JPH10217214A - Molding method for hydraulic material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding hydraulic material to practically mold even a molding with various projection and recess shape and undercut with large mold cost reduction and excellent mass productivity by immediately mold releasing uncured molding enclosed as it is after material is charged without using a split mold. SOLUTION: A porous ventilating mold 10 on a vacuum sucking bas 11 is covered with a heated thermoplastic resin film 13, sucked to a shaping surface of a cavity of the mold 10, and a convexo-concave shape is transferred by plastic deformation. Then, fresh concrete S is charged, excited and compacted. Thereafter, a normal plate 15 having vent holes 15a is matched, vacuum evacuated to vacuum seal the molding by the plate 15 and the film 13 and mold released. The plate 15 is superposed on a back surface side of the molding, mold released together with the enclosed film 13 as it is. Then, since a lump of the molding is restricted for its deformation by the plate 15, the lump of the molding can be mold released without mold collapse with elastic lump of compacted state contracted by the film 13 with expansibility.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding method for hardening and molding a slurry molding material, and more particularly to a hydraulic material such as a cement kneading material used for obtaining a building plate, an outer wall tile and the like. To a molding method.

[0002]

2. Description of the Related Art For example, as a method of forming a concrete decorative outer wall plate (patterned concrete product) for covering the outer wall of a house or a fence, as described in JP-A-63-172608, Is known. In this molding method, a plastic film is spread on a mold with an uneven pattern, the plastic film is uniformly heated by a heating device, and vacuum suction is performed by a vacuum pump through a suction vent hole provided on the bottom of the mold. After it is brought into close contact with the surface of the uneven pattern, concrete slurry is poured in to cure and cure. When such a molding method is used, the uneven surface of the demolded concrete molded product has a beautiful surface finish on which the uneven pattern of the mold is transferred, and the surface of the uneven pattern of the mold (imprinted) is covered with a plastic film. Since the concrete slurry does not come into contact with the mold surface and does not cause dirt, it is possible to eliminate the step of cleaning the formwork and the step of drying the formwork, thereby contributing to an improvement in productivity. Further, there is an advantage that the mold wear is reduced and the mold life is prolonged.

[0003]

However, the above-mentioned method for forming a patterned concrete product has the following problems.

When a concrete molded product that has been cured and hardened in a mold is extracted from the mold, it is difficult to remove the mold even if a demolding force is applied while vibrating with a vibrator, and chipping or damage to the molding surface is likely to occur. In particular, a molded product having an undercut partially has a reverse draft, and therefore cannot be properly removed without using a split mold. Further, as shown in FIG. 13, not only the surface 2 of the molded product 1 but also the thickness side surface (rise surface).
If there is unevenness in 3, surface damage on the molding surface will inevitably occur, and it will not be possible to remove the mold unless the draft is considerably increased. The fact is that it is limited.

In other words, it is difficult to make the inner surface pattern (grain) of the mold frame rich in roughness (texture) of large and small irregularities, and it is necessary to make the irregular pattern surface including the thickness side surface of the molded product very similar to natural stone ground or the like. Has limitations in terms of random undulation and definition.

The curing period during which the concrete molded product is cured in the formwork requires a day and a night even with rapid-hardening concrete or the accelerated curing method.
The rotational efficiency of the mold was very low. For this reason, in order to secure mass productivity of concrete molded products, initial investment for preparing a large number of molds of the same shape is indispensable, resulting in enormous mold cost. Therefore, the types of designs of patterned concrete products have been limited.

By the way, immediately after filling and compaction of a hydraulic material (hydration-hardened molding material) without hardening and curing the molded product in a mold, the uncured molded body is completely wrapped in a film and removed from the cavity. If the molded body in the uncured state is pulled out of the mold and the shape of the uncured body is kept while the film is adhered, the above-mentioned problems should be solved theoretically.

For example, it is possible to form the mold into a split mold (vertical split mold), and to separate the mold before removing it, but a trace of the dividing line remains on the molding surface, This has the disadvantage that the added value of the product is reduced, it cannot be applied to a molded product in which the appearance of a decorative wall or the like is important, and the mold cost is increased. Of course, it is possible to remove the mold after curing in the mold to a semi-cured state, but it is not possible to expect a significant improvement in the rotational efficiency of the mold.

[0009] The demolding operation in the uncured state (immediately after filling) directly leads to collapse, distortion, and unevenness of the uncured molded surface due to the demolding resistance in the physical separation displacement process. It is practically difficult to immediately remove the mold immediately after the material is filled in a molded product having a molded surface having irregularities.

[0010] In view of the above problems, an object of the present invention is to realize a method capable of removing a mold without losing its shape while wrapping an uncured molded product in a film, thereby reducing the cost of the mold due to the practical use of immediate removal. It is an object of the present invention to provide a method for molding a hydraulic material such as concrete, which is greatly reduced in mass production and excellent in mass productivity.

[0011]

Means for Solving the Problems In order to solve the above-mentioned problems, the means taken by the present invention is such that when an uncured molded body is relatively pulled out from the cavity while being tightly surrounded by a film, the back surface of the molded body is removed. It is characterized in that a backing reinforcing material is superimposed on the side and removed together. That is, the present invention covers the heated thermoplastic resin film in a developed state in a cavity of a mold having ventilation holes, adsorbs the film on the shaping surface of the cavity by vacuum suction of the ventilation holes, After transferring the shaping surface of the cavity to the surface of the film by plastic deformation, a slurry of hydraulic material is filled on the film in the cavity and compacted, and the uncured molded body is molded with the film. In the method of molding a hydraulic material that cures the uncured molded body while the film is adhered after the demolding step of relatively removing the cavity from the cavity while closely contacting and enclosing, the demolding step includes the step of: It is characterized in that the uncured shaped body is held together by the backing reinforcing material and the film, which are superimposed on the back side of the uncured shaped body in the cavity, and then released together.

In such a method of molding a hydraulic material, first, the unevenness of the shaping surface of the cavity is copied to the surface of the thermoplastic resin film which is sucked by vacuum suction and plastically deformed. . It is faithful to the imitation of the uneven surface of the imprinted surface, and has a transferability that precisely reflects the unevenness of the imprinted surface. When the thickness of the resin film is increased to 200 μm or more, the cured film itself exhibits a self-supporting shape, so that the sagging deteriorates the transferability. In addition, when the thickness is increased, the stretch stretching shrinkage is lost. Accordingly, the more flexible and thin the thermoplastic resin film, the better the transferability. The thickness of the thermoplastic resin film is preferably about 20 to 200 μm. From the viewpoint of transferability and strength, desirably 50 to 10
About 0 μm is appropriate.

However, on the other hand, the thin film surface heated to a high temperature can be easily partially adhered to the uneven surface of the shaping surface of the cavity by fusion or bite adhesion, so that the uncured state after the filling of the hydraulic material. Even if you try to remove the molded body with the molded body in close contact with the film, if you apply a demolding force, the anisotropic film tension will appear on the film surface at the point of adhesion with the shaping surface. Local sliding flow occurs at the boundary with the surface, causing collapse, distortion, and unevenness of the formed surface.

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

Therefore, in the present invention, in order to ensure the shape retention of the molded article at the time of demolding, a backing reinforcing material is laminated on the back side of the uncured molded article in the cavity, and the backing reinforcing material is provided. It is characterized in that the molded body in an uncured state is held together with the film and the mold is released together. As the backing reinforcing material, a rigid board, a flexible board, an elastic board, a paper board, a resin film (sheet), a backing resin coating layer or a resin impregnated layer can be employed.

As described above, when the mold is removed together using the backing reinforcing material, the deformation of the lump of the molded body is restrained to some extent by the backing reinforcing material. Local sliding flow with the film surface as a mold is less likely to occur, and it is possible to remove the whole compact as a compacted elastic mass as if it were squeezed with an elastic film. Even if the film surface is pressed locally due to the release resistance at the time of release, the surface protection of the film does not damage the surface of the molded surface, and the once recessed portion is the surface tension of the film and the uncured molded product itself Restored by the setting viscoelasticity of Therefore, it is possible to successfully remove a molded product having various undulations on the shaping surface of the cavity, a molded product having a certain degree of undercut, and a molded product having an uneven surface on the rising surface without breaking the molding. For this reason, the immediate demolding process can be put into practical use in earnest, and a molded article with a concavo-convex pattern can be provided at low cost by greatly reducing the mold cost.

After the mold is released, the wrapped film is cured, for example, with the upper side (the molding surface facing upward). Since the uncured molded body is wrapped in a shape-preserving film and participates in wet curing by membrane curing, as compared to open-curing,
This is advantageous because the strength of the cured molded article is increased and a high-quality molded article can be obtained. Furthermore, after curing and curing, if shipped from the factory with the film and the like as it is,
The curing material (packaging or cushioning material) in the transportation process can be saved, and the film curing can be continued until the film is peeled, so that a high quality molded product can be provided.

Further, in the present invention, after filling the hydraulic material and before the demolding step, the inside of the air surrounded by the backing reinforcement and the film is preliminarily sucked by vacuum suction of the ventilation hole of the backing reinforcement. Is exhausted, and a vacuum contact operation is employed in which the film and the backing reinforcing material are adsorbed to the uncured molded body. According to this vacuum contact operation, air bubbles mixed in the uncured molded body are degassed and compacted, and the molding surface adheres strongly to the transfer surface of the film, and the surface adsorption force of the film becomes strong, Even though the molded body is in an uncured state, it is formed into a solid elastic solid body by a so-called vacuum pack. Therefore, even if the side surface or the like of the molded body is deformed by demolding resistance at the time of demolding, it is elastically restored immediately after demolding, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

In the vacuum contact operation, at the same time, the molded body wrapped with the film is slightly separated from the shaping surface of the cavity and is adsorbed to the backing reinforcing material. At the time of this adsorption, the rear side of the molded body (near the backing reinforcing material) of the film is only slightly loosened, so that the molding surface is not substantially distorted or deformed. The fact that the film is substantially slightly separated from the imprint surface of the cavity means that the film and the cavity are completely separated, and the preparation stage of the demolding operation is also completed.

When the backing reinforcing material is a porous permeable material, the entire back surface of the uncured molded article can be adsorbed,
It is possible to suppress the overall deformation of the molded body at the time of demolding.

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

In the case of a molded product having a deep and thick cavity, the molded product is heavy, so that the above-mentioned suction does not provide sufficient suction force to the backing reinforcing material. Therefore, in the present invention, prior to the demolding step, a gravity separation operation for integrally turning the mold and the backing reinforcing member upside down is employed. The molded body may be separated from the imprint surface by accelerating and decelerating the molding die by inertia, but the gravity separation operation is easier, and the thicker the molded product, the more its own weight. It becomes easy to separate.

Further, the cavity is considerably deep, and
In the case of a three-dimensional solid, self-collapse (buckling) due to its own weight when unmolded
It is easy to do, but if the mold and the backing reinforcement are integrally submerged and the film is adhered and the molded body is turned upward in water and then removed from the mold, and then cured in water, the buoyancy The self-weight is reduced, and the self-collapse of the molded article at the time of demolding can be prevented. For this reason, it is possible to remove the mold without any trouble even in a three-dimensional body, and because the molded body participates in submerged curing,
The strength of the molded body is improved. Before filling the material, a braided body may be loaded in the cavity to further enhance the shape retention force.

In the case where there is a step of stacking the back foot-shaped forming material before stacking the backing reinforcing material on the back side of the formed body, the obtained formed body is given an overall shape by a forming die, and is formed by a film. Irregularities on the imprinted surface are given,
Unevenness on the back side is provided by the back foot-shaped molding material.
As this back foot-shaped molding material, a rubbery unevenness imparting plate or a bubble projection sheet can be used, and an undercut hole can be formed on the back surface.

[0025]

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

[First Embodiment] In a method of forming a decorative exterior wall panel made of concrete according to a first embodiment of the present invention, first, as shown in FIG. 1, a multi-cavity concave cavity 12 is carved. A porous permeable mold plate (molding die) 10 made of porous epoxy resin is prepared, and the mold plate 10 is placed on a vacuum suction table 11 connected to a vacuum pump (not shown). Then, a film adhesion inhibitor such as a non-polar urethane paint is applied or sprayed into the cavity 12 as necessary. Next, the cavity 12 of the template 10 is heated
Covered with a vinyl acetate plastic film (thermoplastic resin film) 13 having a thickness of about 60 μm in a developed state heated to 0 to 150 ° C.
It draws a vacuum at 0 and inhales. Thereby, the cavity 1
2 is exhausted out of the adsorption table 11 through the porous continuous holes (air holes) of the mold plate 10, so that the cavity 12
The inside is in a reduced pressure state, and as shown in FIG.
Is cooled and hardened, so that the film 13 comes into contact with the uneven surface of the shaping surface 12a of the cavity 12, and the uneven surface is transferred to the surface of the film 1 by plastic deformation. This heated thin film 13 is rich in flexibility. Since the film 13 used for the film surface forming is thinner than the film (200 μm or more) used for general vacuum forming by half or less, the thin film 13 itself has no self-retaining property after the film surface forming. Even the portion of the imprint surface pattern transferred to the surface of the film 13 can still be flexibly deformed. An embossed film may be used as the film 13.

Next, as shown in FIG. 3, the cavity 12 is filled with an appropriate amount of fresh concrete (cement-kneaded material) S in a vacuum suction state, and the template 10 is vibrated at a high frequency of several thousand cycles / minute for 10 seconds. The concrete S is densely compacted by vibrating to a certain degree, and bubbles in the filled concrete S are removed. Due to the vibration, floating water is generated on the upper surface of the filled concrete S by bleeding. In addition, compaction unnecessary concrete may be used. At this time, the pattern-formed thin film 1 is formed on the inner surface of the cavity 12.
Since the concrete 3 is in close contact, the concrete S slides on the film 13 when the concrete S is filled, so that the fluidity is good. The inner surface of the cavity 12 itself does not touch the filled concrete S, and the unevenness of the molding surface of the concrete S is substantially reduced by the shaping surface 12 of the cavity 12.
a is transferred. The vibration of the template 10 after the filling of the material by the vibrator promotes the separation of the bonding interface between the film 13 and the shaping surface 12a of the cavity 12.

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

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

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

Since the thin molded body is light, the molded body is
Adsorb to 5. Then, the vacuum suction is continued, the platen 15 is moved upward while the molded body is being sucked upward, and the mold is removed.
As shown in FIG. 6, the molded body with the molding surface facing upward is supported on the platen 15 while being covered with the film as shown in FIG. 6. Then, the vacuum suction is released, the entire surface plate 15 is transferred from the suction pad 19, and the film-coated molded body is cured on the surface plate 15. Alternatively, after the molded body coated with the film is replaced from the base plate 15 to another mounting plate, curing may be performed thereon.

As described above, when the mold is removed together using the platen 15, the deformation of the lump of the molded body is restrained to some extent by the platen 15, so that the molding surface of the uncured molded body and the transfer mold are used. Local slip flow with the film surface is less likely to occur,
It is possible to remove the entire lump as it is as a compacted elastic lump as if it were squeezed with an elastic film. Even if the side surface or the like of the molded body is pressed by the demolding resistance at the time of demolding, it is elastically restored immediately after demolding, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

Incidentally, a porous plate made of a porous epoxy resin may not be used as the template 10, and a template having a plurality of ventilation holes formed in communication with the cavity 12 may be used. If the wide-mouthed air passage is open, needle-like projections are likely to be formed on the molding surface of the molded product, and a removal operation is required. However, when a porous air-permeable mold plate is used as in this example, the porous opening facing the cavity 12 is minute, so that the number of needle-like projections is not so large. Further, in the conventional manufacturing method, in the case of a mold (aluminum mold), corrosion occurs due to a chemical reaction of cement, the cycle of mold exchange is fast, and the durability of a urethane resin mold is inferior. However, in this example, the fact that the template 10 is covered with the film 13 and the concrete S does not come into contact can be avoided from a chemical reaction, corrosion, and the like, so that the degree of freedom in selecting the material of the template 10 is increased.

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

[Second Embodiment] In this example, after the step shown in FIG. 3, as shown in FIG. 7, an uneven ridge 35a for transferring an anchor dent (back sole shape) on the lower surface is used as a base plate 35, as shown in FIG.
A porous air-permeable breathable plate (backing covering material) 35 made of a porous epoxy resin having the following is superimposed on the template 10. Then, as shown in FIG.
5 is integrally turned upside down, the blow pad 16 is applied to the upper surface of the template 10, the lower suction table 11 is evacuated, and air is supplied from the blow pad 16, and the film 1 is blown.
When a pressure difference is applied at the boundary of the film 3, the film 13 and the filled concrete S in contact with the mold contact surface are sucked to the upper surface of the platen 35, and the film 13 is pressed downward by blowing from the blow pad 16. As a result, the film 13 is substantially separated from the contact surface of the mold plate 10 and the inner surface of the cavity 12, and the film 13 and the plate 3
5 is vacuum-adsorbed. Here, in the case of a thin formed body, the film 13 can be sucked to the formed body only by sucking the base plate 15 without integrally reversing the mold plate 10 and the base plate 35 in the matched state. In addition, the entire back surface of the uncured molded body can be adsorbed, and the overall deformation of the molded body during demolding can be suppressed. In addition, you may invert the adsorption stand 11 together.

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

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

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

As described above, in this example, since the concrete S is filled in a state where the inner surface of the cavity 12 of the template 10 is covered with the film 13, the inner surface of the cavity 12 does not touch the concrete S, There is no clogging of the background. It is possible to prevent mold damage at the time of mold release and surface damage of a molded product, thereby reducing mold management and improving the yield rate. Further, since the template 10 after demolding can be reused as it is without going through a washing step, a great improvement in productivity can be realized.

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

Therefore, in this embodiment, after the concrete S is filled, as shown in FIG. 11, a rubber unevenness-imparting plate (a back foot-shaped molding material) 25 having a dovetail-shaped uneven strip 25a is spread on the concrete S, as shown in FIG. An iron base plate (backing reinforcing material) 30 through which the pores 30a penetrate is placed thereon. Since the air holes 30a penetrate through the base plate 30, the film 13 can be vacuum-sealed by vacuum suction immediately after the concrete S is filled. Further, since the unevenness providing plate 25 is made of rubber, the unevenness imparting plate 25 can be easily separated from the hardened concrete S, and the undercut anchor recess 25b can be formed. Further, the plate 30
It is easy to clean because of its flat surface and less contamination with concrete. In addition, as the unevenness imparting plate 25, an air bubble projection sheet or the like can be used.

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

Furthermore, the instant demolding practical application process of the present invention is not limited to slurry of hydraulic material, but is applied to food molded products such as chocolate and curry roux, and cosmetic / chemical molded products such as lipstick, soap, ski wax and the like. It can be used for forming and protecting a slurry of a material having a lower melting point than a thin film. Instead of the curing process after the mold release, heat treatment, cooling treatment, freezing treatment, infrared irradiation, microwave irradiation, or other external heating treatment may be performed while the film is covered.

[0044]

As described above, according to the present invention, when the uncured molded body is relatively extracted from the cavity while being tightly surrounded by a film, the backing reinforcing material is stacked on the back side of the molded body. It is characterized in that it is released together with the film while holding it.

Therefore, the following effects are obtained.

Since the deformation of the lump of the compact is restrained by the backing reinforcing material, the lump of the lump can be completely removed as a compacted elastic lump as if it were squeezed with an elastic film. Even if the film surface is pressed locally due to the release resistance at the time of release, the surface protection of the film does not damage the surface of the molded surface, and the once recessed portion is the surface tension of the film and the uncured molded product itself Restored by the setting viscoelasticity of Therefore, it is possible to successfully remove a molded product having various undulations on the shaping surface of the cavity, a molded product having a certain degree of undercut, and a molded product having an uneven surface on the rising surface without breaking the molding. For this reason, the immediate demolding process can be put into practical use in earnest, and a molded article with a concavo-convex pattern can be provided at low cost by greatly reducing the mold cost.

After filling the hydraulic material and before the demolding step, the air inside the backing reinforcing material and the film is exhausted by vacuum-suctioning the air holes of the backing reinforcing material in advance. When the vacuum contact operation of adsorbing the film and the backing reinforcing material to the cured molded body is employed, the air bubbles mixed into the uncured molded body are degassed and compacted, and the molding surface is formed of the film. The film adheres strongly to the transfer surface, the surface attraction force of the film becomes strong, and the molded body is in an uncured state, and becomes a solid elastic mass with a so-called vacuum pack even though it is in an uncured state. Therefore,
Even when the side surface of the molded body is deformed by the resistance against the mold release during the mold release, the molded body is elastically restored immediately after the mold release, and the shape retention is maintained. For this reason, a molded product having a certain negative draft angle can be released from the mold, and a molded product partially undercut can be obtained.

Further, in the vacuum contact operation, the fact that the film is substantially slightly separated from the shaping surface of the cavity means that the film and the cavity are completely separated from each other.
Distortion at the time of demolding can be reduced.

When the backing reinforcing material is a porous gas permeable material, the entire back surface of the uncured molded body can be adsorbed, and the deformation of the molded body during demolding can be suppressed.

When the ventilation hole of the backing reinforcing material is open at a position facing the vicinity of the edge of the cavity in the contact surface with the molding die, the opening of the ventilation hole does not face directly in front of the rear surface of the molded body. Therefore, the air in the inner space can be exhausted in a state where the floating water is not discharged as much as possible, so that the water mixing ratio of the hydraulic material does not need to be changed.

In the case where a gravity separation operation in which the mold and the backing reinforcing member are integrally inverted before and after the demolding step is employed, even a molded product having a deep and thick cavity is easily separated by its own weight.

Further, if the molding die and the backing reinforcing material are integrally submerged, the molded body is deposed in an upward posture in water while the film is adhered, and then the molded body is cured in water, Since the cavity is quite deep and self-weight due to buoyancy is reduced and self-destruction at the time of demolding can be prevented, even if the molded body is a three-dimensional solid, it can be demolded without hindrance, and the molded body can be submerged. Therefore, the strength of the molded body is improved.

In the case where there is a step of stacking the back foot-shaped forming material before stacking the backing reinforcing material on the back side of the formed body, the obtained formed body is given an overall shape by a forming die, and is formed by a film. Irregularities on the imprinted surface are imparted, and irregularities on the back side are imparted by the back foot-shaped molding material. As this back foot-shaped molding material, a rubbery unevenness imparting plate or a bubble projection sheet can be used, and an undercut hole can be formed on the back surface.

[Brief description of the drawings]

FIG. 1 is a process cross-sectional view showing a first half of a film forming (transferring) process in a method for forming a concrete decorative outer wall plate according to a first embodiment of the present invention.

FIG. 2 is a process sectional view showing a latter half of the molding process.

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

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

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

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

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

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

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

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

FIG. 11 is a process cross-sectional view showing a process of laying a concavo-convex surface imparting plate in the method for molding a concrete decorative outer wall plate according to the third embodiment of the present invention.

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

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

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Concrete exterior wall plate 2 ... Surface 3 ... Thickness side surface 25b, 35b ... Anchor dent 12 ... Cavity 10 ... Porous air-permeable mold plate 11 ... Vacuum suction stand 12a ... Impression molding surface 13 ... Thermoplastic plastic film 15, Reference Signs List 30: Plates 15a, 35a: Vent hole 16: Blow pad 19: Suction pad 25: Rubber unevenness-imparting plate 25a: Dove groove-shaped unevenness 35: Porous air-permeable plate S: Concrete.

Claims (7)

[Claims] 1. A heated thermoplastic resin film is covered in a developed state on a cavity of a molding die having an air hole, and the air hole is evacuated to vacuum to adsorb the film on a shaping surface of the cavity. After the molding surface of the cavity is transferred to the surface of the film by plastic deformation, a slurry of hydraulic material is filled on the film in the cavity and compacted, and the uncured molded body is closely adhered to the film. In a method of molding a hydraulic material that cures the uncured molded body while the film is adhered, after the demolding step of relatively extracting the cavity from the cavity, the demolding step includes: Of a hydraulic material, characterized in that the uncured molded body is held together with the backing reinforcing material and the film stacked on the back side of the uncured molded body and released together. Form method. 2. The backing reinforcing material and the film according to claim 1, wherein after filling the slurry and before the demolding step, the air holes of the backing reinforcing material are previously vacuum-suctioned to surround the backing reinforcing material and the film. A method of molding a hydraulic material, comprising: exhausting the air inside the vacuum chamber and adsorbing the film and the backing reinforcing material to the uncured molded body. 3. The method of molding a hydraulic material according to claim 2, wherein the backing reinforcing material is a porous breathable material. 4. The backing reinforcing material according to claim 2, wherein the ventilation hole of the backing reinforcing member is opened at a position facing a vicinity of an edge of the cavity in a contact surface with the molding die. A method for molding hydraulic materials. 5. The hydraulic property according to claim 1, wherein the mold and the backing reinforcing material are integrally turned upside down before the demolding step. Material molding method. 6. The demolding step according to claim 1, wherein in the demolding step, the molding die and the backing reinforcing material are integrally submerged and the molding is performed while the film is adhered. A method for molding a hydraulic material, characterized in that after the body has been demolded in an upward posture in water, the curing step is followed by curing in water. 7. The hydraulic material according to claim 1, wherein a back foot-shaped forming material is stacked on the back side of the formed body, and then the backing reinforcing material is stacked. Molding method.