JPH01122407A - Molding method - Google Patents

Abstract

PURPOSE:To contrive prevention of a deformation of a mold and making of a product of high accuracy, by a method wherein a thin mold having the inside corresponding to an external form of the product is fitted in the inside of a receiving mold and after solidification of a material in a fluid state by casting the same into the thin mold, the same is removed from the receiving mold along with the receiving mold. CONSTITUTION:A receiving mold 7 having the inside 7a slightly larger than an external form of a product by thickness amount of a mold 8 possesses a receiving mold body 10 and protrusion 11 fixed to the bottom of the receiving mold body 10 and is comprised of a rigid synthetic resin material. The mold 8 fitted in the inside 7a of the receiving mold 7 removably possesses the continuous inside 8a corresponding to the external form of the product and a thin and uniform thickness. The mold 8 is fitted in the receiving mold 7 closely, a material 15 of a cement composition in a fluid state is solidified by casting the same on the inside 8a and then the mold 8 is removed from the receiving mold 7 along with the material 15. In succession to the above, the product comprised of the material 15 is removed from the mold 8. With this construction, the surface of the product is protected by the mold and a high-accuracy product is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION Technical Field The present invention relates to a molding method for molding and manufacturing a product using, for example, cement.

Background technology A typical prior art is shown in FIG.

A fluid cement material 2 is poured into a hard synthetic resin mold 1, and the material 2 is solidified by curing.
After this solidification, the material 12 is removed from the mold 1.

The mold 1 has a protrusion 4 fixed to the bottom of a mold main body 3 which is open upwardly using an adhesive. A recess is formed in the product corresponding to the protrusion 4, and a cloisonné product, metal, or photograph, for example, can be attached to the recess formed in the product, and the photograph can be placed on the surface of the product. It can be used as an object, an analogy, a trinket, etc.

Problems to be Solved by the Invention If a hard synthetic resin material is used, as in the prior art, the manufacturing cost of the mold will be high, and the products using it will also be expensive. In the case of mass production, it is necessary to prepare a considerable number of molds because it requires replacement when scratches occur due to use, preparation for cleaning and drying the molds, and considerable curing time during drying. - It will bring you much-needed good luck.

An object of the present invention is to provide a molding method for producing concrete products at low cost and with excellent precision.

Means to solve problems In the present invention, (a) the shape of the inner surface is larger than the outer shape of the product;

Prepare a slightly larger and rigid receiving mold, and a thin mold that is removably fitted to the inner surface of the receiving mold, is made of synthetic resin, and has a continuous inner surface that corresponds to the external shape of the product, b) Fitting a mold to the inner surface of the receiving mold, (c) Using this base plate, pouring a solidified fluid material into the inner surface of the cell, (d) After solidifying the material, together with the solidified material. This is a molding method characterized by removing the mold from the receiving mold.

Function According to the present invention, by fitting a thin mold to the inner surface of the receiving mold, the mold will not be deformed even if a fluid material such as cement material is poured into the mold.

After the material poured into the mold has solidified, the mold is removed from the receiver along with the solidified material, so the surface of the product made of the solidified material is protected by the mold, and therefore the mold cannot be attached to the product until it is used. It can remain attached. Additionally, if necessary, it can be used as is as a product packaging material during transportation. This type of mold is one piece of meat,
The manufacturing cost is low because it can be easily produced in large quantities, for example by vacuum forming. After separating this material from the product, it may be washed and used again.

If the inner surface of the pear gets damaged due to repeated use of the mold, the mold can be discarded and replaced with a new mold. This desire, as mentioned above, is thin and therefore inexpensive. In this way, products can be molded and manufactured with high precision.

Example FIG. 1 is a sectional view of one embodiment of the present invention.

A receiving mold 7 and a mold 8 to be fitted thereto are prepared, and a photographic mold 9 shown in FIG. 6 of the description is manufactured using a cement composition material. As shown in the plan view of FIG. 2, the receiving mold 7 has an inner surface 7a that is approximately 8 times thicker than the outer shape of the product, which is a photographic mold. This mold 7
is made of synthetic resin and has a mold body 10 and a protrusion 11 fixed to the bottom surface of the mold body 10 using an adhesive or the like. The receiving mold 7 is made of a hard synthetic resin material.

The protrusion 11 is used to form a recess 12 in which a photograph of the photo mold 9 shown in FIG. 5 is embedded.

The mold 8, as shown in its plan view in FIG. 3, is removably fitted onto the inner surface 7a of the receiving mold 7, and has a continuous inner surface 8a corresponding to the outer shape of the photographic mold 9 which is the product. This mold 8 has a thickness of 0.5 to 0.7 mm and is thin,
It has a uniform thickness throughout. Vinyl chloride or the like is used as the material for the mold 8, and it can be mass-produced by a method such as vacuum forming, and its inner surface 8a can be easily manufactured with high precision. The inner surface 8a of the mold 8 is a product. A portion 8al corresponding to the front of the photo mold 9 and a recess 12
a portion 8a2 corresponding to , and these portions 8al, 8a2
It includes an inclined portion 8εL3 that is continuous with the lateral portion 8εL3, and a lateral portion 8a71 that is continuous with the portion 8al.

The mold 8 has an outward flange 13, which is mounted on the upper end 141 of the receiving mold body 10.

Referring to FIG. 11, fit the mold 8 tightly into the receiving mold 7.
Then, material 15, which is a fluid cement composition, is poured into the inner surface 8a of this blade 8. This material n15 is solidified in acid poured into the mold 8, and after solidification, the solidified material fl
15 and the mold 8 are removed from the receiving mold 7; from the mold 8;
By removing the photographic mold 9 consisting of the material 15'),
f) Photographic mold 9 is obtained as a product.

By keeping the mold 8 attached to the solidified material 15 until the photographic mold 9 is used as a product, damage to the surface of the product can be prevented. The mold 8 can be used several times by removing the solidified material F115, and the inner surface 8a of the mold 8 can be cleaned and soiled after each use.

Since the blade 8 is thin and therefore flexible, the inner surface of the blade 8 can be thoroughly cleaned from every corner.

As described above, the mold 8 is thin, so if the inner surface 8a is damaged after multiple moldings, the mold 8 can be discarded and replaced with a new mold. Such a mold 8 is inexpensive and does not increase cost.

The mold 8 may be discarded each time each product is molded and replaced with a new mold 8.

Material F115 will be explained. This material 15 includes a cement admixture, cement, and aggregate.
! ■It is a synthetic composition. Cement admixtures are mainly composed of calcium chloride, natural or synthetic rubber and urea resin.
Water and organic solvents are used as solvents. The product obtained by molding in this way does not require a firing process, has gloss and water repellency, does not powder, and does not cause efflorescence.
Furthermore, it has excellent chemical resistance. Such materials are
It is far superior to conventional cement, brick, and tile. As mentioned above, the cement admixture contains calcium chloride, natural or synthetic rubber, and resin as the main components, and uses water and an organic solvent as the solvent. It may further contain a solubilizing agent.

The weight ratio of the main components is 20% for salt (Hikaru Shiuno 4, 4 to 4% for cement admixture), and 20% for cement admixture.
0ffiu%, preferably 27-36% by weight, natural or synthetic rubber 0-25. ffi amount%, preferably 10-1
5% by weight, resin 10-25% by weight, preferably 10-1
It is 5% by weight. The ff11% of water and organic solvent are 20-40% by weight and 10-20% by weight, preferably 27-36% by weight and 14-15% by weight, respectively.

Note that various latexes may be used as the natural or synthetic rubber. As the organic solvent used here, alcohols are preferable, and methanol, ethanol, etc. are particularly preferable. As the natural or synthetic rubber, arabic rubber is preferred, and as the resin, urea resin and/or acrylic resin are used. The solubilizing agent may be any agent used to dissolve the resin in water and organic solvents, but especially ammonium salts such as ammonium carbonate or ammonium bicarbonate and/or hydrochloric acid, especially ammonium salts and hydrochloric acid. A combination is preferred. Ammonium salt is 2% of the total weight of cement admixture.
~'1 m 2%, preferably 2.7-3.61!1%
, hydrochloric acid is 3.5 to 5.5% by weight, preferably 4.2 to -
1.85i1t% is used. The Φ element used as desired is, for example, iron oxide, chromium oxide, or the like. This cement admixture consists of a mixture of calcium chloride, dissolved Mγ1i auxiliary agent and water, dissolved in an organic solvent of natural or synthesized rubber; α
It can be manufactured by adding , and then adding resin thereto. When using, add about 1 liter of this cement admixture to water, etc.
It is preferable to use it after diluting it 0 to 20 times. Hereinafter, the diluted solution of this cement admixture will be referred to as "diluted solution".

By adding this cement admixture to a mixture of cement and aggregate, the composition for producing ordinary artificial stone can be
Rahru. Here, artificial stone has an appearance similar to natural stone due to molding.
Including those that have a shape and those that have the appearance of tiles, bricks, etc., i.e. cement and aggregate at about 1:2
Add the above diluted cement admixture to the mixture in a ratio of ~1:3. What is the cement used here?
- The aggregate may be gray cement commonly used in construction or the like, or white Portland cement, and the aggregate is sand, cold water sand, silica sand, etc. The particle size of these aggregates determines the density of the surface of the product produced, so if a smooth surface is desired, the diameter of the particles is preferably 1 mrnφ or less, and if a colored product is desired. In some cases, 3-5% by weight of the cement may be dispersed in the cement and aggregate mixture with an inorganic raw material, preferably wood.

Note that the use of inorganic pigments improves weather resistance.

The mixing ratio of the cement-aggregate mixture and the cement admixture of the present invention is determined as shown in the table below, depending on the countersunk of the aggregate used. The smaller the amount of diluent used, the greater the strength of the product; however, if it is too small, fluidity will be lost, making bubbles more likely to occur during pouring during molding, resulting in less smooth surface of the product. On the other hand, if there is too much cement admixture, the strength will decrease.

Note: The mixing ratio in the table above represents the weight ratio.

Next, a method for manufacturing the photo frame 9 using the above-mentioned artificial stone manufacturing composition as the material 15 will be illustrated.

First, we will describe the case of producing a single color with uniform density.

Process 1: Mix cement material and aggregate at a ratio of approximately 1:2 to 1:3, add inorganic pigment 13 powder of approximately 3 to 5% of the cement, and dry mix these to disperse the pigment. let

Step 2 Add 10-20% of the cement admixture according to the present invention to water (
Dilute to rj to obtain a diluted solution.

Step 3 The diluted solution obtained in Step 2 is poured into the kneaded material obtained in Step 1 at the ratio shown in the table above and mixed.

Step 1: Pour the mixture from Step 3 as desired, and vibrate the mold to defoam. This vibration only takes about 1 minute.

Step 5 Next, natural curing is generally performed at room temperature for 1 to 2 days. It may take about 1 day in summer and about 3 days in winter. It should be noted that steam curing is undesirable as it will cause the product to lose its luster, and the surface of the material f1 must be in close contact with the inner surface of the mold until it is removed from the mold in order to achieve luster. Avoid vibration etc. Furthermore, if water partially evaporates from the inner surface of the mold during curing,
To avoid loss of gloss, it is recommended to place a vinyl sheet over the mold and place a wet cloth on top of it. In addition,
In order to give the product a glossy appearance, it is recommended that the inner surface of the mold be extremely smooth; for example, a glass plate or the like may be used.

Step 6: Remove the mold and leave it for at least 3 days. In order to sufficiently evaporate the moisture, it is preferably left for about 2 times, more preferably several times for about 431 minutes, and completely cured.

Example of adding a pattern of multiple colors: The above-mentioned composition for producing artificial stone with various B ingredients added,
As shown in FIG. 6, materials 16a to 16f of different colors are made into lumps and arranged alternately on a plane and vibrated. Materials 16a to 16f
may contain different pigments, and material 1 may contain different pigments.
One or more of 6a to 16f does not need to contain pigment.Hereinafter, the same process as in the case of making a single color with uniform color density is performed to create a photo frame with a pattern of multiple colors. Get 9.

Example of making a photo frame with a blurred patternFor example, if you want to make a product with a yellow and white blurred pattern,
As shown in FIG. 7, a material 17, which is a mixture of white cement and the diluent, is poured onto the surface of the mold 8. Next, material I'118, 19, which is a composition of white cement, aggregate, the above-mentioned diluent, and yellow pigment, is poured in a lump. Material 18.
19 may be different in color from each other; f4: is vibrated to mix the white cement and the above composition. The pattern can be changed depending on the vibration time, amplitude, etc.

After shaking, press the top of the poured mixture with a brush so that it almost reaches the bottom. The following steps are performed in the same way as for the single-color field, and the result is an artificial stone with a blurred pattern of yellow and white.

Specific compositions are shown below, but these do not limit the present invention in any way.

Calcium chloride 100g Ammonium carbonate 10g Water 100g Hydrochloric acid 15(c Rubber for 6th grade 42g Methanol 56CC urea resin
42 g A cement additive having the above composition is manufactured according to the following method.

Dissolve calcium chloride and ammonium carbonate in water,
Mix hydrochloric acid with this solution. Add edible gono, methanol, and urea resin to this.

Water is added to the cement admixture obtained by the above method to prepare a 10-fold diluted solution. Add this diluted solution to 100% white cement.
Add 38 parts to a mixed solution of 200 parts of Kansui sand. After thoroughly kneading this composition, it is poured into a mold for a photo frame, and the mold is vibrated up and down for about 1 minute.

Pour into a mold and let it naturally cure at room temperature for 2 days.

After removing the mold after 2 days and leaving it at room temperature for 4 weeks, the photo frame 9 shown in FIG. 5 was obtained.

As the material, not only the cement composition having the above-mentioned composition but also other materials may be used.

Effects As described above, according to the present invention, it is possible to mold and manufacture products with high precision and improved aesthetic appearance, and it is also possible to manufacture inexpensive products.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing a receiving mold 7 and a mold 8 according to an embodiment of the present invention, FIG. 2 is a plan view of the receiving mold 7, FIG. 3 is a plan view of the mold 8, and FIG. 5 is a perspective view of the photo frame 9 manufactured using the receiving mold 7 and the mold 8, and FIG. 6 is a sectional view showing the state in which the materials 16a to 16f are molded. The cross-sectional view shown in FIG. 7 shows material 17,1.
Sectional view showing the state of molding using 8.19, No. 80
is a cross-sectional view of the prior art. 7...Mold, 8...Wish, 9...Photo frame, 10.
...Mold body, 11 ...Protrusion, 15.16a ~1
6f, 17゜18.19...Material agent Patent attorney Number of strokes Kei part of the drawing Nini bi (1-; 宕i 二台 = none) 7 mold Fig. 3 Fig. 4 a Fig. 5 Fig. 6 , /''9 a M7 figure jf ¥8 figure procedural amendment writing method) % formula % 2. Invention name forming method 3, relationship with the case of the person making the amendment Applicant address name (028) Osaka Gas Co., Ltd. Representative 4 , Agent address: 1-13-38 Nishihonmachi, Nishi-ku, Osaka Shinko Sangbu Building Country Equipment EXO525-5985INTAPT J
International FAX GIII&G■ (06)538-0247
6. Description and drawings to be amended 7. Engraving of the description and drawings to be amended (no change in content). that's all

Claims (1)

[Scope of Claims] (a) A rigid receiving mold whose inner surface is slightly larger than the external shape of the product; A thin-walled mold having a continuous inner surface corresponding to the outer shape is prepared, (b) the mold is fitted to the inner surface of the receiving mold, and (c) a fluid material that solidifies is placed on the inner surface of the mold in this fitted state. (d) After solidifying the material, the mold together with the solidified material is removed from the receiving mold.