JP2000043161A - Manufacture of plastic block with tilelike uneven pattern - Google Patents

Abstract

PROBLEM TO BE SOLVED: To reproduce a deeply uneven grain texture pattern by laying a film on the surface of a frame to suck air from a suction hole and pouring a specific aqueous composition containing microhollow ceramic particles and then mortar and further laminating the mortar face to a rigid foamed plastic hollow block. SOLUTION: A mold having a tilelike uneven pattern with minute suction holes formed inside the mold is installed in a frame 4 equipped with an air suction device 8. Next a plastic film is laid on the surface of the frame 4 to suck air. After that, a composition 10 constituted of fine hollow ceramic particles, natural crushed stone particles and a synthetic resin emulsion is poured into the frame 4 and further a composition 10 for forming a tilelike pattern is poured into the recessed part of the mold to the fill capacity to be followed by the addition of a cement mortar 11. In addition, a rigid foamed plastic hollow block face is placed on the cement mortar 11 face and the frame 4 is rotated 180 deg. to set the rigid foamed plastic hollow block on the underside. Thus the suction of air from the minute holes is suspended to press the mortar face 11 to be laminated on the hard foamed plastic hollow block.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to the inner and outer walls of a building,
This is a method for producing a plastic block having a stone-grained tile-like uneven pattern that can be used easily for a gate, a fence, etc., and is lightweight and can be easily constructed.

[0002]

2. Description of the Related Art Conventionally, natural stones, artificial stones, ceramic tiles, and the like have been used as a method for forming a stone texture having a tile-like uneven pattern on the surface of a block or the like. It was difficult, poor in workability, and expensive. There is also a method in which natural stone is processed into a thin plate and laminated with other materials such as concrete, but there are drawbacks in terms of workability, workability, cost and the like.

[0003] Coating materials using various stone-grain coating compositions that can be applied by spraying or troweling a stone-grained tile-like irregular pattern have been proposed, and artificial stone-grain has been put to practical use. However, even if a natural stone pattern is formed by spraying or ironing with a stone-grained coating material, it can only give a flat monotonous color tone feeling and can express a deep pattern with three-dimensional unevenness Did not.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has a high external appearance that uses natural crushed stone particles and faithfully expresses a tile-like pattern with deep irregularities such as tiles without post-processing. It is an object of the present invention to provide a method for producing a plastic block having a stone-grain tile-like uneven pattern that is easy to apply, has lightness, and is lightweight.

[0005]

According to the method of the present invention for producing a plastic block having a tile-like irregular pattern, a minute suction hole is provided in the mold, and the mold having the tile-like irregular pattern is attached to a mold provided with an air suction device. Installation step, laying a plastic film on the surface of this form and sucking air from micro suction holes, pouring a composition composed of ceramic fine hollow particles, natural crushed stone particles and synthetic resin emulsion, The process of pouring cement mortar into
It is characterized in that it comprises a step of attaching the cement mortar surface to the front surface or the front and back surfaces of the hard foamed plastic hollow block. Hereinafter, the present invention will be described in detail.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the manufacturing method of the present invention, a minute suction hole is provided in a mold, and a mold having a tile-like irregular pattern is set in a mold provided with an air suction device. The micro suction holes are for completely absorbing the plastic film laid on the mold surface into the mold, and are provided so as to be evenly distributed on the mold inner surface. If the suction hole is too small, there is a risk of clogging, and if it is too large, the partial suction attraction force of the film becomes large. The minute suction hole is connected to the air suction device and sucks air substantially uniformly from the entire surface of the mold.

The mold having the tile-like uneven pattern is made of metal or synthetic resin, and for example, aluminum, polyurethane, synthetic rubber, rigid polystyrene foam and the like can be used. The formwork may be a general concrete formwork, such as wooden,
Both metal and synthetic resin can be used.

[0008] A plastic film is laid on the surface of the mold to suck air. The plastic film is used as a surface protection and release material, and may be any as long as it is uniformly and completely adhered to the inner surface of the mold by suction. The material can be vinyl chloride, polypropylene, polyethylene, or the like.

[0009] A composition composed of fine ceramic hollow particles, natural crushed stone particles and a synthetic resin emulsion is poured into a tile to be formed on the surface of a plastic block. The composition is poured and filled into a concave portion which becomes a tile-like pattern of a mold having a tile-like uneven pattern. When filling, it is not necessary to apply pressure from the surface. This is because if pressure is not applied, the surface becomes somewhat rough, and if pressure is applied, the tile becomes a dense tile, which can exhibit excellent texture.

Using a synthetic resin emulsion as a binder, a water pressure resistance of 600 kgf / cm ² and a melting point of 150
By molding a composition comprising fine ceramic hollow particles at 0 ° C. or higher and natural crushed stone particles into a tile shape, the surface exhibits a stone-like pattern composed of natural crushed stone particles. In addition, the ceramic fine hollow particles can reduce the weight, and the ceramic fine hollow particles reflect light and exhibit excellent gloss and light brightness on the tile surface. Furthermore, the grain pattern can be arbitrarily changed by combining various kinds of natural crushed stone particles.

The synthetic resin emulsion used in the present invention includes an acrylic resin emulsion, a vinyl acetate resin emulsion, a vinyl chloride resin emulsion, a vinylidene chloride resin emulsion, a styrene / butadiene resin emulsion, an epoxy resin emulsion and acrylic acid. Ester, styrene, ethylene, vinyl ester, vinyl acetate, copolymerized with synthetic rubber and the like.

For example, copolymers of these include acrylic / vinyl acetate copolymers, vinylidene chloride / butyl acrylate copolymers, ethylene / vinyl acetate copolymers and the like. The amount of the synthetic resin emulsion composition used is in the range of 5 to 8% by weight in terms of solid content. If it is less than 5% by weight, the physical properties of the tile will not be improved, and if it is more than 8% by weight, the nonflammability of the tile will be reduced.

In the present invention, in addition to the above, various surfactants as emulsifiers, emulsifiers for stabilizing emulsions, anti-wrinkling agents for emulsions, thickeners, sagging are used to improve the properties of tiles as required. You may add an anti-settling agent, an anti-settling agent, an anti-freezing agent, etc. Further, for the purpose of improving the performance of the tile, a plasticizer, a stabilizer for preventing deterioration due to heat and light, a fungicide for preventing the occurrence of mold, and the like may be added.

Light weight non-fired tile has a water pressure resistance of 600 kg
Use ceramic fine hollow particles of f / cm ² or more.
The hydrostatic strength is synonymous with the compressive strength of the ceramic fine hollow particles. When the compressive strength of the ceramic fine hollow particles is measured, the particles are put into water and pressure is applied to the water, and the pressure applied to the water is transmitted to the ceramic fine hollow particles to measure the compressive strength. If the ceramic fine hollow particles have low water pressure resistance, most of them are broken at the time of kneading the raw materials and forming the tiles, so that a stone-like tile surface having light brightness cannot be formed.

The hollow ceramic fine particles used have a water pressure resistance of 600 kgf / cm ² or more and a bulk specific gravity of 0.3 to 0.5.
g / cm ³ and a melting point of 1500 ° C. or higher. Therefore, it is not broken at all under the kneading conditions in the tile manufacturing process, nor is it broken at all during molding. In addition, the hardness and impact strength of the tile surface can be increased, and the ceramic fine hollow particles are uniformly dispersed on the tile surface, and exhibit excellent gloss and light brightness. That is, the ceramic fine hollow particles have a small particle size and are transparent or translucent in appearance, reflect when irradiated with light, exhibit an extremely high gloss and luminance surface, and can exhibit a stone-like texture color. .

The fine hollow ceramic particles are 20 to 350
The fine particles having a diameter of 20 μm to 75 μm, a medium diameter of 75 μm to 150 μm, and a coarse diameter of 150 μm to 350 μm are used by adjusting the particle size. The bulk specific gravity is heavy for fine particles and light for rough ones, so the range of bulk specific gravity is 0.3 to
0.5 g / cm ³ . The amount of the hollow ceramic fine particles is in the range of 3 to 25% by weight. If it is less than 3% by weight, the gloss and light brightness of the stone texture cannot be said to be sufficient, and if it is more than 25% by weight, the physical properties of the tiles deteriorate.

Conventional inorganic fine hollow foams include shirasu balloons, glass balloons, silica balloons, etc., but the water pressure resistance of shirasu balloons is only 80 kgf / cm ² , and glass balloons and silica balloons are 150 to ² g / cm ^2.
Since it is about 00 kgf / cm ² , the object of the present invention cannot be satisfied.

Since the present invention uses fine ceramic hollow particles having a water pressure resistance of not less than 600 kgf / cm ² , the fine hollow particles are not destroyed at all during the kneading step of the tile raw material and the tile molding. Therefore, there is no reduction in volume due to the destruction, and no change in the composition due to the destructed particles. Tile molded on a plastic block can achieve its intended purpose completely as designed.

The natural stone used as a raw material of the natural crushed stone used in the present invention may be any of granite, andesite, marble, serpentine and the like. These may be used alone or in combination of two or more. Natural crushed stone particles
Fine, medium, and coarse
0.5 to 1.5 mm, medium grain 0.5 to 1.5 mm, coarse grain 1.
Adjust to 5 to 3.4 mm for use. The particle size of the natural crushed stone is preferably adjusted to 10 to 60 parts by weight, 10 to 40 parts by weight, and 10 to 20 parts by weight.

In addition to natural crushed stone particles, silica powder, fly ash, silica fume, clay, talc, kaolin, pulverized slow-cooled blast furnace slag, siliceous dust and the like may be added as necessary.

Synthetic resin emulsion and water pressure resistance 600
By molding a composition composed of fine hollow particles of ceramics of not less than kgf / cm ² and natural crushed stone particles into a tile-like pattern, the surface of the plastic block can exhibit excellent stone-like gloss and light brightness. You can.

The shape and dimensions of the tile-like pattern formed on the surface of the plastic block can be arbitrarily designed.
The dimensions are free and varied, and square, rectangular, triangular, round and other special shapes are possible. Any size and shape can be formed from small mosaic tiles to large tiles of 1 m or more.

A composition for forming a tile-like pattern is poured and filled into the concave portion of the mold, and then cement mortar is poured. A plastic block and a tile-like uneven pattern are laminated via a cement mortar. The cement mortar has a function as an adhesive, a backup substrate for the tile, and a function as a joint material for the tile.

The hard foam plastic hollow block surface is placed on the cement mortar surface, and the mold frame is rotated by 180 degrees so that the hard foam plastic hollow block faces down. Air suction from the minute suction holes is stopped to press and adhere. I do. The rigid foamed plastic hollow block is made by extrusion molding or bead molding, and the material of the plastic may be any material that can be extruded or bead molded, and vinyl chloride, polystyrene, phenol, polyisocyanurate and the like can be used. Polystyrene is preferred. The size of the hard plastic hollow block may be the same as that of concrete, and because of its light weight, larger dimensions than the concrete block are possible.

After the tile is adhered to the surface or the front and back surfaces of the hard foamed plastic hollow block via cement mortar, the surface protection and the plastic film as the release material are removed and cured. Through the above steps, a plastic block having a tile-like uneven pattern can be manufactured.

The construction of the plastic block having the tile-like uneven pattern according to the present invention is exactly the same as that of the concrete block. The plastic blocks are successively stacked on the upper part on which the basic concrete has been cast, and a reinforcing bar or an aluminum material is inserted into a hollow portion of the plastic block, and a cement mortar is cast into the hollow portion.

[0027]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described in detail.

Example A mold having a tile-like uneven pattern in which fine air suction holes were uniformly provided in a soft polyurethane rubber was set on a wooden formwork. A commercially available vinyl chloride film was laid on the mold, air was sucked by an air suction device, and the vinyl chloride film was completely suction-contacted to the mold.

In the concave portion of this mold, a synthetic rubber-modified acrylic copolymer emulsion as a synthetic resin emulsion was 12% by weight.
(6% by weight in terms of solid content), ceramic fine hollow particles 1
0.0% by weight, natural crushed stone particles 64.5% by weight, organic additives (dispersant etc.) 4.0% by weight, inorganic pigment 4.0% by weight, and other tiles containing 5.5% by weight or more The composition was sufficiently mixed, stirred and poured by a vacuum deaeration kneading apparatus.

The ceramic fine hollow particles are alumina 43.
A composition comprising 0 to 44.0%, silica 54.5 to 55.5%, and other 1.5 to 2.5% is used, and has physical properties of a compressive strength of 700 kgf / cm ² and a bulk specific gravity of 0. 4g
/ Cm ³ , melting point 1600 ° C., and composed of only perfect hollow particles. The particle size of the fine ceramic hollow particles was adjusted to 20 parts by weight, 20 parts by weight, and 30 parts by weight. As the natural crushed stone particles, crushed granite particles were used, and the particle size was adjusted to 20 parts by weight, 20 parts by weight, and 10 parts by weight.

On top of the tile composition, cement mortar is poured to a thickness of 7 mm, and a rigid foamed plastic hollow block is placed thereon. The mold is rotated by 180 ° so that the rigid foamed plastic hollow block is on the lower side, and air is blown. The suction device was stopped and the form was removed from the rigid foamed plastic hollow block. A tile-like irregular pattern was stuck on the upper surface of the hard foamed plastic hollow block via cement mortar, and the coated vinyl chloride film was peeled off and cured at room temperature for 24 hours.

Through the above steps, a high-quality stone-grain tile-like uneven pattern with excellent appearance was formed on the front and back surfaces of the hard foamed plastic hollow block.

[0033]

The method for producing a plastic having a tile-like uneven pattern according to the present invention requires no post-processing, has a deep tile-like uneven pattern, has a high grain-like appearance, and has excellent mechanical strength.
It does not require large-scale manufacturing equipment and can be easily manufactured by unskilled persons. Also, the manufactured plastic block having a tile-like uneven pattern was light in weight and could be easily applied.

By using natural crushed particles and using a synthetic resin emulsion as a binder, it is possible to produce a stone-grain tile having a performance comparable to that of a baked ceramic tile, despite the fact that the calcination is an underfire. Was.

By mixing and blending various natural crushed stone particles, various natural stone-like tone can be arbitrarily expressed.

The ceramic fine hollow particles are uniformly arranged on the surface of the tile, and the ceramic fine hollow particles are transparent or translucent fine hollow, and can be reflected by light irradiation to exhibit extremely high gloss and light brightness. By further puffing, a more excellent texture was able to be expressed.

By using the lightweight ceramic fine hollow particles, a lightweight tile is formed. The plastic block to which the lightweight tile is attached with high heat insulating property can prevent the temperature rise due to the solar heat in summer and can reduce the weight of the lightweight tile. The surface is high in hardness and hard to be scratched, can express the same smoothness as natural stone, and is strong against acid, so it is not contaminated by acid rain.

[Brief description of the drawings]

FIG. 1 is a perspective view of a plastic block having a tile-like uneven pattern according to an embodiment.

FIG. 2 is a perspective view of a mold having a tile-like uneven pattern installed on a mold.

FIG. 3 is a process of installing a mold having a tile-like uneven pattern on a mold.

FIG. 4 is a sectional view illustrating an embodiment of a process of laying a plastic film on a mold.

FIG. 5 is a sectional view illustrating an embodiment of a step of pouring a tile-like uneven pattern composition.

FIG. 6 is a sectional view illustrating an embodiment of a step of pouring cement mortar.

FIG. 7 is a cross-sectional view illustrating an embodiment of a step of placing a hard foamed plastic block on a cement mortar.

FIG. 8 is a cross-sectional view showing a state where the mold is rotated by 180 degrees.

FIG. 9 is a perspective view of another example of a plastic block having a tile-like uneven pattern.

FIG. 10 is a perspective view showing a construction state of a plastic block having a tile-like uneven pattern.

[Explanation of symbols]

 1. 1. Tile-like uneven pattern type Recess 3. Convex part 4. Formwork 5. Micro suction hole 6. 6. Air suction box Rubber hose 8 Air suction device 9. Plastic film 10. 10. Tile-like uneven pattern composition Cement mortar for lamination 12. Hard foam plastic hollow block 13. Joint 14. Hollow part 15. Reinforcing bars 16. Cement mortar 17. Foundation concrete

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F202 AA21 AA31 AA42 AA45 AB11 AB12 AB16 AB17 AD04 AF01 AF09 AG05 AH81 CA03 CA07 CA19 CB01 CB13 4F213 AA21 AA31 AA42 AA45 AB11 AB12 AB16 AB17 AD04 AF01 AF09 AG05 AH81 WA53 WA56 WA83 WA89 WB01 WB13

Claims (2)

[Claims] 1. A step of providing a minute suction hole in a mold, and installing a mold having a tile-like uneven pattern in a mold provided with an air suction device, laying a plastic film on the surface of the mold to form a minute suction hole. A step of sucking air from, a step of pouring a composition composed of ceramic fine hollow particles, natural crushed stone particles, and a synthetic resin emulsion, a step of pouring cement mortar into the upper surface, the surface of the cement mortar surface of the hard foamed plastic hollow block or A method for producing a plastic block having a tile-like concave-convex pattern, comprising a step of attaching the plastic block to front and back surfaces. 2. The ceramic fine hollow particles have a water pressure resistance of 6.
The method for producing a plastic block having a tile-like irregular pattern according to claim 1, wherein the plastic block has a melting point of not less than 00 kgf / cm ² , a melting point of not less than 1500 ° C, and a bulk specific gravity of 0.3 to 0.5 g / cm ³ .