method such as heating and humidifying the molded body, or performing autoclave curing. You can
The mechanical properties can be improved.

[0016]

EXAMPLES The present invention will be described in more detail by way of examples. Example

100 parts by weight of ordinary Portland cement (manufactured by Onoda Cement Co.), polypropylene fiber (fiber diameter 1
5 μm, fiber length 6 mm) 2 parts by weight, fly ash (average particle size 100 μm, true specific gravity 2.3, bulk specific gravity 0.
6; 40 parts by weight according to JIS A 6201), hydroxypropylmethyl cellulose (2% at 20 ° C.)
Aqueous solution concentration of 30,000 cps) and 25 parts by weight of water are mixed by a mixer, and the kneaded product obtained by kneading is supplied to an extruder having a screw diameter of 200 mm, and an extrusion direction attached to the tip of the extruder. Was passed through a die having a parallel portion of 100 mm and extruded at a speed of 100 mm / sec to obtain an uncured inorganic continuous extrusion molded article having a width of 400 mm and a thickness of 6 mm. The resulting uncured inorganic continuous extruded product was treated with a decorative roll having natural stone pattern irregularities on the surface and a cutting blade having a tip thickness of 0.7 mm and a taper of 2 ° to form a continuous inorganic extruded product. Surface of 10
It was pressed with a pressing force of kg / cm ^{2 and} the side surface was cut while imparting the irregularities of a natural stone pattern to obtain a molded product having a length of 800 mm. The obtained molded body was steam-cured at 60 ° C. and 90% RH for 6 hours to obtain a roof tile. The production capacity is 1500kg /
It was hr. Comparative Example After obtaining an uncured inorganic continuous extrusion-molded product having a width of 400 mm and a thickness of 6 mm in the same manner as in the example, it was cut into a length of 800 mm and supplied to a pressing mold having natural stone pattern irregularities on the surface, 10kg / cm by 200ton press molding machine
^It was pressed with a pressing force of ² and molded at 20 seconds / sheet. The production capacity was 590 kg / hr.

[0018]

EFFECTS OF THE INVENTION The method of manufacturing roof tiles of the present invention is as described above, and therefore enables molding with a small amount of water.
It is possible to provide a simple roof tile manufacturing method capable of molding various designs, surface decorations, and large molded products.

[Brief description of drawings]

FIG. 1 is a schematic front view showing an example of a manufacturing method of the present invention.

FIG. 2 is a schematic plan view showing an example of the manufacturing method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Extrusion molding machine 2 Hydraulic inorganic composition 3 Dies 4 Inorganic plate-like continuous extrusion molding body 5 Decorative rolls 6 Uneven pattern 7 Cutting blade 71 Part parallel to axial direction 72 Part continuous in circumferential direction 8 Roof tile

Claims (1)

[Claims] 1. A cutting blade which includes a portion parallel to the axial direction and a portion continuous in the circumferential direction and which sharply projects in the radial direction from the outer circumference, and has an uneven pattern formed on the outer circumferential surface and is rotatable. Cylindrical decorative roll which is said to be an extruder installed near the exit of the die attached to the tip of the extruder, supplies the hydraulic inorganic composition to the extruder, and passes through the die and is uncured. By extruding the inorganic plate-shaped continuous extruded product and pressing the inorganic plate-shaped continuous extruded product while rotating the decorative roll in the transport direction of the inorganic plate-shaped continuous extruded product, the inorganic plate-shaped continuous extruded product A method for producing a roof tile, which comprises cutting the body surface while providing an uneven pattern corresponding to the uneven pattern of a decorative roll.