JP2648703B2 - Inorganic plate having uneven pattern and method for producing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to an inorganic plate made of a hydraulic inorganic material as a main raw material and a method for producing the same, and more particularly to an inorganic plate having an uneven pattern and a method for producing the same.

<Prior art> Inorganic plates made mainly of hydraulic inorganic materials are used for inner and outer walls of houses, and various attempts have been made to improve the design by forming an uneven pattern or an embossed pattern on the surface. It has been done.

For example, Japanese Patent Application Laid-Open No. 56-12447 discloses that after forming a hydraulic inorganic raw plate by papermaking, a grid-like groove having a depth of 0.5 to 3 mm is formed on the surface of the hydraulic inorganic raw plate by pressing, and then culturing. Thus, there has been proposed a method of manufacturing an inorganic plate having an uneven pattern. Also, JP-A-62-111105
In Japanese Patent Application Laid-Open Publication No. H10-209, an engraved pattern of the plate is transferred to the uncured molded body by pressing a plate engraved with a pattern on an uncured extruded body mainly composed of a hydraulic substance and then releasing the plate. At least, a method of forming a concavo-convex pattern on an extruded product has been proposed. Each of these conventional methods is a method of forming a desired concavo-convex pattern by pressing a press member having a shape matching the shape of a groove to be formed on an uncured body, and a method using an emboss roll. Compared to,
It is excellent in that a sharp uneven pattern with a sharp outline is formed and undesired deformation does not occur in the product.

<Problems to be Solved by the Invention> However, in these conventional technologies, the concave grooves formed densely by receiving the pressing force of the press member have a high specific gravity, and the specific gravity difference from other flat plate-shaped portions is remarkable. Be demonstrated. For this reason, the strength (bending strength)
Is improved, but on the other hand it is weak against impact and easily cracked. In addition, since the expansion / contraction characteristics due to water absorption, moisture absorption, and drying are different between the concave groove portion and the flat plate portion, the product is likely to be warped or screwed. Furthermore, in the case where the design is improved by applying a coating or the like on the surface, the suction of the paint is different due to a difference in specific gravity between the concave groove portion and the flat plate portion, and color unevenness and gloss unevenness occur, and uniform There was a disadvantage that the finishing was difficult.

<Means for Solving the Problems> Accordingly, the present invention solves such disadvantages of the prior art,
An object of the present invention is to form a concave / groove portion formed by the press member with substantially the same specific gravity as other flat plate portions, while employing a method of forming a concavo-convex pattern using a press member.

In order to achieve such an object, the present invention was devised after elaborate devising.In an inorganic plate having an uneven pattern due to pressing on the surface, the elastic granular material having water retention is 0.1% by weight with respect to a hydraulic inorganic material as a main raw material. % To less than 10% by weight, the depth of the concave portion forming the concavo-convex pattern is 10 to 40% with respect to the plate thickness, and the area ratio of the concave portion to the total surface area is 10 to 40%. And the specific gravity of the concave and convex portions in the concavo-convex pattern is substantially the same.

Further, the present invention comprises a hydraulic inorganic material as a main raw material, an elastic granular material having a water retention of 0.1% by weight or more and less than 10% by weight based on the main raw material, and further adding an appropriate amount of water to obtain a kneaded material. After that, the kneaded material is formed into a plate-shaped green plate, and then the surface of the plate-shaped green plate is pressed with an uneven pressing die to have an area of 10 to 40% with respect to the total surface area and its depth. This is a method for producing an inorganic plate having a concavo-convex pattern characterized by forming a concave portion having a thickness of 10 to 40% with respect to the plate thickness, followed by curing after curing.

<Use> Since elastic granules having a water retention property are kneaded inside the plate-shaped green plate, the elastic granules are deformed when the plate-shaped green plate is pressed by an uneven pressing die, and are retained inside. The water is squeezed out and acts as a lubricant. At the same time, the pressed granular material attempts to restore its original shape due to its elasticity. By the function as the lubricant and the restoring pressure of the granular material, the fluidity of the mixed material in the pressing portion is improved, and the flow to the portions other than the pressing portion is actively performed. As a result, the specific gravity of the concave portion and the convex portion forming the concavo-convex pattern becomes substantially the same, and the specific gravity of the whole becomes uniform.

<Specific description of the constitution of the present invention> The kneaded material formed on the plate-shaped green plate is mainly composed of a hydraulic inorganic material such as cement, slag, calcium silicate, gypsum, etc., and 0.1 wt. % And less than 10% by weight of an elastic granular material having a water retention property and an appropriate amount of water. Elastic granules are plastics,
Granules or ground particles of foamed rubber are used and have water retention. Foamed plastics include polyvinyl chloride, polyethylene, polypropylene, ethylene-vinyl acetate copolymer resin, polystyrene, polyurethane, ABS
Examples thereof include resin, polyvinyl formal, acrylic resin, epoxy resin, phenol resin, and urea resin. Examples of the foamed rubber include natural rubber, synthetic rubber, and rubber latex. This elastic granular material having water retention is
Preferably, it has a foaming ratio of 10 to 60.

When obtaining the kneaded material, a fibrous material of less than 35% by weight based on the main raw material can be further mixed. As the fibrous raw material, organic or inorganic fibers such as acrylic fiber, vinylon fiber, polypropylene fiber, carbon fiber, glass fiber, rock wool, slag wool, asbestos, aramid fiber, nylon and pulp are used. The kneaded material may further include, if necessary, an increase in the amount of slag, borax, calcium carbonate, silica, silica flour, etc., reaction materials, melamine, acryl, methylcellulose, polyethylene glycol,
A reinforcing agent such as polypropylene glycol, a water reducing agent, and a lubricant are mixed.

The obtained kneaded material is formed into a plate-like green plate having a desired thickness. Examples of the molding method include an extrusion molding method, a fourdrinier method, a casting method, and a molding method by entanglement of the fibrous material in the kneaded material.
A thick plate-like raw plate cannot be obtained, and a large amount of fibrous material is required, so that it is difficult to form a sufficiently deep uneven pattern in a later process. It is not preferable because it has disadvantages such as easy peeling.

The resulting plate-like green plate is pressed by using a pressing device with a concave and convex pressing die to perform molding. At this time, since elastic granules having a water retention property are mixed in the inside of the plate-like green plate, it is deformed when pressed by the concave and convex pressing die,
The retained water is squeezed out and acts as a lubricant. Also, does the pressed and deformed granular material restore its original shape by its elasticity? By the function as the lubricant and the restoring pressure of the granular material, the fluidity of the mixed material in the pressing portion is improved, and the flow to the portions other than the pressing portion is actively performed. As a result,
The specific gravity at the concave portion and the convex portion forming the uneven pattern is substantially the same, and the specific gravity of the whole is made uniform.

In order to exert the above-mentioned effects, the mixing ratio of the elastic particulate matter is important.
It needs to be less than% by weight. When the content is less than 0.1% by weight, the function of the internal water squeezed out at the time of pressing as a lubricant becomes insufficient, and the restoring pressure of the granular material is also insufficient to promote the flow of other mixed materials. Becomes
On the other hand, if the mixing amount of the elastic granular material with respect to the main raw material is 10% by weight or more, both the amount of water squeezed out and the restoring pressure become excessive, causing excessive flow of the mixed material,
The mixing ratio of the granular material in the convex portion of the concave-convex pattern becomes large, and minute irregularities are formed on the surface of the convex portion due to the restoring pressure of the granular material when the pressure is released.

Furthermore, the concave part of the concave and convex pattern formed by the concave and convex pressing die,
The area ratio is in the range of 10 to 40% of the total surface area of the slab, and the depth is in the range of 10 to 40% of the plate thickness. Recess area ratio is 10
%, The pressing force of the concavo-convex pressing tool against the green plate becomes insufficient, and the amount of water which is squeezed out as the granular material deforms and acts as a lubricant becomes too small, and at the same time, the restoring pressure of the granular material Is not sufficiently exhibited, and the required fluidity of the mixed material cannot be obtained. On the other hand, if the area exceeds 40%, on the other hand, the amount of both moisture acting as a lubricant becomes excessive and the restoring pressure of the granular material also becomes excessive, resulting in excessive flow of the mixed material and causing Fine irregularities are formed. If the depth of the recess is less than 10% of the plate thickness, the desired effect cannot be exerted because sufficient pressing force does not act. If the recess is formed to a depth exceeding 40%, the pressing force becomes excessive. As a result, excessive flow of the mixed material is caused, and the strength of the inorganic plate is reduced. In order to adjust the depth of the concave portion to 10 to 40% of the plate thickness, a concave / convex die having a concave pattern portion corresponding to a desired concave depth within the above range is used, or a concave pattern portion deeper than the desired concave depth. It can be easily performed by adjusting the pressure at the time of pressing by using the concave and convex pressing die having the above or by adjusting the penetration depth of the concave and convex pressing die at the time of pressing by using a height adjusting bar or the like.

As described above, a fibrous material can be mixed into the kneaded material, but the mixing ratio is limited to less than 35% by weight.
This is because, when 35% by weight or more of the fibrous material is mixed, the fluidity of the mixed material in the pressing portion is suppressed by the entanglement of the fibers, so that the specific gravity of the concave portion and the convex portion cannot be equalized. It is.

The plate-shaped green plate on which the surface irregularity pattern is formed by the concave-convex pressing of the press device is put into a steam curing room and primary cured, and then put into an autoclave device and secondary cured, whereby the inorganic material of the present invention is obtained. A board is manufactured.

<Effect of the Invention> According to the present invention, an inorganic plate in which a sharp uneven pattern having a sharp contour is formed on the surface by using a press device and the specific gravity of the concave portion and the convex portion is uniformized is obtained, and It is suitably used for inner and outer walls and the like.

Claims (3)

(57) [Claims] An inorganic plate having a concave-convex pattern formed by pressing on its surface, wherein elastic granules having water retention are mixed in a proportion of 0.1% by weight or more and less than 10% by weight with respect to a hydraulic inorganic material as a main raw material. The depth of the concave portion forming the concavo-convex pattern is 10 to 40% with respect to the plate thickness, and the area ratio to the total surface area of the concave portion is 10 to 40%. And an inorganic plate characterized in that the specific gravity of the protrusion and the specific gravity of the protrusion are substantially the same. 2. A kneaded material comprising a hydraulic inorganic material as a main material, an elastic particulate material having a water retention of 0.1% by weight or more and less than 10% by weight based on the main material, and further adding an appropriate amount of water. After that, the kneaded material is formed into a plate-shaped green plate, and then the surface of the plate-shaped green plate is pressed with an uneven pressing die to have an area of 10 to 40% with respect to the total surface area and its depth. A method for producing an inorganic plate having a concavo-convex pattern, wherein a mold is formed so as to form a concave portion having a thickness of 10 to 40% with respect to the plate thickness, followed by curing after curing. 3. The method for producing an inorganic plate according to claim 2, wherein, when the kneaded material is obtained, a fibrous material of less than 35% by weight based on the main raw material is further mixed.