JPS5848512B2 - Manufacturing method of colored slate material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a colored slate material using a thermosetting inorganic mold material.

The present invention is a thermosetting inorganic molding material (in some cases The main raw material is asbestos or its substitutes (rock wool, glass fiber, etc.) or the addition of silicic materials to these, and wet or A plastic plate called a green sheet is prepared by dry molding, and uneven scratches such as a rough shape are given to the surface of this green sheet using a rough roll or the like, and then the surface of this green sheet is After sprinkling with water, a powdered colored surface decorative material made by mixing a coloring pigment and, if necessary, asbestos powder, is applied to the same thermosetting inorganic molding material as above, and then this powdered colored surface decorative material is further applied. Water is sprinkled on the sprayed surface, and then the sprayed powder is pre-pressurized and degassed through a heated roll to make the surface smooth. In this way, a colored surface decorative layer is integrally formed, and then a mold release agent is applied. Pressure molding is carried out in a pressure molding machine equipped with a pressure molding machine, whereby a certain shape or molding, coloring and patterning, and cutting into various shapes are performed at the same time.After curing, the outermost surface is coated with transparent or transparent material as required. This is a method for producing a colored slate material, characterized in that it is produced by the above-mentioned series of steps of forming a finishing coat layer of a translucent resin paint.

In the above method according to the present invention, when the powdered colored surface decorative material is spread on the surface of the green sheet, the screw roll is vibrated downwardly so that the powder is evenly distributed over the spreading width. A horizontally elongated funnel-shaped powder dusting tube with a machine attached is installed, and a powdered colored surface decorative material is applied onto the green sheet surface through a steam-heated powder roll with uneven grooves installed at the powder drop opening at the bottom end. It is appropriate to spray the

The above-mentioned thermosetting inorganic molding material used in the present invention is a hydraulic bonding material that exhibits quick release properties when heated, and its composition is primarily a mixture of Bortland cement, alumina cement, and gypsum. As a component, hemihydrate gypsum is added to improve strength and setting properties.
It is advisable to add slaked lime and chelate compounds.

As a commercially available product of this thermosetting inorganic molding material, there is a product of Osaka Cement Co., Ltd. under the trade name "Osaka TSAJ", and as mentioned above, this product is made of alumina cement, gypsum-based thermosetting cement, and is heated at approximately 70℃ and 30℃. It has the property of thermosetting within minutes.

In the present invention, it is also desirable to use such Inusaka TSAJ.

An example of the component ratio of the thermosetting inorganic material, which is a thermosetting cement with the trade name ``Inusaka TSAJ'', is as follows.

Chemical composition c%) Burning loss (Ig./, oss) 3.6
Insoluble component (Insot.) 0. IS
t 02 9. 5A
'203 11.6Fe20
3 4.9Ca0
52.9Mg0
0.7SO315.4 Total 9 8.7
Furthermore, ``The physical properties of Osaka TSAJ are as follows.

Specific gravity: 3.01 Powderability (a'g): 6500 When the above thermosetting inorganic mold material is heated (60 to 90'C) immediately after adding water, it has a compressive strength of 140 kg/1 in JIS mortar after 1 hour. It is characterized by its ultra-fast hardening properties, but in addition, it is also important to have a long pot life (pot life, 2 hours at 20°C) at room temperature.

Although ultra-fast hardening and long pot life are contradictory physical properties, in conventional fast-setting cement, ultra-fast hardening usually results in short pot life, while long pot life usually results in slow hardening. Moreover, if you try to make it harden quickly by heating it early, the strength will not increase.

On the other hand, the above-mentioned thermosetting inorganic molding material used in the present invention can eliminate and improve these drawbacks, and has hydraulic properties that combine a long pot life, ultra-fast hardening, and high strength-enhancing properties. It can be called the joining material department.

As mentioned above, the thermosetting inorganic molding material used in the present invention has the following conditions: in contrast to ordinary Boltland cement, it is composed of ultrafine particles, has excellent powder compression moldability, and is strong. It must have adhesive properties.

As a result of experiments, it was found that it is appropriate to use the above-mentioned thermosetting cement manufactured by Osaka Cement Co., Ltd. under the trade name "Inusaka TSAJ" as a material that satisfies these conditions.

In the present invention, the pigments used for forming a colored surface decorative layer by blending with a thermosetting inorganic mold material include general coloring pigments,
Metallic pigments can be used.

In other words, colored surface decorative materials are mainly composed of a thermosetting inorganic molding material and are mixed with suitable coloring pigments. In order to improve the efficiency and strength of the thermosetting inorganic molding material, it is preferable to add filler such as silica powder and inorganic fiber in approximately the same amount as the thermosetting inorganic molding material.

In this case, suitable fillers include silica powder, mica powder, barite powder, etc., and asbestos, asbestin, etc. are suitable as inorganic fibers.

According to experiments, good results were obtained when the coloring and whitening cosmetic material was mixed with 70 to 150 parts by weight of silica powder, 5 to 30 parts by weight of asbestos, and 1 to 3 parts by weight of pigment to 100 parts by weight of thermosetting inorganic molding material. Obtained.

The above-mentioned green sheet is a combination of boltland cement or thermosetting inorganic material (or a mixture thereof), asbestos or its substitutes (rock wool, glass fiber, etc.), or a combination of these with silicic material. It is a plastic plate material obtained by using it as the main raw material and shaping it by wet or dry molding.

Generally, asbestos cement boards as building materials are used as they are without surface decoration treatment, but increasingly they are used with colored surface coating.

Colored surface painting uses expensive paint in a separate process and is a manual multi-coating process, making it extremely expensive, and in the case of three-dimensional shapes such as corrugated plates, the painting process is particularly complicated and manufacturing is difficult. Therefore, this type of product has not reached the point where it is widely distributed in general.

In particular, the present invention utilizes a thermosetting inorganic molding material, which is a new material, to form green sheets (asbestos cement or similar raw materials as described above) in a series of continuous processes. A colored slate material with excellent durability can be produced economically by integrally forming a colored surface decorative layer for surface decoration.

Previous attempts have been made to form a colored layer for surface decoration using Boltland cement, but Boltland cement has problems such as slow curing and coarse particles.
Not achieving sufficient results.

In other words, slow curing means that the process of forming a colored surface decorative layer cannot be incorporated into a series of continuous processes, and coarse particles and large shrinkage mean that it is not possible to create a fine uneven pattern on the surface. The smoothness was also poor, and it was not possible to manufacture products that were valuable as commercial products.

However, simply using a thermosetting inorganic molding material as a replacement for Boltland cement does not immediately produce high-quality products.

Through trial and error, it was possible to produce high-quality colored slate by combining improvements in several methods, processes, and equipment.

The colored slate material according to the present invention is suitable as a building material for roofing, interior and exterior walls, partitions, floors, ceilings, and the like.

Next, the gist of the present invention will be explained with reference to the process flow diagram shown in FIG. 1. First, a roughness scratch such as a rough-hewn pattern is imparted to the surface of the green sheet 1 using a roughening roll or the like.

2 in the figure is the uneven roll (first step).

Next, water is sprinkled onto the surface of the green sheet using a water sprinkler 3 such as a shower (second step).

Furthermore, a colored surface decorative material f4 (mixed powder of thermosetting inorganic molding material, pigment, asbestos, etc.) is spread by the powder spreader 4 (third step).

Water sprayer such as a shower 5 on the colored surface cosmetic material that has been sprayed
Sprinkle water (4th step).

After doing this, it is passed through a heating roll 6 (fifth step),
Next, after spraying the mold release agent with the mold release agent spraying machine 7 on the molding surface of the pressure machine, molding is performed with the pressure machine 8, or coloring and patterning and cutting are carried out along with molding (sixth step). ).

Next, curing 9 is performed (7th process), and demolding 10 is performed (8th process), and then, if necessary, a finishing coat is applied to the outermost surface using a transparent or translucent resin paint applicator 11 (
9th step), product 12.

The action and effect of each step of the present invention described above will be explained.

First, the first step is to make uneven scratches in a row-resoto pattern or criss-cross pattern on the surface of the green sheet 1 using the uneven roll 2 or the like, otherwise the green sheet 1 and the colored surface decorative layer will peel off. However, this method improved the adhesion between the two and prevented them from peeling off.

The depth of uneven scratches such as curvature is 0.5 to 1.
Approximately O1It1IL is appropriate.

Next, in the second step, the surface of the green sheet 1 is sprinkled with water using a water sprayer 3 such as a shower in order to improve the adhesion of the green sheet and the colored surface decorative material, and is not used in the normal manner. It is a process.

Furthermore, as a third step, the colored surface decorative material is subsequently spread on the water-sprinkled green sheet 1, but it is quite difficult to spread it uniformly and efficiently in a continuous process.

Therefore, in the present invention, for example, the second
We were able to uniformly spread the powder by using one or more devices as needed using a steam-heated powder roll spreading device as shown in Figures 3 and 4. (described later).

Next, in the fourth step, water is sprinkled on the colored surface decorative material using a shower or the like, and this is a commonly used step to adjust the moisture content for the hardening of cement and the like.

Initially, attempts were made to directly pressurize the moisture-adjusted colored surface decorative material and the green sheet, but such direct pressurization left bubbles and unevenness, making it impossible to obtain a smooth surface. There were many defective products in which the adhesion between the green sheet and the colored surface decorative material was not sufficient, and a satisfactory product could not be obtained.

After various studies on this point and through trial and error, they recognized that it was necessary to perform a preliminary treatment before the pressing step, and adopted a preliminary pressing step in which the material is passed through heating rolls as the fifth step.

This pre-pressing step (fifth step) smoothes the colored surface cosmetic material spread in the previous step, and with degassing,
This is for pre-pressurizing at a pressure of 0 kg/ca degree.

In this case, heated steam is injected near the center axis of the pressure roll,
It is appropriate to heat to about 80 to 90°C.

This is to prevent the colored surface decorative material from adhering to the surface of the heating roll and staining the roll surface by heating to this temperature.

Note that one or more pre-pressing devices using heating rolls can be installed as necessary.

After preliminary pressure is applied through a heating roll, as a sixth step, the material is pressurized or shaped in a press machine 8 to which a mold release agent has been previously sprinkled.

The pressurization pressure at this time is up to 40 kg/i at low pressure and up to 70 kg/d at high pressure, and one cycle typically takes about 20 seconds.

In this pressurizing process, it is not only possible to simply bond the colored surface decorative material and the green sheet, but also to simultaneously perform molding, coloring and patterning, and cutting into various shapes, thereby simplifying the process. .

In other words, by providing the upper mold for the press mold of the press machine with an uneven shape that becomes a pattern, pressurization and patterning can be performed at the same time, and by providing a cutter on the upper mold. , it is possible to pressurize and simultaneously cut according to the desired shape.

Furthermore, by using an appropriate mold, various deformations including waveform shapes can be simultaneously achieved in a single process at the same time as the press-bonding of the colored surface decorative layer.

Through the above steps, pressurized source plates having various patterns and shapes on the surface of which the colored decorative layer is tightly pressed and shaped can be obtained.

The pressurized raw original plate obtained in this way is first maintained under thermosetting conditions according to the thermosetting inorganic molding material used to heat and rapidly harden the colored surface decorative layer, and then the raw original plate portion is It is maintained under appropriate conditions to complete curing (seventh step).

For example, when using thermosetting inorganic molding materials whose main components are Voltland cement, alumina cement, and gypsum, the pressurized original plate is usually demolded by steam curing at a temperature of 60°C or higher for about 30 minutes to 8 hours. (8th step).

The colored slate material obtained in this way may be used as a product as is, but in order to further improve the gloss, sharpness, and durability of the colored surface decorative layer, acrylic resin, epoxy resin, etc. may be added to the colored surface decorative layer. It can be finished by applying a finish coating treatment with transparent or translucent resin (No. 9)
process).

In addition, in the third step, the coloring surface decorative material spreading step,
9. By placing an appropriate cutout mold such as a plastic sheet with a design cut out on the coated surface of the gun sheet and spreading it, the desired design and multicolored powder distribution can be obtained on the raw original plate. You can also do it.

Next, we will explain the spreading device using a steam-heated dusting roll used for spreading colored surface decorative materials.As shown in Figs. Inside a horizontally elongated funnel-shaped dusting cylinder 14 having a bunker 13 at the top for throwing in powder, two rows of screw rolls is provided in parallel so as to rotate in opposite directions, and these screw rolls 15. The screws 16, 16 are reversed from section to side, thereby ensuring that the powder is evenly distributed over the spreading width.

In addition, a vibrator 17 is attached to the side surface of the dusting tube 14, and by pielating this by known means, the dusting tube 1
4 is given a fine vibration to eliminate the catching of the powder in the middle of the dust-sprinkling cylinder 14 and to make the powder uniform in density.

The powder-spreading roll 18 is cylindrical, and a continuous groove 19 is cut in the axial direction over the entire length of the cylindrical outer circumferential surface. The concave groove 1 is provided at the discharge port 20, and the groove 1 is formed by rotating the powder sprinkling port 18.
The powder on the powder 9 is made to fall uniformly and smoothly from the lower end discharge port 20.

It is particularly effective for powders containing short fibers such as asbestos.

A steam heating pipe 21 is installed in the hollow part of the dusting roll 18, and heated steam is passed through the pipe to heat the dusting roll 18.

This heating is effective in preventing powder from adhering to the grooves 19.

A confirmation window 22 is provided in the bunker 13 to confirm the amount of the above-mentioned powdery mixture containing thermosetting inorganic molding material as a main component to be charged into the bunker 13, so that the amount of the powdered mixture to be charged can be controlled.

As mentioned above, the colored slate material according to the present invention has an inorganic material compared to the surface colored layer made of conventional organic paint.
Moreover, since it is a dense and thick layer, it is strong and has excellent durability.

Moreover, due to the excellent moldability of thermosetting inorganic molding materials,
It can have a smooth surface or a precise and elegant textured pattern, resulting in an excellent aesthetic appearance.

Furthermore, the manufacturing process according to the present invention is a consistent and continuous process, which allows mass production, and there is no need to use expensive paints, so the manufacturing cost is extremely low, which is a great advantage.

In addition, the time required to ship the product has been shortened by using thermosetting inorganic molding materials.In particular, when thermosetting inorganic molding materials are used as the green sheet material, it takes 10 days to ship.
Items that previously took two weeks can now be shipped in just one day.

Examples of the method for producing colored slate materials according to the present invention will now be described.

A raw material consisting of 85 parts by weight of Voltland cement and 15 parts by weight of asbestos is kneaded with water and then made into a paper using a paper making machine, which is then rolled and cut into a thickness of approximately 5 mm using a winding roll, or a mixed material is pressure molded to form a green sheet. A plastic plate called oneto was prepared.

In this case, a thermosetting inorganic molding material can also be used in place of part or all of the Boltland cement.

As the thermosetting inorganic molding material, "Inusaka TSAJ" manufactured by Osaka Cement Co., Ltd. was used.

Next, a knurled pattern of uneven scratches with a depth of about 1.0 mm is applied to the surface of this green sheet using an uneven roll, and after water is sprinkled on the surface, a powder colored surface makeup having the following composition is applied. Composition of the powdered colored surface decorative material (weight 7o) which was sprayed with a scattering device and water was then sprinkled on the sprayed surface: Thermosetting inorganic molding material (product of Osaka Cement Co., Ltd., trade name: "Inusaka TSAJ") ) 88% asbestos
10% facial medicine (lid mouth cyanine clean) 2% This is then pre-pressurized through heated rolls using heated steam, and then pressurized at about 70 kg by a mold press for manufacturing asbestos slate that has been previously applied with a release agent. Molded.

The obtained pressurized original plate was steam cured for about 4 hours in a steam curing chamber at a temperature of about 60°C, and then demolded.

This demolded product was then finished and coated on the outer surface with a transparent acrylic urethane resin paint.

The resulting product is extremely sturdy and beautiful, and is perfect for roofs. It was suitable as a colored slate material for roofing.

[Brief explanation of the drawing]

Fig. 1 is a process diagram showing the gist of the structure of the present invention, Fig. 2 is a side view showing a dusting device equipped with a dusting roll, Fig. 3 is a partially cutaway front view of Fig. 2, and Fig. 4. FIG. 2 is a partially cutaway front view showing a part of the fine powder roll. 1... G9 seat, 2... Concave and convex roll, 3... Water sprinkler, 4... Powder spreader, 5... ...Water sprayer, 6...Heating roll, 7...Release agent sprayer, 8...Pressure machine, 9...Steam curing, 10. ...Demolition, 1
1... Finishing resin paint applicator, 12...
・Product, 13... Bunker, 14... Curved powder cylinder, 15, 15... Curved screw roll, 16, 16... Curved screw, 11... Vibrator, 18... ...
Powder dusting roll, 19... Concave groove, 20... Discharge port, 21... Curved steam heating pipe, 22... Curved confirmation window.

Claims (1)

[Claims] 1. (a) Bortland cement or Naka), thermosetting inorganic molding made by blending Bortland cement with alumina cement and gypsum, and further adding hemihydrate gypsum, slaked lime, and chelate compound. The main raw materials are materials (including a mixture of (a) and (0) above in some cases) and (c), asbestos or its substitutes (rock wool, glass fiber, etc.), or silicic materials added to these materials. Then, a plastic plate called a green sheet is prepared by molding it using a wet or dry method, and uneven scratches such as a rough pattern are given to the surface of this green sheet using a rough roll or the like. After sprinkling water on one surface, a powdered colored surface decorative material made of the same thermosetting inorganic molding material as above mixed with a coloring pigment and, if necessary, asbestos powder, is then applied to the sprayed surface. The sprayed powder is pre-pressed through a heating roll to form a colored surface decorative layer, and then pressure molded in a pressure molding machine coated with a mold release agent, thereby molding or molding. Manufactured through a series of processes: coloring and patterning, cutting into various shapes at the same time, followed by curing, demolding, and finishing coating with transparent or translucent resin paint on the outermost surface as necessary. A method for producing colored slate material, characterized by: 2. When distributing the powdered colored surface decorative material on the green sheet surface, a vibrator was placed below the screw roll that spread the powdered colored surface decorative material uniformly over the spreading width. A horizontally elongated funnel-shaped spreading tube is installed, and a powdered colored surface decorative material is spread onto the green sheet surface through a steam-heated powder roll with uneven grooves installed at the powder drop opening at the bottom end of the spray tube. A method for manufacturing a colored slate material according to claim 1.