JP2001287211A - Inorganic panel with pattern and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inorganic panel having a new surface irregular pattern which does not exist formerly while its manufacturing method which does not impair remarkably diversity of use materials, freedom of a pattern and a transfer property which are merits of injection molding is provided. SOLUTION: An inorganic mold 15 having a micro irregularity 17 forming a secondary pattern on a surface, and an irregularity 16 forming a primary pattern in the same face is laid on a bottom of a formwork 21, and concrete slurry is casted from an upper part. After curing and hardening, the mold is released to obtain an inorganic panel 18 having the secondary pattern 19 and the primary pattern 20 on the surface. The secondary pattern can be recognized only by an incident light of a low angle, and in the case where an angle of the incident light changes in the morning, the evening or the daytime, a decorative effect of the surface can be changed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic panel having an uneven pattern on its surface and a method for producing the same.

[0002]

2. Description of the Related Art In the past, inorganic panels excellent in fire resistance, heat insulation and sound insulation properties have been widely used for building materials such as exterior walls or interior partitions, and the surface design is uneven. Various patterns such as brick, tile, and natural stone are also known.
In addition, there are several methods for providing an uneven pattern as a design on the surface of the inorganic panel.However, in view of the simplicity of equipment, the variety of materials used, the degree of freedom of the pattern, and the transferability, etc. 2. Description of the Related Art A method of injecting a hydraulic material into an injection mold provided with a pattern and curing the material to obtain an inorganic panel having an uneven pattern on its surface is widely used.

However, there is a feeling that the uneven pattern as the surface design of the inorganic panel is exhausted,
In recent years, a completely new uneven pattern has not been found. In other words, each of them is a partial modification of the past pattern or a combination of the patterns, and there is a problem that the user has no fresh taste and is easily bored. In order to solve the above problem, crushed stone is sprayed on the surface of the injection mold in advance, and the crushed stone is cured together to obtain a panel with natural stone embedded in the surface, or a substance that inhibits hydraulic reaction Is applied to the surface of an injection mold, and a natural roughness appearing on the panel surface after curing is used as a design. However, even with these methods, it is difficult to obtain the above-mentioned new design, and the problem has not been solved at all.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and has as its object to provide an inorganic panel having a novel and uneven surface pattern which has never been seen before, and a method of manufacturing the same.

[0005]

That is, the present invention is as follows. (1) An inorganic panel formed in a plate shape by injecting a hydraulic material into an injection mold, wherein the inorganic panel has a secondary pattern on the panel surface. (2) An inorganic panel formed into a plate shape by injecting a hydraulic material into an injection mold, wherein the panel has a primary pattern and a secondary pattern on the panel surface.

(3) The height of the unevenness of the secondary pattern is 0.01 m
The inorganic panel according to (1) or (2), which has a length of m to 0.5 mm. (4) In a method of manufacturing a plate-like inorganic panel by injecting a hydraulic material into an injection mold, a part of the injection mold is formed of an inorganic mold having minute irregularities forming a secondary pattern on a surface. (5) A method for manufacturing a plate-like inorganic panel by injecting a hydraulic material into an injection mold, wherein a part of the injection mold is formed with unevenness forming a primary pattern, It is characterized by comprising an inorganic mold having fine irregularities forming the next pattern on the same surface,
Hereinafter, the present invention will be described in more detail.

In the present invention, the term "inorganic panel" refers to a panel whose main constituent material is an inorganic material, and includes a hardened material composed of a hydraulically hard inorganic material such as cement or gypsum, or an inorganic filler, and embedded therein. And a so-called precast concrete plate composed of a reinforcing material. The primary and secondary patterns of the present invention are:
It is not particularly limited as long as it has a design that is generally used as the inner and outer walls of a building, and examples include a geometric pattern, a stone tone, a brick tone, or a pattern in which each is combined.

[0008] The secondary pattern is a surface irregularity pattern that can be recognized only by incident light at a low incident angle with respect to the panel surface, whereas a pattern that can always be recognized is a primary pattern. The low incident angle is in the range of 0.01 to 45 degrees, and in this case, the angle parallel to the panel surface is 0.0 degrees. The primary pattern is a surface uneven pattern that can be recognized not only by incident light at a low incident angle but also by normal light with respect to the secondary pattern, and is generally a surface pattern.

The height of unevenness of the secondary pattern is several μm to several hundred μm.
And it has minute irregularities. Therefore, it cannot be recognized by incident light having a normal high incident angle. However, when the incident light at a low incident angle is applied to the panel surface, a slight shadow due to the secondary pattern appears on the surface,
As a result, a secondary pattern can be recognized. Due to the secondary pattern, depending on the angle of the incident light with respect to the panel surface,
A design different from a design that can be generally recognized can be provided on the panel surface, and a panel having a surface design that has never been seen before can be obtained.

For example, if the panel of the present invention is used on the outer wall of a building, the secondary pattern can be recognized as a shadow only in the morning and evening when the panel is obliquely lit, and the secondary pattern can be recognized during the day when the light is shining. Patterns are difficult to recognize. As a result, the expression of the outer wall of the building changes between morning, evening and daytime, and the concept of time is introduced into the design, and a novel design effect can be obtained. Another example is a case where the panel of the present invention is used as an interior material. In other words, although a normal interior light cannot recognize a secondary pattern, the secondary pattern can be recognized by applying light having a low incident angle from a separately installed light. Thereby, the expression of the inner wall can be changed according to the situation at the place, and a great design effect can be obtained.

Further, it is preferable that a primary pattern and a secondary pattern coexist on the same surface. This is because the primary pattern and the secondary pattern are in the same plane of the panel surface, so that the impression of the primary pattern can be greatly changed depending on the angle of the incident light, and the expression of the wall surface can be produced richly. For example, there is a panel in which the primary pattern is a lattice brick pattern and the secondary pattern is a hanging pattern. In other words, the brick panel design is usually shown, but the incident light at a low incident angle causes the hanging pattern to float on the brick surface, and a different design can be shown on the same panel wall surface.

Another example is a case where the panel of the present invention is used as an outer wall of a store.
In other words, if the primary pattern is a border pattern and the secondary pattern is a symbol for the store, it is usually recognized only as a border pattern wall, but in the morning, evening oblique light, or at night, from lights installed separately. The oblique light makes it possible to make the store's symbol mark, which is a secondary pattern, appear on the store wall surface. For this reason, a wall surface that satisfies both the desire for the advertisement of the store and the aesthetic appearance can be obtained.

The height of the unevenness of the secondary pattern can be arbitrarily set depending on the condition of incident light to be recognized. If it is necessary to widen the range of the incident angle that can be recognized, the height of the unevenness may be increased. If it is necessary to narrow the range of the incident angle that can be recognized, the height of the unevenness may be reduced. However,
If the height of the unevenness of the secondary pattern is too large, the secondary pattern cannot be distinguished from the primary pattern, and the effect of the secondary pattern, which is originally recognized only by incident light having a low incident angle, may be reduced. Therefore, the uneven height of the secondary pattern is 0.0
The range of 1 mm to 0.5 mm is preferable, and 0.02 mm to
When it is in the range of 0.2 mm, the secondary pattern can be recognized only by incident light at an extremely low angle, which is more preferable.

The height of the unevenness of the primary pattern is not particularly limited as long as it can be always recognized as a general surface design.
The following is preferred. Next, a method for producing the inorganic panel of the present invention will be described. The composition of the inorganic panel used in the present invention is not particularly limited as long as an inorganic material having hydraulic properties is used as a part of the main raw material. As the hydraulic material in the present invention, commercially available ordinary Portland cement, early-strength Portland cement, alumina cement, blast furnace cement and the like are used. Other main raw materials include inorganic fillers such as silica stone, silica sand and river sand, water, and the like. If necessary, gypsum, a foam material, an admixture, a molding auxiliary material, and the like can be mixed.

[0015] The concrete slurry obtained by mixing the above composition is injected into an injection mold in which a reinforcing material is previously arranged. Until the concrete slurry is hardened, the injection mold in the present invention can maintain the shape and have a strength and airtightness that can be formed into a plate shape, if it can have a material,
Although there is no particular limitation on the structure and the like, it is necessary to use an inorganic mold having fine irregularities for forming a secondary pattern on the surface at a position corresponding to a predetermined secondary pattern on the inorganic panel.

In the case of an inorganic mold having fine irregularities forming a secondary pattern on the surface, for example, a pressing mold for imparting minute irregularities is pressed against a soft inorganic plate before it is completely cured and cured. Is obtained. The material is not limited at all, as long as it has a strength of imparting irregularities to the concrete slurry as an injection mold.For example, cement, an inorganic material such as gypsum, an inorganic filler,
An inorganic type composed of reinforcing fibers and the like can be given.

A pressing die for providing minute irregularities for forming a secondary pattern has the following configuration. That is, it is composed of a surface material that comes into contact with the panel at the time of pressing, and a backing material that is integrated with the panel and has a higher compression modulus than the surface material, and has an uneven portion at the boundary surface between the surface material and the backing material. are doing. Uneven portions provided on the boundary surface between the surface material and the backing material are compressed in the height direction,
An inorganic mold having fine irregularities is obtained. Further, using this mold, an inorganic panel having a secondary pattern transferred from this mold can be obtained.

FIG. 1 is a schematic sectional view showing a method for producing an inorganic mold constituting a part of an injection mold in the production method of the present invention. The substrate before being completely cured (not shown) is pressed against the pressing die 3 having the above-described structure, and becomes an inorganic die 6 having fine irregularities 5 that form a secondary pattern on the surface. Micro unevenness 5
The concave and convex portion 4 provided at the boundary between the pressing surface material 1 and the backing material 2 is formed by being reduced in the height direction. The height of the fine unevenness 5 can be roughly calculated from the compression elastic modulus of the surface material 1 and the backing material 2, the depth of the uneven pattern 4, and the pressure at the time of pressing.

For example, as the surface material 1, a compression elastic modulus of 6
Assuming that a pressing die 3 composed of 86 MPa epoxy resin, a backing material 2, a cast iron plate having a compression elastic modulus of 210843 MPa, and a depth of 10 mm of a concavo-convex pattern 4 provided at the boundary is pressed against the base material at a pressure of 6.9 MPa, Inorganic type 6
The height of the minute unevenness 5 on the surface is calculated by the following equation. Height of minute unevenness = ｛(6.9 / 686) − (6.9 / 2)
10843)｝ × 10 = 100 μm

As described above, the uneven portion provided at the boundary between the surface material and the backing material is reduced in the height direction and is transferred to the surface of the inorganic mold constituting a part of the injection mold. It is possible to easily control the fine irregularities such as the following patterns, and it is possible to manufacture the inorganic panel of the present invention.

After curing and curing, the inorganic mold obtained as described above is used as a part of an injection mold to obtain an inorganic panel having a secondary pattern on the surface. FIG. 2 is a schematic sectional view showing an example of the production method of the present invention. An inorganic mold 6 having fine irregularities 5 on its surface is laid on the bottom of a mold frame 7, and a concrete slurry having a predetermined composition (not shown) is poured from above. Curing,
After curing, the mold is released, and the inorganic panel 8 of the present invention having the secondary pattern 9 on the surface is obtained.

Further, when an uneven pattern serving as a primary pattern is provided on the surface of the inorganic mold used as a part of the injection mold,
An inorganic panel having a primary pattern and a secondary pattern in the same plane can be obtained. FIG. 3 is a schematic cross-sectional view showing a method for producing an inorganic mold which has a part of the injection mold and has fine irregularities and irregularities that become a primary pattern on the surface in the production method of the present invention. The base material (not shown) before being completely cured is pressed against a pressing die 10 to form fine irregularities 1 on the surface of the base material.
An inorganic mold 15 having 7 and irregularities 16 serving as a primary pattern is obtained.

The minute irregularities 17 are formed on the pressing surface material 11.
The uneven portion 13 provided at the boundary between the backing material 12 and
It has a shape reduced in the height direction. The height of the minute unevenness 17 can be calculated from the compression elastic modulus of the surface material 11 and the backing material 12, the height of the uneven portion 13, and the pressure at the time of pressing, as described above. The inorganic mold 15 is completely cured by a method such as steam curing or autoclave curing. FIG.
An example of the production method of the present invention is shown in a schematic sectional view.

An inorganic mold 15 having microscopic irregularities 17 as a secondary pattern and irregularities 16 as a primary pattern on the same surface is laid on the bottom of a mold 21 and a concrete (not shown) of a predetermined composition is formed from above. Inject the slurry. After curing and curing, the mold is released and an inorganic panel 18 having a secondary pattern 19 and a primary pattern 20 on the surface is obtained.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the method for producing an inorganic panel of the present invention will be described with reference to examples, but the present invention is not limited to these examples.

[0026]

Example 1 50 parts by weight of cement, 45 parts by weight of crushed silica and 5 parts by weight of silica fume were mixed for 1 minute by an omni mixer. Thereafter, 31 parts by weight of water was added to 100 parts by weight of the powder, and 1.3 parts by weight of vinylon was added for 2 minutes and mixed for 2 minutes to prepare a mixture. Next, the mixture was placed in a lump having a diameter of about 20 cm at the center of a 440 mm × 330 mm × 20 mm formwork, and the mixture was pressed by a dehydrating press from one side with a pressing mold at a pressure of 6.864 MPa. A vacuum dehydration press for removing water by depressurizing from one side was performed for 10 seconds to obtain a molded body having a thickness of 8 mm.

The above-mentioned pressing type is configured as follows. In other words, a 6 mm high, 10 mm wide, 100 mm pitch, grid pattern with a height of 10 mm is cast on the surface of a 30 mm thick cast iron surface, which is filled with epoxy resin so that the thickest part is 12 mm, and the surface is smooth. It is a pressing type that is covered with a suitable epoxy resin and has a lattice pattern with a height of 6 mm at the boundary. Here, the compression elastic modulus of the epoxy resin is 6
85MPa, the compression elastic modulus of cast iron is 210843MP
a.

After pressing the mold, the molded body was heated at 60 ° C. and 95%
Cured and cured for 24 hours under the condition of RH, and is an inorganic type.
A cement mold was obtained. Next, the above-mentioned cement mold is inserted into an inner dimension
0mm × 330mm × 100mm steel formwork (thickness 10
mm) and used as a pattern. A cement mortar consisting of 100 parts by weight of Portland cement, 100 parts by weight of sand, and 50 parts by weight of water was placed on the formwork with a thickness of 1
The mixture was poured so as to be 0 mm and smoothed. Curing,
After curing, the panel was removed from the mold to obtain a panel. A smooth protrusion having an average of 52 μm was observed on the surface of the panel as measured by a surface roughness meter, and when oblique light was applied at an incident angle of 3 °, a grid-like pattern was observed on the panel surface.

[0029]

Example 2 50 parts by weight of cement, 45 parts by weight of crushed silica, and 5 parts by weight of silica fume were mixed with an omni mixer for 1 minute. Thereafter, 31 parts by weight of water was added to 100 parts by weight of the powder, and 1.3 parts by weight of vinylon was added for 2 minutes and mixed for 2 minutes to prepare a mixture. Next, the mixture was placed in a lump having a diameter of about 20 cm at the center of a 440 mm × 330 mm × 20 mm formwork, and the mixture was pressed by a dehydrating press from one side with a pressing mold at a pressure of 6.864 MPa. A vacuum dehydration press for removing water by depressurizing from one side was performed for 10 seconds to obtain a molded body having a thickness of 8 mm.

The above pressing die has a surface with a depth of 10 m.
m, a width of 10 mm, a pitch of 200 mm, and a thinner 10 mm epoxy resin provided with a convex lattice pattern, and a 30 mm thick casting plate as a backing material, and a maximum uneven height at the boundary between the epoxy resin and the casting plate. It has a configuration in which a Kotaki pattern having a length of 10 mm exists. Here, the compression elastic modulus of the epoxy resin is 685 MPa, and the compression elastic modulus of the cast iron is 210843 MPa.

After pressing the mold, the molded body was heated at 60 ° C. and 95%
Cured and cured for 24 hours under the condition of RH, and is an inorganic type.
A cement mold was obtained. Next, the above-mentioned cement mold is spread on the bottom of a steel mold frame (thickness: 10 mm) having an inner size of 440 mm × 330 mm × 100 mm, and is used as a pattern mold. A cement mortar consisting of 100 parts by weight of Portland cement, 100 parts by weight of sand, and 50 parts by weight of water was placed on a mold, having a thickness of 1 part.
The mixture was poured so as to be 0 mm and smoothed. Curing,
After curing, the panel was removed from the mold to obtain a panel.

In a normal state, this panel was recognized as a panel in which a lattice pattern was carved, and when the panel surface was measured with a surface roughness meter, smooth irregularities of 94 μm on average were observed. Further, when the panel was irradiated with oblique light having an incident angle of 3 degrees or less, a fine uneven pattern different from the lattice pattern appeared on the panel surface, and the panel could be recognized as a panel having a completely different design.

[0033]

According to the present invention, it is possible to obtain an inorganic panel having an unprecedented novel surface unevenness pattern, and to further increase the versatility of materials used, the degree of freedom of pattern, and the transferability, which are the advantages of injection molding. It can be manufactured without loss.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing an inorganic mold and a production example thereof.

FIG. 2 is a schematic sectional view showing an example of an inorganic panel and a method for manufacturing the same.

FIG. 3 is a schematic sectional view showing an inorganic mold and a production example thereof.

FIG. 4 is a schematic sectional view showing an example of an inorganic panel and a method of manufacturing the same.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Press-type surface material 2 Press-type backing material 3 Press-type 4 Uneven part 5 Fine unevenness 6 Inorganic type 7 Formwork 8 Inorganic panel 9 Secondary pattern 10 Press-type 11 Press-type surface material 12 Press-type backing material 13 Concavo-convex part 14 Primary pattern 15 Inorganic mold 16 Irregularities forming primary pattern 17 Fine irregularities forming secondary pattern 18 Inorganic panel 19 Secondary pattern 20 Primary pattern 21 Formwork

Claims (5)

[Claims] An inorganic panel formed in a plate shape by injecting a hydraulic material into an injection mold, wherein the panel has a secondary pattern on its surface. 2. An inorganic panel formed in a plate shape by injecting a hydraulic material into an injection mold, wherein the panel has a primary pattern and a secondary pattern on the panel surface. 3. The uneven height of the secondary pattern is 0.01 mm to
3. The method according to claim 1, wherein the distance is 0.5 mm.
The inorganic panel as described. 4. A method of manufacturing a plate-like inorganic panel by injecting a hydraulic material into an injection mold, wherein a part of the injection mold is
A method for manufacturing an inorganic panel, comprising: an inorganic mold having fine irregularities forming a secondary pattern on a surface. 5. A method for producing a plate-like inorganic panel by injecting a hydraulic material into an injection mold, wherein a part of the injection mold is
A method for manufacturing an inorganic panel, comprising an inorganic mold having unevenness forming a primary pattern and fine unevenness forming a secondary pattern on the same surface.