JP2006007456A - Manufacturing method of artificial stone material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for simply manufacturing an artificial stone material having a strong color film, which has a stable hue, in a short time. <P>SOLUTION: The manufacturing method of the artificial stone material has a process for filling a form 6, in which aggregate is preliminarily put, with a kneaded mixture 5 of sand soil 1, cement 2 and water 3, a process for working a pattern simulating a natural stone on the surface of the kneaded mixture 5 in a semi-dried state, a process for spraying washing water 9 on the surface of the kneaded mixture 5 to wash the kneaded mixture 5, a process for forming a first color film on the surface of the kneaded mixture 5 using colored India ink and a process for forming a second color film on the surface of the first color film using a mixture composed of either one of a metal chloride, a metal sulfide and a metal nitride and potassium permanganese. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing an artificial stone material mainly composed of pure sand and ordinary Portland cement, and relates to a method for producing an artificial stone material mainly used in the landscaping industry, such as stone frames, stepping stones, and stalagmites.

  Stone is strong and durable, and is used as a material for civil engineering or construction. Among them, natural stone is indispensable for buildings and gardens that need a profound atmosphere or a sense of luxury. However, since natural stone is largely dependent on imports from overseas in addition to the difficulty of construction, there are problems that it is expensive and it is not easy to ensure quality.

In order to cope with such a problem, development of artificial stone material imitating natural stone has been progressed, and some inventions and devices have been disclosed in connection therewith.
For example, Patent Document 1 discloses an invention relating to a method for producing a colored cement concrete product using a metal salt under the name “a method for producing a colored cement concrete product”.
The method for producing a colored cement concrete product disclosed in Patent Document 1 includes a metal salt selected from the group consisting of metal nitrate, metal chloride, metal acetate, metal sulfamate, and metal sulfate, or a reaction product thereof. It is characterized by impregnating or coating cement concrete products and treating the surfaces with alkali.
According to such a manufacturing method, a metal salt or a reaction product thereof is colored to form a colored coating on the surface of the cement concrete product. Moreover, since the densified surface layer and the colored coating block elution of alkali contained in the product to the outside, the so-called white flower phenomenon in which cotton-like white powder blows out on the product surface can be prevented. .

Patent Document 2 discloses an invention relating to a method for easily producing an artificial stone material imitating natural stone under the name of “manufacturing method of artificial stone material”.
In the method for producing artificial stone disclosed in Patent Document 2, a raw material obtained by kneading a solidified material, an aggregate, and water after previously laying and laying a granular or massive earth on a mold bottom in advance is molded. It fills the frame and removes the soil on the stone surface after solidification.
According to such a manufacturing method, it is possible to form uneven unevenness on the surface of the stone material, and it is possible to manufacture an artificial stone material having a surface state similar to natural stone.

Patent Document 3 discloses an invention relating to a method for simply and efficiently producing a thin plate-like pseudo-stone having a surface state very similar to natural stone and a desired strength under the name of “method for producing pseudo-stone”.
In the method for producing a pseudo stone disclosed in Patent Document 3, a laminate is formed by alternately laminating a layer in which a soil is dispersed in a mold and a cement layer having a predetermined thickness made of a cement material. The cement layer is compacted by vibration or pressing, demolded after the cement material is solidified, and sliced thinly so that the earth spreading layer is exposed at least on one side to obtain a plate-like body.
According to such a manufacturing method, the place where the earth has adhered forms irregularities on the cement layer surface to express a natural porous texture, and a pseudo-stone plate-like body very similar to natural stone can be obtained. . Further, since the obtained plate-like body is sufficiently compacted, even a thin plate has sufficient strength.

JP-A-8-259355 Japanese Patent Laid-Open No. 9-255455 JP 2000-000807 A

  However, the invention disclosed in Patent Document 1, which is the above-described prior art, relates to a coating coloring method for generating a colored coating on a cement concrete surface that has been dried for a long period of time, and must be manufactured in a short time. There is no description or suggestion about a manufacturing method related to artificial stone used for garden stones or the like. There is also room for improvement in the method of coloring the coating.

  In addition, in the invention disclosed in Patent Document 2, it is possible to form unevenness on the cement surface that is similar to the surface of natural stone by dispersing and laying red clay in the mold in advance, but the cement surface is colored. There was a problem that there were few variations in color tone.

  Finally, in the invention disclosed in Patent Document 3, it is possible to obtain a plate-like body having sufficient strength even with a thin plate by vibration or compaction by pressing, but it is sufficient with respect to the coloring or coloring method. Not described or suggested.

  The present invention has been made in view of such conventional circumstances, and an object of the present invention is to provide a method for easily producing an artificial stone material having a stable colored coating and a strong colored film in a short time.

In order to achieve the above object, the method for producing an artificial stone according to the first aspect of the present invention includes a step of filling a kneaded material of pure sand, cement and water into a formwork in which aggregate has been previously placed, and a semi-dry state. A process of crafting a pattern imitating a natural stone on the surface of the kneaded material, a step of spraying water on the surface of the kneaded material and washing, and a step of generating a first colored film using colored ink on the surface of the kneaded material And a step of forming a second colored film on the surface of the first colored film using a mixture of any one of metal chloride, metal sulfide, metal nitride and potassium permanganate.
Such a manufacturing method has the effect of adding a desired shape and pattern to the stone and forming minute irregularities on the surface of the stone by washing with water. In addition, the first colored film is formed by applying colored ink to give stones various colors and using a mixture of metal chloride, metal sulfide, metal nitride and potassium permanganate. The colored coating 2 has the effect of giving various color tones such as reddish brown by changing the blending amount and combination of each substance. In addition, in this application, colored ink ink means colored ink inks, such as red, blue, yellow, white, green, and vermilion, in addition to black. Therefore, the first colored film may be applied by selecting at least one of black, red, blue, yellow, white, green, vermilion ink, and the like. The same applies to the following colored inks.

According to a second aspect of the present invention, there is provided a method for producing an artificial stone material, the step of filling a kneaded material of pure sand soil, cement and water into a mold in which aggregate has been previously placed, and the kneaded material in a semi-dry state. A process of crafting a pattern imitating a natural stone on the surface; a process of spraying water on the surface of the kneaded product; washing; and a surface of the kneaded product with any of metal chloride, metal sulfide, metal nitride and permanganese And a step of producing a colored film using a mixture of potassium acid and colored ink.
Such a manufacturing method has substantially the same function as that of the first aspect of the invention.

The method for producing an artificial stone material according to a third aspect of the present invention is the method for producing a colored coating film according to the first aspect using only colored ink.
Such a manufacturing method has the effect of adding a desired shape and pattern to the stone and forming minute irregularities on the surface of the stone by washing with water. Moreover, it has the effect | action of producing | generating the film of a various color tone on the stone surface by apply | coating colored ink.

The method for producing an artificial stone material according to the invention described in claim 4 is about 1 to 4 when the mixing ratio of pure sand is 1 in the kneaded material according to any one of claims 1 to 3. Within the range.
Since the strength of the stone material produced by curing the kneaded material is determined by the ratio of cement mixed with the true sand soil, according to such a production method, an artificial stone material having a desired strength can be obtained.

According to a fifth aspect of the present invention, there is provided a method for producing an artificial stone material comprising: a step of producing a first colored film using colored ink on a surface of natural stone; and a metal chloride and a metal sulfide on the surface of the first colored film. And a step of producing a second colored film using a mixture of any of the above-mentioned materials and metal nitrides and potassium permanganate.
In such a manufacturing method, the first colored coating gives a natural stone various colors by applying colored ink, and a mixture of metal chloride, metal sulfide, metal nitride and potassium permanganate. The second colored film produced by use has the effect of giving various colors to the surface of natural stone such as reddish brown by changing the blending amount and combination of each substance. In addition, although this invention uses natural stone as a material, since it has a production | generation process of a colored film and the stone material produced by this manufacturing method is considered to be artificial, it is set as the manufacturing method of artificial stone material as invention.

According to a sixth aspect of the present invention, there is provided a method for producing an artificial stone material, wherein a colored film is formed on a surface of natural stone using a mixture of any one of metal chloride, metal sulfide, metal nitride, potassium permanganate and colored ink. And a step of generating.
Such a manufacturing method has substantially the same function as that of the fifth aspect of the invention.

The manufacturing method of the artificial stone material which is invention of Claim 7 produces | generates a colored film only in colored ink using Claim 5.
Such a manufacturing method has the effect of generating a coating film of various colors on the stone surface by applying colored ink.

Invention of Claim 8 added the process of apply | coating the water glass melt | dissolved with the sodium hydroxide solution in the manufacturing method of the artificial stone material which is invention of any one of Claim 1 thru | or 7 It is.
Such a manufacturing method has the effect of forming minute irregularities on the surface of the stone.

  As described above, in the method for producing artificial stone material according to claim 1 of the present invention, various shapes such as stones such as field areas used in the landscaping industry, stone steps such as staircases, stepping stones, glazed stones, scenic stones, etc. It is possible to easily manufacture an artificial stone material having a pattern in a short time. Moreover, the minute unevenness formed on the surface of the stone material nurtures the atmosphere of natural stone and promotes the generation of moss. As a result, the appearance of the stone can be made closer to natural stone. In addition, various color tones are selectively added to a part of the stone surface by the generation of the first colored coating, and the color tone is adjusted in the generation of the second colored coating, so that various color tones are applied to the surface of the stone. Can be added. As a result, it is possible to utilize artificial stone materials for a wide range of uses. Furthermore, since the produced colored coating blocks elution of alkali contained in the stone material to the outside, so-called white flower phenomenon can be prevented. Furthermore, when a colored film is formed using metal chloride and potassium permanganate, even if potassium chloride, which is the reaction product of both, flows out of the stone surface, it is harmless and has an adverse effect on the environment. There is no worry. In addition, with ordinary blocks, decorative blocks, bricks, concrete retaining walls, etc., the aesthetics are impaired as they become older, such as the color becoming black or moss, but the artificial stone produced by the method of the present invention is old. The more natural the stone is, the more natural it will be.

  Further, in the method for producing an artificial stone material according to claim 2 of the present invention, it has substantially the same effect as that of the invention according to claim 1, and in particular, by applying colored ink, metal chloride, metal sulfide, metal Various colors can be added as a whole to the coating that develops color by the reaction of any of the nitrides with potassium permanganate.

  Furthermore, in the method for producing artificial stone according to claim 3 of the present invention, the method has substantially the same effect as that of the invention according to claim 1, and in particular, the stone is colored at a low cost and in a simple process. Can do.

  In the method for producing an artificial stone according to claim 4 of the present invention, it is possible to impart strength to the stone according to the application, and the use of unnecessary cement can be reduced.

  In the method for producing artificial stone according to claim 5 of the present invention, natural stone can be easily colored, natural stone having a new color tone can be easily produced, and natural stone can be utilized for a wide range of applications. It becomes.

  The method for producing an artificial stone according to claim 6 of the present invention has substantially the same effect as that of the invention according to claim 5, and in particular, by applying colored ink, metal chloride, metal sulfide, metal nitride. Various colors can be added as a whole to the coating that develops color by the reaction of any of the above and potassium permanganate.

  The method for producing an artificial stone according to claim 7 of the present invention has substantially the same effect as that of the invention according to claim 5, has substantially the same effect as the invention of claim 5, and in particular, stone. Can be colored inexpensively and in a simple process.

  In the method for producing an artificial stone according to claim 8 of the present invention, the minute unevenness formed on the surface of the stone nurtures the atmosphere of natural stone and promotes the generation of moss, making the appearance of the stone closer to natural stone. Can do.

  Below, the Example of the manufacturing method of the artificial stone material which concerns on the best embodiment of this invention is described based on FIG.

FIG. 1 is a process diagram of Example 1 of a method for manufacturing an artificial stone material according to an embodiment of the present invention.
In the method for producing an artificial stone according to the present invention, water is added to kneaded clay and ordinary Portland cement and kneaded, and a pattern and a colored film are added to the surface in a semi-dry state.
As shown in FIG. 1, in step S1, pure sand soil 1 and cement 2 are mixed at a ratio of 3: 1, water 3 is added, and then stirred with a stirrer 4 to obtain a kneaded product 5. Next, in step S2, the kneaded material 5 is poured into a mold 6 in which aggregates (not shown) such as reinforcing bars are previously placed. Furthermore, a pattern that looks like the finish on the surface of the kneaded material 5 is designed with the trowel 7 in a state where about 30 to 80% of the whole is solidified in Step S3, and solidification has progressed to the extent that the outer shape does not collapse in Step S4. The kneaded material 5 is removed from the mold 6 to give stone wrinkles and joint patterns.
Before the solidification of the surface is completed, cleaning water 9 is sprayed onto the surface of the kneaded product 5 using the cleaning nozzle 8 in step S5. Thereafter, in step S6, water 10 colored with colored ink is sprayed on the surface of the kneaded product 5 in a state where about 90% of the whole is solidified to generate a first colored film. Next, in step S7, a solution 11 in which ferric chloride and potassium permanganate are dissolved in hot water is sprayed onto the surface of the kneaded product 5 using a coating nozzle 12 to generate a second colored film. Further, it is left to dry for 3 to 6 hours, and then washed with water. It should be noted that the series of steps from step S3 to step S6 is preferably performed in a state where the kneaded product 5 is semi-dry, but the present invention is not limited to this, and the solidification of the kneaded product 5 has been completed in step S6. Also good. In step S7, the hot water for dissolving ferric chloride and potassium permanganate is desirably 98 degrees or higher, and the ambient temperature is desirably 20 degrees or higher.

  The reaction by mixing ferric chloride and potassium permanganate in Step 7 will be described. Formula (1) shows an example of this reaction.

  As shown in the formula (1), this reaction is to add a oxidant to a metal chloride to produce a metal oxide. Metal chlorides are often liquids such as ferric chloride. In this case, it is possible to evenly color the stone surface. On the other hand, the metal oxide produced by the above reaction is often a solid with a color such as black or reddish brown that is unique to rocks, and is difficult to peel off once formed as a colored film on the stone surface Have

As described above, in the method for manufacturing an artificial stone material according to the present embodiment, it is possible to manufacture a stone material having a desired shape by using the mold 6 having various shapes, and it is semi-dry in the middle of the process. A desired pattern can be imparted to the stone by crafting the pattern on the surface of the kneaded product 5 in the state. Further, by spraying the washing water 9, minute irregularities are instantaneously formed on the surface of the kneaded product 5. This unevenness has an effect of forming a rough appearance peculiar to natural stone and promoting the generation of moss. Furthermore, various water colors are selectively added to a part of the surface of the stone material by watering the water 10 colored with colored ink, and the mixing ratio of ferric chloride and potassium permanganate dissolved in the solution 11 is adjusted. Thus, various color tones can be added to the surface of the stone. In addition, potassium chloride which is a reaction product of ferric chloride and potassium permanganate is harmless, and even if it flows out from the surface of the stone, there is no fear of adversely affecting the environment. In addition, since the produced colored coating blocks elution of alkali contained in the stone material to the outside, the so-called white flower phenomenon can be prevented.
In addition, since the artificial stone material manufactured by the said method is a cement, it is possible to connect stones and to repair the damaged part. In this case, the connecting surface and the repaired surface can be made inconspicuous by adjusting the color tone added to the artificial stone material.

  In the above process, washing may be performed to adjust the concentration of the water 10 colored with colored ink after step 6, and the standing time before washing in step S7 is not limited to 3 to 6 hours. Depending on the ambient temperature and humidity conditions, it may be left further. Further, instead of the pure sand soil 1 mixed with the cement 2, residual soil generated on site may be used. In this case, the residual soil can be reduced. Moreover, although the mold 6 in FIG. 1 is in a horizontal state, when the masonry with a very low height is to be carried out on site, the kneaded material 5 is poured into the vertical mold 6 and solidified. It is also possible.

Next, Example 2 will be described. Constituent elements that are the same as those in the first embodiment will be omitted by using the same reference numerals as those in FIG. In particular, the processes from step S1 to step S5 are exactly the same as those in the first embodiment.
In Example 2, only the production | generation process of a colored film differs from Example 1. FIG. That is, a solution 11 in which colored ink, ferric chloride and potassium permanganate are dissolved is sprayed on the surface of the kneaded material 5 in which about 90% of the whole is solidified using the coating nozzle 12 in step S6 of FIG. To produce a colored coating. Furthermore, it is left to dry for 3 to 6 hours, and then washed with water. The series of steps from Step 3 to Step S6 are performed in a state where the kneaded product 5 is semi-dry, and in Step 6, the solution 11 is hot water of 98 ° C. or higher, and the ambient temperature is 20 ° C. or higher. To do.

  In the method for producing an artificial stone material of Example 2, a reaction similar to the formula (1) of Example 1 occurs by mixing ferric chloride and potassium permanganate, and a colored coating is generated. In Example 1, various colors are selectively added to a part of the surface of the stone by sprinkling water 10 colored with colored ink, and the mixing ratio of ferric chloride and potassium permanganate dissolved in the solution 11 is changed. By adjusting, it is possible to add various color tones to the surface of the stone, whereas in Example 2, by applying colored ink, a film that develops color by the reaction of ferric chloride and potassium permanganate is applied. On the other hand, it is possible to add various color tones as a whole. In addition, about another point, it has an effect | action and effect similar to Example 1. FIG.

In Example 3, a colored film is produced using only colored ink in Example 1.
In such a manufacturing method, the stone can be colored at a low cost and in a simple process. The steps other than coloring have substantially the same functions and effects as those of the first embodiment.

Example 4 is a case where the ratio of true sand soil 1 and cement 2 is not limited to 3: 1 in step S1 in any of Examples 1 to 3, but the ratio of true sand soil 1 is set to 1. It is within the range of about 1 to 4.
The strength required of stone varies depending on the application, but according to such a manufacturing method, it is possible to reduce the use of cement more than necessary after securing the minimum necessary strength for the stone. .

In the fifth embodiment, the steps S6 and S7 of FIG. 1 described in the first embodiment or the steps of the second embodiment in which the steps S6 and S7 are performed once are applied to natural stone.
In the method for producing the artificial stone material of Example 5, the first colored coating produced using the colored ink juice gives various colors to natural stone, and is produced using a mixture of ferric chloride and potassium permanganate. The second colored coating has the effect of giving various colors to the surface of natural stone such as reddish brown by changing the blending amount and combination of each substance. Therefore, a desired color tone can be imparted to the natural stone. This makes it possible to use natural stone for a wide range of purposes.

In Example 6, the process of Example 2 in which the processes of Step S6 and Step S7 of FIG. 1 are performed at once is applied to natural stone.
In the method for producing the artificial stone material of Example 6, it is possible to add various colors to the coating film that is colored by the reaction between ferric chloride and potassium permanganate by applying colored ink. And has substantially the same effect as the fifth embodiment.

Example 7 produces | generates a colored film only using colored ink in Example 5. FIG.
In such a production method, the natural stone can be colored at a low cost with a simple process. The steps other than coloring have substantially the same operations and effects as those in Example 5.

Example 8 is colored in one or two times using colored ink, ferric chloride, and potassium permanganate in the colored film producing process according to any one of Examples 1 to 5. After the coating is formed, a treatment solution in which water glass is dissolved with a sodium hydroxide solution is applied to the kneaded material 5 of natural sand soil 1, cement 2 and water 3 or the surface of natural stone.
The method for producing the artificial stone material of Example 8 has an effect of forming minute irregularities on the stone surface. The unevenness creates an atmosphere of natural stone and promotes the generation of moss, so that the appearance of the stone can be made closer to natural stone.

In addition, this invention is not limited to the said Example, A various deformation | transformation is possible. For example, the number of times of coloring treatment applied to the kneaded product 5 or natural stone or application of water glass dissolved in a sodium hydroxide solution is not limited to one, and may be repeated a plurality of times. Moreover, the method is not limited to the said Example, It can select from impregnation, brush coating, application | coating, spraying, etc. In addition, the application of the water glass dissolved in the sodium hydroxide solution of Example 8 may be performed before the coloring process or may be performed twice before and after the coloring process.
Further, the chemical to be reacted with potassium permanganate is not limited to ferric chloride, and other metal chlorides, metal sulfides or metal nitrides may be used.

  The method for producing artificial stone according to the present invention is not limited to the production of stone used in the landscaping industry, but can also be applied to stone used as civil engineering or building materials.

These are process drawings of Example 1 of the manufacturing method of the artificial stone material which concerns on embodiment of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Pure sand 2 ... Cement 3 ... Water 4 ... Stirrer 5 ... Kneaded material 6 ... Formwork 7 ... Iron 8 ... Cleaning nozzle 9 ... Washing water 10 ... Water colored with colored ink 11 ... Solution 12 ... Coating nozzle

Claims (8)

  Filling a formwork in which aggregate has been preliminarily filled with kneaded material of pure sand, cement and water, crafting a pattern imitating natural stone on the surface of the kneaded material in a semi-dry state, A step of spraying water on the surface to wash, a step of producing a first colored film using colored ink on the surface of the kneaded product, a metal chloride, a metal sulfide on the surface of the first colored film, The manufacturing method of the artificial stone material which consists of the process of producing | generating a 2nd colored film using the mixture of either of metal nitrides and potassium permanganate.   Filling a formwork in which aggregate has been preliminarily filled with kneaded material of pure sand, cement and water, crafting a pattern imitating natural stone on the surface of the kneaded material in a semi-dry state, A step of spraying water on the surface and washing, and a step of generating a colored film on the surface of the kneaded product using a mixture of metal chloride, metal sulfide, metal nitride, potassium permanganate and colored ink. A method for producing artificial stone.   Filling a formwork in which aggregate has been preliminarily filled with kneaded material of pure sand, cement and water, crafting a pattern imitating natural stone on the surface of the kneaded material in a semi-dry state, A method for producing an artificial stone material comprising a step of spraying water on the surface and washing, and a step of generating a colored coating on the surface of the kneaded product using colored ink.   The artificial stone material according to any one of claims 1 to 3, wherein the mixing ratio of the pure sand soil in the kneaded material is within a range of approximately 1 to 4 when cement is 1. Method.   A step of producing a first colored film on the surface of the natural stone using colored ink, and a mixture of metal chloride, metal sulfide, metal nitride and potassium permanganate on the surface of the first colored film; And a step of producing a second colored film by using the natural stone.   An artificial stone material using natural stone, characterized in that it has a step of forming a colored film using a mixture of any one of metal chloride, metal sulfide, metal nitride and potassium permanganate and colored ink on the surface of natural stone Manufacturing method.   A method for producing an artificial stone material using natural stone, characterized in that a colored film is formed on the surface of natural stone using colored ink.   The artificial stone material production according to any one of claims 1 to 7, wherein, in the colored film forming step, water glass and sodium hydroxide solution are used in addition to the colored ink or the mixture. Method.