JP4914973B2 - Cement-based cured body manufacturing method and cement-based molded body molding apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a cement-based cured body and a molding apparatus, and more particularly, to a method for manufacturing a molded-cured product such as a building outer wall material made of a cement-cured plate, and the manufacture of such a mold-cured product The present invention is directed to an apparatus for molding a cement-based molded body to be used.

A technique using a cement hardened plate as an outer wall material of a building is known. If the outer wall surface is constructed by arranging hardened cement plates, it is easier to construct an outer wall that is more productive, has better quality performance, and has a higher appearance design than the outer wall surface that is constructed by mortar or concrete construction on site.
The cement hardened plate is made by adding fibers and resins and other materials to hydraulic materials such as cement as necessary, and then pouring water into the mold and extruding the molding material. It is manufactured by molding into a desired outer shape and drying and curing naturally or forced curing by steam curing or the like. If a concavo-convex pattern is formed on the mold surface of the mold, it is possible to produce a cement-hardened plate with a high design property having a concavo-convex pattern on the surface.

As a method of manufacturing a cement hardened plate having a concavo-convex pattern on its surface, a technology is used in which a cement material is formed into a flat plate shape, a concavo-convex pattern is formed on the surface of this flexible cement molded plate, and then cured and cured. Are known. In forming the concavo-convex pattern, the embossing roll having the concavo-convex pattern is rolled while being pressed against the surface of the cement molding plate, or a press die having the concavo-convex pattern is pressed.
Furthermore, not only the flat surface of a cement molding board but the technique which forms an uneven | corrugated pattern in the several surface and curved surface which cross | intersect at different angles is also proposed.
In Patent Document 1, a concavo-convex pattern is formed on the surface of a flat extruded product with an embossing roll, a concave groove for folding is cut out on the back surface, and then the extruded product is folded with a convex ridge for bending. A technique for forming a concavo-convex pattern on a bent surface or curved surface of an extruded product by following a tray having a shape is shown.
JP-A-5-131422

In the technique of Patent Document 1 described above, a bending recess must be processed on the back surface of an extrusion-molded product on which an uneven pattern is formed. It is difficult to turn over the extruded product in a soft state, and it is difficult to process the back surface while the extruded product is supported flat.
If the extruded product is bent into a predetermined shape, the folding groove is closed, but still there is a break in the folding groove. This cut portion tends to be weak in strength.
Furthermore, when forming a concavo-convex pattern with an embossing roll, it is easy to form a groove-like or protruding line-like concavo-convex pattern continuous in the longitudinal direction, but it is difficult to form irregularities that are intermittent in the longitudinal direction. Since the cylindrical surface of the embossing roll rolls on the horizontal surface of the extruded product, the uneven surface is formed on the surface of the extruded product. It is difficult to avoid the upper end being chipped or distorted.

  An object of the present invention is to make it possible to easily form a clear concavo-convex pattern on the curved surface of a cement-based molded body, which is difficult to obtain with the above-described prior art.

A method for producing a cement-based cured body according to the present invention is a method for producing a cement-based cured body by molding a cement-based molded body from a cement-based material and curing and curing the cement-based molded body. A step (a) of obtaining a plastic preform preform supported on a flexible liner by extruding on the base plate, and a step (b) of pressing an uneven design on the surface of the preform, The preformed plate is placed together with the flexible base plate in a curved mold having a curved surface, and is molded into a curved plate shape along the curved mold by the weight of the flexible base plate and the preformed plate. A step (c) of obtaining a cement-based molded body having a plate-like shape and an uneven design on the surface; and a curved plate obtained by curing and curing the cement-based molded body having the curved plate shape supported by the flexible floor A cell with an irregular design on the surface. And a step (d) of obtaining a cement-based hardening material, Asker hardness of the preformed plates at the time of starting the curving in the step (c) is 10 to 60, it is characterized.

[Cement-based materials]
The same materials, blending, and manufacturing techniques as those of ordinary cement-based cured products can be applied to the cement-based material that is the main material of the cement-based molded body.
Those containing a W / O emulsion of oily substance and water and cement are preferred. A polymerizable oily substance is preferable as the oily substance.
Specifically, for example, the techniques described in Patent Document 1 (Japanese Patent Laid-Open No. 5-246747) and Japanese Patent Laid-Open No. 2002-47040 can be applied.
It is desirable to set the selection of each material and the manufacturing conditions so that a cement-based molded body having properties capable of satisfactorily deforming due to its own weight in curve molding described later.

<Cement>
It is a material that determines basic mechanical strength and other properties of hardened cementitious materials. Normal cement material can be used. Examples thereof include Portland cement, fly ash cement, blast furnace cement, and alumina cement. Multiple types of cement can be used in combination.
10 to 40% by volume can be blended in the cement-based material (in the total amount of the cement-based material including water). Preferably, it is 15-30 volume%.
<Polymerizable oily substance>
Among oily substances capable of forming a W / O emulsion with water, polymerizable substances are used. The polymerizable oily substance is polymerized by a polymerization reaction in the curing and curing process, and constructs a skeleton structure of a cement-based cured body together with cement that is hydrated and cured. When the skeletal structure of the cement-based cured body is well constructed, dimensional shrinkage associated with curing is less likely to occur.

As an oily substance, a hydrophobic liquid substance tends to form a W / O emulsion with water.
As specific examples of the polymerizable oily substance, those having a polymerizable double bond (vinyl monomer) such as styrene, divinylbenzene, methyl methacrylate, trimethylolpropane trimethacrylate, and unsaturated polyester resin are useful. The polymerization reaction of the oily substance having a polymerizable double bond and the hydration reaction of the cement proceed favorably at the same time, and the skeleton structure of the above-mentioned cement-based cured body is favorably formed.
The polymer of the oily substance, together with the cement, constructs a skeleton structure of a cement-based hardened body and determines basic characteristics. It functions to improve the physical properties and surface properties of hardened cementitious materials. Usually, 4 to 10% by volume can be blended in the cement-based material, although it varies depending on the use and required performance of the cement-based cured body and the type of oily substance to be used. Preferably, it is 5-7 volume%.

In order to accelerate the polymerization reaction of the polymerizable oily substance, a polymerization initiator composed of an organic peroxide, a persulfate or the like can be used in combination with the polymerizable oily substance.
<W / O emulsion>
The W / O emulsion is also called a water-in-oil emulsion and is a state in which fine water particles are dispersed in a continuous phase of an oily substance.
By mixing water and a polymerizable oily substance so as to constitute such a W / O emulsion, and stirring and mixing, the target W / O emulsion can be obtained.
As the oily substance, an oily substance other than the polymerizable oily substance described above can be blended. In addition to water, other liquid or solid particles may be added. The cement can be dispersed in the W / O emulsion as fine solid particles.

After preparing the W / O emulsion, other materials such as cement can be mixed, or the emulsification treatment can be performed in a state where other materials are mixed in addition to water and oily substances.
<Emulsifier>
In order to promote the formation of the W / O emulsion, it is effective to add an emulsifier.
As the emulsifier, an emulsifier used in a usual emulsion technique can be used. A material that is effective for forming a W / O emulsion of an oily substance and water, hardly adversely affects the molding and curing of the cementitious material, and does not impair the quality performance of the cemented cured body is preferable.

Specific examples of emulsifiers include nonionic surfactants such as sorbitan sesquioleate, glycerol monostearate, sorbitan monooleate, diethylene glycol monostearate, sorbitan monostearate, diglycerol monooleate, various anionic surfactants, cations And surface active agents.
The amount of emulsifier used varies depending on the blending ratio and required performance of the oily substance and water, but can usually be set in the range of 1 to 3% by volume with respect to the total amount of water and solid content in the cementitious material.
<Reinforcing material>
It is useful for improving physical properties such as mechanical strength of a cement-based cured body.

Various reinforcing materials used in the production of ordinary cement-based hardened bodies can be used. Specifically, there is a material known as a so-called cement aggregate. There are materials known as reinforcing fibers. Examples of the reinforcing fiber include synthetic fibers such as polypropylene fiber, acrylic fiber, vinylon fiber, and aramid fiber, carbon fiber, glass fiber, and pulp. Inorganic particles such as gravel, perlite, shirasu balloon, glass powder, and alumina silicate are also used. There are also porous or hollow inorganic particles.
These reinforcing materials can be blended at about 0.5 to 10% by volume with respect to the total amount of the cementitious material.

<Other materials>
It is possible to combine additive materials used for the production of ordinary cement-based cured bodies. For example, a coloring agent etc. are mentioned.
<Preparation of cement-based material>
Basically, the materials constituting the cement-based material described above may be uniformly stirred and mixed. Each material may be stirred and mixed at the same time, or a part of the materials may be stirred and mixed, and then the remaining materials may be added and further stirred and mixed.
It is desirable to set production equipment and production conditions so that a W / O emulsion of water and an oily substance is formed satisfactorily.

As a stirring device, a dissolver, a screw line mixer, an ultrasonic homogenizer, a colloid mill, a planetary mixer, a static mixer, a nauter mixer, a ribbon blender, a tumble mixer, a paddle mixer, and the like can be used.
It is effective to knead a material whose viscosity is increased by adding cement or a reinforcing material to the W / O emulsion with a kneading apparatus. As the continuous kneading apparatus, a continuous kneader, a twin screw extruder, or the like can be used.
(Extrusion molding)
Basically, an extrusion technique for a normal cement-based material is applied.

By extruding the cement-based material supplied to the extrusion molding device from the extrusion die onto the flexible floor plate, the preformed plate corresponding to the die shape of the extrusion die is supported by the flexible floor plate. can get. A preformed plate with a predetermined size and shape can be obtained by intermittently extruding a cement-based material or by cutting a strip-shaped preformed plate obtained by continuous extrusion molding into predetermined dimensions. It is done. The preformed plate at the extrusion stage is in a plastic state and easily deforms. By supporting the flexible sheet, it is easy to handle the preformed sheet.
<Shape of preformed plate>
The shape of the preformed plate is generally a rectangular thick plate shape that is extruded by a rectangular extrusion die, for example. By changing the detailed shape of the extrusion die, it is possible to form a rectangular thick plate having longitudinal grooves or ridges.

For example, when manufacturing the cement-type hardened | cured material used for the exterior board | substrate for buildings, the preforming board which makes | forms the rectangular plate shape of thickness 1-5cm, length 90-380cm, width 30-100cm can be formed. Preferably, it can be set to a rectangular plate shape having a thickness of 2 to 5 cm, a length of 240 to 360 cm, and a width of 45 to 100 cm.
<Flexible floor plate>
As the material of the floor plate, a flexible material that can support the preformed plate and can be deformed in the curve forming described later is used. Specifically, a thin steel plate can be used. Plated steel can be used. Metals other than steel, such as aluminum, aluminum alloys, copper, copper alloys, etc., can also be used. Synthetic resin boards, reinforced resin boards, and wood boards can also be used. The thickness of the laying plate varies depending on conditions such as the material, the size and shape of the preformed plate, and the degree of curve forming, but can usually be set to a thickness of 0.1 to 0.4 mm. Preferably, it is 0.2-0.3 mm.

The shape dimension of the floorboard is set according to the size of the preformed board. It is the same size as the preformed plate or slightly larger.
〔Press molding〕
An uneven design is press-molded on the surface of the preformed plate.
Basically, a press molding technique for a normal cement-based molded body can be applied.
The press molding apparatus usually includes a pair of molds and a press mechanism that applies a press pressure to the molds. Of the pair of molds, one mold is fixed and the other mold is movable. Usually, the concave and convex shape corresponding to the concave and convex shape to be press-molded on the cement-based molded body is provided on the mold surface of the movable mold. Therefore, the movable mold may be referred to as a press mold, and the fixed mold may be simply referred to as a support plate or a support table for the extruded product. Of course, if necessary, the mold surface of the fixed mold may be provided with an uneven shape for press molding. In a general press molding apparatus, a fixed mold and a movable mold are arranged vertically.

An upper movable mold, that is, a press mold having an uneven mold surface on the lower surface is pressed from the upper side of the extruded preform plate to the surface of the preform mold to the uneven mold surface of the press mold. The corresponding uneven design is press-molded to obtain a preformed plate having the uneven design on the surface. In addition, since the preformed plate is placed on the flexible laying plate, the concave and convex press molding by the lower fixed mold is basically not performed. When the joint structure is formed on the edge of the preformed plate outside the flexible floor plate, a predetermined uneven shape is provided on the mold surface of the fixed mold.
The press pressure for pressing the press mold varies depending on the material composition of the preformed plate and the required performance of the finally produced cement-based hardened body, but is usually in the range of 0.5 to 1.0 MPa. Can be set. If the press pressure is too low, sufficient press molding cannot be performed.

The preformed plate obtained after the press molding has an uneven design corresponding to the mold surface shape of the mold on the surface.
[Uneven design]
The uneven design formed on the surface of the cement-based molded body is not particularly limited as long as it can be formed by press molding.
The shape that can be formed when extruding the preform is not included in the uneven design formed by press molding, but the shape formed by press molding is combined with the shape of the preform to form the uneven design. In some cases.

As an uneven design, for example, there is one in which a large number of convex portions or concave portions having the same geometric shape are arranged in a predetermined pattern. If the convex portions are rectangular in a plane and are arranged at intervals in the vertical and horizontal directions, an external appearance design such as a tile finish surface or a brick finish surface is exhibited, which is useful for a building exterior board. The convex part can be made into a shape with fine irregularities such as natural rocks, stones, and bricks. An uneven shape representing a picture, a character, a symbol, or the like may be used. The uneven design does not simply represent the appearance design. For example, a concavo-convex structure for attaching another member to the cement-based cured body, a concave groove for wiring, or the like can be provided as a part of the concavo-convex design.
(Curved molding)
The preformed plate is placed in a curved mold having a curved surface together with the flexible sheet, and is formed into a curved plate along the curved mold by the weight of the flexible sheet and the preformed plate. A cement-based molded body having an uneven design on the surface is obtained.

The curved mold is made of the same rigid material as the press mold described above. However, since no pressing pressure is applied, mechanical strength and deformation resistance are not so required as compared with a press mold. What is necessary is just to be able to maintain a shape in the state which supported the preforming board and the flexible laying board. A material with good workability, which is easy to produce a curved surface having a curved surface, is desirable. Among the bay phase molds, specific materials corresponding to the curved mold surface include metals such as steel, synthetic resins, fiber reinforced resins, and wood materials.
The curved surface shape in the curved mold means that it is formed of a smooth curved surface such as a cylinder. This includes cases where multiple planes are connected by a smooth curved surface. In addition, it is necessary for the flexible floor plate to have a deformable curved shape. Usually, a flexible laying board can only bend in one vertical and horizontal direction, and it is difficult to bend in both vertical and horizontal directions. The curved surface is also formed in a shape that curves in one direction. It may be a convex curve or a concave curve. The curvature in the convex direction and the curvature in the concave direction may be combined.

As the curved surface, a circumferential surface having a curvature radius R = 50 to 200 cm can be employed. Combining planar portions on both sides of such a circumferential surface enables bending plate-like curve forming with curved corners. A curved surface can be configured by combining curved surfaces having different radii of curvature.
The curved mold surface can be provided with an inner peripheral wall for positioning the preformed plate or the flexible laying plate at a position where the edge of the preformed plate is disposed. The edge shape of the preformed plate can be formed by the inner peripheral wall.
The preformed plate and the flexible floor plate are formed into a curved plate shape along the curved mold by their own weight. The support of the preformed plate and the flexible laying plate arranged on the curved mold surface of the curved mold is released so that deformation by its own weight is possible. A member or means for guiding the preformed plate and the flexible laying plate so that the posture and position of the preformed plate and the flexible laying plate are not shifted can be provided. The above-described inner peripheral wall is also one of the guide means.

The uneven design on the surface of the preformed plate changes its posture or part of its shape as the preformed plate is curved, but retains its basic shape. As a result, a cement-based molded body having a curved plate shape and an uneven design on the surface is obtained.
The processing time for curve forming is set to such an extent that the preformed plate and the flexible floor plate are deformed by their own weight and the deformed state is stabilized. It varies depending on conditions such as the material and structure of the preformed plate and the degree of deformation. The transfer time to the curing and curing process, which is a subsequent process, and the time until the preformed plate progresses in the curing and curing process are also included in the holding time in the curve molding. The total time in all the steps of holding the preformed plate and the flexible laying plate with the curved mold can be set to 24 hours or more.

It is desirable to appropriately set the flexibility or deformation characteristics of the preformed plate at the time of starting the curve forming so that the curve forming is performed satisfactorily. For example, those having an Asker hardness of 10 to 60, preferably 20 to 40 can be used. Such deformation characteristics can be adjusted by the composition of the cement-based molding material, the extrusion molding conditions, and the like.
[Curing curing of cement-based moldings]
A cement-based cured body is obtained by curing and curing the curved cement-based molded body in a state where it is supported by a flexible laying board.
Basically, a curing and curing apparatus and curing and curing conditions in a normal cement-based cured body manufacturing technique are applied. For example, steam curing, autoclave curing, etc. are adopted.

The curing conditions vary depending on the blending of cementitious materials and the performance required of the cementitious hardened body, but are usually set at 40 to 100 ° C. for 20 to 48 hours. During the curing process, the temperature can be changed stepwise or continuously.
The cement-based molded body and the flexible laying board are supplied to curing and curing while maintaining the curved shape, and the curved shape is maintained during curing and curing. Curing and curing may be performed together with the bending mold while supporting the cement-based molded body and the flexible laying board on the bending mold. In this case, the bending mold may be made of a material that can withstand the heating and atmosphere during curing. Curing and curing can also be performed by transferring the cement-based molded body and the flexible laying board to a curing support member having a curved surface shape similar to that of the curved mold. In this case, the curing support member may have the same curved surface shape as the curved surface, or may be a portion that partially supports the curved shape of the flexible siding plate without changing. Among the curved molds, some members including a curved mold surface that supports the cement-based molded body and the flexible laying board can be separated from the main body of the curved mold and used as a curing support member.

[Cement hardened body]
When the curing of the cement-based molded body is completed, a cement-based cured body is obtained.
The cement-based cured body has an outer shape formed by extrusion molding, press molding of an uneven design, and curve molding. It has a curved plate shape and an uneven design on the surface. It is used as a building exterior board.
If necessary, further processing can be added to the cemented hardened body. For example, the surface can be painted, a hole or groove for attachment can be processed, or another metal fitting can be attached.

The method for producing a cement-based molded body according to the present invention is such that a cemented cured body having a curved plate shape and an uneven design on the surface can be easily manufactured with good productivity, and the surface uneven design is clear and finished. It is good.
In conventional extrusion molding or press molding, it is necessary to produce a complicated mold, a clear uneven design cannot be formed, the uneven design may be deformed when the mold is opened, and the uneven design is designed. However, in the present invention, the press forming technology for forming a concavo-convex design can be directly applied to the technology for forming a concavo-convex design on a flat, flat cement-based molded product. Without being restricted by molding, a variety of complex uneven designs and fine uneven designs can be formed.

Since the curve forming performed after forming the uneven design only uses a curve forming mold having a relatively simple curved surface shape, the curve forming mold can be easily manufactured and the manufacturing cost does not increase.
By simply changing the curved shape of the curved mold, it is possible to easily obtain a cement-based molded body in which an uneven design is formed on different curved surfaces. When the design of the concave / convex design is changed with the same curved shape, it is only necessary to change the concave / convex design of the press mold, and there is no need to change the curved mold.
Conventionally, when both a curved shape and an uneven design are to be formed simultaneously by only press molding, it is necessary to manufacture a new press mold for each different curved shape and uneven design, which is extremely expensive. . In the present invention, since only the press mold or the curved mold needs to be remade, it is possible to greatly reduce the labor and cost of the design change.

The embodiment shown in FIGS. 1 to 3 shows the manufacturing process of the cement-based cured body stepwise.
[Extrusion of preformed plate]
As shown in FIG. 1, an extrusion molding apparatus 20 in a state where a flexible base plate 24 made of a thin steel plate having a thickness of 0.22 mm, a length of 320 cm and a width of 90 cm is arranged on a support base 22 made of a running surface of a belt conveyor. The cement-based material in a kneaded state is extrusion-molded on the flexible floor plate 24 from the extrusion die 21 having a horizontally long rectangular shape. The flexible floor plate 24 is moved and moved in the horizontal direction with respect to the extrusion die 21. The extrusion-molded preform 16 has a rectangular shape with a horizontally long cross section and forms a thick plate that continues in the length direction. The preformed plate 16 is cut near the end of the flexible laying plate 24 to obtain the preformed plate 16 having a rectangular planar shape. The surface of the preformed plate 16 is flat.

[Press molding of uneven design]
As shown in FIG. 2A, the preformed plate 16 having a rectangular thick plate shape is disposed on a support plate 32 having a flat surface provided in the press molding apparatus 30 together with the flexible base plate 24. The support plate 32 can also be used as the support base 22 of the flexible laying plate 24 at the time of extrusion molding. The conveyance from the extrusion molding process to the press molding apparatus 30 is performed in a state where the flexible base plate 24 on which the preformed plate 16 is placed is supported flat so as not to be bent or bent. Specifically, for example, the extrusion molding device 20 and the press molding device 30 may be sequentially installed on the travel path of the belt conveyor that supports the flexible floor plate 24. If the support base 22 and the support board 32 are also used, the flexible base plate 24 and the preformed board 16 placed on the support base 22 (support board 32) are transferred.

A resin mold 34 is provided on the lower surface of the press molding apparatus 30 that moves up and down above the support plate 32, that is, a movable mold. An uneven mold surface is formed on the lower surface of the resin mold 34. If only the resin mold 34 is replaced, mold surfaces having different concavo-convex shapes can be easily configured.
As shown in FIG. 2 (b), the press molding apparatus 30 and the resin mold 34 are lowered, the resin mold 34 is brought into contact with the upper surface of the flat preforming plate 16, and the resin mold 34 is pressed downward. The forming plate 16 is press-molded.
An uneven design 12 corresponding to the uneven shape of the resin mold 34 is formed on the surface of the preformed plate 16. Specifically, rectangular trapezoidal convex portions are arranged at intervals in the vertical and horizontal directions, and lattice-shaped valley grooves are provided between the rectangular trapezoidal convex portions. It has a form in which small tile-shaped uneven patterns are arranged in a mosaic pattern.

(Curved molding)
As shown in FIG. 3, the preformed plate 16 having the uneven design 12 formed on the surface thereof is mounted on the curved mold 40 together with the flexible laying plate 24.
The bending mold 40 has a rigid shape constructed of steel or the like. On the upper surface of the bending mold 40, a curved surface 42 having a circumferential surface that is convex upward is provided. As shown in FIG. 3B, the curved surface 42 has an arcuate surface shape with a radius of curvature R = 103 cm and an included angle θ = 45 °. On both sides of the curved surface 42, there are inner peripheral walls 44 that rise in the radial direction from the curved surface 42.
As shown in FIG. 3A, the preformed plate 16 and the flexible floor plate 24 abut on the upper center end of the curved mold surface 42. In this state, the support of the flexible floor plate 24 is released. Since gravity is applied to the preformed plate 16 and the flexible base plate 24, both sides of the flexible base plate 24 and the preformed plate 16 that are not supported by the curved surface 42 are deformed so as to hang downward due to their own weight. .

As shown in FIG. 3B, the flexible laying plate 24 is bent along the curved surface 42 and comes into contact with the entire surface. The flexible floor plate 24 and the preformed plate 16 are formed into a curved plate shape along the curved mold surface 42, and the cement-based molded body 10 is obtained. Both side ends of the flexible laying plate 24 and the cement-based molded body 10 are positioned by inner peripheral walls 44, 44 provided at both side ends of the curved mold surface 42.
At this time, the concavo-convex design 12 formed on the surface of the cement-based molded body 10 is gradually deformed or changes its posture according to the curvature of the cement-based molded body 10. Since the cement-based molded body 10 is deformed so as to be evenly curved in the circumferential direction, the uneven design 12 of each part is also deformed little by little evenly. In FIG. 3 (b), the individual rectangular trapezoidal convex portions constituting the concavo-convex design 12 are arranged on the circular arc surface in a state where the posture is gradually changed.

[Curing curing]
The cement-based molded body 10 becomes a cement-based cured body by curing and curing.
As shown in FIG. 3B, the curving mold 40 is carried into the curing treatment chamber while the flexible floor plate 24 and the cement-based molded body 10 are supported in the curving state by the curving mold 40, and the curing process is performed. be able to. In this way, a cement-based cured body having an accurate curved shape as the curved shape of the curved mold 40 is obtained without being deformed during the handling of the cement-based molded body 10 or applying an excessive load. be able to.
After the cement-based molded body 10 is supported by the curved mold 40, it is dried to the extent that it loses plasticity or deformability or is naturally cured, and then the cement-shaped molded body 10 is removed from the curved mold 40. It can also be removed and carried into the curing chamber. In this case, the cement-based molded body 10 can be dried and cured to the extent that the shape can be maintained without the flexible floor plate 24.

It is also possible to remove the flexible floor plate 24 and the cement-based molded body 10 from the curved mold 40 and send them to the curing treatment chamber in a state where they are placed on another conveyance table. In this case, it is preferable that the conveyance table is a curved surface similar to the curved mold surface 42 of the curved mold 40. It may be a support base or a support frame having a simple structure capable of partially supporting an appropriate portion of the flexible floor plate 24.
[Use of cement-based hardened body]
FIG. 4 shows a construction state of the cement-based cured body P obtained after the curing and curing is completed.
The cement-based cured body P has a curved plate shape that is curved in an arc shape as a whole, and the uneven design 12 is clearly formed on the surface in an orderly manner.

In the construction of an outer wall of a building such as a house, if a cemented hardened body P is applied to a corner portion or the like of the outer wall, a beautiful finish in which a clear and uniform uneven design 12 is arranged on a smooth curved surface can be obtained.
The planar portion of the outer wall, the cement hardened body P ₀ of the flat plate-like are used. The cement-based cured body P ₀ can be manufactured by curing and curing the flat preformed plate 16 having the irregular design 12 formed on the surface, which is produced in the steps of FIGS. .
In this way, if the curved plate-like cement-based cured body P manufactured by sharing the basic manufacturing process and the flat plate-shaped cement-based cured body P ₀ are combined, the outer wall construction of the building is performed. From the flat portion to the curved portion, a continuous smooth uneven design 12 continues, and a finish with extremely excellent appearance design can be easily obtained.

[Partial curve forming]
The embodiment shown in FIG. 5 is slightly different from the above embodiment in the form of curve molding.
The curved mold surface 42 of the curved mold 40 is a circular arc with a radius of curvature R at the center in the cross-sectional shape, but has linear portions on both sides of the arc. The whole forms a “h” shape.
The preformed plate 16 formed by the curved mold 40 is obtained through the manufacturing steps of FIGS. 1 to 2 of the above embodiment. The entire surface is flat and has a concavo-convex design 12 on the surface, and is supported by a flexible floor plate 24.
When the preformed plate 16 is disposed on the curved mold 40 as in the above-described embodiment, the preformed plate 16 is curvedly formed according to the curved mold surface 42. The obtained cementitious molded body 10 has a shape in which a central portion has a curved portion having a radius of curvature R and straight portions extending obliquely downward on both sides thereof.

The cement-based cured body P obtained by curing and curing the cement-based molded body 10 formed in such a shape is used for finishing an outer wall of a building. In the construction state, one cement-based hardened body P can be configured from the corner of the outer wall to a part of the planar portions on both sides. There is no seam between the flat portion and the curved portion of the outer wall, and a beautiful finished appearance is obtained.
(Concave curved molding)
The embodiment shown in FIG. 6 is basically the same as the curve forming shown in FIG. 3 except that a concave curve is formed.
The curved mold surface 42 of the curved mold 40 has an arc shape with a recessed central portion. The inner peripheral walls 44 at both ends of the curved surface 42 rise vertically.

When the preformed plate 16 and the flexible laying plate 24 that are flat and have the uneven design 12 formed on the surface thereof are arranged on the curved mold surface 42, the preformed plate 16 and the flexible laying plate 24 are deformed so that the central portion is recessed by their own weight. The cement-based molded body 10 is formed by forming a circumferential surface along the curved mold surface 42.
If the cement-based molded body 10 of this form is cured and cured, a cement-based cured body P in which the concave and convex design 12 is formed on the concave circumferential surface is obtained. It can be applied to the corner of the outer wall surface of the building, or it can be applied to the wall portion curved in a concave shape.
In ordinary press molding, it is extremely difficult to form an uneven design on a concave curved surface. The mold cannot be removed, and even if the mold is divided or a core mold is used, the mold becomes considerably difficult. However, in this embodiment, it is only necessary to press-mold the preformed plate 16 that is flat and has the irregular design 12 formed on the surface. A cement-based cured body P on which the design 12 is formed can be obtained.

  INDUSTRIAL APPLICATION This invention can be utilized for manufacture of the cement-type hardened | cured material used as the exterior board used for the outer wall finishing of a building, for example. An exterior board having a high appearance design with a concavo-convex design on the curved surface can be manufactured with high productivity, and a building with a high commercial value can be provided.

Sectional drawing which shows an extrusion process among the manufacturing methods used as embodiment of this invention. Cross-sectional view showing step-by-step press forming process of uneven design Sectional view showing the curve forming process step by step The perspective view which shows the use condition of a cement hardening body Sectional drawing which shows the curve shaping | molding process in another embodiment. Sectional drawing which shows the curve shaping | molding process in another embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Cement-type molded object 12 Concavity and convexity design 16 Preliminary shaping | molding board 20 Extrusion molding apparatus 21 Extrusion die 22 Support stand 24 Flexible laying board 30 Press molding apparatus 32 Supporting board 34 Resin type | mold 40 Curved shaping | molding die 42 Curved type | mold surface 44 Inner peripheral wall P Cement type Cured body

Claims (4)

A method for producing a cement-based cured body by molding and curing a cement-based molded body from a cement-based material,
A step (a) of extruding the cement-based material onto a flexible base plate to obtain a plastic preformed plate supported by the flexible base plate;
A step (b) of press-molding an uneven design on the surface of the preformed plate;
The preformed plate is placed together with the flexible base plate in a curved mold having a curved surface, and is molded into a curved plate shape along the curved mold by the weight of the flexible base plate and the preformed plate. A step (c) for obtaining a cement-based molded body having a plate-like shape and having an uneven design on the surface;
A step (d) of obtaining a cement-based cured body having a curved plate shape and an uneven design on the surface by curing and curing the cement-based molded body having the curved plate shape in a state of being supported by the flexible slat ;
Only including,
In the step (c), the Asker hardness of the preformed plate at the time of starting the curve forming is 10 to 60,
A method for producing a cement-based hardened body. In the step (a) , a preformed plate having a rectangular plate shape having a thickness of 1 to 5 cm, a length of 90 to 380 cm, and a width of 30 to 100 cm is formed from a plastic sheet having a thickness of 0.1 to 0.4 mm. was extruded over, in the step (c), said preformed plate, is curved in a curvature radius R = 50 to 200 cm, the production method of cementitious cured product according to claim 1. A curved mold used in the manufacturing method according to claim 1 or 2 , comprising a curved mold surface made of a rigid material and having a curved surface, and the preformed plate disposed on a peripheral edge of the curved mold surface. An apparatus for molding a cement-based molded body , comprising: an inner peripheral wall on which an edge of the cement is disposed. The curved surface is a circumferential surface of the curvature radius R = 50 to 200 cm, the molding apparatus of the cement-base molded article as claimed in claim 3.

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