JP2004203717A - Method of producing lightweight cellular concrete panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing an ALC (Autoclaved Lightweight Concrete) panel which can be excellently designed and has waterproof characteristics and durability. <P>SOLUTION: In the method of producing a lightweight cellular concrete panel the surface of which is subjected to facing, the surface of the ALC panel is coated with a mortar composition and is thereafter subjected to surface working by physical means such as an air current, a water jet, pressing, carving and scratching in a semi-hardened state. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a lightweight cellular concrete panel (hereinafter referred to as an ALC panel) having a decorative surface and a method for producing the panel.
[0002]
[Prior art]
The ALC panel is a light-weight, ready-made panel reinforced with reinforcing reinforcing bars and the like, and is known as a large panel having a width of 60 cm and a length of several meters, for example. This ALC panel has the characteristics of being economical, lightweight, fire-resistant and heat-insulating, and excellent in workability. In the construction industry, it is a private house, a house with a store, a building roof, a floor, an outer wall and a partition material. It has been heavily used.
[0003]
However, although the ALC panel is a material excellent in various properties as described above, it is generally produced as a panel having a flat flat surface due to production efficiency, and thus has poor design properties when used as an outer wall material. Also, ALC panels are painted at construction sites for the purpose of beautifying, waterproofing, acid resistance, etc., because the materials themselves have water absorbency and use calcareous raw materials during production. That is common.
Therefore, in order to overcome these problems, a method of forming a design groove on the surface of an ALC panel (Patent Document 1: Japanese Patent Application Laid-Open No. 58-160106, Patent Document 2: Japanese Patent Application Laid-Open No. 59-167203), A method of forming a concave portion on the surface of an ALC panel by a shot blast method (Patent Document 3: JP-A-63-25284) has been proposed. However, there are problems that designs obtained by these techniques are limited to mechanical and uniform ones, and when used as an outer wall of a building, painting is required at a construction site.
[0004]
In addition, there have been proposed methods of manufacturing colored wallboards in which two colors are classified (Patent Document 4: Japanese Patent Application Laid-Open No. 55-75978, Patent Document 5: Japanese Patent Application Laid-Open No. 2-252677). Since the engraving method is based on cutting means, there are problems in appearance such as that the obtained design is limited to a monotonous one such as a block tone or a striped pattern.
Further, a method of applying a slurry of a mortar composition having good adhesion to ALC and having similar expansion and contraction coefficients on the surface of the ALC panel, and polishing the surface after hardening the surface (Patent Document 6: Japanese Patent Laid-Open No. 11- No. 278962) has been proposed, but there are problems such as that the obtained ALC panel is limited to a smooth one, and that it is necessary to perform a siller treatment or the like in order to impart waterproofing performance during construction.
[0005]
[Patent Document 1]
JP-A-58-160106 [Patent Document 2]
JP-A-59-167203 [Patent Document 3]
JP-A-63-25284 [Patent Document 4]
JP-A-55-75978 [Patent Document 5]
Japanese Patent Application Laid-Open No. H2-225274 [Patent Document 6]
JP-A-11-278962 [0006]
[Problems to be solved by the present invention]
The present invention has been made in order to solve the above problems, and provides a method for manufacturing a decorative ALC panel in which a decorative layer is laminated on an ALC panel surface having excellent design, waterproof performance, and durability. Aim.
[0007]
[Means for Solving the Problems]
That is, the present invention has achieved the above objects, and is as follows.
(1) After applying the mortar composition to the surface of the ALC panel, the mortar composition is subjected to physical means such as air flow, water flow, pressing, sculpting, scratching, etc. in a semi-cured state with a compressive strength of 0.2 to 10 kg / cm ^2. A method for producing an ALC panel, characterized in that the surface is subjected to surface treatment and laminated as a decorative layer.
(2) The method for producing a lightweight cellular concrete panel according to claim 1, wherein 0.1 to 20 parts by weight of a powder coloring pigment is further added to the mortar composition according to (1).
[0008]
Hereinafter, the present invention will be described in detail.
First, an example of the present invention is schematically shown in FIGS.
The ALC panel 1 used as the base of the present invention is one obtained by the following manufacturing method.
For example, a mortar slurry obtained by adding water, a foaming agent, etc. to a calcareous raw material or a siliceous raw material is injected into a mold in which a large number of reinforcing bars are arranged, and a large mold-shaped block containing bubbles is semi-cured during curing. It was cut in a state using a piano wire and cured in an autoclave.
The ALC panel 1 referred to in the present invention includes any size and shape, including a reinforcing bar shape and a shape cut by a cutting process into a predetermined shape, a building outer wall material, and a flat material used as a partition material. Panels, L-shaped and R-shaped corner panels used at the outer corner and the inner corner of the outer wall, those without a design groove on the surface of the panel, those with a design groove, and the like.
[0009]
The mortar composition 2 used in the present invention is preferably a composition comprising Portland cement, an aggregate, an acrylic latex emulsified with a nonionic dispersant, and a powder coloring pigment to which an appropriate amount of water has been added. It is not limited.
As the aggregate, it is general to make it suitable for the physical property value of the ALC panel 1 used as a base. For example, silica powder, calcium carbonate, ALC powder, silica sand, obsidian pearlite, clay mineral, etc. Good and preferably ALC powder and obsidian perlite are used. The particle size of the aggregate is preferably 1.2 mm or less, and if it is larger than 1.2 mm, it adversely affects the coating method described later.
[0010]
The added amount of the aggregate is preferably 140 to 1000 parts by weight, and if the amount is less than 140 parts by weight, curing and drying shrinkage become large, so that a crack is easily generated on the mortar composition surface. The strength equivalent to ALC cannot be obtained.
As the acrylic latex emulsion, an acrylic latex emulsified with a nonionic dispersant is suitable, and even with the same acrylic latex emulsion, if an acrylic latex emulsified with an anionic dispersant having a functional group such as carboxylic acid is used, cement latex is used. The amount of calcium ions therein decreases, causing a delay in curing, and cracks and the like occur.
[0011]
When the amount of the acrylic latex emulsified with the nonionic dispersant is more than 40 parts by weight in terms of solid content, hydration of the cement is hindered, and the hardening time becomes extremely long. If the amount is less than 10 parts by weight in terms of solid content, the adhesion to ALC is remarkably reduced, and the mortar composition itself cannot have sufficient waterproofing performance.
The amount of the acrylic latex is preferably 35 parts by weight or less based on 100 parts by weight of Portland cement, and more preferably 5% by weight or more based on the total solid content. If the amount is more than 35 parts by weight with respect to Portland cement, hydration of the cement will be hindered, and the hardening time will be significantly increased. If the amount is less than 5% by weight based on the total solid content, waterproof performance and adhesion to lightweight cellular concrete will be reduced.
[0012]
As the color pigment, inorganic powder pigments such as red iron oxide, nickel titanium yellow, yellow iron oxide, graphite, ultramarine blue, navy blue, cobalt blue, carbon black, titanium oxide, and cobalt green can be used. It is also possible to use paste pigments, but depending on the type of surfactant used to disperse the powder pigment, there is a possibility that the setting of the cement may be delayed. Preferably, an inorganic powder pigment having excellent weather resistance is used.
The amount of the coloring pigment to be added is preferably 0.1 to 20 parts by weight, and an excellent coloring effect is exhibited in this range.
[0013]
In the case where dripping occurs after the mortar composition is applied to an ALC panel, the mortar composition is preferably provided with a thickening property. For example, a small amount of methyl cellulose or the like may be added.
The method of applying the mortar composition 2 is performed by troweling, pouring, spraying for painting, a universal gun, or the like, but is generally determined from the design, productivity, production cost, and the like of the ALC panel. . If the mortar composition has a high viscosity and is applied by hand, a good trowel application, a low coating viscosity, and a machine-applicable mortar composition should be poured or spray applied. good.
[0014]
The surface treatment of the present invention means that the mortar composition is applied by physical means such as air flow, water flow, pressing, sculpting, scratching, etc. at the time of semi-curing, and mainly the shape of the decorative layer to be obtained Selected by.
For example, when a decorative layer of any shape is obtained, pressing and engraving are suitable. Pressing is performed by applying a compressive force to the mortar composition 2 using a design roller 10 having an arbitrary shape as shown in FIG. In sculpting, the mortar composition 2 formed into an arbitrary shape using a design form 14 or the like as shown in FIG.
[0015]
In the case of providing a gentle natural uneven pattern, airflow and water flow are suitable. The air current is generated by ejecting a gas such as air with a tool connected with the ejection nozzle 5 or the like as shown in FIG. 1 and directly colliding with the mortar composition 2 to process the surface. In addition, the water stream is jetted with a tool to which a jet nozzle 8 or the like as shown in FIG. 3 is connected, and the surface is processed by spraying or colliding with the mortar composition 2.
When a scratch pattern is obtained, surface processing by scratching is suitable, and surface processing can be performed by scratching the mortar composition 2 with a scratching tool 16 or the like having projections arranged in rows as shown in FIG.
[0016]
The compressive strength of the mortar composition 2 as referred to in the present invention is a physical property value that can be measured during the period from application to the surface of the ALC panel 1, after curing is started until completion, and the optimum value is obtained. Is determined by the processing method of the mortar composition 2, the shape of the decorative layer, productivity, production cost and the like.
For example, when a concavo-convex pattern is to be obtained by an air current, the mortar composition 2 is preferably applied at a time when the compressive strength is 0.2 to 1.0 kg / cm ² , preferably 0.3 to 0.6 kg / cm ^2. It is better to carry out in the range of cm ² . This is because if less than 0.3 kg / cm ^2, more likely the mortar composition is scattered around ALC panel, also exceeds 0.6 kg / cm ^2, is required a large amount of air flow, production efficiency decreases, This is because the production cost increases.
[0017]
In the case of obtaining a concavo-convex pattern by a water flow, the mortar composition 2 is preferably carried out at a time when the compressive strength is 0.2 to 10 kg / cm ² , but is preferably carried out within a range of ^{2 to} 5 kg / cm ² . Is good. This is because, if less than 2 kg / cm ^2, water flow by having a flowability said mortar composition immediately is because formation of the uneven pattern is difficult, and if greater than 5 kg / cm ^2, a large amount of water flow Is required, which causes a reduction in production efficiency and an increase in manufacturing cost.
Case of forming a decorative layer by pressing is better to implement the timing of 0.2~10kg / cm ^2, preferably better carried out at a range of 0.5 to 5 kg / cm ^2. If the mortar composition 2 is less than 0.2 kg / cm ² , the mortar composition 2 is too soft and may lose its shape after processing. If the mortar composition ² exceeds 5 kg / cm ² , the required pressure increases, This is because the workability is reduced.
[0018]
Case of forming a decorative layer by sculpture, but it is preferable to implement the timing of 0.2~3kg / cm ^2, preferably better to implement a range of 0.5~2kg / cm ^2. This is because if it is less than 0.5 kg / cm ² , the molded mortar composition 2 is too soft and easily deformed. If it exceeds ² kg / cm ² , the mortar composition becomes too hard. This is because molding becomes difficult.
Case of forming a decorative layer by scratching is better to implement the timing of 0.2~5kg / cm ^2, preferably better to implement a range of 0.5~3kg / cm ^2. This is because if less than 0.5 kg / cm ^2, molding the said mortar composition remains scratch too soft is because it becomes easy to return to its original shape, also exceeds 3 kg / cm ^2, the mortar composition This is because the object 2 is too hard to form a scratch mark.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, the present invention will be described in more detail with reference to examples.
The mortar composition was applied to one surface of the ALC panel having a large area, and when the compressive strength of the mortar composition reached a predetermined value, arbitrary surface processing was performed, and the design of the produced sample was evaluated.
The mortar composition was sprayed onto the ALC surface with a universal gun so that the application amount was 8 kg / m ² .
[0020]
Embodiment 1
An ALC panel 1 as shown in FIG. 1 has 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (in terms of solid content), After applying a mortar composition 2 composed of 5 parts by weight, 1 part by weight of methylcellulose, and an appropriate amount of water, the injection nozzle shown in FIG. 1 was used when the compressive strength of the mortar composition 2 was 0.5 kg / cm ² . By colliding the airflow 6 with the mortar composition 2 at 5, the ALC panel FIG. 2 on which a decorative layer having a natural uneven pattern was laminated was obtained.
As a result, it was confirmed that the decorative layer had a rock-like design.
[0021]
Embodiment 2
An ALC panel 1 as shown in FIG. 3 was prepared by adding 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), oxidation After applying a mortar composition 2 composed of 5 parts by weight of titanium, 1 part by weight of methylcellulose and an appropriate amount of water, when the mortar composition 2 has a compressive strength of 2.0 kg / cm ² , the injection nozzle shown in FIG. By colliding the mortar composition 2 with the water stream 9 in 8, an ALC panel FIG. 4 in which a decorative layer having a natural uneven pattern was laminated was obtained.
As a result, it was confirmed that the decorative layer had a rock-like design.
[0022]
Embodiment 3
An ALC panel 1 as shown in FIG. 5 includes 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (solid content conversion), cobalt After applying a mortar composition 2 consisting of 5 parts by weight of blue, 1 part by weight of methylcellulose and an appropriate amount of water, the design roller shown in FIG. 5 was obtained when the mortar composition 2 had a compressive strength of 2.0 kg / cm ² . By pressing the mortar composition 2 from the surface with 10, an ALC panel FIG. 6 on which a decorative layer having the same shape as the design roller 10 was laminated was obtained.
As a result, it was confirmed that the decorative layer had a sandstone-like design.
[0023]
Embodiment 4
An ALC panel 1 as shown in FIG. 7 includes 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (in terms of solid content), carbon A mortar composition 2 consisting of 5 parts by weight of black, 1 part by weight of methylcellulose and an appropriate amount of water was placed in a design mold 14 as shown in FIG. 7 when the mortar composition 2 had a compressive strength of 1.0 kg / cm ² . ALC panel diagram in which a decorative layer having a design like a stone is laminated by forming the mortar composition 2 on the ALC panel surface 1 and processing the mortar composition 2 after molding by using the mortar composition 2 after molding. 8 was obtained.
As a result, it was confirmed that the decorative layer had a stone-paste design.
[0024]
Embodiment 5
An ALC panel 1 as shown in FIG. 9 includes 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (in terms of solid content), carbon After applying a mortar composition 2 consisting of 5 parts by weight of black, 1 part by weight of methylcellulose and an appropriate amount of water, the mortar composition 2 is applied when the compressive strength of the mortar composition 2 is 2.0 kg / cm ² . By scratching with a scratching tool 16 as shown in FIG. 9, an ALC panel FIG.
As a result, it was confirmed that the decorative layer had a scratch-like design.
[0025]
[Comparative Example 1]
An ALC panel 1 as shown in FIG. 1 is provided with 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (solid content conversion), After applying a mortar composition 2 composed of 5 parts by weight, 1 part by weight of methylcellulose, and an appropriate amount of water, when the mortar composition has a compressive strength of 0.05 kg / cm ² , the injection nozzle 5 shown in FIG. Then, an air stream 6 was caused to collide with the mortar composition 2.
As a result, the mortar composition 2 scattered around the ALC panel 1, and a decorative layer having a desired shape could not be obtained.
[0026]
[Comparative Example 2]
An ALC panel 1 as shown in FIG. 5 includes 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian pearlite, 30 parts by weight of an acrylic latex emulsified with a nonionic dispersant (solid content conversion), cobalt After applying a mortar composition 2 consisting of 5 parts by weight of blue, 1 part by weight of methylcellulose and an appropriate amount of water, the design roller shown in FIG. 5 was obtained when the mortar composition 2 had a compressive strength of 0.02 kg / cm ² . At 10, the mortar composition 2 was pressed from the surface.
As a result, the mortar composition 2 after pressing was deformed, and a decorative layer having a desired shape could not be obtained.
[0027]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, since the surface-processed mortar composition is laminated | stacked as a decorative layer on the ALC panel surface, the manufacturing method for obtaining the ALC panel excellent in design property, waterproof performance, and durability is provided. In addition, since it can be used as a final finishing panel, it is possible to omit the work such as painting which is usually performed at a construction site, and to shorten a construction period and improve workability.
As described above, the present invention solves all the problems of the conventional ALC panel and the ALC panel manufacturing technology, and sufficiently satisfies the recent needs of the building market such as differentiation, individuality, and high added value. Can be done.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view illustrating a state where a mortar composition in a semi-cured state is subjected to surface processing by an air current.
FIG. 2 is a cross-sectional view of the ALC panel whose surface has been processed by the method of the first embodiment.
FIG. 3 is a cross-sectional view illustrating a state where a mortar composition in a semi-cured state is subjected to surface processing by a water flow.
FIG. 4 is a cross-sectional view of an ALC panel whose surface has been processed by the method of Example 2.
FIG. 5 is a cross-sectional view illustrating a state in which a mortar composition in a semi-cured state is subjected to surface processing by pressing.
FIG. 6 is a cross-sectional view of an ALC panel whose surface has been processed by the method of the third embodiment.
FIG. 7 is a cross-sectional view illustrating a state in which a mortar composition in a semi-cured state is subjected to surface processing by sculpting.
FIG. 8 is a cross-sectional view of an ALC panel whose surface has been processed by the method of Example 4.
FIG. 9 is a cross-sectional view showing a state in which the surface of the mortar composition in a semi-cured state is scratched.
FIG. 10 is a cross-sectional view of an ALC panel surface-processed by the method of the fifth embodiment.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ALC panel 2 Mortar composition 3 Uneven part 4 Air supply hose 5 Jet nozzle (for gas)
6 Air flow 7 Liquid supply hose 8 Jet nozzle (for liquid)
9 Water flow 10 Design roller 11 Design roller rotation direction 12 Design roller pressing direction 13 Design roller traveling direction 14 Design form 15 Design form press direction 16 Scratching tool 17 Scratched scratch

Claims (2)

After applying the mortar composition to the surface of the lightweight cellular concrete panel, the mortar composition is applied in a semi-cured state with a compressive strength of 0.2 to 10 kg / cm ² by physical means such as air current, water current, pressing, sculpture, scratching, etc. A method for producing a lightweight cellular concrete panel, characterized in that the surface is processed and laminated as a decorative layer. The method for producing a lightweight cellular concrete panel according to claim 1, wherein 0.1 to 20 parts by weight of a powder coloring pigment is further added to the mortar composition according to claim 1.

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