JP2005029446A - Manufacturing process of lightweight cellular concrete panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an ALC panel that is excellent in pattern properties, waterproof abilities and durability. <P>SOLUTION: The method for manufacturing the light weight cellular concrete panel comprises performing surface-processing within a period keeping fluidity of a colored paint and a mortar composition coated on the surface of the ALC panel by the physical means of an gaseous stream, a water stream, pressing, sculpturing, scratching and the like and laminating the same as a decoration layer. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for producing a lightweight cellular concrete panel (hereinafter referred to as an ALC panel) having a decorative surface.

  The ALC panel is a lightweight ready-made panel reinforced with a reinforcing reinforcing bar or 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 that it is economical, lightweight, fireproof and heat-insulating, and excellent in workability. In the building industry, it is a private house, a house with a store, a roof of a building, a floor, an outer wall, a partition material, etc. It is often used as.

  However, although the ALC panel is a material excellent in various properties as described above, in terms of production efficiency, it is generally produced as a panel having a flat flat surface, so that it is poor in design when used as an outer wall material. In addition, ALC panels need to be painted for construction, waterproofing, acid resistance, etc. at the construction site due to the fact that the material itself has water absorption and that calcareous raw materials are used during production. Become.

  In order to overcome these problems, a method of forming a design groove on the surface of the ALC panel (Patent Document 1: Japanese Patent Laid-Open No. 58-160106, Patent Document 2: Japanese Patent Laid-Open No. 59-167203), A method of forming a recess on the surface of an ALC panel by a shot blast method (Patent Document 3: Japanese Patent Laid-Open No. 63-25284) has been proposed. However, the designs obtained by these techniques have problems such as being limited to mechanical and uniform designs and, when used as the outer wall of a building, painting is also required at the construction site.

  In addition, methods for producing colored wall plates with two different colors (Patent Document 4: Japanese Patent Laid-Open No. 55-75978 and Patent Document 5: Japanese Patent Laid-Open No. 2-252675) have been proposed. Since the engraving method is based on the cutting means, there is a problem in appearance such that the obtained design is limited to a monotonous one such as a block tone or a striped pattern.

JP 58-160106 A JP 59-167203 A JP-A 63-25284 JP-A-55-75978 Japanese Patent Laid-Open No. 2-252675

  The present invention was devised to solve the above-described problems, and provides a method for producing a decorative ALC panel in which a decorative layer is laminated on the surface of an ALC panel having excellent design properties, waterproof performance, and durability. With the goal.

That is, the present invention has achieved the above-described problem, and is as follows.
(1) After applying a mortar composition to the surface of the lightweight cellular concrete panel, then applying a colored paint, an air stream at a time when the colored paint or both the colored paint and the mortar composition have fluidity, A method for producing a lightweight cellular concrete panel, characterized in that the surface is processed by physical means such as water flow, pressing, sculpting, scratching, and the like, and laminated as a decorative layer.
(2) A colored paint is applied to the surface of the lightweight cellular concrete panel, then a mortar composition is applied, and an air current is generated when the mortar composition or both the colored paint and the mortar composition have fluidity. A method for producing a lightweight cellular concrete panel, characterized in that the surface is processed by physical means such as water flow, pressing, sculpting, scratching, and the like, and laminated as a decorative layer.
Hereinafter, the present invention will be described in detail. First, the example of this invention is typically shown in FIGS.

  The ALC panel 1 used for the base of the present invention refers to the one obtained by the following manufacturing method. For example, mortar slurry in which water, foaming agent, etc. are added to calcareous raw material, siliceous raw material is poured into a mold with a large number of reinforcing bars, and a large block of foam-like form is semi-cured during curing. In this state, it was cut with a piano wire and cured by autoclaving.

  The ALC panel 1 as used in the present invention includes any size and shape, and is cut into a predetermined shape by the shape of a reinforcing bar or cutting, a flat used as an outer wall material of a building, or a partition material. Examples of the panel include L-shaped and R-shaped corner panels used for the outer corner and the corner of the outer wall, those having no design groove on the panel surface, and those having a design groove.

  As the mortar composition used in the present invention, a generally used mortar composition can be used, but as a preferred mortar composition for an ALC panel, portland cement, aggregate, acrylic latex emulsified with a nonionic dispersant, And a composition comprising a powder coloring pigment and an appropriate amount of water added.

The aggregate is generally made suitable for the physical properties of the ALC panel 1 used as the base, but for example, silica powder, calcium carbonate, ALC powder, quartz sand, obsidian perlite, clay mineral, etc. Good, preferably ALC powder, obsidian perlite. The aggregate particle size is preferably 1.2 mm or less, and if it is larger than 1.2 mm, it adversely affects the coating method described later.
The amount of aggregate added is preferably 140 to 1000 parts by weight.If the amount is less than 140 parts by weight, the mortar composition surface is liable to crack because of increased curing and drying shrinkage. The strength equivalent to ALC cannot be obtained.

As the acrylic latex emulsion, an acrylic latex emulsified with a nonionic dispersant is suitable. Even if the same acrylic latex emulsion is used, for example, an acrylic latex emulsified with an anionic dispersant having a functional group such as carboxylic acid is used as a cement. The calcium ion in the inside decreases, delays hardening, and cracks occur.
When the amount of the acrylic latex emulsified with the nonionic dispersant is more than 40 parts by weight in terms of solid content, the hydration of the cement is hindered and the setting time is significantly increased. If it is less than 10 parts by weight in terms of solid content, the adhesion with ALC is remarkably lowered, and sufficient waterproof performance cannot be obtained for the mortar composition itself.

  The amount of the acrylic latex is preferably 35 parts by weight or less with respect to 100 parts by weight of Portland cement, and is preferably added in an amount of 5% by weight or more based on the total solid content. If it exceeds 35 parts by weight with respect to Portland cement, the hydration of the cement will be hindered, and the hardening formation time will be significantly increased. If it is less than 5% by weight with respect to the total solid content, the waterproof performance and the adhesion performance with lightweight lightweight concrete will be lowered.

As the coloring pigment, inorganic powder pigments such as Bengala, nickel titanium yellow, yellow iron oxide, yellow lead, ultramarine, bitumen, cobalt blue, carbon black, titanium oxide, cobalt green and the like can be used. Other paste pigments can be used, but depending on the type of surfactant used to disperse the powder pigment, there is a risk of delaying the setting of the cement. Preferably, an inorganic powder pigment having excellent weather resistance is used. The addition amount of the color pigment is preferably 0.1 to 20 parts by weight, and an excellent coloring effect is exhibited in this range.
Further, when dripping occurs after the mortar composition is applied to the ALC panel, it is better to give the mortar composition thickening, for example, a small amount of methyl cellulose or the like is preferably added.

  The mortar composition 2 is applied by trowel coating, pouring, spray for coating, universal gun, etc., but it is generally determined from the design properties, productivity, manufacturing cost, etc. of the ALC panel. When using a mortar composition that can be applied by machine, such as when the mortar composition has a high viscosity and is applied manually, the trowel is good and the paint viscosity is low. Is good.

  Examples of the colored paint used in the present invention include, for example, titanium dioxide, a resin solution in which an acrylic resin, a styrene / acrylic resin, a vinyl acetate resin, an acrylic / silicone resin, and the like are dispersed in water to form an emulsion. Black iron oxide, bengara, chrome green, carbon black, copper phthalocyanine, calcium carbonate, barium sulfate, talc, clay, etc. and dispersants, antifoaming agents, leveling agents, thickeners, This refers to a mixture obtained by adding a necessary amount of additives such as a film auxiliary agent and an antifungal agent, and mixing and dispersing.

As a method for applying the colored paint, a general painting method can be adopted. For example, brush coating, spray coating, roller coating, coating with a roll coater, and the like can be given.
The surface treatment of the present invention is performed by physical means such as air flow, water flow, pressing, sculpting, scratching, etc., when the colored paint and mortar composition have fluidity, and is mainly intended to obtain It is selected according to the shape of the layer.

  For example, when obtaining a decorative layer having an arbitrary shape, pressing and engraving are suitable. The pressing is performed by applying a compressive force to the mortar composition 2 and the colored paint 3 using a design roller 10 having an arbitrary shape as shown in FIG. In the engraving, the mortar composition 2 having an arbitrary shape using a design mold 14 as shown in FIG. In order to give a gentle natural uneven pattern, an air flow or a water flow is suitable. The airflow is subjected to surface processing by jetting a gas such as air with a tool to which a jet nozzle 5 or the like as shown in FIG. 1 is connected, and directly colliding with the mortar composition 2 and the colored paint 3. Further, the surface of the water stream is processed by spraying water with a tool connected to a spray nozzle 8 or the like as shown in FIG. 3 and spraying or colliding with the mortar composition 2 and the colored paint 3.

  When obtaining a scratch pattern, surface processing by scratching is suitable, and surface processing is performed by scratching the mortar composition 2 and the colored paint 3 with a scratching tool 16 in which protrusions as shown in FIG. 9 are arranged. I can do it.

The time when the colored paint and the mortar composition have fluidity as used in the present invention means that the viscosity measured with a B-type viscometer is, for example, in the range of 100 to 500,000 mPa · s, and the optimum value thereof is that of the colored paint. It is determined by the processing method, the shape of the decorative layer, productivity, manufacturing cost, and the like.
For example, when an uneven pattern is obtained by an air flow, the viscosity of the colored paint and the mortar composition is preferably 100 to 100,000 mPa · s, but preferably 100 to 50,000 mPa · s. Good to do. If it is less than 100 mPa · s, the colored paint and the mortar composition are likely to be scattered around the ALC panel, and if it exceeds 50,000 mPa · s, a large amount of airflow is required, resulting in reduced production efficiency and manufacturing cost. This is because an increase in the number of times occurs.

  In the case of obtaining a concavo-convex pattern by a water flow, the viscosity of the colored paint and the mortar composition is preferably in the period of 1,000 to 300,000 mPa · s, preferably in the range of 5,000 to 200,000 mPa · s. It is good to carry out. This is because if it is less than 1,000 mPa · s, the colored paint or mortar composition has fluidity immediately due to water flow, and it becomes difficult to form an uneven pattern, and if it exceeds 200,000 mPa · s. This is because a large amount of water flow is required, resulting in a decrease in production efficiency and an increase in manufacturing cost.

  When the decorative layer is formed by pressing, the viscosity of the colored paint and the mortar composition is preferably in the period of 1,000 to 300,000 mPa · s, preferably 5,000 to 100,000 mPa · s. It is good to carry out in a range. This is because if the viscosity is less than 5,000 mPa · s, the viscosity of the colored paint and the mortar composition may be too soft and cause deformation after processing, and if it exceeds 100,000 mPa · s, the required pressure may be reduced. This is because it becomes large and the workability deteriorates.

  When the decorative layer is formed by sculpting, the viscosity of the colored paint and the mortar composition is preferably 1,000 to 300,000 mPa · s, preferably in the range of 5,000 to 200,000 mPa · s. It is good to carry out. This is because if it is less than 5,000 mPa · s, the molded colored paint and mortar composition are too soft and easily deformed, and if it exceeds 200,000 mPa · s, the mortar composition is too hard. This makes it difficult to mold.

  When forming a decorative layer by scratching, the viscosity of the colored paint and the mortar composition is preferably 5,000 to 300,000 mPa · s, preferably 10,000 to 200,000 mPa · s. It is good to carry out in a range. This is because, if it is less than 10,000 mPa · s, the molded mortar composition is too soft and the scratch marks easily return to the original shape, and if it exceeds 200,000 mPa · s, the mortar composition This is because the object is too hard and scratch marks are hardly formed.

ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method for obtaining the decorative ALC panel excellent in design property, waterproof performance, and also durability can be provided, Moreover, the mortar composition by which surface processing was carried out on the ALC panel surface. Since it is laminated as a decorative layer, it can be constructed as a final finished panel, so that it is possible to omit construction such as painting that is usually performed at the construction site, shortening the work period and improving workability.
As described above, the present invention solves all the problems of the conventional ALC panel and ALC panel manufacturing technology, and fully responds to recent needs of the building market such as differentiation, individualization, and high added value. It is possible.

Next, the present invention will be described in more detail with reference to examples.
A mortar composition was applied to one side of the large area of the ALC panel, and when the viscosity of the colored paint and the mortar composition was a predetermined value, arbitrary surface processing was performed to prepare a sample. Subsequently, the design property evaluation of the preparation sample was implemented.
The colored paint is sprayed on the ALC surface or the mortar composition surface with an airless gun so that the coating amount is 0.1 to 1.0 kg / m ^2, and the mortar composition is the ALC surface or the colored paint surface. Was sprayed with a ricin gun so that the coating amount was 2 kg / m ² .

ALC panel 1 as shown in FIG. 1 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), Bengala After applying 2 kg / m ^{2 of a} mortar composition 2 consisting of 5 parts by weight, 1 part by weight of methylcellulose and an appropriate amount of water, then 0.2 kg / m ^{2 of} a colored paint 3 mainly composed of an acrylic silicone resin is applied. When the viscosity of the mortar composition 2 is 30,000 mPa · s and the viscosity of the colored paint 3 is 28,000 mPa · s, the mortar composition 2 and the colored paint 3 are injected by the spray nozzle 5 shown in FIG. 2 can be obtained by making a decorative layer 17 having a natural concavo-convex pattern and color laminated by causing an air current to collide with it. It came.
As a result, it was confirmed that the decorative layer had a rock-like design.

ALC panel 1 as shown in FIG. 3 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), oxidation 2 kg / m ^{2 of a} mortar composition 2 composed of 5 parts by weight of titanium, 1 part by weight of methyl cellulose and an appropriate amount of water, and then 0.1 kg / m ^{2 of} a colored paint 3 mainly composed of an acrylic silicone resin, When the viscosity of the mortar composition 2 is 100,000 mPa · s and the viscosity of the colored paint 3 is 120,000 mPa · s, the spray nozzle 8 shown in FIG. 3 applies the mortar composition 2 and the colored paint 3 to the mortar composition 2. By making the water flow collide, an ALC panel in which a decorative layer 17 having a natural uneven pattern and color is laminated can be obtained. It was.
As a result, it was confirmed that the decorative layer had a rock-like design.

After applying 0.8 kg / m ^{2 of} a colored paint 3 mainly composed of acrylic / silicone resin to the ALC panel 1 as shown in FIG. 5 and curing the colored paint 3, 100 parts by weight of ordinary Portland cement, A mortar composition comprising 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), 5 parts by weight of titanium oxide, 1 part by weight of methylcellulose, and an appropriate amount of water. after 2 was 2 kg / ^{m 2} coating, the time the viscosity of the mortar composition 2 is 50,000 mPa · s, by pressing the mortar composition 2 from the surface of the design roller 10 shown in FIG. 5, the design The ALC panel FIG. 6 in which the decorative layer 17 having the same shape and color as the roller 10 was laminated was obtained.
As a result, it was confirmed that the decorative layer had a sandstone-like design.

After applying 1.0 kg / m ^{2 of} a colored paint 3 mainly composed of an acrylic / silicone resin to the ALC panel 1 as shown in FIG. 7 and curing the colored paint 3, then 100 parts by weight of ordinary Portland cement, A mortar composition comprising 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), 5 parts by weight of cobalt blue, 1 part by weight of methylcellulose, and an appropriate amount of water. after was 2 kg / m ² coating, the time the viscosity of the mortar composition 2 is 50,000 mPa · s, advance molded in advance using a design-type frame 14 as shown in FIG. 7, then the after molding By applying the mortar composition 2 to the ALC panel surface 1 and processing it, the decorative layer 17 having a pattern and color like a stone is laminated. The ALC panel shown in FIG. 8 was obtained.
As a result, it was confirmed that the decorative layer had a stone-pasting design.

An ALC panel 1 as shown in FIG. 9 has 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), carbon 2 kg / m ^{2 of a} mortar composition 2 composed of 5 parts by weight of black, 1 part by weight of methyl cellulose and an appropriate amount of water, and then 1.0 kg / m ^{2 of} a colored paint 3 mainly composed of an acrylic silicone resin, When the viscosity of the mortar composition 2 is 120,000 mPa · s and the viscosity of the colored paint 3 is 100,000 mPa · s, the mortar composition 2 and the colored paint 3 are scratched as shown in FIG. The ALC panel in which the decorative layer 17 containing the crust-like scratches having a color is laminated by scratching with the 16 Rukoto was able.
As a result, it was confirmed that the decorative layer had a scratch-like design.

  The present invention can be suitably used in the field of lightweight cellular concrete panels.

It is sectional drawing showing a mode that the colored coating material and the mortar composition are surface-processed by airflow. 2 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 1. FIG. It is sectional drawing showing a mode that the colored coating material and the mortar composition are surface-processed with a water flow. 6 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 2. FIG. It is sectional drawing showing a mode that the surface processing is carried out by pressing the mortar composition. 6 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 3. FIG. It is sectional drawing showing a mode that the surface processing of the mortar composition is carried out by engraving. 6 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 4. FIG. It is sectional drawing showing a mode that the colored coating material and the mortar composition are scratched. 6 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 5. FIG.

Explanation of symbols

1 ALC panel
2 Mortar composition
3 Colored paint 4 Air supply hose 5 Ejection nozzle (for gas)
6 Airflow 7 Liquid supply hose 8 Jet nozzle (for liquid)
9 Water Flow 10 Design Roller 11 Design Roller Direction 12 Design Roller Pressing Direction 13 Design Roller Direction 14 Design Form 15 Design Form Pressing Direction 16 Scratching Tool 17 Cosmetic Layer

Claims (2)

  After the mortar composition is applied to the lightweight cellular concrete panel surface, the colored paint is then applied, and when the colored paint or both the colored paint and the mortar composition have fluidity, air current, water flow, pressure A method for producing a lightweight cellular concrete panel, characterized in that the surface is processed by physical means such as sculpting, scratching, and the like, and laminated as a decorative layer. After a colored paint is applied to the lightweight cellular concrete panel surface, a mortar composition is then applied, and when the mortar composition or both the colored paint and the mortar composition have fluidity, an air current, a water stream, A method for producing a lightweight cellular concrete panel, characterized in that the surface is processed by physical means such as pressing, engraving, scratching, and the like, and laminated as a decorative layer.

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