JPH0832415B2 - Inorganic plate having uneven pattern and method for producing the same - Google Patents

Description

TECHNICAL FIELD The present invention relates to an inorganic plate containing a hydraulic inorganic material as a main raw material and a method for producing the same, and more particularly to an inorganic plate having an uneven pattern and a method for producing the same.

<Prior art> Inorganic plates made mainly of hydraulic inorganic materials are used for inner and outer walls of houses, and various attempts have been made to improve the design by forming an uneven pattern or an embossed pattern on the surface. It has been done.

For example, in JP-A-56-12447, after forming a hydraulic inorganic raw plate by paper making, a grid-like groove having a depth of 0.5 to 3 mm is formed on the surface of the hydraulic inorganic raw plate by pressing, followed by curing. By doing so, a method for producing an inorganic plate having an uneven pattern has been proposed. Also, JP-A-62-111105
Japanese Patent Laid-Open Publication No. 2003-242242 discloses a method of transferring an engraved pattern of a plate to an uncured molded body by pressing a plate engraved with a pattern on an uncured molded body of an extruded product containing a hydraulic material as a main material and then releasing the plate. A method of forming a concavo-convex pattern on the extruded body has been proposed. Each of these conventional methods is a method of forming a desired concavo-convex pattern by pressing a press member having a shape matching the shape of a groove to be formed on an uncured body, and a method using an emboss roll. Compared to,
It is excellent in that a sharp uneven pattern with a sharp outline is formed and undesired deformation does not occur in the product.

<Problems to be Solved by the Invention> However, in these conventional techniques, the concave groove portions densely formed by the pressing force of the press member have a high specific gravity, and the specific gravity difference from other flat plate portions is significantly exhibited. To be done. For this reason, the strength (bending strength)
Is improved, but on the other hand it is weak against impact and easily cracked. Further, since the expansion / contraction characteristics differ between the concave groove portion and the flat plate portion due to water absorption, moisture absorption, and drying, the product is likely to be warped or twisted. Furthermore, when coating the surface to improve the design, the suction of the paint is different due to the difference in specific gravity between the concave groove portion and the flat plate portion, and uneven color and gloss are generated, resulting in a uniform However, it has a drawback that it is difficult to finish.

<Means for Solving the Problems> Therefore, the present invention aims to solve the above-mentioned drawbacks of the prior art and to provide a novel inorganic plate capable of adding a novel surface shape and a method for producing the same. And

The present invention, which was devised after intensive efforts to achieve such an object, is an inorganic plate having an uneven pattern due to pressing on the surface, with respect to the main raw material, a heat-shrinkable granular material having elasticity of 0.1 to 25% by weight. , And less than 35% by weight of a fibrous material are mixed, and a large number of fine granular concave portions formed by the heat shrinkage of the heat-shrinkable granular material are formed on the convex portions forming the uneven pattern. It is a characteristic inorganic plate.

Furthermore, the present invention uses a hydraulic inorganic material as a main raw material, and mixes a heat-shrinkable granular material having elasticity of 0.1 to 25% by weight, and a fibrous material of less than 35% by weight with respect to the main raw material. After adding water to form a kneaded product, the kneaded product is formed into a plate-shaped green plate, and then the surface of the plate-shaped green plate is pressed by a concave-convex die to perform molding, and then the heat-shrinkable granular material It is cured and cured at a temperature higher than the shrinking temperature of the body, and a large number of fine granular concave portions are formed on the surface of the convex portion of the uneven surface of the plate-shaped raw plate due to the heat shrinkage of the heat-shrinkable granular body. It is a method for producing an inorganic plate having a concavo-convex pattern characterized by being densified.

<Function> Since the elastic granular material having water retention property is mixed in the inside of the plate-shaped raw plate, the elastic granular body is deformed when the plate-shaped raw plate is pressed by the concave-convex die, and the internal retention Water is squeezed out and acts as a lubricant. At the same time, the particles that are pressed and deformed try to restore their original shape due to their elasticity. Due to the function as a lubricant and the restoring pressure of the granular material, the fluidity of the mixed material in the pressing portion is improved, and the flow to the area other than the pressing portion is actively performed. As a result, the corresponding part of the granular material itself is also moved to the convex side forming the concave-convex pattern, and when the pressure is released, it is restored by its elasticity and a large number of fine granular projections are formed on the convex surface. After that, since the heat-shrinkable granules are aged at a temperature equal to or higher than the melting temperature, the granules are melted and shrunk, and a large number of fine granular projections formed on the surface of the convex portion are destroyed to form fine granular concave portions. It is expressed on the surface.

<Detailed Description of Configuration of the Invention> The kneaded product formed into a plate-like green plate is mainly composed of a hydraulic inorganic material such as cement, slag, calcium silicate, and gypsum, and 0.1 to It is obtained by adding and mixing a heat-shrinkable granular material having elasticity of 25% by weight and an appropriate amount of water.
The elastic heat-shrinkable granules are granules or crushed granules of expanded plastic and have water retention properties. Examples of the foamed plastic include polyvinyl chloride, polyethylene, polypropylene, ethylene-vinyl acetate copolymer resin, polystyrene, polyurethane, ABS resin, polyvinyl formal, acrylic resin, epoxy resin, phenol resin, urea resin and the like. It is preferable that the elastic granular material has an expansion ratio of 10 to 60.

When obtaining the kneaded material, less than 35% by weight of the fibrous material is further mixed with the main raw material. As fibrous materials, acrylic fiber, vinylon fiber, polypropylene fiber, carbon fiber, glass fiber, rock wool, slag wool,
Organic or inorganic fibers such as asbestos, aramid fiber, nylon and pulp are used. If necessary, the kneaded product may further contain slag, silica sand, calcium carbonate, silica, silica flour, etc., a reactive material, melamine, acrylic, methylcellulose, polyethylene glycol, polypropylene glycol, etc., a reinforcing agent, a water reducing agent, a lubricant. To mix.

The obtained kneaded material is formed into a plate-like green plate having a desired thickness. As the molding method, an extrusion molding method, a fourdrinier papermaking method, a pouring method, etc. are preferable, and a molding method by the entanglement of the fibrous material in the kneaded product, for example, the round netting papermaking method, is thick due to papermaking. Since it is not possible to obtain a plate-like green plate and a large amount of fibrous material is required, it becomes difficult to form a sufficiently deep uneven pattern in the subsequent process, and further delamination occurs when a pressing pressure is applied. It is not preferable because it has a drawback that it easily occurs.

The resulting plate-like green plate is pressed by using a pressing device with a concave and convex pressing die to perform molding. At this time, since elastic heat-shrinkable granules having water retention capacity are mixed inside the plate-like green plate, when pressed by the concave-convex die,
It is flowed together with other mixed materials and moves to the convex portion side in the uneven pattern. In addition, since the granular material has elasticity and water retention, it is deformed by the pressure of the concave-convex mold, the retained water is squeezed out and acts as a lubricant, and the elastically deformed granular material tries to restore to its original shape. To do. The function of the lubricant and the restoring pressure of the granules promote the flow of the mixed material, so that the recesses are smoothly formed. Further, as a result of such a flow, the mixing ratio of the heat-shrinkable granules becomes high in the convex portions, so that when the pressure is released from the pressing device, a large number of fine granular projections are generated by the restoring force of the elastic granular bodies. Will be formed. In particular, at the moment when the surface of the convex portion of the plate material separates from the concave-convex mold during depressurization, the restoring force of the elastic granular body suddenly works to form fine granular projections on the surface of the convex portion.

In order to exert the above-mentioned effects, the mixing ratio of the elastic heat-shrinkable particles is important in the present invention, and it is necessary that the mixing ratio is 0.1 to 25% by weight with respect to the main raw material. If the mixing amount is less than 0.1% by weight, it is difficult for the mixed material to flow to the convex side, and the amount of particles in the convex part of the uneven pattern is too small, so the elastic restoring force is fully exerted. Therefore, when the pressure is released, fine granular projections are not formed over the entire surface of the convex portion. On the other hand, if more than 25% by weight of granules are mixed, the amount of granules in the protrusions becomes too large and fine granule projections are formed not only on the surface of the protrusions but also on the cotton side of the protrusions during or after decompression. However, the contour of the uneven pattern tends to be unclear.

As described above, a fibrous material is mixed into the kneaded product to improve the shape retention and strength of the molded product, but the mixing ratio is limited to less than 35% by weight. This is because when fibrous material of 35% by weight or more is mixed, the fluidity of the mixed material in the pressing portion is suppressed by the entanglement of fibers, so that the specific gravity of the concave portion becomes significantly higher than that of the convex portion. This is because the problems in the prior art are revealed.

A plate-shaped raw plate having a surface irregular pattern formed by the concave-convex die of a pressing device and a large number of fine granular projections formed on the convex surface due to the restoring force of the elastic granular body is put into a steam curing chamber for primary Cure and cure. Since this primary curing and hardening is performed at a temperature equal to or higher than the shrinking temperature of the heat shrinkable granules,
The mixed heat-shrinkable granules are melted and shrunk, and the fine granular projections formed on the surface of the convex portion are collapsed to appear as granular concave portions on the surface, and the internal granular material is formed as voids. The curing temperature in the primary curing depends on the shrinking temperature or melting temperature of the heat-shrinkable granules to be mixed, but it is generally in the range of 60 to 100 ° C. Also, the curing time is
It is sufficient that the time is at least sufficient to melt and shrink the particles present in the surface layer portion of the plate-like green plate, and it is, for example, 10 to 48 hours. Next, the inorganic plate of the present invention is manufactured by introducing it into an autoclave and performing secondary curing.

Melt shrinkage of the heat-shrinkable granules can be performed during secondary curing. In this case, the curing temperature and the curing time in the primary curing may be performed under normal conditions, and the secondary curing is performed at a temperature equal to or higher than the melting temperature of the heat-shrinkable granules and at least the heat-shrinkable granules in the surface layer part melt-shrink. Do enough time to do.

<Effects of the Invention> According to the present invention, an inorganic material having a novel surface design in which a concavo-convex pattern having a sharp contour is formed on the surface by using a pressing device and a large number of fine granular concave portions are formed on the convex surface A plate can be obtained and is suitably used for the inside and outside walls of a house.

Claims (2)

[Claims] 1. An inorganic plate having an uneven pattern due to pressing on the surface, in which heat-shrinkable granules having elasticity of 0.1 to 25% by weight and less than 35% by weight of fibrous material are mixed with the main raw material. An inorganic plate having a plurality of fine granular concave portions formed by the heat shrinkage of the heat-shrinkable granular material on the convex portion forming the uneven pattern. 2. A hydraulic inorganic material as a main raw material, which is mixed with a heat-shrinkable granular material having elasticity of 0.1 to less than 25% by weight and a fibrous material of less than 35% by weight with respect to the main raw material, After further adding an appropriate amount of water to form a kneaded product, the kneaded product is formed into a plate-shaped green plate, and then the surface of the plate-shaped green plate is pressed with a concave-convex die to mold it, and then the heat shrinkage is performed. Of the heat-shrinkable granules, which are cured and cured at a temperature equal to or higher than the shrinkage temperature of the heat-shrinkable granules, and formed on the surface of the projections in the uneven pattern of the plate-like green plate. A method for producing an inorganic plate having a concavo-convex pattern, characterized in that a large number are formed.