JPH106314A - Preparation of decorative cement board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative cement board with enough color development of the product by feeding a slurry of a coloring material wherein a pigment and water are main ingredient on the surface of a base material layer under uncured condition. SOLUTION: After a base material 104 passes through below a pressure roll 24 under uncured condition, it passes below a coloring layer feeding mechanism 26. The coloring layer feeding mechanism 26 sprays continuously downward a slurry 200 of a coloring material and feeds the slurry 200 of the coloring material on the top face of the base material layer 104. The slurry 200 of the coloring material for forming the coloring material layer 104 is a slurry consisting of a pigment and water. A molded body 112 prepd. by press molding of a colored sheet-like body 108 wherein the pigment is distributed from the surface layer part of the base material layer 104 to a part of the inside is cured.

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 decorative cement board having a base material forming step of forming a water-containing base material layer mainly composed of cement, and further comprising coloring the base material layer. The present invention relates to a method for producing a decorative cement board provided with coloring means.

[0002]

2. Description of the Related Art Conventionally, as a conventional method for producing this type of decorative cement board, (1) a coating layer consisting of only a paint is applied to a base layer (containing water or non-water) as the coloring means. (2) a method of forming a colored cement layer in the form of a dry powder or a slurry on the base material layer as the coloring means; and (3) a method of forming a base material layer on the base material layer as the coloring means. A method using a method in which a coloring pigment is mixed into the compound itself is known.

[0003]

The above-mentioned conventional methods all have drawbacks and have room for improvement. That is, the method using the coating layer (1) has a drawback that the formed coating layer itself is inferior in weather resistance, so that the color of the product is rapidly faded with age. In the case of the method using the colored cement layer of (2), when the colored cement layer is formed in the form of dry powder, the dry powder layer is a different material in the sense that at least the water content is completely different for the base material layer, and the properties are different. Therefore, when the product is subjected to frost damage, peeling between the layers of both materials is likely to occur, and when forming the colored cement layer in the form of slurry, only when the base material layer has already entered the dehydration step,
Since the slurry cannot be placed on the base material layer, a time lag in the water-containing state has occurred between these two materials,
Also, there was a drawback that peeling between the layers of both materials easily occurred when the product was subjected to frost damage. Moreover, at least the base material layer often contains fibers for the purpose of reinforcing or filtering effects at the time of molding, and in this case, since the fibers are oriented along the surface of the base material layer, the peeling tendency is further increased. Appeared big. Next, in the case of the method of mixing the color pigment of (3), no tendency of fading or peeling was observed, but the coloring effect of the surface of the substrate was obtained by the pigment uniformly mixed in the entire region of the substrate layer. As a result, despite the use of large amounts of expensive pigments as a result, the coloring effect of the finished decorative cement board surface is low,
There was room for improvement in terms of manufacturing costs and the degree of color development of products.
The object of the present invention, in view of the above-mentioned drawbacks seen in the method of manufacturing a decorative cement board according to the conventional method exemplified above, the colored layer has weather resistance, is hardly faded, and has a low tendency to peel off from the substrate layer, Another object of the present invention is to provide a method of manufacturing a decorative cement board which has a relatively low manufacturing cost and a sufficient degree of color development of the product.

[0004]

Means for Solving the Problems In order to achieve the above object, in the method for producing a decorative cement board according to the present invention, there is provided a base material forming step of forming a water-containing base layer mainly composed of cement. A coloring step of supplying a coloring agent slurry mainly containing pigment and water to the surface of the substrate layer in a cured state, and a molding step of press-molding the plate-like body obtained in the coloring step to obtain a molded body And a curing and curing step of curing the molded body.

[Effects of the Invention] Due to the above-mentioned features,
In the method for producing a decorative cement board according to the present invention, the colorant slurry mainly containing pigment and water is supplied to the surface of the uncured water-containing base material layer, and cement and other materials. Since it does not contain a powdery material that hinders the movement of the pigment in the water slurry, the pigment alone or relatively freely penetrates into the uncured base material layer with water to form the base material layer. And a colorant layer physically integrated with the colorant layer.For this integration, a colorant layer that is difficult to peel off from the base material layer even when subjected to frost damage is obtained, and the colorant layer has a pigment as a substance. Since it is a layer containing, it has weather resistance and is hardly faded over time.Furthermore, even after the coloring material layer penetrates into the base material layer, it is distributed around the surface of the base material layer until it gets tired. , A decorative cement board with high surface coloring effect can be obtained at relatively easy manufacturing cost It occurs specific effect say.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Here, a roof material is taken as an example of a decorative cement board, and an embodiment of a method of manufacturing a decorative cement board according to the present invention will be described. FIG. 1 shows a main part of a facility for manufacturing a roofing material 112 by a flow-on method. The equipment includes a head tank 10 as a slurry container, a flow meter 12, a flow control valve 14, a flow box 16, a first belt conveyor 18 made of felt, a suction dewatering tank 20,
Vacuum pump 22, pressure roll 24, coloring layer supply mechanism 2
6, a second belt conveyor 28, a cutting machine 30, a molding press 32, and an autoclave 34. The slurry 100 for producing the water-containing base material layer is an aqueous slurry, and its solid content is mainly required by forming a hydrated reaction with the silica sand constituting the aggregate and making a decorative cement plate. Powdered cement for developing strength (40-50% by weight)
And mica (5 to 15% by weight) for suppressing the propagation of cracks, and pulp fibers (5 to 8% by weight) for supplementing the strength and providing a filtration function during suction dehydration. ing. The solid content of the slurry 100 is about 40.
%. The coloring material slurry 200 for forming the coloring layer 122 is a slurry comprising a pigment and water, and the pigment may be either an inorganic pigment or an organic pigment.

(Base Material Forming Step) A slurry 100 separately prepared by using a kneader or the like is first charged into the head tank 10. The slurry 100 in the head tank 10 is
It 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 simultaneously receives the slurry 100 from a horizontally long rectangular outlet provided thereunder.
Pour out a fixed amount at a time. The slurry 100 discharged in this manner is moved at a predetermined speed in the horizontal direction (the horizontal right direction in FIG. 2).
As a result, the first belt conveyor 18 is moved from the lower outlet of the flow box 16 to the slurry 1.
00 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 and dewatered by the suction dewatering tank 20 arranged on the back side of the first belt conveyor 18 in the middle stream area of the first belt conveyor 18, and further adjusted to a predetermined thickness by the pressure roll 24. At the same time, it is further dehydrated under pressure to form a continuous plate-shaped substrate 104 (see FIG. 2-A) adjusted to a moisture content suitable for molding. A vacuum pump 22 communicates with the suction / dehydration tank 20.

(Coloring Step) The base material 104 passes under the pressure roll 24 while being uncured, and then passes under the coloring layer supply mechanism 26 while moving further to the right. The coloring layer supply mechanism 26 is provided with a spray mechanism at a lower portion, and the coloring material slurry 200 is directed downward as long as the lateral movement of the base material layer 104 is continued.
, And the colorant slurry 200 is supplied to the upper surface of the base layer 104 (see FIG. 2B). The coloring layer supply mechanism 26 adjusts the width of the base layer 104 in the width direction so that the supplied coloring material slurry 200 becomes a coloring layer 122 (see FIG. 2C) having a substantially uniform thickness on the base layer 104. The colorant slurry 200 is sprayed at a width substantially equal to the above. For this purpose, the spray mechanism of the coloring layer supply mechanism 26 may have the same width, but on the other hand, a spray mechanism having a width smaller than the width dimension of the base material layer 104 is provided, and this is provided in the width direction. Spraying while moving at a predetermined speed and period may be adopted. The pigment contained in the coloring layer 122 starts to penetrate into the uncured base material layer 104 (the base material layer 104 at this time shows a water content of 30% or more) from the time of placement, and Before reaching the conveyor belt 28, the colored plate-like body 108 (FIG. 2) in which the pigment is distributed from the surface portion of the base material layer 104 to a part of the inside thereof.
-See d).

(Molding Step) Next, the colored plate 108 is
After being cut one after another by the cutting machine 30 to form the unit molded body 110 having a predetermined length, the molded body 32 is pressed and molded by the molding press 32, and has a density and a shape substantially similar to a final product state. (See FIG. 2-E). (Curing and curing step) After the primary curing (natural curing) for 1 to 2 days, the molded body 112 is coated with an acrylic emulsion for undercoating, and is cured by applying a high-temperature and high-pressure steam curing for about 15 hours in an autoclave 34 to cure. And obtain the required strength as a final product. The molded body that has undergone autoclave curing is coated with an acrylic emulsion for overcoating and dried to form the final product 114.

[Other Embodiments] <1> The method for producing a decorative cement board according to the present invention is not limited to the flow-on method as described in the above-mentioned embodiment, but also includes a water-based cement-based material. The present invention can be applied to those having a step of forming a material layer. For example, a dry method including a pre-process of first forming a layer of the composition in a dry powder state and a post-process of adding water to the layered composition corresponds to this, so that the decorative cement plate according to the present invention also corresponds to this. Of the manufacturing method. <2> The method for producing a decorative cement board according to the present invention can be applied to a wall material as long as it has a base layer containing cement and a colored layer provided on the base layer.

[0011] In the claims, reference numerals are provided for convenience of comparison with the drawings, but the present invention is not limited to the configuration of the attached drawings by the entry.

[Brief description of the drawings]

FIG. 1 is a schematic view showing a manufacturing process of a decorative cement board according to the present invention.

FIG. 2 is a schematic sectional view showing a state of a decorative cement board corresponding to each step of FIG.

FIG. 3 is a schematic sectional view showing a state of a decorative cement board according to the conventional method (1).

FIG. 4 is a schematic sectional view showing a state of a decorative cement board according to the conventional method (2).

FIG. 5 is a schematic sectional view showing a state of a decorative cement board according to the conventional method (3).

[Explanation of symbols]

 104 base material layer 108 colored plate-like body 112 molded body 200 coloring material slurry

Claims (1)

[Claims] 1. A base material forming step of forming a water-containing base layer (104) mainly containing cement, and a step of forming a base material containing pigment and water on the surface of the base layer (104) in an uncured state. A coloring step of supplying a coloring material slurry (200) to be performed, a molding step of press-molding the colored plate-like body (108) obtained in the coloring step to obtain a molded body (112),
12) A method for producing a decorative cement board comprising a curing step of curing.