JPH1034636A - Manufacture of external facing building-material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent pigments from being conspicuously left singly on decorative particles by a method wherein water film containing the pigments, which are developed by separating from a colored cement layer formed by being placed after the dusting of the decorative particle and before the pressing of the colored cement layer, is removed. SOLUTION: Decorative particles 300 stored in a decorative particle tank is dusted by a certain amount with a vibrating mechanism so as to obtain an uncured plate-like body 108, into the neighborhood of the surface of a colored layer 202 of which the decorative particles 300 are adhered. Next, the plate-like body 108 is successively cut with a cutter into place-like bodies 110 having the predetermined length. Next, by spraying a comparatively large amount of water onto the surface of the plate-like bodies 110 with a washing mechanism provided above a line, the water film 230 containing pigments is washed away from the surfaces of the plate-like bodies 110 so as to obtain plate-like bodies 111, from which pigments floating together with the water on the surface of the dusted decorative particles 300 are removed.

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 an exterior building material, and more specifically, to supply a cement slurry containing a pigment onto an uncured base material layer mainly composed of cement and a fiber material. By placing an uncured colored cement layer on the base material layer, spraying decorative particles on the colored cement layer formed as described above, and thereafter, at least the decorative particles are coated with the colored cement. The present invention relates to a method for producing an exterior building material in which the base material layer and the colored cement layer are press-molded so as to be captured by a layer and then cured and cured.

[0002]

2. Description of the Related Art Conventionally, in a well-known example of this type of exterior building material manufacturing method, a colored cement layer is placed and formed on a base material layer, and decorative particles are sprayed on the colored cement layer. Immediately, by pressing the base layer and the colored cement layer from above in an uncured state,
Cosmetic particles were buried in the colored cement layer and were trying to be captured by the same layer.

[0003]

However, in the above-mentioned conventional production method, the slurry concentration of the colored cement layer is set low in order to improve the affinity with the decorative particles to be sprayed. Before the pressure molding, as shown in FIG. 4A, the water film 230 tends to be separated from the original slurry and located on the surface of the colored cement layer 202. 23
In many cases, the pigment component 235 in the colored cement layer 202 was preferentially liberated in 0. Therefore, in the molded body obtained by spraying the cosmetic particles 300 in this state and performing press molding, a part of the pigment 235 remains on the upper surface of the cosmetic particles 300 as shown in FIG. There was a tendency that the texture of the cosmetic particles 300 was hindered (the water film 230 sometimes appeared after the cosmetic particles 300 were sprayed. Become). In addition, when this tendency is observed, the decorative particles 300 are contaminated by the pigment 235 so as to exhibit a different color tone, so that the decorative particles 300 are visible together with the colored cement layer 202 as a surface state of the exterior building material completed as a product. Or if you expect to see and hide, and especially the cosmetic particles 3
It is particularly inconvenient when a material having a different color tone from the colored cement layer 202 is selected as 00 and the color contrast between the two is configured as an important design value of the exterior building material, and there is room for improvement. there were.

[0004] As a measure for solving the above-mentioned drawbacks, a method of simply setting the slurry concentration of the colored cement layer higher is to lower the affinity between the decorative particles and the colored cement layer, or to configure the colored cement layer. This was also not feasible because of the other disadvantages due to the insufficient fluidity of the resulting slurry. That is, in this case, when the decorative particles 300 are sprayed on the colored cement layer 202 having a higher slurry concentration, the decorative particles are brought into a state as shown in FIG. When pressed below the surface, as shown in FIG. 3-B, a layer of air separating the colored cement layer 202 from the decorative particles 300 is formed around the decorative particles 300, and the trapping of the decorative particles can be reliably achieved. There is a tendency for other disadvantages to occur, such as the absence of the colored cement layer and the loss of flatness of the surface of the colored cement layer, making it unusable. In view of the above-mentioned drawbacks seen in the conventional manufacturing method exemplified above, the object of the present invention is that even when the colored cement layer placed and formed on the base material layer has a low slurry concentration, It is an object of the present invention to provide a method for producing an exterior building material in which decorative particles are scattered on a cement layer and a part of the pigment is hardly left on an upper surface of the decorative particles when press forming is performed on the decorative particles.

[0005]

In order to achieve the above object, a method of manufacturing an exterior building material according to the present invention is characterized in that, after the decorative particles are scattered and before the press molding, the colored cement is formed and placed. The method is characterized in that a water film containing a pigment separated from the layer and located on the decorative particles is removed.

[Effects of the Invention] Due to the above-mentioned features,
In the manufacturing method of the exterior building material according to the present invention, after the decorative particles are sprayed, the water film containing the pigment which is separated and generated from the colored cement layer and located on the decorative particles is removed, and then press-molded. Therefore, after press molding and at the time when the exterior building material is completed as a product, the decorative particles are directly exposed on the surface, or appear or hide under a very thin colored cement layer. In addition, a unique effect is produced in that the pigment is prevented from being left alone on the cosmetic particles to be seen.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Here, an outer wall material is taken as an example of an exterior building material, and a manufacturing method in a case where it is manufactured by a flow-on method will be described. FIG. 1 shows a main part of a facility for manufacturing the outer wall material 114 mainly using a flow-on method. The equipment includes a first slurry 100 for supplying a first slurry 100 for the substrate layer.
A slurry supply mechanism 2, a second slurry supply mechanism 4 for supplying a second slurry 200 for a colored layer, and a makeup particle supply mechanism 6 for supplying makeup particles 300 are provided. The first slurry supply mechanism 2 mainly includes a head tank 10 as a slurry container, a flow meter 12, a flow control valve 14, and a flow box 16, and the second slurry supply mechanism 4 mainly includes:
A head tank 30 as a slurry container, a flow meter 32,
It comprises a flow control valve 34 and a flow box 36. The makeup particle supply mechanism 6 includes a makeup particle tank 40 and a vibrating mechanism 42 for spraying the makeup particles 300 downward through a sieve provided at a lower portion of the makeup particle tank 40. Specifically, it is composed of a small electric vibrator fixed to the outside of the makeup particle tank 40. In addition to the manufacturing equipment, the first belt conveyor 18 made of felt, the suction / dehydration tank 20 and the vacuum pump 22, the pressure roll 24, the second belt conveyor 28, the cleaning mechanism 80,
Cutting machine 50, molding press 60, and autoclave 70
Etc. are included. The first slurry 100 is a water-based slurry, and its solid content is mainly the silica sand (3
6-57% by weight), powdered cement (36-57% by weight) for causing a hydration reaction to develop the strength required as a decorative cement board, and a filter function at the time of suction dehydration by supplementing the strength development. And pulp fibers (5 to 10% by weight, which is an example of a fiber material) for imparting a weight reduction material (eg, pearlite, foamed resin, etc.). The solid content of the slurry 100 is about 20 to 40%. The second slurry 200 contains silica sand (36) constituting the aggregate.
-57% by weight), powdered cement (36-57% by weight), and pulp fibers (5
-10% by weight), a lightening material (perlite, foamed resin, etc.), a pigment, and water. The pigment may be either an inorganic pigment or an organic pigment. Also,
The solids concentration of the slurry 200 is about 20-40%.
The cement may be ordinary Portland cement or white cement. As the cosmetic particles 300,
Various ceramic materials such as sand, natural stone and glass,
It can be appropriately selected from powders such as metals and resins, or a mixture of a plurality of them.

(Base Layer Forming Step) The slurry 100 separately prepared by using a kneader or the like is first charged into the head tank 10. Slurry 100 in head tank 10
Is supplied into the flow box 16 under flow control by the flow meter 12 and the flow control valve 14. The flow box 16 receives the slurry 100 and at the same time,
The slurry 1
Pour out 00 in fixed amounts. The slurry 100 discharged in this manner is received by the first belt conveyor 18 made of felt which is moving at a predetermined speed in the lateral direction (to the right in FIG. 1), and as a result, the first belt conveyor 18
From the lower outlet of the flow box 16
Is drawn out by a fixed amount, and the pulled out slurry 100 becomes a continuous plate-shaped slurry 102 on the first belt conveyor 18. Next, the slurry 102 is sucked by a suction / dehydration tank 20 (a vacuum pump 22 communicates with the suction / dehydration tank 20) disposed on the back side of the first belt conveyor 18 in the middle stream area of the first belt conveyor 18. Then, a continuous plate-shaped base layer 104 adjusted to have a water content suitable for molding by being dehydrated by the squeezing effect of the pressure roll 24 (see FIG. 2A). Further, the pressure roll 24 is used for the base layer 1.
It also has a function of adjusting the thickness of the substrate 04 to a predetermined thickness.

(Coloring Layer Forming Step) The base layer 104 passes under the pressure roll 24 in an uncured state, and then moves rightward to pass under the second slurry supply mechanism 4. Here, the second slurry 200 in the head tank 30 is discharged by a predetermined amount from the opening at the lower end of the flow box 36 under the flow rate control of the flow meter 32 and the flow rate adjusting valve 34, and is discharged onto the base material layer 104 by a predetermined amount. The plate-shaped body 106 on which the colored layer 202 (an example of a colored cement layer) having a thickness is mounted is obtained (see FIG. 2B).

(Cosmetic Particle Spraying Step) The base material layer 104 on which the coloring layer 202 is formed, that is, the plate-like body 106 is further moved to the right while both the base material layer 104 and the coloring layer 202 remain uncured. And passes under the makeup particle supply mechanism 6. At this time, the cosmetic particles 300 stored in the cosmetic particle tank 40 are sprinkled by the vibrating mechanism 42 in a substantially constant amount, and the uncured plate-like body having the cosmetic particles 300 adhered to the vicinity of the surface of the colored layer 202 108 are obtained (see FIG. 2-C).

(Cutting Step) Next, the plate-like body 108 is cut by the cutting machine 50 one after another, and the plate-like body 1 having a predetermined length is cut.
10 (see FIG. 2-D). By the way, at the end of this cutting step, on the surface of the plate-like body 110, a thin water film 230 is separated and floated on the surface of the colored layer 202 having a lower slurry concentration from the beginning, and moreover, A part of the pigment contained in the colored layer 202 in the water film 2
There is a phenomenon that 35 is present in a free state. Then, the water film 230 containing the pigment 235 is also covered on the sprinkled decorative particles 300. (Cleaning step) In this step, a relatively large amount of water is sprayed on the surface of the plate-like body 110 by the cleaning mechanism 80 provided at the upper part of the line, so that the water film containing the pigment is removed from the surface of the plate-like body 110. The plate-like body 111 from which the pigment floating with the water on the surface of the cosmetic particles 300 that have been washed away and dispersed is removed.
(See FIG. 2E). In the same process stage as the cleaning mechanism 80, the suction dehydration tank 20 'is placed below the belt conveyor.
(A vacuum pump 22 'is connected to the suction / dehydration tank 20'.) The extra water that has newly permeated into the plate-like body 110 by the washing can be dewatered.

(Molding Step) Next, the plate-like body 111 is pressure-molded by the molding press 60 to form a molded body 112 having a density and a shape substantially similar to a final product state (see FIG. 2F). . At the end of the cosmetic particle dispersion process, that is, in the state of the plate-like body 110, the cosmetic particles 300 that have only adhered to the vicinity of the surface of the coloring layer 202 are pushed into the coloring layer 202 in this molding process. The colored layer 20
2 will be in a captured state. Second slurry 200
The pulp fiber contained in the varnish has effects such as suppressing the occurrence of cracks in the colored cement layer due to the press molding, and improving the strength after the start of use as an exterior building material.

(Curing and curing step) The molded body 112 is
After the primary curing for a day, a clear coating for undercoating is applied to the upper surface, and is subjected to high-temperature and high-pressure steam curing for about 15 hours in an autoclave 70 to be cured, thereby obtaining a strength required as a substantially final product. The molded body that has been cured by the autoclave 70 is further coated with a clear coating for overcoating on the upper surface, and dried to become the final product 114.

[Another Embodiment] The cleaning step may be carried out by spraying water vapor or air containing mist-like water instead of spraying water.

In the claims, reference numerals are provided for convenience of comparison with the drawings, but the present invention is not limited to the configuration shown in the attached drawings.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a method for manufacturing an exterior building material according to the present invention.

2 is a schematic cross-sectional view showing a state of an outer wall material corresponding to each step of the manufacturing method of FIG.

FIG. 3 is a schematic sectional view showing a surface state of an exterior building material according to a conventional method at a high slurry concentration.

FIG. 4 is a schematic cross-sectional view showing a surface state of an exterior building material according to a conventional method at a low slurry concentration.

[Explanation of symbols]

 202 Colored cement layer 230 Water film 235 Pigment 300 Makeup particles

Claims (1)

[Claims] 1. An uncured colored cement layer is placed on a base material layer by supplying a cement slurry containing a pigment onto the uncured base material layer mainly composed of cement and fiber material. Forming, spraying decorative particles on the colored cement layer formed as described above, and thereafter, the base material layer and the colored cement layer so that at least the decorative particles are captured by the colored cement layer. After press molding,
A method for producing an exterior building material to be cured and cured, wherein said colored cement layer (202) is formed after said decorative particles (300) are sprayed and before said press molding.
A method of manufacturing an exterior building material for removing a water film (230) containing a pigment (235) separated from and located on the decorative particles (300).