JPS5810202B2 - Manufacturing method for inorganic molded products with decorative layer - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing an inorganic molded article with a decorative layer.

Conventionally, casting, press molding, and roll extrusion methods have been used to mold inorganic molded product compositions such as cement compositions.

In the casting method, the cement composition must be filled into the details of the mold, so it was necessary to increase the water content of the cement composition to improve its fluidity.

As a result, a large amount of water is present in the cement composition, which reduces the density of the molded product obtained, and the strength of the cured cement product obtained by curing and hardening the molded product is low.

In addition, since the cement composition is injected into one mold and left to cure and harden in that state, the ability to remove bubbles is extremely poor, leaving air bubbles and making it impossible to create a product with a smooth surface, which also reduces productivity. It was extremely bad.

Press molding methods include wet methods and dry methods.

In the wet method, it is necessary to use a cement composition with a high moisture content, so a large amount of alkaline waste water is generated after press molding, and its disposal becomes a problem.In the dry method, there is no need to use a cement composition with a high moisture content. , problems like the wet method do not occur.

However, due to the poor fluidity of the cement composition used, even if the molding pressure is increased, a molded product with a high specific gravity cannot be obtained, and spider web-like cracks occur on the surface of the molded product. The problem was the long press cycle time and low productivity.

In the roll extrusion molding method, the cement composition is pressurized and shaped using rolls, the surface of the shaped body is pressurized with a forming die, and the shaped body is extruded forward in this state to form the cement composition, so it is possible to create a cement composition with a low moisture content. In addition, molded products with smooth surfaces can be manufactured continuously and efficiently.

Therefore, problems such as a decrease in specific gravity of a molded article and generation of a large amount of alkaline waste water, which occur when using a cement composition with a high moisture content, do not occur.

Moreover, there is no problem of poor productivity.

That is, the roll extrusion molding method is an extremely excellent method that does not cause any of the problems that the casting method and the press molding method have.

However, in recent years, river sand used in cement compositions,
Because it is difficult to obtain sea sand, crushed stone, which is relatively easy to obtain, is used instead, and when cement compositions containing such crushed stone are used, it can be made smooth even by roll extrusion. It has become extremely difficult to obtain a molded product with a surface.

Therefore, a decorative layer is provided on the surface of a molded article in the following manner to improve its appearance.

That is, a composition for a decorative layer is deposited in a layer on the surface of a molded article by scattering with a mortar gun or a brush.

However, the decorative layer formed in this way had poor bonding and fixing properties because it was merely attached.

Further, the density of the decorative layer was low, its strength was low, and the surface smoothness of the decorative layer was also poor.

Therefore, a cured cement body with a decorative layer produced by curing and curing such a molded product with a decorative layer also lacks the bonding fixability, strength, and surface smoothness of the decorative layer.

That is, when such a hardened cement body with a decorative layer is left outdoors, the decorative layer peels off due to changes in temperature and the like.

In addition, the surface of the decorative layer is easily damaged when the hardened cement body with the decorative layer is transported or applied, and the surface of the decorative layer is uneven, resulting in problems in appearance.

This invention was made in view of the above circumstances, and involves supplying an inorganic molded product composition onto a lower mold that moves in one direction, and distributing the inorganic molded product composition so that it faces the lower mold. The shaped body is shaped by applying pressure with a pressure roll provided, the composition for a decorative layer is supplied onto the surface of the shaped body, and then the shaped body supplied with the composition for a decorative layer is placed in front of the pressure roll. The gist of this method is to obtain an inorganic molded product with a decorative layer by pressure molding with a pressure molding roll provided so as to face a lower die.

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

That is, in FIG. 1, a lower mold 2 is attached to the surface of a belt conveyor 1 moving in the direction of arrow A, and the lower mold 2
Above, a cement composition 3 for inorganic molded articles is supplied from a composition supply hopper 4.

As the lower mold 2 advances, the cement composition 3 supplied onto the lower mold 2 passes through a pressure roll (
It rotates in the direction of arrow B and is pressurized by the lower die 2 (which rotates in synchronization with the speed of the belt conveyor) 5 and is shaped into a plate shape.

The thickness of the plate-shaped shaped body 6 is set to be slightly thicker than the thickness of the plate-shaped shaped body 6 after passing through the pressure forming roll 7.

Next, a fixed amount of cement slurry 8 for the decorative layer is supplied onto the surface of the plate-shaped shaped body 6 from the slurry supply hopper 9.

As the lower die 2 advances, the plate-shaped shaped body 6 whose surface has been supplied with the cement slurry 8 for the decorative layer is moved to the pressure forming roll (in the direction of arrow C) provided facing the lower die 2. rotation, synchronized with belt conveyor speed) 7 and lower mold 2
Pressure molded by

At this time, the cement slurry 8 supplied to the surface of the plate-shaped shaped body 6 is strongly pressed against the plate-shaped shaped body 6 and becomes integrated.

In this way, the decorative layer-equipped molded product 11 having the decorative layer 10 is manufactured continuously in a short time.

The molded product 11 thus obtained is made by supplying the cement slurry 8 for the decorative layer onto the surface of the uncured plate-shaped shaped body 6 and pressing it with the pressure forming roll 7 to integrate the decorative layer. The layer 10 and the plate-shaped shaped body 6 fit well and are firmly fixed together, and the decorative layer 10 has a high density and high strength.

Further, the surface of the decorative layer 10 is pressed by the roll surface of the pressure forming roll 7, so that the surface is smooth.

Therefore, a hardened cement body with a decorative layer (not shown) obtained by curing and hardening such a molded product 11 with a decorative layer 10 cannot be used outdoors because the decorative layer is firmly bonded and fixed to the hardened cement body. It will not peel off even if left for a long time.

In addition, the decorative layer has a high density and strength, so it is less likely to be damaged.

Furthermore, the surface of the decorative layer is extremely smooth.

Another example of this invention is shown in FIG.

That is, in this example, in place of the pressure roll 5 and pressure forming roll 7 shown in FIG. These irregularly shaped rolls 12.
Using a lower mold 14 having a surface shape corresponding to the surface shape of 13, a wavy decorative layer-attached molded product 16 is molded,
A forming die 15 in which the surface of the decorative layer of the wavy decorative layer-attached molded product 16 is provided on the front side of the irregularly shaped pressure forming roll 13
to further improve the smoothness of the surface of the decorative layer and to further improve the degree of bonding and fixation between the decorative layer 17 and the plate-shaped shaped body 6 by pressing the molded product 16 with the decorative layer forward in that state. It is something to do.

The rest is the same as the previous example.

Still other embodiments of the invention are shown in FIGS. 3 and 4.

That is, in this example, a hopper plate 18 as shown in the figure is used in place of the slurry supply hopper 9 in FIG. This hopper plate 18 and the irregularly shaped pressure forming roll 1
Cement slurry 8 is stored between the rollers 3 and 3, and the cement slurry 8 is supplied in fixed amounts onto the plate-shaped body 6 as the irregularly shaped pressure forming rolls 13 rotate.

The rest is the same as the previous example. In the above explanation, cement composition 3 is used as the composition for inorganic molded products, but the composition is not limited to this, and compositions containing hydraulic binders other than cement (e.g. calcium silicate, gypsum) can also be used. objects can be used.

Further, the composition for the decorative layer is not limited to the cement slurry 8, and a slurry using a hydraulic binder other than cement can be used.

Furthermore, the composition for a decorative layer in the present invention includes not only a composition but also cement and a hydraulic binder other than cement alone.

Of course, a coloring agent such as a pigment may be mixed into such a makeup layer composition.

In addition, in the above explanation, the obtained molded product with decorative layer 11.
16 is cured and hardened, but such molded product 11
, 16 are not essential.

As described above, according to the present invention, the inorganic material with a decorative layer has a high bonding and fixing strength of the decorative layer, the density of the decorative layer is high, the strength is high, and the surface smoothness of the decorative layer is high. Molded products can be manufactured.

In particular, in this invention, since the decorative layer is formed during pressure molding of the excipient, the manufacturing time can be shortened.

Next, examples will be described.

[Example 1] A cement composition for an inorganic molded article was prepared as follows.

That is, crushed stone and cement are mixed so that the weight ratio of crushed stone/cement is 3.0, and water is added to the cement so that the weight ratio of water/cement is 0.4 to 0.5. and mixed to form a cement composition.

On the other hand, cement powder was prepared as a composition for a decorative layer.

Next, the above cement composition and cement powder were applied to an apparatus as shown in FIG.

At this time, the conveyor speed was set at 10 m/min, and the cement powder supply rate was set at 60 S'/m2 to ensure uniform distribution.

In this way, a molded article with a smooth and beautiful decorative layer was produced.

Next, when this was cured and cured, the decorative layer was firmly bonded and fixed to the hardened cement body, and a hardened cement body with a decorative layer was obtained whose hardness was resistant to scratches by dogs and whose surface was rich in smoothness. .

[Example 2] Instead of cement powder for the decorative layer, a cement slurry prepared by mixing 50 parts by weight of cement (hereinafter referred to as "parts"), 50 parts of No. 8 silica sand, and 50 parts of water was used, and the supply amount was 100 g/
I made it m2.

The rest was the same as in Example 1.

This example also produced the same effects as Example 1.

[Example 3] Instead of cosmetic cement powder, 50 parts of cement, 8
A colored cement slurry prepared by mixing 50 parts of No. silica sand, 50 parts of water, and 5 parts of red iron was used, and the supply amount was 100 g/
I made it m2.

The rest was the same as in Example 1.

In addition to the same effects as in Example 1, this example also has the effect that the decorative layer of the inorganic molded product is colored red, further improving the appearance.

[Brief explanation of drawings]

FIG. 1 is a partially cutaway side view explaining the present invention in detail, FIG. 2 is a partially cutaway side view explaining another example, and FIG. 3 is a side sectional view of a manufacturing apparatus used in yet another example. FIG. 4 is a plan view thereof. DESCRIPTION OF SYMBOLS 1... Belt conveyor, 2... Lower mold, 3... Cement composition, 5... Pressure roll, 6... Plate-shaped excipient, 7... Pressure forming roll, 10... Decorative layer, 11... ...Molded product with decorative layer.

Claims (1)

[Claims] 1. An inorganic molded product composition is supplied onto a lower mold that moves in one direction, and this inorganic molded product composition is applied with a pressure roll provided to face the lower mold. The shaped body is pressed and shaped, a composition for a decorative layer is supplied onto the surface of the shaped body, and then the shaped body supplied with the composition for a decorative layer is placed in front of the pressure roll and facing the lower die. 1. A method for producing an inorganic molded product with a decorative layer, the method comprising obtaining the inorganic molded product with a decorative layer by pressure molding with a pressure molding roll provided in a. 2. The method for producing an inorganic molded product with a decorative layer according to claim 1, wherein the molded product pressure-formed with a pressure-forming roll is further pressure-formed with a forming die.