JP2007031206A - Method of manufacturing colored aggregate and surface decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing colored aggregate by which aggregate is colored with simple work and the aggregate itself holds a natural stone tone. <P>SOLUTION: The method of manufacturing the colored aggregate comprises: a coating film forming step for forming a coating film of a moisture curing type urethane prepolymer on the surface of the aggregate by mixing aggregate with the moisture curing type urethane prepolymer and stirring the mixture for a prescribed time; and a coloring step for dispersing a pigment in the coating film before the coating film formed by the coating film forming step is cured by mixing the pigment with the aggregate on which the coating film is formed and stirring the mixture for a prescribed time. The surface decorative material uses the colored aggregate obtained in this way. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a colored aggregate that is colored in a desired color while making use of the ground pattern of the aggregate, and a surface decoration material using the colored aggregate produced by this method. The present invention relates to a method for producing a colored aggregate that can easily produce a colored aggregate that is natural stone-like and colored in a desired color.

Conventionally, in order to bring out the appearance of natural stone to building materials and landscape materials, natural stone is used as it is as an aggregate, or a natural stone-like concrete molded body is used by using colored slurry mainly composed of cement and siliceous materials. Materials have been manufactured using colored aggregates to obtain (see, for example, Patent Document 1).
JP 2000-72498 A

  However, when natural stones are used as they are, in order to obtain a surface decoration material with a desired color, the natural stones of that color must be collected, and the production area is limited for each color, so the output is also limited. Therefore, stable supply was difficult. In addition, if the production area is overseas, transportation costs are required and it takes time to obtain, so orders for the production of surface modifiers are expensive compared to the case where materials can be procured in Japan. The time from delivery to delivery was also long.

  In addition, the aggregate colored in a natural color tone using the colored slurry can obtain an aggregate of a desired color, but the molded product in a concrete molded product has a natural stone tone, and the aggregate itself Since the surface was thickly covered with a cement material, it was produced as a colored aggregate regardless of the ground pattern of the aggregate, and the colored aggregate itself did not maintain a natural stone tone. Furthermore, this colored aggregate is obtained by dehydrating, solidifying, pulverizing and drying the surplus slurry to obtain an aggregate, and the colored slurry is used as a raw material by mixing a plurality of types of components, and has been manufactured by a very complicated operation.

  Then, this invention aims at providing the manufacturing method of the colored aggregate which can be colored by simple operation and the aggregate itself is maintaining the natural stone tone in order to eliminate the above-mentioned problem. .

  The method for producing a colored aggregate of the present invention includes a raw material mixing step of mixing an aggregate and a moisture-curable urethane prepolymer, and stirring the mixed aggregate and the moisture-curable urethane prepolymer on the surface of the aggregate. A film forming process for forming a film of moisture-curing urethane prepolymer, a pigment mixing process for mixing the aggregate on which the film is formed and the pigment, and a film by stirring the aggregate and pigment on which the film is formed And a coloring step for dispersing the pigment therein.

  The surface decoration material of the present invention is characterized in that the aggregate obtained by the method for producing a colored aggregate of the present invention is bonded and fixed on a base material.

  According to the method for producing a colored aggregate of the present invention, a desired color can be colored while taking advantage of the ground pattern of the aggregate. In particular, when using a natural aggregate, a desired color tone is maintained while maintaining a natural stone tone. A colored aggregate having the following can be provided. The aggregate obtained by this production method can be used as a normal building material, or can be used as a surface decoration material by adhering and fixing on a base material for surface decoration.

  Moreover, according to the surface decoration material of this invention, the surface decoration material which has a desired color can be provided cheaply and rapidly.

  In the method for producing a colored aggregate of the present invention, first, a raw material mixing step of mixing the aggregate and the moisture-curable urethane prepolymer is performed. In this step, the colored aggregate finally obtained is 100% by mass. The aggregate is preferably mixed in the range of 95.0 to 99.8% by mass and the moisture-curable urethane prepolymer in the range of 0.1 to 3.0% by mass, and the aggregate is 97.0 to 99. It is particularly preferable to mix 0.0 mass% with a moisture-curing urethane prepolymer in the range of 0.5 to 2.0 mass%. By setting it as such a mixing | blending range, the film formed at the next process can be formed with the thickness of the grade which the ground pattern of an aggregate can be seen through.

  In addition, the coating in the present specification includes a film that covers the entire aggregate surface, and a film that does not cover the entire aggregate surface but is locally formed, and is formed locally. In this case, it is required that a film is formed on 50% or more of the aggregate surface. When the film formed on the aggregate surface is less than 50% of the aggregate surface, coloring as the colored aggregate becomes insufficient.

  When the addition amount of the moisture-curable urethane prepolymer is less than 0.1% by mass, the coating film formed on the surface of the aggregate cannot be sufficiently formed on the aggregate surface, and when the amount exceeds 3.0% by mass. The coating becomes thicker than necessary, the pigment becomes sparse and the coloring becomes thin, the aggregate ground pattern cannot be seen at all, or an extra coating is formed, which increases the cost.

  Next, the mixed aggregate and the moisture-curing urethane prepolymer are stirred to form a film of moisture-curing urethane prepolymer on the surface of the aggregate. This is achieved by mixing the urethane prepolymer and then stirring for a predetermined time.

  The predetermined time here refers to a time for forming a film that covers at least 50% of the aggregate surface, and at this stage, the coating is in an uncured state. The predetermined time may be appropriately adjusted depending on the type and amount of the urethane prepolymer to be used, and is generally preferably in the range of 30 to 60 minutes, particularly preferably in the range of 30 to 40 minutes.

  As described above, the film formed at this time has a thickness such that the ground pattern of the aggregate can be seen through after curing, and the thickness is preferably 0.1 to 10 μm, It is especially preferable that it is -2micrometer.

  After the film is formed in this film forming process, a pigment mixing process is performed in which a pigment is added to the aggregate on which the film has been formed and mixed. In this process, the finally obtained colored aggregate is 100 When the content is set to mass%, the pigment is preferably added in an amount of 0.1 to 2.0 mass%, particularly preferably 0.5 to 1.0 mass%. If the added amount of the pigment is less than 0.1% by mass, the coloring becomes insufficient, and if it exceeds 2.0% by mass, the coloring is too dark and the aggregate ground pattern cannot be seen.

  Next, the aggregate on which the film is formed and the pigment are stirred, and a coloring process is performed in which the pigment is dispersed in the film of the moisture-curable urethane prepolymer. After mixing, it is performed by stirring for a predetermined time.

  The predetermined time here refers to at least the time during which the pigment is uniformly dispersed in the coating, and it is preferable to cure the coating to such an extent that it does not stick to other aggregates in this step. The predetermined time may be appropriately adjusted depending on the type of urethane polymer to be used, and is generally in the range of 5 to 60 minutes, particularly preferably 20 to 40 minutes.

  In this coloring step, a pigment can be dispersed in the uncured film to obtain a colored aggregate colored in a desired color while maintaining the natural stone tone as described above.

  Next, materials used for the production method of the present invention will be described.

  Examples of the aggregate used in the present invention include aggregates such as gravel, sand, slag, and artificial aggregate. This aggregate may be used as it is, or may be obtained by crushing rocks, and examples thereof include marble powder such as cryolite, granite powder, and other natural stone powders. Aggregates thus obtained can be used alone or in combination of two or more.

  The aggregate preferably has an average particle size of 0.1 to 100 mm, particularly preferably 1.0 to 4.0 mm. In order to obtain an aggregate having a desired average particle diameter, it can be obtained by sizing by sieving.

  The moisture-curing urethane prepolymer used in the present invention is a type of urethane prepolymer that reacts with moisture in the air and cures, and curing proceeds gradually when mixing and stirring with the aggregate. It has properties.

  This urethane prepolymer contains, as a component, an isocyanate prepolymer obtained by bonding an isocyanate to a hydroxyl group of a polyol, and the terminal isocyanate group of this isocyanate prepolymer reacts with moisture in the air to produce other It polymerizes by reacting with the terminal isocyanate group of the isocyanate prepolymer to become a polyurethane resin as a cured product.

  As the pigment used in the present invention, any of an inorganic pigment and an organic pigment can be used. For example, titanium oxide, zinc white (white), iron oxide (red), yellow lead (yellow), phthalocyanine blue (blue), Examples thereof include pigments such as chromium oxide (green). These can be used individually or in mixture of 2 or more types.

  And it is preferable that the addition amount of a pigment is 0.01-1 mass%, By setting it as such a compounding quantity, the ground pattern of the colored aggregate can be seen through, and it is natural stone tone. While holding, it can be colored to a desired color.

  FIG. 1 shows a cross-sectional view of a colored aggregate obtained by the production method of the present invention. This colored aggregate 1 is configured by forming a colored coating 3 on the surface of an aggregate 2. Here, the colored coating 3 is a coating made of a polyurethane resin that is thin enough to visually recognize the ground pattern of the aggregate, and the pigment is dispersed and colored in the coating.

  In addition, when the addition amount of the moisture-curable urethane prepolymer and the pigment is respectively small, a film is not formed on the entire aggregate surface, and the aggregate surface is often exposed. A cross-sectional view of the colored aggregate is shown in FIG.

  The colored aggregate 11 shown in FIG. 2 is configured by forming a colored coating 3 on the surface of the aggregate 2. The colored aggregate 11 has a portion where a film is formed and the background pattern of the aggregate is colored, and a portion where no film is formed and the background pattern of the aggregate is directly observed, The thus obtained aggregate becomes a more natural aggregate. That is, although the aggregate of FIG. 1 is colored in natural style, the entire surface is colored, so there is often a sense of incongruity with one type of aggregate. When used as a natural style aggregate, the aggregate is not colored. It is preferable to use a mixture with natural aggregate of a size. On the other hand, since the aggregate of FIG. 2 has a colored portion and a non-colored portion, even one type of aggregate can be used as a natural-style aggregate and is more preferable.

  Next, the surface decoration material obtained using the colored aggregate manufactured by this invention is demonstrated, referring FIG.3 and FIG.4.

  The surface decoration material of the present invention is obtained by spreading the colored aggregate produced according to the present invention on the surface of a base material and bonding it onto the surface of the base material. That is, this surface decoration material is constituted by adhering the aggregate 1 to the base material layer 4 via the adhesive layer 5 as shown in FIG.

  Here, the base material layer 4 is not particularly limited as long as it does not hinder the function as a surface decoration material, and is a concrete layer, a cement board (extruded cement board, hollow extruded cement board, fiber reinforced cement board, etc. Mortar plates, asphalt layers, metal plates such as aluminum, stainless steel, and iron plates, wood plywood, synthetic resin plates or sheets, fibrous sheets such as synthetic fibers and inorganic fibers, etc. it can.

  Here, examples of the adhesive layer 5 include various synthetic resin solutions or emulsions, and an emulsion type is preferable from the viewpoint of environmental conservation. The component constituting this adhesive is not particularly limited, but it has less deterioration over time, satisfying weatherability, alkali resistance, acid resistance, water resistance, etc. in addition to adhesiveness as a property after drying. Required. Specific examples include acrylic resins, vinyl acetate resins, vinyl chloride resins, urethane resins, and the like.

  In addition, if the base material itself such as a concrete layer, cement board, mortar board, asphalt layer, synthetic resin board, synthetic resin sheet has adhesiveness as the base material layer, the colored aggregate is adhered simultaneously with the formation of the base material. In this case, the adhesive layer is not always necessary because the base material layer can function as the adhesive layer.

  In addition, when the base material is relatively thin and flexible, such as a synthetic resin sheet or a fibrous sheet, an adhesive is further applied to the back side of the base material to which the colored aggregate is adhered. If necessary, release paper can be provided on the adhesive-coated surface to effectively use it as wallpaper. In the case of a fibrous sheet, an adhesive layer is formed on both sides of the sheet by impregnating the adhesive, colored aggregates are provided on one side, release paper is provided on the back side as necessary, and wallpaper is provided. can do.

  As shown in FIG. 4, the surface decoration material is produced by dropping the colored aggregate 1 obtained by the production method of the present invention from the hopper 6 onto the substrate surface on the substrate layer 4 coated with the adhesive layer 5. This can be carried out by spreading and adhering the colored aggregate 1 to the surface of the base material by applying pressure between the press rolls 7 and 7 from above and below. By this manufacturing method, a surface decoration material as shown in FIG. 2 can be obtained.

  In addition, using a release sheet instead of the base material in the method of manufacturing the surface decoration material, once the colored aggregate is bonded and fixed on the release sheet, and further, the surface on which the colored aggregate is fixed is concrete, It is also possible to produce a surface decoration material by providing a base material layer with cement, mortar, asphalt, synthetic resin or the like, curing the base material layer, and then peeling off the release sheet. In this case, the adhesion between the release sheet and the colored aggregate is preferably performed by using, for example, an adhesive or the like having a weak adhesive force so that the release can be easily performed.

  Furthermore, a waterproof layer can be provided between the base material and the colored aggregate. When the waterproof layer is provided, a surface decoration material for rooftop waterproof protection can be obtained. This waterproof layer can be produced, for example, by coating the waterproof layer on one side of the base material layer, further providing an adhesive layer on the waterproof layer, and bonding and fixing the colored aggregate. Examples of the waterproof layer include asphalt, modified asphalt, a sheet formed from a resin, a coating film, and the like.

  It is preferable that the colored aggregate used for the surface decoration material for roof waterproofing has a particle diameter of 1 to 2 mm. Moreover, it is preferable that the colored aggregate used for the surface decoration material for normal roofing has a particle size of 2 to 4 mm.

The present invention will be described below with reference to examples.
Example 1
As agglomerate, cinnabar No. 2 (average particle size: 3.0 mm) 98.4% by mass and as moisture-curable urethane prepolymer, Polyflex PR-42 (trade name, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) 1.0% by mass Were placed in a mixer driven at a speed of about 60 revolutions / minute and stirred and mixed for 5 minutes.

  After confirming that the moisture-curing urethane prepolymer is well-adapted to the surface of the aggregate, add 0.6% by mass of GN (trade name, manufactured by Bayer Co., Ltd.) as a pigment, and stir and mix with a mixer The pigment was dispersed. The mixture was stirred for 60 minutes to sufficiently cure the urethane prepolymer and confirm that a polyurethane film was formed, and then the mixer was stopped to obtain a colored aggregate.

(Example 2)
Each of the colored aggregates obtained in Example 1 was placed on a 0.28 mm urethane plain sheet and heat embedded in a dryer at 140 ° C. to produce a surface decoration sheet.

It is sectional drawing which shows the colored aggregate obtained by the manufacturing method of this invention. It is sectional drawing which shows another colored aggregate obtained by the manufacturing method of this invention. It is a side view of the surface decoration material of this invention using a colored aggregate. It is the figure which showed the manufacturing method of the surface decoration material of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1,11 ... Colored aggregate, 2 ... Aggregate, 3 ... Polyurethane resin coating, 4 ... Base material layer, 5 ... Adhesive layer, 6 ... Hopper, 7 ... Crimp roll

Claims (8)

A raw material mixing step of mixing the aggregate and the moisture-curing urethane prepolymer;
A film forming step of stirring the mixed aggregate and the moisture curable urethane prepolymer to form a film of the moisture curable urethane prepolymer on the surface of the aggregate;
A pigment mixing step of mixing the aggregate on which the coating is formed and the pigment;
A coloring step of dispersing the pigment in the coating by stirring the aggregate on which the coating is formed and the pigment;
The manufacturing method of the colored aggregate which consists of.   When the colored aggregate is 100% by mass, the aggregate is 95.0-99.8% by mass, the moisture-curable urethane prepolymer is 0.1-3.0% by mass, and the pigment is 0.1% by mass. The method for producing a colored aggregate according to claim 1, wherein mixing is performed at a ratio of ˜2.0 mass%.   The method for producing a colored aggregate according to claim 1 or 2, wherein the aggregate is a natural aggregate.   The method for producing a colored aggregate according to any one of claims 1 to 3, wherein the stirring time in the film forming step is 30 to 60 minutes.   The method for producing a colored aggregate according to any one of claims 1 to 4, wherein the stirring time in the coloring step is 5 to 60 minutes.   The method for producing a colored aggregate according to any one of claims 1 to 5, wherein the average particle size of the aggregate is 1.0 to 2.0 mm.   The method for producing a colored aggregate according to any one of claims 1 to 5, wherein an average particle size of the aggregate is 2.0 to 4.0 mm.   The surface decoration material formed by adhere | attaching and fixing the colored aggregate manufactured by the method of any one of Claims 1 thru | or 7 on a base material.

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