JPH10331418A - Manufacture of fibrous facing form - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a facing form with uneven patterns having large difference between unevennesses on the surface by pouring fibrous material in the form surrounding the perimeter of a water permeable type by a frame member, and covering the surface of a layer obtained by sucking and dehydrating water with a sheet having extension efficiency. SOLUTION: Liquid waste paper material is poured in a form device fixing a frame member 12 on the peripheral surface section on the upper surface of a water permeable type II, and after it is stirred, water is sucked and dehydrated in a suction section 14 to form a layer 2 of paper material on the surface 15a of a resin type 15. Then, the layer 2a is covered with a sheet 3, and when water in the layer 2a is again sucked and hydrated in the suction section 14, and the sheet 3 sucked together with water is adhered to the surface of the layer 2a to push the surface uniformly, and a molding is formed on the surface 15a of the resin type 15. When the sheet 3 is stripped from the layer 2a to strip and dry, a facing form forming uneven patterns having large uneven difference can be obtained. Since uniform pressure making use of closing efficiency of the sheet 3 is pushed against the fibrous material layer 2a along the uneven patterns on the surface of the water permeable type II, a molding having required strength can be obtained even if it is thin.

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 fiber-based decorative form that can be effectively used as a measure against industrial waste.

[0002]

2. Description of the Related Art Conventionally, in order to form a concavo-convex pattern on a wall surface or the like of a concrete structure, a decorative form having a surface on which a transfer surface of the concavo-convex pattern is formed has been used. As a material for such a decorative mold, a fiber-based material (recycled paper material, pulp fiber, or the like) is often used, and is effectively used as an industrial waste countermeasure product.
On the other hand, in the case of molding a decorative mold, the entire shape of the decorative mold 5 is made to have a shape somewhat along the transfer surface of the surface as shown in FIGS. Often do. In FIG. 8, reference numeral 5 denotes a decorative mold,
Reference numeral a denotes a transfer surface of the concavo-convex pattern, and reference numeral 6 denotes a frame body to which the decorative mold 5 is fixed. In FIG. 9, reference numeral 7 denotes a support that supports the back surface of the decorative mold frame 5.

[0003] Such a decorative mold 5 is generally constructed as shown in FIG.
It is manufactured using a mold device as shown in FIG. That is, the above-mentioned mold device is used for the lower mold seal frame 21 in which the lower mold 23 made of porous with continuous pores is fitted inside, and the upper mold 24 in which the upper mold 24 made of porous with continuous pores is fitted inside. A seal frame 22 is provided.
An uneven portion for forming the molding space 25 is formed. Further, a gap 26 is formed in a lower portion of the lower mold 23 and an upper portion of the upper mold 24. Reference numeral 27 denotes a storage tank, and a liquid paper material 28 stored in the storage tank 27 is cast into the molding space 25 via a pipe 29 under pressure. 3
Reference numeral 0 denotes a suction / discharge pipe provided with a three-way valve 31. By switching the three-way valve 31, during molding, as shown by an arrow A, the two gaps 26 are sucked to pass through the continuous pores of the two dies 23 and 24. The moisture of the liquid paper material 28 in the molding space 25 is suctioned and dehydrated, and at the time of demolding, pressurized air is discharged into the molding space 25 as shown by an arrow B. In the figure, reference numeral 32 denotes a packing, and both seal frames 21 and
2 and serves to seal the inside of both seal frames 21 and 22. When the decorative mold 5 is produced using this mold apparatus, the liquid paper material 28 is pressed in a closed state as shown in the figure while pressing from above and below as shown by the arrow C.
Is cast into the molding space 25 at a predetermined pressure. Next, vacuum suction is performed from the suction / discharge pipe 30 as shown by an arrow A, and the state is maintained for 30 to 60 seconds to form the molding space 25.
The moisture of the liquid paper material 28 in the inside is sucked and dehydrated, whereby
A molded article made of a paper material is formed in the molding space 25.

[0004] However, in the above-mentioned mold device, both seal frames 2 and 22 are prevented from leaking a large amount of water (moisture amount 1 to 10%) contained in the liquid paper material 28 from between the seal frames 21 and 22.
Since airtightness is required between the first and second seal frames 2,
It is necessary to provide the packing 32 between the first and the second 22, so that the cost of the mold apparatus is increased. Therefore, there is an apparatus using a mold apparatus 10 as shown in FIG. This mold device 10
Includes a mold 13 including a water-permeable mold 11 and a frame 12, and a suction unit 14. The water permeable mold 11 is a porous resin mold 15 having continuous pores having an uneven pattern 15a formed on the surface.
And a frame 16 integrally attached to the outer periphery of the resin mold 15. The frame member 12 is formed of a cylindrical body in which a flange 12a is formed at an upper end and a lower end of a body portion 12b. It is integrally mounted on the water-permeable mold 11 in a state of being in airtight contact. This allows
An upper space of the resin mold 15 is formed in a molding space. The suction section 14 is formed in a hollow frame body, and an upper suction port 14a is formed in a ceiling wall thereof, and an outer peripheral portion of the upper suction port 14a is formed on a mounting table of the water-permeable mold 11. . The suction section 14 has an air inlet 14b on the left side of the side wall and an air suction port 14c on the right side, and a suction device (not shown) communicates with the air suction port 14c. I have. Then, by operating the suction device to suck the air in the suction unit 14 from the air suction port 14c, the outside air is taken into the suction unit 14 from the air intake port 14b, and the resin mold 15 is drawn from the upper suction port 14a. The air in the upper space is sucked into the suction part 14 through the continuous pores of the resin mold 15.

[0005] Using the above mold apparatus 10, the decorative mold 5 can be manufactured as follows. That is, first, a predetermined amount of the liquid paper material 28 is placed in the molding space of the mold device 10.
(See FIG. 11). Next, the suction device is operated to remove the water of the liquid paper material 28 on the resin mold 15 to the suction unit 14.
Then, a layer 17 made of a paper material is formed on the surface 15a of the resin mold 15 as shown in FIG. Next, the upper surface of the layer 17 is pressed by a press plate 18 having a press surface 18 a formed in the same shape as the surface 15 a of the resin mold 15. In this state, the suction device is operated again, the water in the layer 17 is further suctioned and dehydrated, and the press plate 18 is removed. As a result, FIG.
As shown in FIG. 3, a molded article 19 made of a paper material is formed on the surface 15a of the resin mold 15. After that, molding 1
9 is removed from the mold and dried, and the surface is impregnated with a waterproofing agent (acrylic,
By applying an epoxy-based or urethane-based wax), a decorative mold 5 as shown in FIG. 8 can be obtained.

[0006]

However, in the above-described mold apparatus 10, since the press plate 18 is used, the cost is increased. In addition, the unevenness of the unevenness pattern on the surface 15a of the resin mold 15 (the distance between the bottom of the concave portion and the top of the convex portion) is 1
If it is 0 mm or less, it is possible to obtain a decorative mold frame 5 in which the above-mentioned uneven pattern is well transferred to the surface.
14A) (see FIG. 14D) due to the movement of the fiber at the rising portion of the uneven pattern of the layer 19 (formed on top of FIG.
(See part E of FIG. 1)). For this reason, in the above mold apparatus 10, if it is intended to completely eliminate the above-mentioned problems, only the decorative mold frame 5 having a flat back surface with a difference of 5 mm or less in the uneven pattern on the front surface can be manufactured, and the design is free. It has the disadvantage of lacking in sex.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and a thin decorative mold having a large unevenness of the surface unevenness pattern and a similar unevenness pattern formed on the back surface is also provided by a fibrous material. It is an object of the present invention to provide a method for producing a fiber-based decorative form that can be molded, and that can realize cost reduction and design freedom.

[0008]

Means for Solving the Problems In order to achieve the above-mentioned object, a method for producing a fiber-based decorative mold according to the present invention comprises a mold formed by surrounding a water-permeable mold having an uneven pattern on its surface with a frame material. Is prepared, a liquid fibrous material is injected into the molding space of the mold, and the moisture of the liquid fibrous material is sucked and dehydrated from the permeable mold to form a layer made of the fibrous material on the surface of the permeable mold. Then, the layer made of the fibrous material is air-tightly covered with an extensible sheet, and in this state, the moisture of the layer made of the fibrous material is sucked and dehydrated from the water-permeable mold, and the sheet is drawn with this suction force. A configuration is adopted in which a decorative mold is obtained by pressing and contacting the surface of the layer made of the fibrous material, and then forming and drying it.

That is, in the method of manufacturing a fiber-based decorative mold according to the present invention, first, a mold formed by surrounding a water-permeable mold having an uneven pattern on its surface with a frame material is prepared. Next, after the fibrous material obtained by disintegrating the waste paper material with water is put into the molding space of the mold, in order to uniformly disperse the fibers in the fibrous material, for example, air is blown out from a water-permeable mold. Stir. Next, the water in the fibrous material is suctioned and dehydrated from the permeable type. Thereby, the fibrous material is formed into a layer having a uniform thickness along the uneven pattern on the surface of the water-permeable type. However, in this state, since the water content is still high and the degree of adhesion between the fibers is low, breakage and deformation at the time of demolding and dimensional change at the time of drying are large, and the shape maintaining strength is not exhibited. Therefore, the layer is air-tightly covered with an extensible sheet so that a uniform pressing pressure can be ensured even in an uneven pattern having a large unevenness, and in this state, moisture in the layer is suctioned and dehydrated from the water-permeable type. I do. The sheet is also suctioned to the surface side of the layer by the suction force, and adheres to the surface of the layer, and then presses the surface of the layer with a uniform pressure. The molded article thus formed on the layer is released from the mold and dried to obtain a decorative mold. As described above, in the present invention, the layer of the fibrous material formed on the surface of the water-permeable type is pressed with uniform pressure along the uneven pattern on the surface of the water-permeable type by utilizing the sealing property and elongation of the sheet. In addition, a required strength can be obtained even for a thin molded product, and an uneven pattern having a large unevenness difference can be formed on the surface of the molded product. Moreover, unlike the conventional example, since a press plate is not used, the cost can be reduced, and the structure can be simplified.

In the present invention, when the fiber-based material is a paper material, a decorative formwork made of paper can be manufactured, which can greatly contribute to industrial waste countermeasures. Further, in the present invention, by fixing the outer peripheral portion of the sheet in an airtight manner between the water-permeable mold and the frame member in a state where a gap is provided between the water-permeable mold and the sheet, the sheet is made of a fiber material. In the case of covering the upper layer, the above layer can be covered with a sheet with a simple structure.

Next, the present invention will be described in detail.

In the method of manufacturing a decorative mold frame of the present invention, a mold frame and a sheet comprising a water-permeable mold and a frame material surrounding the periphery of the water-permeable mold are prepared.

As the water-permeable mold, a mold having water permeability and air permeability is used, and preferably, a resin mold or a synthetic resin foam using an inorganic material having continuous pores as a pore-forming material is used. Used. The pore diameter of the continuous pores is determined by the accuracy of the shape of the concavo-convex pattern, the efficiency at the time of dehydration and air blowing (particularly, when the dehydration and air blowing are forcibly performed using an air suction device and an air blowing device) and the separation. In order to greatly affect the moldability and the like, it is appropriately set in consideration of the air blowing force and the type and concentration of a fibrous material to be described later, which is a molding material. Usually 50-1000 μm
It is preferable to set to. In addition, such a water-permeable type, when deformed at the time of filling or dehydration of the fibrous material,
Since a desired uneven pattern cannot be formed on the surface of the obtained decorative mold, it is preferable to use a relatively hard material.

The frame material may be any material that can surround the upper space of the water-permeable mold and form a molding space on the surface of the water-permeable mold. A cylindrical body capable of forming a space, a mold material capable of forming a closed molding space on the surface of a water-permeable mold (in this case, the entire shape of the obtained decorative mold can be formed into a desired shape, For example, the thickness can be substantially uniform.)
Are used. Such a frame material is manufactured integrally with or separately from the water-permeable mold, but if manufactured separately, it is convenient in that it can be used for fixing the sheet.

As the material of the sheet, vinyl chloride, polyethylene, polypropylene, rubber and the like are used. The sheet needs to be extensible. In particular, a sheet capable of elongation of 120% or more is suitably used.

The fibrous material to be injected into the mold of the present invention may be a material used for ordinary papermaking, for example, a material obtained by dissociating waste paper material, pulp fiber, etc. with water (concentration: about 3%). Can be In order to give a certain shape retention and strength, an additive such as polyvinyl alcohol (hereinafter abbreviated as “PVA”) which is a water-soluble paste may be added. And, it is preferable that the solid content concentration of the fibrous material is usually set to 0.1 to 30% by weight.
Thereby, the dewatering effect at the time of molding can be made excellent.

As a method for uniformly dispersing the fibrous material injected into the molding space of the mold during the production of the decorative mold of the present invention, a method of forcibly blowing air to the lower side of the water-permeable mold to form A method of blowing air out of the air. In the case of the above-mentioned forced air blowing, it is preferable that the forced air blowing be performed at an air pressure of 2 to 5 kg / cm ² for 5 to 10 seconds after the start of the injection. Examples of a method of dehydrating the water of the fiber material from the water-permeable type include a method of forcibly dehydrating the water-permeable type from the lower side by vacuum suction or the like. In the case of suction dehydration by vacuum suction, the vacuum suction is performed at 600 to 760 mmHg and 30 to 240 mmHg.
Preferably, it is performed for seconds.

The drying performed during the production of the decorative mold of the present invention is carried out under appropriate conditions in consideration of the size, thickness, material and the like of the decorative mold to be removed. 1
Provide for ~ 6 hours of drying.

[0019]

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

FIG. 1 shows a mold apparatus 1 used in the present invention. This mold device 1 has the same structure as the mold device 10 shown in FIG. However, in the mold device 1 of FIG. 1, the permeable mold 11 and the frame material 12 are manufactured separately,
The frame member 12 can be detachably mounted and fixed on the outer peripheral portion of the upper surface of the device. In addition, a vacuum pump (not shown) and a compressor (not shown) are connected to an air suction port 14c of the suction unit 14 via a three-way valve (not shown). The other parts are the same as those of the mold device 10 shown in FIG. 11, and the same parts are denoted by the same reference numerals.

The decorative mold 5 made of paper can be manufactured in the following manner by using the above mold apparatus 1. That is, as shown in FIG. 2, the compressor is operated while a predetermined amount of the liquid waste paper material 2 (concentration: 3%) is poured into the molding space of the mold device 1.
-5 kg / cm ² ) and blown out from the resin mold 15 (see FIG. 2), and the waste paper material in the liquid waste paper material 2 is stirred. Next, the vacuum pump is operated, and the moisture of the liquid waste paper material 2 on the resin mold 15 is rapidly sucked and dehydrated from the upper suction port 14a of the suction unit 14 into the suction unit 14 (600 to 760 mm).
Hg), and as shown in FIG.
Layer 2a made of paper material on top (water content 250 to 400%)
To form Next, the frame member 12 is lifted, and the sheet 3
(Material: vinyl chloride # 370S [3 types], thickness: 0.
After covering the layer 2a with 1 mm), the frame member 12 is lowered, and the outer peripheral portion of the sheet 3 is clamped and fixed between the water-permeable mold 11 and the frame member 12 (see FIG. 4). Next, the vacuum pump is operated again to remove the water in the layer 2a from the upper suction port 1 of the suction unit 14.
When the sheet 4 is sucked and dehydrated into the suction section 14, the sheet 3 is also sucked by the suction and dehydration and approaches the layer 2 a (see FIG. 5). To form a molded product 4 (water content 64 to 70%) on the surface 15a of the resin mold 15 (see FIG. 6). Next, as shown in FIG. 7, the frame member 12 is lifted, and the sheet 3 is peeled off from the surface of the layer 2a. Then, the mold is removed, dried at 100 ° C. for 3 hours, and impregnated waterproofing agent (acrylic, epoxy, urethane wax, etc.) is applied to the surface to form an impregnated waterproofing agent layer, as shown in FIG. A decorative paper frame 5 made of natural paper is obtained. On the surface of the decorative mold frame 5 thus obtained, an uneven pattern having an unevenness difference of 10 to 150 mm can be formed.

As described above, in the above embodiment, the surface of the layer 2 a formed on the surface 15 a of the resin mold 15 is
, The layer 2a can be pressed with a uniform pressure. Moreover, unlike the conventional example, the cost can be reduced because the press plate 18 is not used.

[0023]

As described above, according to the method for manufacturing a decorative mold frame of the present invention, the layer of the fibrous material formed on the surface of the water-permeable type is formed by utilizing the sealing property and elongation of the sheet. Since uniform pressure is pressed along the surface irregularities, it is possible to obtain the necessary strength even for thin molded products, and to form irregularities with large irregularities on the surface of molded products. it can. Moreover, unlike the conventional example, since a press plate is not used, the cost can be reduced, and the structure can be simplified.

[Brief description of the drawings]

FIG. 1 is a sectional view of a mold apparatus used for a method for manufacturing a decorative mold frame of the present invention.

FIG. 2 is an explanatory diagram showing a method of manufacturing the decorative mold.

FIG. 3 is an explanatory view showing a method for producing the decorative mold.

FIG. 4 is an explanatory view showing a method of manufacturing the decorative mold.

FIG. 5 is an explanatory view showing a method of manufacturing the decorative formwork.

FIG. 6 is an explanatory view showing a method for producing the decorative formwork.

FIG. 7 is an explanatory view showing a method of manufacturing the decorative formwork.

FIG. 8 is an explanatory view showing one mode of the decorative mold frame.

FIG. 9 is a sectional view of a main part of the decorative mold frame.

FIG. 10 is an explanatory diagram of a conventional example.

FIG. 11 is an explanatory diagram of another conventional example.

FIG. 12 is an explanatory view showing the operation of the above another conventional example.

FIG. 13 is an explanatory diagram showing the operation of the above another conventional example.

FIG. 14 is a cross-sectional view of a main part showing the operation of the other conventional example.

[Explanation of symbols]

 2a layer 3 sheet 11 water-permeable type 12 frame material 13 mold 15a surface

Claims (3)

[Claims] 1. A mold is prepared by surrounding a water-permeable mold having an uneven pattern on its surface with a frame material, and a liquid fibrous material is poured into a molding space of the mold, and the liquid material is injected into the molding space. The water of the fibrous material is suctioned and dehydrated from the permeable type to form a layer made of the fibrous material on the surface of the permeable type, and the layer made of the fibrous material is air-tightly covered with an extensible sheet. In this state, the moisture of the layer made of the fibrous material is sucked and dehydrated from the water-permeable mold, and the sheet is pressed and adhered to the surface of the layer made of the fibrous material by this suction force, and then the mold is dried and removed to make up. A method for producing a fiber-based decorative mold, characterized in that a mold is obtained. 2. The fiber material according to claim 1, wherein the fiber material is a paper material.
A method for producing the fiber-based decorative form according to the above. 3. The sheet is made of a fibrous material by fixing the outer peripheral portion of the sheet in an airtight manner between the water-permeable mold and the frame member with a gap provided between the water-permeable mold and the sheet. The method for producing a fiber-based decorative form according to claim 1 or 2, wherein the method covers the layer.