JP2004122455A - Method for manufacturing calcium silicate decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a calcium silicate decorative material showing a natural feeling near to a natural stone while realizing reduction of a manufacturing cost. <P>SOLUTION: In a sprinkling process S10, a decorative powder 3 is sprinkled over the bottom surface of the cavity 1a of a mold 1. Subsequently, in a water replenishing process S20, moisture is supplied to the decorative powder 3 in the cavity 1a. Thereafter, in a molding process S30, cement, silica hume and water-containing mortar 5 are cast in the cavity 1a to form a molded object 6. Then, in a curing process S40, the molded object 6 is aged to obtain a tile 10 cured by calcium silicate hydrate produced by the ageing. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing a calcium silicate-based cosmetic material. The production method of the present invention is suitable for producing decorative materials in which design is important, such as building materials such as wall tiles, floor tiles, and siding, artificial stones, top plates, bathtubs, counters, louvers, and handrails.
[0002]
[Prior art]
Conventionally, a general calcium silicate-based decorative material has been manufactured by the following manufacturing method (for example, see Patent Document 1). First, a mortar containing CaO and SiO _{2 components} and water is prepared, and the mortar is poured into a cavity having a bottom surface having an uneven pattern to obtain a molded body. Next, a cured product is obtained by curing the molded product. Next, an aqueous paint in which the decorative powder is dissolved in water is prepared, and the aqueous paint is applied to the uneven pattern of the cured product removed from the molding die. Then, after the water-based paint is dried, the surface of the cured body is washed with water using a brush, and the water-based paint on the convex portion of the cured body is scraped off.
[0003]
In the thus obtained decorative material, the concave and convex pattern of the cavity is transferred, and the transferred concave portion is given a strong coloring, while the convex portion has little or no coloring. Because it is not performed, it will have a natural texture. This decorative material can be used as an interior or exterior building material.
[0004]
[Patent Document 1]
JP-A-5-309621 (Page 2, paragraphs "0002" to "0005")
[0005]
[Problems to be solved by the invention]
However, when a cosmetic material is manufactured by the above-described conventional manufacturing method, a trace of a brush tends to remain on the obtained cosmetic material, and it cannot exhibit a natural texture close to natural stone.
[0006]
In this regard, it is conceivable that after the decorative powder is sprayed on the bottom surface of the cavity in advance, mortar is poured into the cavity. When the decorative material is manufactured in this manner, the obtained decorative material has no trace of a brush and is colored in a manner similar to nature, so that it can exhibit a natural texture closer to natural stone than before. However, if the decorative material is manufactured in this manner, since the decorative powder is in a dry powder form, the decorative powder hardly adheres to the mortar and is easily left on the bottom surface of the cavity. For this reason, extra decoration powder must be used, and reduction in manufacturing cost cannot be realized. As a mold for such a decorative material, a mold made of urethane or silicone is generally used, but this tendency is large when a mold made of urethane is used.
[0007]
On the other hand, it is also conceivable to apply mortar into the cavity after applying a water-based paint obtained by dissolving the decorative powder with water to the bottom surface of the cavity. When a cosmetic material is manufactured in this manner, the mortar is surely colored and the water-based paint hardly remains on the bottom surface of the cavity, which is preferable from the viewpoint of reducing the manufacturing cost. However, if the decorative material is manufactured in this manner, the decorative powder is uniformly dispersed or dissolved in water, so that the decorative powder exhibits only a monotonous color far from natural texture.
[0008]
The present invention has been made in view of the above conventional circumstances, and a method for producing a calcium silicate-based cosmetic material capable of exhibiting a natural texture close to natural stone while realizing a low production cost. Is to be solved.
[0009]
[Means for Solving the Problems]
The method for producing a calcium silicate-based cosmetic material of the present invention includes a spraying step of spraying the decorative powder on the bottom surface of the cavity of the mold,
A water replenishment step of supplying water to the decorative powder in the cavity,
A molding step in which a mortar containing CaO and SiO ₂ and water is poured into the cavity to form a molded body;
Curing the formed body to form calcium silicate hydrate to obtain a hardened calcium silicate-based decorative material.
[0010]
In the manufacturing method of the present invention, the decorating powder is sprayed on the bottom surface of the cavity of the molding die in the spraying step, and then the decorating powder in the cavity is replenished with water in the water refilling step. Thereafter, as a molding step, mortar is poured into the cavity. For this reason, even if the decorating powder is a dry powder, the decorating powder easily adheres to the mortar due to appropriate viscosity, and hardly remains on the bottom surface of the cavity. For this reason, it is not necessary to use an extra decoration powder, and the manufacturing cost can be reduced.
[0011]
Further, in this manufacturing method, since the decorative powder is not dissolved in water in advance, the decorative powder is not uniformly dispersed or dissolved in water in the cavity, and the decorative powder is unevenly dispersed. It is only dispersed in water. In addition, the decorative powder having an appropriate viscosity also has excellent shape retention. For this reason, the decorative material thus obtained can exhibit a natural texture close to natural stone.
[0012]
Therefore, according to the manufacturing method of the present invention, it is possible to manufacture a decorative material capable of exhibiting a natural texture close to that of natural stone while realizing a low manufacturing cost.
[0013]
In addition, a manufacturing method having means for spraying the decorative powder on the bottom surface of the cavity is also disclosed in Patent Document 1 described above. However, in the manufacturing method disclosed in Patent Document 1, the amount of the release agent is made different depending on the unevenness of the bottom surface, and such work is troublesome, which leads to an increase in product cost. On the other hand, according to the production method of the present invention, the cosmetic agent can be produced by a relatively simple operation without making a difference in the amount of the release agent, so that the product cost can be reduced.
[0014]
A production method having a means for spraying the decorative powder is also disclosed in JP-A-2001-138315. However, in the manufacturing method disclosed in the publication, the decorative powder is sprayed on the surface of the molded body which can generate and harden calcium silicate hydrate, and the decorative powder is easily wasted at the time of spraying. In addition, in this manufacturing method, it is difficult to spray the decoration powder so that a natural texture is obtained, and even if the decoration powder is sprayed with such a difficulty, the decoration powder is preferably formed. The reality is that it is difficult to produce a cosmetic agent that hardly adheres to the body surface and consequently exhibits a natural texture close to natural stone. On the other hand, according to the production method of the present invention, it is possible to relatively easily produce a cosmetic agent exhibiting a natural texture close to natural stone.
[0015]
As the decorative powder, one or more kinds of general pigments such as red iron, titanium white, and the like can be used. In addition, silica sand, feldspar powder and the like can be mixed with the decorative powder. In addition, a mold having an uneven pattern formed on the bottom surface of the cavity can be used as the mold. In the spraying step, the decorative powder can be appropriately sprayed by smoothing the decorative powder with a brush or the like.
[0016]
In the production method of the present invention, the water replenishment step is a first water replenishment step of replenishing the interior of the cavity with more water than the amount in which the decorative powder becomes a paste, and the excess water from the cavity until the decorative powder becomes the paste. Preferably, the method comprises a second rehydration step for removing. If the first water refilling step and the second water refilling step are performed, the effect of the present invention can be sufficiently obtained without performing strict water control to make the decorative powder have an appropriate viscosity. The improvement can further reduce the manufacturing cost.
[0017]
At that time, it is preferable to spray water in the first rehydration step. This is because water can be uniformly supplied to the decorative powder by spraying. As the second rehydration step, it is possible to employ a means for absorbing excess moisture with a water-absorbing material, but it is preferable to employ a means for inverting the mold. This is because, although it is relatively easy to invert the mold, surplus moisture can be reliably removed. Even if the mold is inverted, the decorative powder does not fall out of the cavity due to appropriate viscosity. Even if the decorating powder moves a little, the decorative material will exhibit a natural texture close to natural stone.
[0018]
In the production method of the present invention, the mortar preferably contains cement and silica fine particles.
[0019]
As the cement, besides white cement, ordinary Portland cement and the like can be used. If a white cement is adopted, coloring becomes easy and a decorative material having excellent design properties can be obtained.
[0020]
As the silica fine particles, those containing silica having a small particle diameter such as silica fume, colloidal silica, microsilica, aerosil, and fly ash can be used. In particular, in the manufacturing method of the generic cement-based structures, calcium silicate tricalcium silicate contained in the cement (3CaO · SiO ₂₎ and dicalcium silicate (2CaO · SiO ₂₎ reacts with water When hydrate is formed, calcium hydroxide (Ca (OH) ₂ ) is generated, which becomes calcium carbonate (CaCO ₃ ) on the surface of the cosmetic material, and exists as a white powder (so-called white flower phenomenon). However, the cosmetic material has a very bad appearance. In this regard, in the preparation and the production method of the present invention, a preparation containing silica fine particles can be employed, so that the molded product is one in which silica fine particles enter gaps between cement particles and fill the gaps. Then, in the curing step, the molded body is cured, and calcium silicate hydrate is generated to obtain a cured cosmetic material. At this time, the silica fine particles that have entered the gaps between the cement particles form dense calcium silicate hydrate crystals. For this reason, since the decorative material thus obtained exhibits extremely high transferability to the inner surface of the cavity, it is possible to make the surface glossy or to express a delicate texture, etc. Can look good. Calcium hydroxide, which causes the efflorescence phenomenon, reacts with the silica fine particles to form dense calcium silicate hydrate. For this reason, the decorative material thus obtained is less likely to cause a blushing phenomenon, and can exhibit an excellent appearance in this respect as well. According to the test results of the inventors, it is preferable to employ silica fume as the silica fine particles. This is because silica fume is fine among these silica fine particles, has a high reaction rate with calcium hydroxide (Ca (OH) ₂ ), and can form an extremely dense structure during curing.
[0021]
If the mortar includes a lightening material, it is possible to manufacture a lightweight decorative material. In particular, since the decorative material obtained by this manufacturing method has a dense structure, even if the mortar contains a large amount of a porous lightweight material, cracks and the like hardly occur. For this reason, an extremely lightweight cosmetic material can be manufactured. Natural lightweight aggregates and artificial lightweight aggregates can be used as the lightweight material. As the natural lightweight aggregate, natural pearlite, shirasu balloon, diatomaceous earth and the like can be adopted. As the artificial lightweight aggregate, perlite, expanded styrene beads, EVA resin chips, expanded glass balloons, fly ash, pulp, organic fibers, and the like can be used. The mortar can also contain inorganic aggregates such as silica powder and river sand as other aggregates.
[0022]
Although sufficient performance can be obtained even if the curing step does not include hydrothermal treatment, it is more preferable that the curing step includes hydrothermal treatment. When the hydrothermal treatment is performed, the formation of calcium silicate hydrate in the curing step is promoted, and the structure of the decorative material becomes more dense. For this reason, the water absorption rate further decreases, and the mechanical strength also increases. Examples of the hydrothermal treatment include steam curing in which a curing process is performed in a heated steam atmosphere, and autoclave curing in which a curing process is performed in a heated and pressurized steam atmosphere in an autoclave apparatus. According to the test results of the inventors, the structure of the cement-based decorative material can be made denser in the autoclave curing than in the steam curing, and the mechanical strength is larger. In addition, when performing a hardening process at normal temperature, it is preferable to perform at 20 degreeC or more. In this case, the formation of calcium silicate hydrate in the curing step is promoted to some extent, and the structure of the decorative material becomes dense.
[0023]
In the manufacturing method of the present invention, it is preferable that a release agent is previously attached to the bottom surface of the cavity. This is because the decoration powder can be prevented from remaining on the bottom surface of the cavity, and the calcium silicate-based decorative material can be surely released.
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, tests in which the method for producing a calcium silicate-based decorative material of the present invention is embodied as a method for producing a tile will be described with reference to the drawings.
[0025]
First, white cement, silica fume as silica fine particles, natural pearlite under 2 mm as a lightening material, and commercially available coarse-grained (foamed) pearlite are prepared. The bulk density of the white cement is 1.3g / cm ^3. The bulk density of silica fume is 0.4 g / cm ³ . The bulk density of the natural pearlite is 1.0 g / cm ^3. The bulk density of the perlite is 0.2 g / cm ^3. These are blended in a blending ratio (mass%) of 100 parts by mass of white cement, 25 parts by mass of silica fume, 125 parts by mass of natural pearlite, and 40 parts by mass of (expanded) pearlite, and are charged into an Erich mixer to perform dry mixing. Water is added to the obtained mixture so that the water / cement ratio becomes 50 (% by mass) and the water / solid content ratio becomes 17 (% by mass), and wet mixing is performed. This is put into a mortar mixer or the like and further kneaded. Thus, the mortar 5 is obtained.
[0026]
Further, as shown in FIG. 2, a release agent 2 is applied to the bottom surface of the cavity 1a of the molding die 1 having an uneven pattern. This prevents the decorative powder 3 from remaining on the bottom surface of the cavity 1a and allows the tile 10 to be reliably released from the mold.
[0027]
`` Spraying process ''
Then, as a spraying step S10 shown in FIG. 1, as shown in FIG. 3, the decorative powder 3 is sprayed on the bottom surface of the cavity 1a. At this time, the decorative powder is smoothed with a brush or the like.
[0028]
"Water replenishment process"
Next, as the water replenishment step S20 shown in FIG. 1, water is supplied to the decorative powder 3 in the cavity 1a. First, as shown in FIG. 4, as the first rehydration step S <b> 21, water 4 is sprayed toward the decorative powder 3, so that the water 4 in an amount equal to or greater than the amount of the decorative powder 3 in a paste state is introduced into the cavity 1 a. Replenish. Thereafter, as a second water replenishment step S22 shown in FIG. 1, the molding die 1 is inverted to remove excess water from the cavity 1a until the decorative powder 3 becomes a paste. If the first water refilling step S21 and the second water refilling step S22 are performed, it is not necessary to perform strict moisture control to make the decorative powder 3 have an appropriate viscosity, and excellent workability can be exhibited. . Even if the mold 1 is inverted, the decorative powder 3 does not fall out of the cavity 1a due to appropriate viscosity. Even if the decorating powder 3 moves a little, the tile 10 will give a natural texture close to natural stone.
[0029]
`` Molding process ''
Next, as a molding step S30, mortar 5 is poured into the cavity as shown in FIG. At this time, since the water rehydration step S20 is performed, even if the decorative powder 3 is in the form of a dried powder, the decorative powder 3 easily adheres to the mortar 5 with an appropriate viscosity and remains on the bottom surface of the cavity 1a. hard. For this reason, it is not necessary to use the extra decorative powder 3, and the manufacturing cost can be reduced.
[0030]
Further, since the decorative powder 3 is not previously dissolved in water, the decorative powder 3 is not uniformly dispersed or dissolved in water in the cavity 1a. It is only dispersed in. In addition, the decorative powder 3 having appropriate viscosity also has excellent shape retention. Thus, a molded body 6 is obtained.
[0031]
"Curing process"
Thereafter, as a curing step S40 shown in FIG. 1, the molded body 6 is removed from the mold 1 after being allowed to stand for 3 to 12 hours in an environment of 40 ° C. under a saturated steam pressure, and 14 to 14 hours in an environment of 60 ° C. under a saturated steam pressure. Let stand for 24 hours to cure. Thereafter, the molded body 6 is placed in an autoclave apparatus, and is subjected to autoclave curing for 24 hours in an environment of a saturated steam pressure of 60 ° C. This autoclave curing is hydrothermal treatment. By curing the molded body 6 in this way, as shown in FIG. 6, a calcium silicate hydrate is generated to obtain a hardened tile 10. In the tile 10 thus obtained, the uneven pattern of the cavity 1a was transferred and had a natural texture close to natural stone.
[0032]
Therefore, according to this manufacturing method, it is possible to manufacture the tile 10 that can exhibit a natural texture close to natural stone while realizing a low manufacturing cost.
[Brief description of the drawings]
FIG. 1 is a process chart showing a manufacturing method according to an embodiment.
FIG. 2 is a cross-sectional view of a molding die according to the embodiment.
FIG. 3 is a cross-sectional view of a forming die and the like in a spraying step according to the embodiment.
FIG. 4 is a cross-sectional view of a forming die and the like in a water refilling step according to the embodiment.
FIG. 5 is a cross-sectional view of a molding die and the like in a molding step according to the embodiment.
FIG. 6 is a perspective view of a tile obtained according to an embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Mold 1a ... Cavity 3 ... Decorative powder S10 ... Spraying process 4 ... Water S20 ... Water replenishment process 5 ... Mortar 6 ... Molded body S30 ... Molding process 10 ... Calcium silicate-based decorative material (tile)
S40: curing step S21: first rehydration step S22: second rehydration step 2: release agent

Claims (9)

A spraying step of spraying the decorative powder on the bottom surface of the mold cavity;
A water replenishment step of supplying water to the decorative powder in the cavity,
A molding step in which a mortar containing CaO and SiO ₂ and water is poured into the cavity to form a molded body;
Curing the formed body to form calcium silicate hydrate to obtain a hardened calcium silicate-based decorative material. The water refilling step is a first water refilling step of replenishing the interior of the cavity with more water than the decorative powder becomes an amount of paste, and a second water removing step of removing excess moisture from the cavity until the decorative powder becomes an amount of paste. 2. The method for producing a calcium silicate-based cosmetic material according to claim 1, comprising two water rehydration steps. The method according to claim 2, wherein water is sprayed in the first water rehydration step. The method for producing a calcium silicate-based decorative material according to claim 2 or 3, wherein in the second water rehydration step, the mold is inverted. The method for producing a calcium silicate-based decorative material according to any one of claims 1 to 4, wherein the mortar contains cement and silica fine particles. The method for producing a calcium silicate-based cosmetic material according to claim 5, wherein the silica fine particles are silica fume. The method for producing a calcium silicate-based decorative material according to any one of claims 1 to 6, wherein the mortar contains a lightening material. The method according to any one of claims 1 to 7, wherein the curing step includes a hydrothermal treatment. The method for producing a calcium silicate-based decorative material according to any one of claims 1 to 8, wherein a release agent is previously attached to a bottom surface of the cavity.

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