JP2000094460A - Manufacture of plastic block with tile-like protrusion and recess pattern - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate a practical use of an industrial waste and an execution with an excellent appearance by attaching a resin film to a surface of a form added with a mold having a tile-like protrusion and recess pattern provided with fine suction holes, sucking the air, charging a composition of pottery scrap comminuted particles and a cement, and then adhering a hard foamed resin hollow block with a mortar. SOLUTION: A vinyl chloride film is laid on a wooden form installed with a mold having a tile-like protrusion and recess pattern having equivalently provided fine air suction holes at a soft polyurethane rubber to suck the air to suck to bring the film into close contact with the form. A tile composition 10 blended with a synthetic rubber modified acrylic copolymer emulsion, a cement, pottery scrap comminuted particles or the like is cast in a recess part of the mold, a mortar 11 is then cast, a hard foamed plastic hollow block 12 is placed thereon, the form is removed, the film covering the pattern 10 on the block 12 is released, and cured. Thus, postprocessing utilizing pottery scraps of an industrial waste is eliminated and an improved appearance, a light weight and an easy execution are provided.

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 formwork and sucking air from minute suction holes, pouring a composition composed of ceramic fine hollow particles, ceramic waste crushed particles, synthetic resin emulsion and cement 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 comprising fine hollow particles of ceramic, ground particles of ceramic waste, a synthetic resin emulsion and cement. 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] Using a synthetic resin emulsion and cement as a binder, a composition comprising fine ceramic hollow particles having a water pressure resistance of 600 kgf / cm ² and a melting point of 1500 ° C or more and ground ceramic waste particles is formed into a tile shape to form a ceramic surface. It has a stone-like or brick-like pattern consisting of crushed 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. By mixing various types of ground ceramic waste particles, it is possible to arbitrarily change the stone-like or brick-like pattern.

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

For example, acrylic / vinyl acetate copolymers, vinylidene chloride / butyl acrylate copolymers, ethylene / vinyl acetate copolymers and the like can be mentioned as copolymers thereof. The amount of the synthetic resin emulsion composition used is in the range of 5 to 8% by weight in terms of solids. 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, emulsifiers for stabilizing emulsions, anti-wrinkling agents for emulsions, thickeners, and sagging can be 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 it is impossible to form a stone-like or brick-like tile surface having light brightness.

The fine hollow ceramic particles used have a water pressure resistance of at least 600 kgf / cm ² 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 and reflect when irradiated with light, exhibit an extremely high gloss and luminance surface, and can express a stone-like or brick-like texture color. You can.

The fine hollow ceramic particles are from 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 the content is less than 3% by weight, it cannot be said that the gloss and the light brightness of the stone-grain or brick tone are sufficient and 25
When the content is more than the weight%, the physical properties of the tile are reduced.

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 ceramic fine 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 crushed ceramic waste particles used in the present invention are obtained by crushing defective products generated in the porcelain production process. Pottery here refers to earthenware, pottery, stoneware, porcelain, and concrete products include black clay tiles, bricks, earthen pipes, earthenware tiles, interior and exterior tiles, sanitary ware, etc.
Stoneware is cold-resistant clay tiles, terracotta, pavement bricks, interior and exterior tiles, floor tiles, pottery tubes, etc., porcelain is interior and exterior tiles,
There are floor tiles, mosaic tiles, sanitary ware, etc. These products are used by crushing defective products and waste.

The crushed ceramic waste particles are fine, medium, and coarse, each having a fine particle size of 0.1 to 0.5 mm and a medium size of 0.5 to 1.5 mm. The roughness is adjusted to 1.5 to 3.4 mm for 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.

The cement used in the present invention is not particularly limited, and includes, for example, Portland cement such as ordinary Portland cement, early-strength Portland cement, ultra-high-strength Portland cement, moderately heated Portland cement, sulfate-resistant Portland cement, and blast furnace cement. , Silica cement, mixed cement such as fly ash cement, white Portland cement, cement-based solidifying material, and special cement such as alumina cement. Of these, ordinary Portland cement is preferably used in terms of price and quality.

The surface of a plastic block is formed by molding a composition comprising fine hollow ceramic particles having a water pressure resistance of 600 kgf / cm ² or more and ground ceramic waste particles into a tile-like pattern using a synthetic resin emulsion and cement as a binder. It was possible to exhibit excellent stone-grain and brick-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 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 foamed plastic hollow block surface is placed on the cement mortar surface, the mold frame is rotated by 180 degrees so that the hard foamed plastic hollow block faces down, the 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.

After a tile is adhered to the surface or the front and back surfaces of the hard foamed plastic hollow block via cement mortar, the plastic film which is a surface protecting and releasing material is 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.

[0030]

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), ordinary Portland cement 1
0.0% by weight, ceramic fine hollow particles 10.0% by weight, ceramic waste ground particles 54.5% by weight, organic additives (dispersants and others) 4.0% by weight, inorganic pigments 4.0% by weight, etc. The tile composition having a composition of 5.5% by weight and a little more than water was sufficiently mixed and stirred by a vacuum deaeration kneading apparatus and then poured.

The ceramic fine hollow particles are alumina 43.
0-44.0%. A material composed of 54.5% to 55.5% silica and 1.5% to 2.5% is used. Its physical properties are a compressive strength of 700 kgf / cm ² and a bulk specific gravity of 0.4 g.
/ 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. The crushed ceramic waste particles used were crushed particles of Sanshu roof tiles, and the particle size was adjusted to 10 parts by weight and 70 parts by weight. To this, 20 parts by weight of a medium size of ground white sanitary ware waste particles were added and blended.

On the tile composition, cement mortar is poured into 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, an excellent brick-like tile-like uneven pattern having excellent appearance can be produced on the front and back surfaces of the hard foamed plastic hollow block.

[0036]

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 even by a skilled worker. 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 crushed particles of defective products generated during the ceramic production process and using a synthetic resin emulsion and cement 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 and brick tones of a natural stone style.

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

Ceramic fine hollow particles are uniformly arranged on the surface of the tile, and the ceramic fine hollow particles are transparent or semi-transparent fine hollow, and can be reflected by light irradiation to exhibit extremely high gloss and light brightness. By further buffing, a more excellent texture could be developed.

By using lightweight ceramic fine hollow particles, a lightweight tile is formed. The plastic block having the lightweight tile with high heat insulating properties can prevent a rise in temperature 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

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C04B 28/02 C04B 28/02 B29K 103: 00 B29L 31:10 F term (Reference) 4F204 AC01 AD02 AD04C AD05 AD08 AF01 AF09 AG03 AG20 AH46 EA03 EB01 EB11 EB22 EF01 EF02 EF27 EF37 EF51 EK09 EK24 4G012 PA02 PA25 PA30 PB11 PB31 PC01 PC14

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 process of sucking air from, a process of pouring a composition composed of ceramic fine hollow particles, crushed ceramic waste particles, a synthetic resin emulsion and cement, a process of pouring cement mortar on the upper surface, and a hard foam plastic hollow block for 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. 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 .