JP2000043162A - 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 natural crushed stone 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 natural crushed stone particles and a synthetic resin emulsion is poured into the frame 4 to manufacture a tile to be formed on a plastic block face. 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. and the suction of air from the minute suction holes is suspended to press the mortar face 11 to be laminated on the rigid 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 natural crushed stone particles and synthetic resin emulsion, 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.

[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 formed of 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.

[0010] By forming a composition composed of natural crushed stone particles into a tile shape using a synthetic resin emulsion as a binder, the surface exhibits a stone-like pattern composed of natural crushed stone particles. 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.

The natural stone used as a raw material of the natural crushed stone particles used in the present invention may be any of granite, andesite, marble, serpentine and the like, and is not limited. 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 blast furnace slag, siliceous dust and the like may be added as required.

By molding a composition comprising a synthetic resin emulsion 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.

The shape and size 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, 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, and pressure bonding is performed. 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.

Tile is adhered to the front surface or the back surface of the hard foamed plastic hollow block via cement mortar, and then the surface protection and the plastic film as a 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 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.

[0022]

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, a synthetic rubber-modified acrylic copolymer emulsion as a synthetic resin emulsion was 12% by weight.
(6% by weight in terms of solid content), 74.5% by weight of natural crushed stone particles, 4.0% by weight of organic additives (dispersants and the like), 4.0% by weight of inorganic extender, and 5.5% by weight or more The resulting tile composition was thoroughly mixed and stirred by a vacuum deaeration kneading apparatus and then poured.

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.

By the above steps, a high-quality stone-grain tile-like uneven pattern having excellent appearance can be produced on the front and back surfaces of the hard foamed plastic hollow block.

[0027]

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 stones and using a synthetic resin emulsion as a binder, it is possible to produce a stone-grained tile having a performance comparable to that of a fired ceramic tile despite being unfired. Was.

By mixing and blending various types of natural crushed stone particles, it was possible to arbitrarily express various types of natural stone tone.

The surface of the stone-grain tile is high in hardness and hard to be scratched, and can express the same smoothness as natural stone. Further, since it is strong against acid, 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

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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 step of sucking air from the surface, a step of pouring a composition composed of natural crushed stone particles and a synthetic resin emulsion, a step of pouring cement mortar into the upper surface, and adhering the cement mortar surface to the front surface or the front and back surfaces of the hard foamed plastic hollow block. A method for producing a plastic block having a tile-like uneven pattern, comprising the steps of: