JPH0890708A - Inorganic panel material having embossed patterns and production thereof - Google Patents

Abstract

PURPOSE: To prevent the generation of warpage at the time of drying in an inorg. panel material having embossed patterns consisting of an hydraulic inorg. material and aggregate, by differentiating the compsn. of the layer on which embossed patterns are formed from that of a flatly formed layer. CONSTITUTION: A slurry composed of a raw material B and a slurry composed of a raw material A are successively arranged in a form 11 and subjected to clamp molding by an embossing plate 10 for forming embossed patterns 14 and subsequently aged and dried to obtain an inorg. panel material having the embossed patterns 14. The raw material A is a non-synthetic fiber compsn. and the raw material B is a synthetic fiber compsn. Therefore, when both of them are molded under the same clamping pressure, the raw material A is easy to become high in density as compared with the raw material B. By arranging a non-synthetic fibrous raw material A containing no synthetic fiber on the layer 12 having the embossed patterns 14 becoming relatively low in clamping pressure to perform molding, the density difference between the layer 12 having the embossed patterns 14 and a flatly formed layer 13 is reduced to uniformize density as a whole.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic board material having an uneven pattern for use as an exterior material, and more specifically,
TECHNICAL FIELD The present invention relates to an inorganic plate material having an uneven pattern having a uniform density without causing any warp deformation during drying, and a method for producing the same.

[0002]

2. Description of the Related Art A conventional inorganic board material having a concavo-convex pattern has a three-dimensional concavo-convex pattern formed on a surface thereof after pouring a slurry prepared by mixing a hydraulic inorganic material with aggregates, fibers and water into a mold. It is manufactured by a method of press-molding with a die-pressing plate for forming, drying and curing.

[0003]

However, in the above-mentioned conventional molding method, the density after pressing is uniform on a flat surface, but on the surface where the uneven pattern is formed, the molding pressure near the uneven pattern is increased. The difference in density causes the density to vary. For this reason, there is a problem that the surface quality is deteriorated and that the drying speed is partially different due to the difference in the density in the plate material, so that the entire surface is warped. That is, water is added to and mixed with a composition comprising a hydraulic inorganic material and an aggregate, and when the obtained slurry is dried into a plate-shaped inorganic molded body, the drying speed depends on the density of the inorganic molded body. Due to the difference, the high-density portion has a low drying rate and the low-density portion has a high drying rate. Therefore, when a molded product with uneven density is dried, due to this difference in density, the time of shrinkage caused by the drying of the molded product is different, resulting in warpage and in the worst case cracking, resulting in poor productivity. Will be a factor. In particular, when molding a molded product having unevenness on the molding surface, unevenness of density appears more prominently because unevenness of pressure occurs in the vicinity of the uneven pattern, and the warpage during the drying occurs. Is an unavoidable problem. The present invention has been made in view of such circumstances, and does not cause a warp during drying,
It is an object of the present invention to provide an inorganic plate material having a concavo-convex pattern having good surface properties and a method for producing the same.

[0004]

Means for Solving the Problems As a result of repeating various experiments, the present inventors have found that a method for forming an inorganic plate-like body having an uneven pattern is such that a surface portion having an uneven pattern and a flat back surface having different pressure states are formed. By changing the material composition of both layers depending on the pressure state, it is possible to balance front and back, that is, reduce the variation in density inside the molded body, and prevent warping during drying. The present invention has been completed based on the findings. That is, the inorganic plate material having a concavo-convex pattern according to claim 1 in line with the above object is a composition of a layer in which the concavo-convex pattern is formed in the inorganic plate material having a concavo-convex pattern composed of a hydraulic inorganic material and an aggregate, The composition of the layer formed flat is different. In addition, the inorganic plate material having a concavo-convex pattern according to claim 2 is the inorganic plate material having a concavo-convex pattern according to claim 1, wherein a raw material composition of a layer on which the concavo-convex pattern is formed is a composition made of a non-synthetic fiber material. The raw material composition of the flatly formed layer is composed of a composition containing synthetic fiber. The method for producing an inorganic plate material having a concavo-convex pattern according to claim 3, wherein the slurry containing the hydraulic inorganic material and the aggregate is pressed from both sides to form an irregular plate pattern on one surface. The raw material composition of the layer on which the uneven pattern is formed is different from that of the layer on which the uneven pattern is formed. The method for producing an inorganic plate material having an uneven pattern according to claim 4, wherein the raw material composition of the layer on which the uneven pattern is formed is a non-synthetic fiber in the method for producing an inorganic plate material having an uneven pattern according to claim 3. It is a composition having a quality, and the raw material composition of the flatly formed layer is composed of a composition containing a synthetic fiber material. Here, differentiating the composition of the layer in which the uneven pattern is formed from the composition of the layer to be formed flat means that in the raw material composition consisting of the inorganic plate material, the hydraulic inorganic material and the aggregate, each raw material component is It means to make a substantial difference in the compaction filling property at the time of pressing by adjusting or adding a synthetic fiber or the like. Further, the positional relationship between the layer on which the uneven pattern is formed and the layer which is formed flat does not mean only the spatial upper and lower positional relationship, and the upper and lower sides may be reversed, and If the clamping direction is horizontal, it is considered to indicate a left-right relationship.

[0005]

In the inorganic plate material having the uneven pattern according to claim 1, since the raw material composition of the layer on which the uneven pattern is formed is different from that of the layer formed on the flat surface, variations in density of both layers are caused. Since the molded body has a small size and a molded body having a uniform density is obtained, even if the molded body is dried, the degree of shrinkage due to drying becomes constant at any part of the molded body, and the warpage can be reduced. In the inorganic plate material having a concavo-convex pattern according to claim 2, since the layer having the concavo-convex pattern does not contain the synthetic fiber, it is possible to further homogenize the density and improve the surface texture. Claim 3
In the method for producing an inorganic plate material having a concavo-convex pattern described above, since the raw material compositions of the layer having a concavo-convex pattern and the flat layer are different from each other and compressed, the difference in density between both layers can be made uniform. In the method for manufacturing an inorganic plate material having a concavo-convex pattern according to claim 4, a raw material containing no synthetic fiber is arranged in a layer having a concavo-convex pattern having a relatively low pressure due to compression, and the pressure due to compression is By molding with a composition that contains synthetic fibers in a highly flat layer, the difference in the clamping force between both layers is balanced by the difference in the compaction characteristics of the molding material, and the variations in the density of both layers are made more uniform. You can

[0006]

Embodiments of the present invention will now be described with reference to the accompanying drawings to provide an understanding of the present invention. Here, FIG. 1 is an explanatory view showing a method for manufacturing an inorganic plate material having an uneven pattern according to an embodiment of the present invention. Here, the molding apparatus shown in FIG. 1 has a long side length of 3100 m.
It is an apparatus for forming a concavo-convex pattern 14 on the surface on one side by pressing a flat inorganic molded body having m, a short side length of 1050 mm, and a thickness of 14 mm without irregularities from both sides. The embossing board 10 for forming the concavo-convex pattern 14 is made of a resin embossing die in which a plurality of concavo-convex patterns having a step of 5 mm are formed on the molding surface.
The inorganic molded body is arranged in the mold 11, and the clamping process is performed from above. 1A shows a state before clamping, FIG. 1B shows a state before clamping,
(C) shows the state of the inorganic plate material taken out after the pressing. First, as a comparative example, 400 Wt% of water was added to each of the raw materials A and B having the composition shown in Table 1 and kneaded to prepare respective slurries.

[0007]

[Table 1]

Next, the inorganic plate-shaped body was placed in the mold 11 and molded by the upper die pressing plate 10 for forming the concave-convex pattern 14 at room temperature under a pressing pressure of 30 kg / cm ² . After the compression, the mixture was cured at room temperature for 1 week and then kept at a drying temperature of 105 ° C. for 24 hours to adjust the water content to 10 Wt%. The two types of inorganic plate materials having the uneven pattern 14 after drying thus obtained had large variations in the density in the vicinity of the uneven pattern 14 and had poor surface properties.

Next, 400 Wt% of water was added to the raw materials A and B having the compositions shown in Table 1 and kneaded to prepare slurries having different compositions. Then, a plate-like body made of the raw material A and a plate-like body made of the raw material B were produced using the slurry, and the total water content of the inorganic plate material was 26 Wt%. Then, in FIG.
As shown in FIG. 1, after the slurry made of the raw material B is placed in the mold 11, the slurry made of the raw material A is placed, and the embossing pattern 10 for forming the concave-convex pattern 14 is placed at a room temperature of 20 kg / c.
It was molded with a clamping pressure of m ² . After clamping it at room temperature for 1
After leaving for a week to cure, the drying temperature in the dryer is 105
It was kept at ℃ for 24 hours and dried to adjust the water content to 10 Wt%. The dried uneven pattern 14 thus obtained
The unevenness of the density in the vicinity of the concavo-convex pattern 14 of the inorganic plate material having the above was small, and the surface texture was remarkably improved as compared with the comparative example.

Here, the composition of the raw material A and the raw material B will be described. The raw material A has a composition of non-synthetic fiber, and the raw material B has a composition of 1 Wt% of vinylon as synthetic fiber. For this reason, when both are molded under the same pressing pressure, the raw material A tends to have a higher density than the raw material B, and the layer 12 having the concavo-convex pattern 14 in which the pressing pressure is relatively low becomes
By arranging and molding the non-synthetic fibrous raw material A containing no synthetic fiber, the difference in density between the layers 12 and 13 can be reduced and the overall density can be made uniform.

The hydraulic inorganic material is an inorganic material which undergoes a hydration reaction upon addition of water to produce a cured product, and examples thereof include cement, slag, gypsum and calcium carbonate. The aggregates include sand, perlite, vermiculite, fly ash and the like. As the synthetic fiber, polypropylene, polyethylene, nylon, acrylic, glass fiber or the like can be used in addition to vinylon. Here, in order to make the above-mentioned difference in compaction property large at the time of molding, the synthetic fiber to be added has a fiber length of 6 to 2
It is necessary that the diameter is 0 mm and the fiber diameter is about 10 μm to 1 mm. In addition, the synthetic fiber itself has elasticity, thereby reducing the packing density during compression,
In addition to having an effect of maintaining a predetermined density, when the molded body is dried, it forms a moisture escape path, promotes evaporation of moisture, and functions to reduce warpage during drying.
The material composition of the flatly formed layer 13 is hydraulic inorganic material: aggregate: fiber: water = 100: 15 to 30: 5-1.
It is suitable to set the weight ratio in the range of 0: 200 to 400. The material composition of the layer 12 having the uneven pattern 14 is: hydraulic inorganic material: aggregate: water = 100: 5-3
It is suitable to set the weight ratio in the range of 0: 200 to 400.

[0012]

EFFECTS OF THE INVENTION In the inorganic plate material having a concavo-convex pattern according to claims 1 and 2, since the raw material composition of the layer having a concavo-convex pattern and the layer formed flat is different, the density is uniform, It is possible to provide an inorganic plate material that does not warp when dried and has an uneven pattern with good surface properties. In particular, in the inorganic board material having a concavo-convex pattern described in claim 2, since the layer having the concavo-convex pattern does not contain synthetic fibers, the surface texture can be further improved. In the method for manufacturing an inorganic plate material having a concavo-convex pattern according to claims 3 and 4, since the raw material compositions of the layer having a concavo-convex pattern and the flat layer are different from each other and compressed, the density difference between both layers is made uniform. can do. Particularly, in the method for producing an inorganic plate material having an uneven pattern according to claim 4,
Since the flat layer having good packing and compaction contains the synthetic fiber and the layer having the uneven pattern does not contain the synthetic fiber, the effect of reducing the difference in density between the two layers is further increased.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a method for manufacturing an inorganic plate material having an uneven pattern according to an embodiment of the present invention.

[Explanation of symbols]

 10 Mold Pressing Board 11 Formwork 12 Layers 13 Layers 14 Concavo-convex Pattern

Claims (4)

[Claims] 1. In an inorganic plate material having a concavo-convex pattern composed of a hydraulic inorganic material and an aggregate, the composition of the layer on which the concavo-convex pattern is formed is different from the composition of the layer formed flat. An inorganic plate material having a characteristic uneven pattern. 2. The raw material composition of the layer on which the concavo-convex pattern is formed is a composition made of non-synthetic fiber, and the raw material composition of the layer formed flat is a composition containing synthetic fiber. An inorganic board material having the uneven pattern of. 3. A method for producing an inorganic plate material, comprising forming a concavo-convex pattern on one surface by pressing a slurry containing a hydraulic inorganic material and an aggregate from both sides, and flattening the layer on which the concavo-convex pattern is formed. 1. A method for producing an inorganic plate material having a concavo-convex pattern, characterized in that the raw material composition is different from that of the layer to be formed. 4. The raw material composition of the layer on which the concavo-convex pattern is formed is a composition made of non-synthetic fiber, and the raw material composition of the layer formed flat is a composition containing synthetic fiber. And a method for producing an inorganic plate material having an uneven pattern.