JPH10151610A - Molding method for hydraulic material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding method for a hydraulic material, such as concrete, easy to be released from a mold even in the case of a fine shaping face of a cavity, further capable of greatly reducing mold cost, and excellent in mass-production. SOLUTION: A porous, air-permeable mold 10 placed on a vacuum adsorption stand 11 is covered with a heated thin film 13 made of a thermoplastic resin in a developed state and, by sucking air in the mold 10, the film 13 is brought into close contact with a shaping face of a cavity, so that a pattern is transferred to a face of the film. After packing the cavity with fresh concrete S, a porous, air-permeable platen 15 is registered to the mold 10. After integrally inverting the mold 10 and the platen 15 upside down, air in the platen 15 is sucked to peel the molding film 13 from the shaping face of the mold 10, and a molded article is then released from the mold 10 while the molded article is being covered with the film. Thereafter, concrete S covered with the film is cured on the platen 15 for a predetermined period of time, and the molding film 13 is peeled to take out the cured molded article from the platen 15.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding method for hardening and molding a slurry molding material, and more particularly to a hydraulic material such as a cement kneading material used for obtaining a building plate, an outer wall tile and the like. To a molding method.

[0002]

2. Description of the Related Art For example, as a method of forming a concrete decorative outer wall plate (patterned concrete product) for covering the outer wall of a house or a fence, as described in JP-A-63-172608, Is known. In this molding method, a plastic film is spread on a mold with an uneven pattern, the plastic film is uniformly heated by a heating device, and vacuum suction is performed by a vacuum pump through a suction vent hole provided on the bottom of the mold. After it is brought into close contact with the surface of the uneven pattern, concrete slurry is poured in to cure and cure. When such a molding method is used, the irregular surface of the demolded concrete molded product has a beautiful surface finish on which the irregular pattern of the mold is transferred, and the surface of the irregular pattern of the mold (imprint) is covered with a plastic film. Shape) does not come into contact with the concrete slurry,
Since no stain is generated, the cleaning step and the drying step of the mold can be eliminated, which contributes to the improvement of productivity. Further, there is an advantage that the mold wear is reduced and the mold life is prolonged.

[0003]

However, the above-mentioned method for forming a patterned concrete product has the following problems.

When a concrete molded product that has been cured and hardened in a mold is removed from the mold, it is difficult to remove the mold even if a demolding force is applied while vibrating with a vibrator, resulting in chipping and damage to the edge and the molding surface. easy. In particular, a molded product having an undercut partially has a reverse draft, and therefore cannot be properly removed without using a split mold. Further, as shown in FIG. 11, when there is unevenness on the thickness side surface (rising surface) 3 as well as the surface 2 of the molded product 1, surface damage on the molding surface is inevitably caused, and the draft angle is considerably increased. Otherwise, the mold cannot be removed, and the fact is that the molding method described above is limited to a molded product whose thickness side surface is almost smooth.

In other words, it is difficult to make the inner surface pattern (grain) of the mold frame rich in roughness (texture) of large and small irregularities, and it is necessary to make the irregular pattern surface including the thickness side surface of the molded product very similar to natural stone ground or the like. Has limitations in terms of random undulation and definition.

The curing period during which the concrete molded product is cured in the formwork requires a day and a night even with rapid-hardening concrete or the accelerated curing method.
The rotational efficiency of the mold was very low. For this reason, in order to secure mass productivity of concrete molded products, initial investment for preparing a large number of molds of the same shape is indispensable, resulting in enormous mold cost. Therefore, the types of designs of patterned concrete products have been limited.

[0007] In view of the above problems, it is an object of the present invention to provide a hydraulic material such as concrete which is easy to remove even if the cavity has a finely shaped surface, is capable of significantly reducing the mold cost, and is excellent in mass productivity. It is an object of the present invention to provide a molding method.

[0008]

Means for Solving the Problems In order to solve the above-mentioned problems, the means taken by the present invention is to transfer the imprinted surface to the surface of a thin film made of a thermoplastic resin adhered to a cavity, and to form a hydraulic material. Immediately after filling, the uncured molded product is released from the mold with the film coated, and the shape is cured with the film coated. That is, the molding method of the hydraulic material according to the present invention,
A thin film made of a heated thermoplastic resin is covered in a developed state on a cavity of a mold having a vent, and the vent is vacuum-sucked and adsorbed on the shaping surface of the cavity, thereby forming the cavity. A film surface forming step of transferring the shape surface to the surface of the film by plastic deformation, a slurry filling step of filling a slurry of hydraulic material into the cavity and compacting, and a vent having a vent hole on the mold. A mold-matching step of mold-matching a plate, and the above-described cavity is sucked from the cavity together with the plate while the molded body in an uncured state is tightly surrounded by the film by vacuum suction of the air holes of the plate in the mold-matched state. It is characterized by comprising a demolding step of relatively extracting and a curing step of curing the molded body in a state where the film is tightly surrounded.

[0009] As described above, when the base plate as the backing reinforcing material is put on the base plate, the vacuum suction, suction, and demolding are performed together. Local sliding flow between the molding surface of the molded body in the state and the film surface as the transfer master is unlikely to occur, and it is completely removed as an elastic mass in a compacted state as if a lump of molded body was squeezed with an elastic film can do. Even if the film surface is pressed locally due to the release resistance at the time of release, the surface protection of the film does not damage the surface of the molded surface, and the once recessed portion is the surface tension of the film and the uncured molded product itself Restored by the setting viscoelasticity of Therefore, even if the unevenness of the surface of the cavity on the shaping surface is various, the molded product has a certain degree of undercut, the molded product has more irregularities on the rising surface, and the draft angle is smaller, the molding can be successfully performed. Can be removed well. For this reason, without using the split type,
The instant demolding process can be put to practical use in earnest, and the molding cost can be reduced at a low cost by greatly reducing the mold cost.

After removal from the mold, the uncured molded product is wrapped in a shape-retaining film and participates in wet curing by film curing, so that the strength of the cured molded product is higher than in the case of open-curing. This is advantageous because a high quality molded product can be obtained. Further, if the film is shipped from the factory with the above-mentioned film or the like adhered after curing and curing, the curing material (packaging or cushioning material) in the transportation process can be saved, and the film is cured until the film is peeled off. , The high quality molded product can be provided.

As the mold, a porous air-permeable mold can be used. By suctioning the air in the cavity under vacuum, the heated thermoplastic resin film can be entirely adhered to the imprint surface. As compared with the case where a mold or a resin mold having a vent such as a vent hole is used, needle-like projections are less likely to be formed at the vent of the molded product, and the removal step is not required.

In the case of a molded product having a small thickness, the molded product is adsorbed to the surface plate only by inhaling the air holes of the surface plate in a mold-matching state, so that the molded film can be peeled from the surface of the molding die. However, when the thickness of the molded body is large, it becomes difficult to peel off. In order to improve this, in the demolding step, the mold and the platen in the mold-matched state are vertically inverted before vacuum suction of the air holes of the platen. In such a case, a minute displacement occurs due to the weight of the molded body, so that the molded film is easily peeled off from the shaping surface of the molding die.

Further, in the demolding step, the air holes in the platen are vacuum-suctioned and, at the same time, the air is supplied from the air holes in the mold and pressurized. In such a case, a back pressure peeling force is applied to the film even in a portion of the base plate where there is no ventilation hole, so that the film peeling operation is ensured.

The base plate can be a porous air-permeable base plate. In the film peeling step, the film can be entirely absorbed, so that the film peeling operation is ensured.

Further, in the present invention, after the slurry filling step and before the mold matching step, a step of laying an uneven surface imparting material made of an elastic material on the filled slurry may be added. Since the ventilation hole penetrates through the plate, the film can be peeled off by vacuum suction immediately after filling with the slurry.However, since the unevenness imparting material is an elastic material, the unevenness imparting plate can be removed from the cured molded product. It is easy to separate, and an undercut anchor recess (back foot shape) can be formed. Further, since the platen itself can be a flat surface having no unevenness imparting surface, labor such as cleaning of the platen can be omitted.

[0016]

Next, an embodiment of the present invention will be described with reference to the accompanying drawings.

[First Embodiment] In a method for molding a decorative exterior wall panel made of concrete according to a first embodiment of the present invention, first, as shown in FIG. 1, a porous epoxy engraved with a large number of cavities 12 is used. A porous permeable mold plate (molding mold) 10 made of resin is prepared, and the mold plate 10 is attached to a vacuum suction table 11.
Place on top. Then, the exposed surface of the template 10 is covered with a heated thin film 13 of vinyl acetate plastic (thermoplastic resin) of about 60 μm in a developed state, and the suction table 11 is evacuated by a vacuum pump (not shown). Pull and inhale. Thereby, as shown by the arrow in FIG.
Since the air inside is drawn out of the adsorption table 11 through the porous continuous holes (air holes) of the template 10, the inside of the cavity 12 is in a reduced pressure state, and as shown in FIG. Since the thin film 13 closely adheres to the shaping surface of the cavity portion 12 and at the same time heat sinks and cools and cures the film 13, the shaping surface of the cavity portion 12 is transferred to the surface of the film 13 by copy molding. Since the film 13 used for the film surface forming is thinner than the film (200 μm or more) used for general vacuum forming by half or less, the thin film 13 itself has no self-retaining property after the film surface forming. Even the portion of the imprint surface pattern transferred to the surface of the film 13 can still be flexibly deformed.

Next, as shown in FIG.
Is filled with an appropriate amount of fresh concrete (slurry of cement kneading material) S, and the template 10 is vibrated with a vibrator to compact the concrete S densely and to remove bubbles in the filled concrete S. Thereafter, if necessary, the mold contact surface is slid off with a squeegee or the like to level the upper surface. Since the molded thin film 13 is in close contact with the inner surface of the cavity portion 12, the concrete S slides on the film 13 when the concrete S is filled, so that the fluidity is good. The shaped surface of the cavity 12 itself does not touch the concrete S, and the contour of the concrete S is substantially transferred to the shaped surface of the cavity 12.

Then, as shown in FIG. 4, a porous air-permeable permeable plate (lid type) made of a porous epoxy resin having an uneven ridge 15a for transferring an anchor dent (a back foot shape) on the lower surface.
After the mold 15 is fitted on the template 10, as shown in FIG.
The mold plate 10 and the fixed plate 15 in the mold matching state are turned upside down integrally. Note that the suction table 11 may be turned upside down at the same time.

Next, as shown in FIG. 6, a blow pad 16 is applied to the upper surface of the template 10 so that
Is evacuated and air is blown from the blow pad 16,
When a pressure difference is applied across the film 13, the portion of the film 13 and the filled concrete S in contact with the mold contact surface are attracted to the upper surface of the base plate 15 and the blow pad 16
As a result, the film 13 is pressed downward, so that the film 13 peels off from the contact surface of the mold plate 10 and the shaping surface of the cavity 12. In addition, since the base plate 15 is porous and air-permeable, the film 13 can be entirely absorbed, so that the film peeling operation is reliable. Here, in the case of a thin molded body, the film 13 can be peeled from the template 10 only by sucking the plate 15 without performing the integrated upside down of the template 10 and the plate 15 in the matched state. It is.

At this time, the surface of the film 13 is plastically deformed by the transfer of the background pattern of the shaping surface of the cavity 12, and as shown in FIG. , And even if the mold plate 10 is released, the filled concrete S is kept shape-protected. At the time of this mold release, the thin film 13 covering the surface of the shaping surface of the cavity portion 12 is peeled off by the air pressure difference, and thereafter the template 10 is separated from the soft mass of the filled concrete S covered with the thin film 13. Of course, it is very easy to remove the mold, and even if the draft angle is small, the mold can be easily removed. Being able to remove the template 10 immediately after filling with the concrete S means that the rotational efficiency of the template 10 is increased. The productivity can be improved or the mold cost can be significantly reduced. In the film peeling step, the blow pad 16 is
The film 13 can be peeled off without performing the blow at 0.

Next, the platen 15 on which the formed body in the upward position shown in FIG.
5 was stacked in several layers and cured for about 24 hours.
3 and the concrete molded product is separated from the platen 15, as shown in FIG.
The concrete exterior wallboard 20 having the transferred anchor recesses (back sole shape) 15b of 5a is obtained. When detaching from the base plate 15, it may be vibrated by a vibrator, but since it is the uneven strip 15a on the flat surface, in this example, it can be easily removed without vibrating.

As described above, in this embodiment, since the concrete S is filled in a state where the inner surface of the cavity 12 of the template 10 is covered with the film 13, the inner surface of the cavity 12 does not touch the concrete S. Also, clogging of the ground surface does not occur. Damage to the mold at the time of demolding and skin damage to the molded product can be prevented, so that mold management can be reduced and the yield rate can be improved. Further, since the template 10 after demolding can be reused as it is without going through a washing step, a great improvement in productivity can be realized.

Incidentally, a porous plate made of a porous epoxy resin may not be used as the template 10, and a template having a plurality of ventilation holes communicating with the cavity 12 may be used. If the ventilation path is open, needle-like projections are likely to be formed on the decorative surface of the molded product, and the removal operation is required. However, when a porous air-permeable mold plate is used as in this example, the number of porous openings facing the cavity portion 12 is so small that the number of needle-like projections is not so large.

In the conventional manufacturing method, in the case of a mold (aluminum mold), corrosion occurs due to a chemical reaction of cement, the cycle of mold exchange is fast, and the durability of a urethane resin mold is inferior. However, in the present embodiment, the fact that the template 10 is covered with the film 13 and the concrete S does not contact can be avoided from a chemical reaction, corrosion, or the like.
The degree of freedom in material selection increases.

[Second Embodiment] An anchor recess 1 formed on the back of a concrete decorative outer panel 20 shown in FIG.
5b is preferably an undercut hole to enhance the anchor effect. However, in the first embodiment, it is difficult to provide an undercut in the uneven shape 15a of the rigid porous air-permeable base plate 15. This is because the molded product cannot be taken out.

Further, in the case of the porous air-permeable base plate 15, the cement milk seeps into the porous body when the film is peeled off, and the washing operation becomes difficult unless the base plate 15 is used up.

Therefore, in this embodiment, after the concrete S is filled, as shown in FIG. 9, a rubber unevenness imparting plate (lid type, spacer) having a dovetail-shaped uneven stripe 25a on the concrete S is provided.
25, and a metal plate 30 having a vent hole 30a penetrated thereon is placed thereon. Vent holes 3 in the plate 30
Since 0a penetrates, the film 13 can be peeled off by the intake air immediately after the concrete S is filled. Further, since the unevenness providing plate 25 is made of rubber, the unevenness imparting plate 25 can be easily separated from the hardened concrete S, and the undercut anchor recess 25b can be formed. Further, the surface plate 30 is hardly stained by concrete, and is easy to clean because of its flat surface. An air bubble projection sheet or the like can be used as the unevenness imparting plate 25.

In this embodiment, concrete (or mortar) as a cement kneading material is used as a hydraulic material of a decorative board molded product, but a mixture given hydraulicity by gypsum, plaster, clay, slag, or the like may be used. I do not care. A mixture of various aggregates, fillers, admixtures, coloring agents, and the like may be used.

Further, the instant demolding practical application process of the present invention is not limited to slurry of hydraulic material, but is applied to food molded products such as chocolate and curry roux, and cosmetic / chemical molded products such as lipstick, soap and ski wax. It can be used for forming and protecting a slurry of a material having a lower melting point than a thin film. Instead of the curing process after the mold release, heat treatment, cooling treatment, freezing treatment, infrared irradiation, microwave irradiation, or other external heating treatment may be performed while the film is covered.

[0031]

As described above, the method for molding a hydraulic material according to the present invention is characterized in that a plate having an air hole is aligned on a forming die, and the air hole is evacuated to vacuum. Immediately after filling, the molded product in an uncured state is released together with the platen while being coated with the film, and is shaped and cured while being coated with the film.

[0032] Since the immediate demolding can be put to practical use without using a split mold, the mold can be reused as it is without going through a washing step, thereby reducing mold cost and greatly improving productivity. In addition, since the mold can be released in the uncured state, it is easy to release the mold even if the molding surface of the cavity is fine,
Also, the draft can be reduced.

When a porous air-permeable mold is used as a mold, the heated thermoplastic resin film can be entirely adhered to the imprint surface by vacuum suction of air in the cavity. In addition, it is difficult to form needle-like projections on the molded product, and the step of removing the projections becomes unnecessary.

In the demolding step, if the molding die and the platen in a matched state are turned upside down integrally before vacuum suction of the air holes of the platen, a minute displacement due to the own weight of the molded body occurs. The film can be easily peeled off from the shaping surface of the mold.

In the demolding step, when the air holes in the platen are vacuum-evacuated and the air is supplied from the air holes of the molding die and pressurized,
Since the peeling force is applied even to the portion of the platen having no vent hole, the film peeling operation is ensured.

When a porous air-permeable plate is used as the plate, the film can be completely absorbed in the film peeling step, so that the film peeling operation is ensured.

In the case where a step of laying an uneven surface-imparting material made of an elastic material on the filled slurry is added after the slurry filling step and before the mold matching step, ventilation holes penetrate through the base plate. Therefore, the film can be peeled off by suction immediately after the slurry is filled. However, since the unevenness imparting material is an elastic material, the unevenness imparting plate can be easily separated from the cured molded product, and the undercut anchor dent (back sole) shape)
Can be formed. Further, since the platen itself can be a flat surface having no unevenness imparting surface, labor for cleaning the platen and the like can be omitted, which contributes to further improvement in productivity.

[Brief description of the drawings]

FIG. 1 is a process cross-sectional view showing a first half of a film forming process in a method for forming a concrete decorative outer wall plate according to a first embodiment of the present invention.

FIG. 2 is a process sectional view showing a latter half of the film forming process.

FIG. 3 is a process sectional view showing a concrete filling process in the manufacturing method.

FIG. 4 is a process cross-sectional view showing a mold matching process in the manufacturing method.

FIG. 5 is a process sectional view showing a state after mold inversion in the same manufacturing method.

FIG. 6 is a process cross-sectional view showing a template removing process in the manufacturing method.

FIG. 7 is a process cross-sectional view showing a state immediately after a die removing process in the same manufacturing method.

FIG. 8 is a cross-sectional view showing a molded article obtained by the same manufacturing method.

FIG. 9 is a process cross-sectional view showing a process of laying a concavo-convex surface imparting plate in the method for molding a concrete decorative outer wall plate according to the second embodiment of the present invention.

FIG. 10 is a process cross-sectional view showing a mold matching process of placing a surface plate next to the state shown in FIG. 9;

FIG. 11 is a perspective view showing an example of a decorative exterior wall plate made of concrete.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Concrete exterior wall plate 2 ... Surface 3 ... Thickness side surface 15b, 25b ... Anchor dent (back sole shape) 12 ... Cavity part 10 ... Porous air-permeable mold plate (molding mold) 11 ... Vacuum adsorption stand 13 ... Heat Plastic plastic film 15: Porous air-permeable flat plate 15a: Irregularities 25: Rubber concave-convex imparting plate 25a: Dove groove type concave-convex stripes 30: Plate 30a: Vent hole 16: Blow pad S: Concrete (molded body).

Claims (6)

[Claims] 1. A heated thermoplastic resin thin film is covered in a developed state on a cavity of a mold having an air hole,
A film surface forming step of vacuum-suctioning the air holes and adsorbing the shaped surface of the cavity portion to the shaped surface of the cavity portion by plastic deformation on the surface of the film; and slurrying the hydraulic material slurry. A slurry filling step of filling and compacting the cavity, a mold matching step of matching a plate having an air hole on the molding die, and vacuum suction of the air hole of the plate in the matched state. A demolding step of relatively extracting the uncured molded body from the cavity together with the base plate while tightly surrounding the unmolded molded body with the film, and a curing step of curing and curing the molded body in a state where the film is tightly surrounded by the film And a method for molding a hydraulic material. 2. The method of molding a hydraulic material according to claim 1, wherein the molding die is a porous air-permeable molding die. 3. The method according to claim 1, wherein in the demolding step, before vacuum suction is performed on the air holes of the base plate.
A method for molding a hydraulic material, wherein the molding die and the base plate in the mold matching state are vertically inverted integrally. 4. The method according to claim 1, wherein, in the demolding step, the air holes of the base plate are vacuum-suctioned and, at the same time, air is supplied and pressurized from the air holes of the molding die. A method for molding a hydraulic material, characterized by the following. 5. The method for manufacturing a hydraulic material according to claim 1, wherein the base plate is a porous air-permeable base plate. 6. The uneven surface-imparting material according to any one of claims 1 to 5, wherein an elastic material is provided on the filled slurry after the slurry filling step and before the mold matching step. A method of molding a hydraulic material, characterized by comprising a step of laying.