JP3243426B2 - Molding method of hydraulic material - Google Patents

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 curing and molding a slurry molding material, and more particularly to a cement kneading material used for obtaining a flat molded product such as a building plate or an outer wall tile. The present invention relates to a method for molding a hydraulic material such as

[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 being brought into close contact with the surface of the concavo-convex pattern, concrete slurry is poured in to cure and cure. When such a molding method is used, the uneven surface of the demolded concrete molded product has a beautiful surface finish on which the uneven pattern of the mold is transferred, and the surface of the uneven pattern of the mold (imparted) is covered with a plastic film. Concrete surface does not come into contact with
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 extracted from the mold, it is difficult to remove the mold even if a demolding force is applied while vibrating with a vibrator, and the molding surface is likely to be damaged. In particular, a molded product having an undercut partially has a reverse draft, and therefore cannot be properly removed without using a split mold. In addition, as shown in FIG.
If there is unevenness on the thickness side surface (rise surface) 3 as well as the surface 2 of the above, the surface of the molding surface is unavoidably damaged, and the mold cannot be removed unless the draft angle is considerably increased. The fact is that the molding method is limited to molded products whose thickness side surfaces are 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.

By the way, immediately after filling and compaction of a hydraulic material (hydration-hardening molding material) without hardening and curing the molded article in a mold, the uncured molded body is completely wrapped in a film and removed from the cavity. If the molded body in the uncured state is pulled out of the mold and the shape of the uncured body is kept while the film is adhered, the above-mentioned problems should be solved theoretically. For example, it is possible to configure the mold as a split mold (vertical split mold) and split the mold before removing it, but traces of the dividing line remain on the molding surface, and the addition of molded products It has a disadvantage that its value is reduced, it cannot be applied to a molded article in which the appearance of a decorative wall or the like is regarded as important, and the mold cost is increased. Of course,
Although it is possible to remove the mold after curing in the mold to a semi-cured state, the removal operation in the uncured state (state immediately after filling) is not cured due to the removal resistance during the physical displacement process. In practice, this is equivalent to reckless operation because it directly leads to collapse, distortion, and unevenness of the molding surface, and it is practically difficult to immediately remove the mold immediately after filling the material with a molding surface with uneven surfaces.

Accordingly, in view of the above problems, an object of the present invention is to realize a practical method that does not use a split mold and can immediately remove the uncured molded product without hindrance while wrapping it in a film before the curing step. As a result, molded products with various irregularities on the molding surface, molded products with a certain degree of undercut, and molded products with irregularities on the rising surface can be molded practically without hindrance, and the mold cost is greatly reduced. It is an object of the present invention to provide a method for forming a hydraulic material such as concrete, which can be realized and is excellent in mass productivity.

[0009]

Means for Solving the Problems In order to solve the above-mentioned problems, the means taken by the present invention is to prepare a self-supporting, flexible, thin-film thermoplastic resin film which has been heated and adsorbed on the uneven surface of the shaping surface of the cavity. After separating the boundary surface, a separation operation involving actual displacement called demolding is performed. That is, the present invention provides a self-retaining shape after cooling and curing at a thickness of 20 to 200 μm heated in a cavity of a porous mold .
The thermoplastic resin film without covered by the expanded state, the multi
After vacuum-suctioning the porous mold, the film is adsorbed on the shaping surface of the cavity, and the unevenness of the shaping surface of the cavity is transferred by plastic deformation to the surface of the film. Mom slurry of hydraulic material was vibrated by filling onto the film in the cavity while the
The hydraulic material and tighten compacted Rutotomoni defoaming, after demolding step of the molded body in an uncured state extracted relatively from the cavity while closely surrounded by the film, the non remains above film was deposited In a molding method of a hydraulic material for curing a molded body in a cured state, after filling the slurry and before the demolding step, a boundary for separating an adhesive boundary surface between the shaping surface of the cavity and the film in advance. Surface separation operation, and the boundary surface separation operation is performed by stopping the vacuum suction.
It is characterized by an air pressure adjusting operation for sending gas into the porous mold .

In such a method of molding a hydraulic material, first, the unevenness of the shaping surface of the cavity is copied to the surface of the thermoplastic resin film which is sucked by vacuum suction and plastically deformed. . It is faithful to the imitation of the uneven surface of the imprinted surface, and has a transferability that precisely reflects the unevenness of the imprinted surface. In particular, softened film
Even if it is adsorbed on the shaping surface of the tee, the shaping surface itself is porous
Therefore, the surface of the film is scattered with microscopic vacuoles.
Because it adheres, the solid adhesive surface disappears naturally, and
In the interfacial peeling operation, gas is transferred from the porosity of the shaping surface to the film surface.
Because it is distributed and evenly applied, boundary surface separation
Make sure. Therefore, as a thermoplastic resin film,
It becomes possible to use an ultra-thin film,
The transferability can be increased, so the transfer
Can be realized. When the thickness of the resin film is increased to 200 μm or more, the cured film itself exhibits self-supporting shape retention, and the sagging deteriorates transferability.

When the thickness is increased, the stretch-shrinkage property is lost. Accordingly, the more flexible and thin the thermoplastic resin film, the better the transferability. The film thickness of this thermoplastic resin film needs to be about 20 to 200 μm. From the viewpoints of transferability and strength, a thickness of about 50 to 100 μm is suitable. Furthermore, after filling the hydraulic material slurry,
Excitation in the vacuum suction state
Not only compaction and defoaming, but also porous vacuoles
Vibrates the adjacent bonding point while sucking the film with
The peeling effect of the adhesive interface between the film and the imprinted surface in advance.
This facilitates the subsequent demolding process.

[0012]

[0013] In the present invention, the boundary surface peeling operation, immediately
That is , an air pressure adjusting operation for sending gas to the bonding interface between the shaping surface of the cavity and the film is adopted. Since the boundary surface is peeled off (including infinitesimal displacement) by the pressure gas sent in and the bonding point (constrained point) is reduced, the demolding force with substantial displacement is applied, so that the film surface Uniform and isotropic surface tension easily spreads to each point, making it difficult for local sliding flow between the molding surface of the uncured molded body and the film surface as the transfer master to expand and contract a lump of molded body It can be completely removed as it is as a compacted elastic mass squeezed with a conductive film. 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 surface unevenness of the shaping surface of the cavity is various, and even a molded product with a certain degree of undercut, and even a molded product with unevenness on the rising surface,
The mold can be successfully removed without breaking the molding. For this reason, the immediate demolding process can be put into practical use in earnest, and a molded article with a concavo-convex pattern can be provided at low cost by greatly reducing the mold cost.

In this air pressure adjusting operation, the vacuum suction is stopped to release the boundary surface to the atmospheric pressure, or the pressure is set further by further proceeding. Even when the film is just opened to the atmosphere, the boundary surface can be easily separated because the rush-like air pressure rushes to the film surface at once. This is mainly for slightly displacing (vibrating) the film surface in the normal direction, but exerts a peeling action not only by pressure pulsation but also by a small-scale blast or shock wave.

[0015]

[0016]

[0017]

In order to reduce the number of bonding points or bonding surfaces between the film and the mold, it is also important to select a thin film material. In the case of a film having a smooth surface, the adhesive surface is easily enlarged, and the peeling operation becomes difficult. Therefore, the means of the present invention is characterized in that the film is a grained film such as an embossed film. The number of film adhesion points is reduced, the film releasability is improved, and the effect of matting the molded surface is also exhibited. In addition, a color powder for coloring a molding surface is good.

As a method of releasing the uncured molded body while closely surrounding the molded body with the film, the semi-sack-shaped film enclosing the molded body may be separated from the cavity so as to be lifted from the cavity. Unless the film around the film is accurately lifted with equal force, the tension at each point of the film may be anisotropic, and the molding surface may be locally distorted.

Therefore, in the present invention, a backing covering material as a backing reinforcing material is stacked on the back side of the uncured molded body in the cavity in order to further secure the shape retention of the molded body at the time of demolding. In addition, the backing covering material and the film hold the uncured molded body and are released together. As the backing covering material, a rigid plate, a flexible plate, an elastic plate, a paper plate, a resin film (sheet), a backing resin coating layer, a resin impregnated layer, or the like can be used. Those having a backing reinforcing effect are more desirable. After demolding, the wrapped film is cured with the wrapped film facing upward (molding surface facing upward).
Since the uncured molded product is wrapped in a shape-retaining film and participates in wet curing by film curing, the strength of the cured molded product is higher than in the case of open-curing, and high quality molded products are obtained. This is convenient. 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.

In particular, in the present invention, after the boundary surface peeling operation and before the demolding step, the air holes of the backing covering material are previously vacuum-evacuated to thereby remove the backing covering material and the film. And a vacuum close-contact operation for exhausting the air inside the enclosed space and vacuum-adsorbing the film and the back cover material to the uncured molded body. According to this vacuum contact operation, air bubbles mixed in the uncured molded body are degassed and compacted, and the molding surface adheres strongly to the transfer surface of the film, and the surface adsorption force of the film becomes strong, Even though the molded body is in an uncured state, it is formed into a solid elastic solid body by a so-called vacuum pack. Therefore, even if the side surface or the like of the molded body is deformed by demolding resistance at the time of demolding, it is elastically restored immediately after demolding, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

In the case where the uncured molded body by the vacuum suction is sealed with the film and the backing covering material as described above, if the opening of the ventilation hole of the backing covering material faces directly in front of the back surface of the molded body, Bleeding (floating water) and fine aggregate on the back surface of the molded product are discharged together with air through the air holes, and there is a possibility that the water mixing ratio of the hydraulic material may be changed. In view of this, the present invention is characterized in that the ventilation hole of the backing covering material is formed at a position facing the vicinity of the edge of the cavity on the surface of the mold contacting the mold. When the opening of the ventilation hole is located near the edge, the air in the inner space can be exhausted without releasing the floating water as much as possible.

In the case of a molded product having a shallow and thin cavity, the molded product is light. Therefore, in the vacuum contact operation, the molded product wrapped with the film is slightly separated from the shaping surface of the cavity and adsorbs to the backing covering material. At the time of this adsorption, the rear side of the molded body of the film (the vicinity of the backing covering material) is only slightly loosened, so that the molding surface is not substantially distorted or deformed.
However, the fact that the film is substantially slightly separated from the imprint surface of the cavity means that the adhesion point between the film and the cavity has been completely eliminated, and the preparation stage for the demolding operation is completed.

In the case of a molded product having a deep and thick cavity, the molded product is heavy, so that the above-mentioned suction does not have sufficient suction power. In view of this, the present invention employs a gravity separation operation in which the mold and the backing covering material are turned upside down integrally before the demolding step. The molded body may be separated from the imprinting surface by applying inertia to the mold by accelerating and decelerating, but the gravity separation operation is simpler and the thicker the molded product, the more
Separation is easy under its own weight.

In order to further ensure film peeling in the above-described boundary surface peeling operation, a film adhesion inhibitor is applied to the molding surface of the cavity before the film is brought into close contact with the molding surface of the cavity. It is desirable to spray. When the spray particles of the film adhesion inhibitor adhere to the shaping surface of the cavity, it becomes difficult for the heated film to fuse to the shaping surface of the cavity. In addition, the spray particles transfer the thin film as fine irregularities, which contributes to the matting effect on the molding surface.

[0026]

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

[First Embodiment] In the molding method of a concrete decorative outer panel according to the first embodiment of the present invention, first, as shown in FIG. 1, a multi-cavity concave cavity 12 is engraved. A porous permeable mold plate (molding die) 10 made of porous epoxy resin is prepared, and the mold plate 10 is placed on a vacuum suction table 11 connected to a vacuum pump (not shown). Then, a film adhesion inhibitor such as a non-polar urethane paint is applied or sprayed into the cavity 12 as necessary. Next, the cavity 12 of the mold plate 10 is set to a proper molding temperature 14.
Covered with a vinyl acetate plastic film (thermoplastic resin film) 13 having a thickness of about 60 μm in a developed state heated to 0 to 150 ° C.
It draws a vacuum at 0 and inhales. Thereby, the cavity 1
2 is exhausted out of the adsorption table 11 through the porous continuous holes (air holes) of the mold plate 10, so that the cavity 12
As shown in FIG. 2, the inside of the cavity 13 is decompressed, and the unfolded film 13 which is heated and easily expanded and contracted adheres to the inner surface of the cavity portion 12, and at the same time, the film 13 is heat-sinked.
3 is cooled and hardened, so that the film 13
And the irregularities are transferred to the surface of the film 1 by plastic deformation. This heated thin film 13 is rich in flexibility. 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. An embossed film may be used as the film 13.

Next, as shown in FIG. 3, the cavity 12 is filled with an appropriate amount of fresh concrete (cement-kneaded material) S in a vacuum suction state, and the template 10 is vibrated at a high frequency of several thousand cycles / minute for 10 seconds. The concrete S is densely compacted by vibrating to a certain degree, and bubbles in the filled concrete S are removed. Due to the vibration, floating water is generated on the upper surface of the filled concrete S by bleeding. In addition, compaction unnecessary concrete may be used. At this time, the formed thin film 13 is formed on the inner surface of the cavity 12.
Since the concrete S adheres, the concrete S slides on the film 13 at the time of filling the concrete S, so that the fluidity is good. The inner surface of the cavity 12 itself does not touch the filled concrete S, and the unevenness of the molding surface of the concrete S is substantially reduced by the shaping surface 12a of the cavity 12.
Is transferred. It should be noted that the vibration of the template 10 after the filling of the material promotes the separation of the adhesive boundary between the film 13 and the shaping surface 12a of the cavity 12.

When the vacuum suction is stopped after the compacting step, the air pressure is rushed from the template 10 to the surface of the film at once, so that the film 13
Then, the bonding boundary surface of the shaping surface 12a of the cavity 12 is peeled off.

Next, as shown in FIG. 4, an iron base plate (backing covering material) 15 having a vent hole 15a is placed on the template 10, and then, as shown in FIG. 19 and vacuum suction. According to this vacuum contact operation, the air bubbles mixed into the uncured molded body are defoamed, the concrete S is compacted, and the transfer surface of the film already peeled off from the shaping surface of the cavity 12 is formed on the molding surface. The film adheres strongly, the surface attraction force of the film becomes strong, and the molded body becomes a solid mass with a so-called vacuum pack while being in an uncured state.

In this embodiment, since the ventilation holes 15a of the base plate 15 are open at positions near the edges of the cavities 12, floating water generated on the upper surface of the molded body due to vibration is not inadvertently drained. For this reason, the water mixing ratio of the concrete S does not change.

Since a thin molded body is light, the molded body is a plate 1
5 adsorbed. Therefore, the vacuum suction is continued, the platen 15 is moved upward while removing the molded body while being sucked, the mold is removed, and the mold is turned upside down. As shown in FIG. It is supported on a plate 15. Release the vacuum suction, transfer the entire plate 15 from the suction pad 19,
The film-coated molded body is cured on the platen 15. Also,
After the film-coated molded body is replaced from the base plate 15 to another mounting plate, curing may be performed thereon.

[0033] Even if the side face of the molded body is pressed by the demolding resistance at the time of demolding, it is elastically restored immediately after demolding, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

By the way, 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 wide-mouthed air passage is open, needle-like projections are likely to be formed on the molding surface of the molded product, and a removal operation is required. However, when a porous air-permeable mold plate is used as in this example, the porous opening facing the cavity 12 is fine, so that the size of the needle-like projection is not so large.
Further, 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 this example, the template 10 is
The concrete S can be prevented from being in contact with and not contacting with the concrete S due to a chemical reaction, corrosion, or the like.

In particular, even when the film 13 is adsorbed on the shaping surface 12a of the cavity 12, the shaping surface itself is porous. Naturally, the solid adhesive surface is eliminated, and in the boundary surface peeling operation, the gas is dispersed and evenly hits the film surface from the porosity of the shaping surface, so that the boundary surface peeling is ensured. Therefore, an extremely thin film can be used as the thermoplastic resin film 13 and the heating temperature can be increased, so that the transferability can be further refined.

[Second Embodiment] In the present embodiment, after the step shown in FIG. 3, as shown in FIG. 7, an uneven ridge 35a for transferring an anchor dent (back sole shape) on the lower surface as a base plate 35, as shown in FIG.
The porous air-permeable base plate (back cover material) 35 made of a porous epoxy resin having the following is superimposed on the template 10. And
As shown in FIG. 8, the mold plate 10 and the fixed plate 35 in the mold-matched state are integrally turned upside down, the blow pad 16 is applied to the upper surface of the mold plate 10, and the lower suction table 11 is evacuated. At the same time, when air is supplied from the blow pad 16 and 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 35, and the blow pad 16 The film 13 is pressed downward by spraying from the
From the mold contact surface and the inner surface of the cavity 12 to the film 13
Are substantially separated, and the film 13 and the base plate 35 are vacuum-adsorbed to the molded body. Here, in the case of a thin formed body, the film 13 can be sucked to the formed body only by sucking the base plate 15 without integrally reversing the mold plate 10 and the base plate 35 in the matched state. The suction table 11 may be turned upside down together.

Next, the air supply from the blow pad 16 is stopped while the platen 35 is being suctioned in vacuum, and the platen 35 is lowered to relatively remove the molded body from the mold plate 10 as shown in FIG. Type. If the mold is removed by such a vacuum contact operation, the air bubbles mixed in the uncured molded body are deaerated and compacted,
In addition, the molding surface is strongly adhered to the transfer surface of the film 13, the surface attraction force of the film is strengthened, and the molded body is in an uncured state, so that a so-called vacuum pack is formed into an elastic mass having solid hardness. Therefore, even if the side surface or the like of the molded body is deformed by demolding resistance at the time of demolding, it is elastically restored immediately after demolding, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

The fact that the template 35 can be immediately removed from the mold immediately after the concrete S is filled improves the rotational efficiency of the template 10. The productivity can be improved or the mold cost can be significantly reduced. In addition, even if it does not blow by blowing the blow pad 16 to the template 10, it may be in an atmospheric pressure open state.

Next, the platen 35 on which the compact is placed is placed on the suction table 11.
After stacking the same plate 35 in several layers and curing it for about 24 hours, the film 13 is peeled off from the cured concrete S molded product, and the concrete molded product is separated from the plate 35. As shown in FIG. 10, a concrete decorative outer wall panel 20 having an anchor recess (back foot shape) 35b on which the concave and convex strips 35a are transferred on the back surface of the molded product is obtained. When the platen 35 is removed from the mold, vibration may be applied by a vibrator.
Since it is 5a, in this example, the mold can be easily removed without applying vibration. Of course, at the time of curing, the molded body may be transferred from the base plate 35 to another base plate, or may be shipped as a curing material for transport without peeling the film 13.

As described above, in this example, since the concrete S is filled in a state in which 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. There is no clogging of the background. It is possible to prevent mold damage at the time of mold release and surface damage of a molded product, thereby reducing mold management and improving the yield rate. 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.

[Third Embodiment] The anchor recess 35b formed on the back surface of the concrete decorative outer panel 20 shown in FIG. 10 is preferably an undercut hole to enhance the anchor effect. Further, in the second embodiment, the cement pace infiltrates into the porous material on the concave and convex strips 35a of the rigid porous air-permeable base plate 35, and the used base plate 3 is used.
Unless it is 5, a washing operation is required.

Therefore, in this example, after the concrete S is filled, as shown in FIG. 11, a rubber unevenness imparting plate (first backing covering material) 25 having a dovetail-shaped uneven strip 25a is placed on the concrete S. The iron base plate (the second backing covering material) 30 which is laid and has the ventilation hole 30a penetrated thereon is placed thereon. Since the air holes 30a penetrate through the base plate 30, the film 13 can be vacuum-sealed by vacuum suction 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. The unevenness imparting plate 2
As 5, a bubble projection sheet or the like can be used.

In this embodiment, concrete (or mortar) as a cement kneading material is used as a molding material for a molded article such as a decorative wall. However, hydraulic properties are given by gypsum, plaster, ceramics, clay, slag, or the like. Or a mixture. It may be a mixture of various fine aggregates, coarse aggregates, fillers, admixtures, polymers, coloring agents and the like. Further, in the present invention, not only the flat molded product described in the embodiment but also an accessory molded product, a panel-shaped molded product, and a three-dimensional molded product can be molded.

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.

[0045]

As described above, the present invention provides a porous
Self-shaping after cooling and hardening with mold and film thickness of 20-200μm
Use a thermoplastic resin film without
After filling the rally, apply vibration while maintaining vacuum suction.
Compacting and defoaming the hydraulic material.
The molded body in the state of
It is characterized by being relatively extracted from the bitty . Therefore, the following effects are obtained.

The film in the softened state is applied to the cavity.
Is the imprint surface itself porous even when it is adsorbed on the imprint surface?
, The film surface comes in close contact with the spots with microscopic vacuoles
As a result, the solid adhesive surface disappears naturally, and the boundary surface peels off.
In the operation, gas is dispersed and diffused from the porosity of the shaping surface to the film surface.
The boundary surface peeling in the subsequent process.
Make sure. Also, after filling the hydraulic material slurry,
Excitation with vacuum suction applied to hydraulic material
Not only compaction and defoaming, but also
Vibration of the nearby adhesion point while adsorbing the film with the cell
The peeling effect of the adhesive interface between the film and the imprinted surface in advance.
As well as a porous mold before the demolding process.
At the boundary surface separation process that performs pressure adjustment operation to feed gas
As a result, the subsequent demolding process is facilitated. These phases
Easy to adhere as a thermoplastic resin film by multiplication
It is possible to use very thin films
Since the temperature can be increased, the transferability can be further improved.
Thinning can be realized. In particular, as a thermoplastic resin film
No self-retaining property after cooling and curing with a film thickness of 20 to 200 μm
The use of a film makes it very flexible and the film surface
Can be suppressed and transferability can be improved. Even if the film surface is locally pressed by the release resistance at the time of release, the surface protection of the film does not cause damage to the molding surface due to the surface protection effect. Restores by setting viscoelasticity. Therefore, it is possible to successfully remove a molded product having various irregularities in the surface of the shaping surface of the cavity, a molded product having a certain degree of undercut, and a molded product having an uneven surface, without breaking the molding. For this reason,
The instant demolding process can be put to practical use in earnest, and a molded product with an uneven pattern can be provided at low cost by greatly reducing the mold cost.

[0047]

[0048]  Use grain processed film as film
The film adhesion point decreases and the film
As well as improving the effect of matting the molding surface.

[0049]  The demolding operation is performed in the uncured state inside the cavity.
The backing covering material on the back side of the
Hold the uncured molded body with the covering material and the film
Removing the mold together improves the shape retention during removal.
Can be In addition, color powder for coloring the molding surface
Good riding.

[0050]  After interface peeling operation and before demolding process
First, a film and a backing
Method with vacuum contact operation for vacuum adsorption of hard materials
Air bubbles mixed in the uncured molded body are degassed,
The compact is compacted and the compact is uncured
However, it is a so-called vacuum pack and it is an elastic mass with solid hardness
You.Therefore, when removing the molded product, the side surface of the molded product is pressed by the removal resistance.
Elasticity immediately after removal from the mold, maintaining shape retention
You. For this reason, even a molded product with a certain negative draft
Because it can be molded, molded products with partial undercuts
Can also be obtained.

[0051]

[0052]  As a ventilation hole for the backing covering material,
Of the mold contact surface facing the edge of the cavity
If it is open, the interior will be empty without floating water being discharged as much as possible.
Between the water mix ratio
And the quality of the molded product can be kept constant.

[0053]  Before the demolding process, the mold and backing
When gravity separation operation is used to reverse the material
The thicker the part, the more it separates under its own weight
It will be easier.

[0054]  Fill the molding surface of the mold cavity
Before contacting the
If there is a step of applying or spraying the adhesion inhibitor, the boundary surface
More reliable film peeling in peeling operation
Of course, a matting effect on the molding surface is also exhibited.

[Brief description of the drawings]

FIG. 1 is a process cross-sectional view showing a first half of a film forming (transferring) 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 molding process.

FIG. 3 is a process cross-sectional view showing a concrete filling / compacting process in the first embodiment.

FIG. 4 is a process cross-sectional view showing a mold matching process in the first embodiment.

FIG. 5 is a process cross-sectional view showing a process immediately before demolding in the first embodiment.

FIG. 6 is a process cross-sectional view showing a state after demolding in the first embodiment.

FIG. 7 is a process cross-sectional view showing a mold matching process in a method for forming a decorative decorative outer wall plate according to the second embodiment of the present invention.

FIG. 8 is a process cross-sectional view showing a state after a reversing process in the second embodiment.

FIG. 9 is a process cross-sectional view showing a state after demolding in the second embodiment.

FIG. 10 is a cross-sectional view illustrating a molded body obtained from the second embodiment.

FIG. 11 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 third embodiment of the present invention.

FIG. 12 is a process cross-sectional view showing a mold matching process of placing a surface plate according to the third embodiment.

FIG. 13 is an external perspective view showing an example of a concrete decorative exterior wall panel having unevenness.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Concrete exterior wall plate 2 ... Surface 3 ... Thickness side surface 25b, 35b ... Anchor dent (back sole shape) 12 ... Cavity 10 ... Porous air-permeable mold plate (molding mold) 11 ... Vacuum adsorption stand 12a ... Shaping Surface 13: Thermoplastic film 15, 30: Plate 15a, 35a: Vent hole 16: Blow pad 19: Suction pad 25: Rubber unevenness imparting plate 25a: Dove groove-shaped unevenness 35: Porous air permeable plate S …concrete.

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B28B 1/00-1/54 B28B ⁷ /00-7/46 B28B 11/00-19/00

Claims (7)

(57) [Claims] 1. The method according to claim 1, wherein the cavity of the porous mold is heated.
After cooling and curing, the thermoplastic resin film having a thickness of 20 to 200 μm and having no self-retaining property is covered with the thermoplastic resin film in a developed state.
Vacuum suction of the mold is performed to adsorb the film on the shaping surface of the cavity, and the unevenness of the shaping surface of the cavity is transferred to the surface of the film by plastic deformation. Filling the film of the hard material on the film in the cavity and applying vibration to the hydraulic
The material was compacted Rutotomoni defoaming tighten, after demolding step of withdrawing relatively compact of uncured from the cavity while close contact surrounded by the film, the uncured state while said film is deposited In the method of molding a hydraulic material for curing a molded body, after the filling of the slurry and before the demolding step, a boundary surface peeling is performed in advance by separating a bonding boundary surface between the shaping surface of the cavity and the film. Having an operation , the interface peeling operation
Stops the vacuum suction and supplies gas to the porous mold.
A method for molding hydraulic material, which is an operation of adjusting the pressure of the air to be sent . 2. The method according to claim 1, wherein the film is a grained film. 3. The method of claim 1 or claim 2, wherein the demolding step, the uncured between the said backing covered material overlaid on the back side of the molding uncured in the cavity film A method for molding a hydraulic material, comprising holding a molded body in a state and releasing the molded body together. 4. The backing covering material according to claim 3 , wherein after the boundary surface peeling operation and before the demolding step, the air holes of the backing covering material are previously vacuum-evacuated and the backing covering material is removed. A hydraulic material characterized by comprising a vacuum contacting operation for exhausting the air enclosed by the film and for adsorbing the film and the backing covering material to the uncured molded body. Molding method. 5. The method according to claim 4 , wherein the ventilation hole of the backing covering member is opened at a position facing a vicinity of an edge of the cavity in a contact surface with the porous mold. Characteristic molding method of hydraulic material. 6. A any one of claims 3 to 5, in front of the demolding step, and characterized by the integrally turned upside down the porous mold and the backing covered material Molding method for hydraulic materials. 7. A any one of claims 1 to 6, wherein the porous mold prior to adsorbing the film shaping surface of the cavity, the film adhesive inhibitor excipients surface of the cavity Coating or spraying a hydraulic material.