JP2000006264A - Manufacture of plastic block having tilelike irregular pattern - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a lightweight, easily executed plastic block having a tilelike irregular pattern which is useful for effective use of industrial wastes and provides good appearance faithfully showing the pattern, such as a grain or brick texture, having the tilelike clear and deep unevenness without the post-processing. SOLUTION: A mold provided with a micro-suction port therein and having a tilelike irregular pattern is disposed in a mold framework, a plastic film is laid on the surface of the mold framework to suction air. A composition consisting of ground particles of scrapped ceramics and an alkali metal silicate solution and siliceous fine particles is fed into the mold framework, on which a cement mortar 11 is fed so as to form a laminate. The surface of the cement mortar 11 is adhered to the surface or the rear surface of a hard formed plastic hollow block 12, thereby manufacturing a plastic block having a tilelike irregular pattern.

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 manufacturing a plastic block having a tile-like uneven pattern such as a stone-grained or brick-like pattern which can be used 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, bricks, and the like have been used as a method of forming a stone-like or brick tone of a tile-like uneven pattern on the surface of a block or the like. It was heavy and difficult to handle, was inferior in workability, and was expensive even at a price. There is also a method in which natural stone or brick 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.

Conventionally, it is an essential condition that tiles are made of porcelain with common sense that firing is required and energy is required. Defective waste such as ceramic products generated during the production process had to be disposed of as industrial waste.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and aims to effectively utilize industrial wastes, and does not require any post-processing. It is an object of the present invention to provide a method for producing a plastic block having a tile-like uneven pattern which has a high appearance, is lightweight, and is easy to construct.

[0006]

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 the minute suction holes, pouring a composition consisting of ground ceramic waste particles, an alkali metal silicate aqueous solution and siliceous fine powder A step of pouring cement mortar into the upper surface and 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.

[0007]

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.

A plastic film is laid on the surface of the mold and air is sucked. 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.

A tile formed on the surface of a plastic block is prepared by pouring a composition composed of ground ceramic waste particles, an aqueous solution of an alkali metal silicate and fine siliceous powder.
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.

[0011] By forming a composition consisting of ground ceramic waste particles and siliceous fine powder into a tile shape using an alkali metal silicate aqueous solution as a binder, the surface exhibits a stone-like or brick pattern consisting of ground ceramic waste particles. . By mixing various types of ground ceramic waste particles, it is possible to arbitrarily change the stone-like or brick-like pattern.

The aqueous alkali metal silicate solution used in the present invention forms a strong glassy film, and the general formula is M ₂
O.nSiO ₂ .nH ₂ O, alkali metal M
There are sodium, potassium and lithium.

The alkali metal silicate hardener is added to turn the alkali metal silicate aqueous solution into a hard glassy hardened product. Acids such as sodium silicate, magnesium silicate and ammonium chloride, and hydroxides Hydroxides of alkali metals such as sodium, potassium hydroxide and lithium hydroxide, carbonates of alkali metals such as sodium carbonate and potassium carbonate, hydroxides of alkaline earth metals such as calcium hydroxide and magnesium hydroxide, oxidation Polyvalent metal oxides such as zinc, alumina, cement and calcium silicate; polyvalent metal powders such as zinc and aluminum; metal salts of acidic oxides such as aluminum phosphate, magnesium phosphate, aluminum borate, calcium borate, etc. Can be used. These may be used alone or in combination of two or more. Of the above, alkali metal hydroxides can be more preferably used. 2 to 15 parts per 100 parts by weight of the aqueous alkali metal silicate solution
Add by weight.

If necessary, various surfactants, anti-sagging agents, anti-settling agents, anti-freezing agents and the like may be added as dispersants to improve the properties. Further, for the purpose of improving the performance, a plasticizer for giving flexibility, a stabilizer for preventing deterioration due to heat or light, a fungicide for preventing the occurrence of mold, and the like may be added.

[0015] The crushed ceramic waste particles used in the present invention are defective in the ceramic production process. Porcelain such as tiles, floor tiles, and ceramic pipes include interior and exterior tiles, floor tiles, mosaic tiles, sanitary ware, and the like.

The crushed ceramic waste particles are fine, medium, and coarse, and the fine particles have a particle diameter of 0.1 to 0.5 mm, a medium of 0.5 to 1.5 mm, and a coarse of 1.5 to 3 mm, respectively. Adjust to 4 mm before use. In addition to the crushed ceramic waste particles, silica powder, fly ash, silica fume, clay, talc, kaolin, slow-cooled blast furnace slag slag, siliceous dust, etc. may be added as necessary. The color of the ground ceramic waste particles differs depending on the original ceramic product, and a unique texture can be obtained by blending them in various ways. For example, it is possible to express a completely new tile-like pattern, which has not existed conventionally, by adding an appropriate amount of the medium size of the white sanitary ware waste particles to the coarse and fine particles of the ground brick waste particles.

As the siliceous fine powder used in the present invention, silica fume, fly ash, silica sand, silica stone powder, clay, kaolin, talc, slow-cooled blast furnace slag fine powder, granulated blast furnace slag, siliceous dust and the like can be used. These preferably have an average particle size of about 1 μm and a specific surface area of about 200,000 cm ² / g. Among the above, silica fume, silica stone powder, blast furnace slag and the like are preferred. 5 to 100 parts by weight are added to 100 parts by weight of the aqueous alkali metal silicate solution.

By forming a composition composed of an aqueous alkali metal silicate solution, ground ceramic waste particles and siliceous fine powder into a tile-like uneven pattern, the surface of the plastic block can be provided with an excellent stone-like or brick-like luster. The high appearance was able to appear.

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

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

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 plastic material may be any material that can be extruded or bead molded, and vinyl chloride, polystyrene, phenol, polyisocyanurate, etc. 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.

[0024]

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 formed 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, 100 parts by weight of an aqueous solution of sodium silicate composed of 9.4% by weight of Na ₂ O and 29.4% by weight of SiO ₂ as an aqueous solution of an alkali metal silicate, 450 parts by weight of ground ceramic waste particles, and 50 parts of silica fume Parts by weight, 8.0 parts by weight of sodium hydroxide, and 5.5 parts by weight or more of the tile composition were sufficiently mixed and stirred by a vacuum deaeration kneader and poured.

On the tile composition, a cement mortar is poured into a thickness of 7 mm, and a hard foamed plastic hollow block is placed on the tile mortar. 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.

By the above steps, a brick-like tile-like uneven pattern with excellent appearance can be produced on the front and back surfaces of the hard foam plastic hollow block.

[0029]

The method for producing a plastic having a tile-like uneven pattern according to the present invention does not require any post-processing and has a high appearance such as a stone-like or brick-like pattern with a deep tile-like unevenness and 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.

The performance is comparable to that of fired ceramic tiles, despite the fact that non-firing is achieved by using defective pulverized particles generated during the ceramic production process and using an aqueous alkali metal silicate solution as a binder. Was able to produce tiles.

By changing the composition of the crushed ceramic waste particles, it was possible to arbitrarily express various stone-tones, brick-tones and the like of natural stone style.

The ceramic wastes disposed of as industrial wastes can be effectively used, and can be formed by non-firing, so that the energy saving effect can be made extremely high.

[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

Claims (1)

[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 process of sucking air from the surface, a process of pouring a composition composed of crushed ceramic waste particles, an aqueous solution of an alkali metal silicate and a siliceous fine powder, a process of pouring cement mortar on the upper surface, and a hard foam plastic hollow block for the cement mortar surface. A method for producing a plastic block having a tile-like concave-convex pattern, comprising a step of sticking to a front surface or front and back surfaces of a plastic block.