JP2007100494A - Cast stone structure and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cast stone structure having a sense of natural stone and mass-producible at low cost, and its manufacturing method. <P>SOLUTION: This cast stone structure comprises a base part 10 and a decorative layer 20. The base part 10 comprises an irregular surface 11 on one surface 101. The decorative layer 20 is adhered to the irregular surface 11 of the base part 10, and has, on the surface 21, an irregular shape reflecting the irregularities on the irregular surface 11. In the method of manufacturing the cast stone structure, first one surface 101 of the base part 10 is worked in an irregular shape to form the irregular surface 11. Then, the decorative layer 20 is adhered to the irregular surface 11, and the irregular shape reflecting the irregularities on the irregular surface 11 is provided to the surface 21 of the decorative layer 20. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a pseudo stone structure, and more particularly to a plate-like pseudo stone structure used for an interior / exterior decorative board of a building, a paving board of a garden or a sidewalk, and the like.

  Natural stone is a decorative means effective for healing the viewer's heart and creating a comfortable living space, so it is widely used for interior and exterior decorative boards for buildings and paving boards for gardens and sidewalks. ing.

  This kind of natural stone material is valuable in its unique texture, but has a problem in mass productivity. For example, the interior / exterior decorative plate is often used in a large amount per construction. Moreover, because of the nature of the interior / exterior decorative board, even when it is used in large quantities, it is required that the texture formed by the color, pattern, and three-dimensional unevenness of the surface has uniformity. The In this regard, it is difficult for natural stone materials to stably supply a large amount of interior / exterior decorative plates having a uniform texture.

  Conventionally, in order to solve the above-described problems relating to mass productivity, attempts have been made to produce a decorative board that artificially reproduces the texture of natural stone. For example, Patent Document 1 discloses a pseudo stone plate formed by melting the surface of a synthetic resin foam plate with an organic solvent and spraying a surface layer material on the surface.

However, in the configuration shown in Patent Document 1, the texture unique to natural stone cannot be sufficiently reproduced, and there is a problem in manufacturing efficiency. Moreover, since the pseudo stone plate described in Patent Document 1 is composed of a synthetic resin foam plate, it has a problem in impact resistance and strength, and cannot be used for, for example, a paving plate in a garden or a sidewalk.
Japanese Patent Laid-Open No. 11-081624

  The subject of this invention is providing the pseudo-stone structure which has the texture of a natural stone material, and its manufacturing method.

  Another object of the present invention is to provide a pseudo stone structure that is excellent in mass productivity and can be manufactured at low cost, and a method for manufacturing the same.

  In order to solve the above-described problem, the pseudo stone structure according to the present invention includes a base portion and a decoration layer. The base portion has an uneven surface on one side. The decorative layer is attached to the concavo-convex surface of the base portion, and has a concavo-convex shape reflecting the concavo-convex surface of the concavo-convex surface on the surface thereof.

  As described above, in the pseudo stone structure according to the present invention, the base portion has a concavo-convex surface on one side, and therefore the three-dimensional concavo-convex shape of the natural stone material can be expressed by the concavo-convex shape of the concavo-convex surface. . Therefore, the pseudo stone structure which has the texture of a natural stone material can be provided.

  Since the decoration layer is attached to one surface of the base portion, the base portion can be easily and inexpensively colored.

  The decorative layer is attached to the concavo-convex surface of the base portion, and has a concavo-convex shape reflecting the concavo-convex surface of the concavo-convex surface on the surface. According to this configuration, the unevenness of the uneven surface of the base portion appears three-dimensionally on the surface through the thickness portion of the decorative layer, and the uneven shape that appears on the surface is colored by the decorative layer. . Therefore, it is possible to provide a pseudo stone structure that faithfully reproduces the texture of the natural stone material by using the three-dimensional uneven shape and the color that decorates it.

  In the pseudolite structure according to the present invention, the decorative layer preferably includes a plurality of types of particulate matter having different colors. According to this configuration, the surface of the decorative layer can be provided with a color and a pattern due to coloring of the particulate matter, and can be provided with a fine uneven shape due to the particle size of the particulate matter. Therefore, it is possible to provide a pseudo stone structure that more faithfully reproduces the texture of the natural stone material.

  Furthermore, in the pseudo stone structure according to the present invention, the decorative layer is preferably a synthetic resin sheet. According to this configuration, for example, a natural stone-like color and pattern are printed on the surface of the synthetic resin sheet in advance by a well-known printing technique, so that the texture of the natural stone is faithful and efficient. Can be reproduced.

  The method for producing a pseudo-stone structure according to the present invention processes one surface of a base portion into an uneven shape, forms an uneven surface, and attaches a decorative layer to the uneven surface, and the uneven surface has an uneven surface. The process of providing the uneven | corrugated shape reflecting this is included. According to the above-described method for manufacturing a pseudo stone structure, a pseudo stone structure having all the above advantages can be efficiently manufactured.

  Other objects, configurations, and advantages of the present invention will be described in more detail with reference to the accompanying drawings. The accompanying drawings are merely examples.

As described above, according to the present invention, the following effects can be obtained.
(1) A pseudo stone structure having a texture of a natural stone material and a method for producing the same can be provided.
(2) A pseudo stone structure that is excellent in mass productivity and can be manufactured at low cost, and a method for manufacturing the same.

  FIG. 1 is a plan view of a pseudolite structure according to an embodiment of the present invention, FIG. 2 is a front view showing a part of the pseudostone structure shown in FIG. 1, and FIG. 3 is a pseudostone structure shown in FIG. It is a figure which expands and shows a part of body.

  Referring to FIGS. 1 to 3, a pseudo stone structure according to an embodiment of the present invention is, for example, a decorative board for interior and exterior of a building, and includes a base portion 10 and a decorative layer 20.

  The base portion 10 can be mainly composed of wood, stone, concrete material, metal material such as iron or aluminum, flame retardant material such as ceramic, and synthetic resin material. The base portion 10 is mainly composed of a synthetic resin material such as a polyester resin, a polyethylene resin, a polystyrene resin, a polypropylene resin, and a polyvinyl chloride resin from the viewpoints of lightness, ease of processing, corrosion resistance, and the like. From the viewpoint, it is preferable to include an inorganic material as an aggregate.

  Next, regarding the shape of the base portion 10, the base portion 10 shown in FIGS. 1 to 3 is a flat plate having a longitudinal dimension L of 300 mm, a width dimension W of 600 mm, a height dimension T of 10 mm, and a weight of about 1.0 kg. In addition, the surface 101 has an uneven surface 11. The concavo-convex surface 11 has a three-dimensional concavo-convex shape formed from a natural stone material such as granite, for example.

  The decorative layer 20 includes a plurality of types of particulate matter (pigments) having different colors and particle sizes. When expressing natural stone materials such as granite, the decorative layer 20 preferably includes mica pieces. Furthermore, the decorative layer 20 can be made of a synthetic resin material or a paint containing a flame retardant material such as ceramic as a main component and mixed with the particulate matter.

  Next, with respect to the shape of the decorative layer 20, the decorative layer 20 shown in FIGS. 1 to 3 is a thin film having a thickness of about 0.1 to 0.2 mm, and has at least unevenness on one surface 101 of the base portion 10. An uneven shape reflecting the unevenness of the uneven surface 11 is imparted to the surface 11 and attached to the surface 11. The surface 21 constitutes the appearance of the pseudolite structure according to one embodiment of the present invention.

  As described above, in the pseudo stone structure according to the embodiment of the present invention, the base portion 10 has the uneven surface 11 on the one surface 101, and therefore the texture of the natural stone material such as granite is given by the uneven surface 11. It can be expressed in three dimensions. Therefore, the pseudo stone structure which has the texture of a natural stone material can be provided.

  Further, since the pseudo stone structure has a two-layer structure having the decorative layer 20 on the uneven surface 11 of the base portion 10, for example, the base portion 10 can be variously colored by using a paint for the decorative layer 20. Can do. Similarly, since the pseudo stone structure has a two-layer structure having the decorative layer 20 on the concavo-convex surface 11, the base portion 10 can be colored at low cost.

  The decorative layer 20 is attached to the uneven surface 11 in a thin film shape, and an uneven shape reflecting the unevenness of the uneven surface 11 is given to the surface 21 thereof. According to this configuration, the unevenness of the uneven surface 11 appears three-dimensionally on the surface 21 through the thickness portion of the decorative layer 20, and the uneven shape of the surface 21 that has appeared is colored by the decorative layer 20. Will be. Therefore, it is possible to provide a pseudo stone structure that faithfully reproduces the texture of a natural stone material with a three-dimensional uneven shape and a color that decorates the three-dimensional uneven shape (see FIGS. 17 and 18).

  In particular, according to the configuration in which the decorative layer 20 includes a plurality of types of particulate matter having different colors and particle sizes, the surface 21 can be provided with a color and a pattern due to the coloring of the particulate matter, A fine concavo-convex shape due to the particle size of the particulate matter can be imparted. Therefore, it is possible to provide a pseudo stone structure that more faithfully reproduces the texture of the natural stone material.

  In the pseudo stone structure according to the present embodiment, the base portion 10 can be manufactured by using an existing plastic molding technique, preferably based on a configuration mainly composed of a synthetic resin material. Therefore, it is possible to provide a pseudo stone structure that is excellent in mass productivity and can be manufactured at low cost. In addition, a pseudo stone structure that is light in weight as compared with natural stone and can be easily transported, moved, and installed can be provided.

  4 to 7 are front cross-sectional views illustrating a method for manufacturing a pseudo stone structure according to an embodiment of the present invention with a part thereof omitted. The pseudo stone structure manufacturing method shown in FIGS. 4 to 7 shows a case where a so-called injection molding technique is used. 4 to 7, parts having the same configuration as the pseudo stone structure shown in FIGS. 1 to 3 are denoted by the same reference numerals.

  First, referring to FIG. 4, a molding apparatus used in the method for manufacturing a pseudolite structure according to the present embodiment includes an upper mold apparatus 31 and a lower mold apparatus 32, and the upper mold apparatus 31 and the lower mold apparatus are included. At least one of them is provided with an injection nozzle 33 made of a synthetic resin material to be molded on the base portion 10. More specifically, the upper mold apparatus 31 has a molding surface 311, and the molding surface 311 has a three-dimensional uneven surface shape obtained by taking a mold from a natural stone material such as granite. On the other hand, the lower mold apparatus 32 has at least one injection nozzle 33 made of a synthetic resin material on the molding surface 321. A synthetic resin material is supplied from an injection nozzle 33 connected to a supply device (not shown) to the molding space 30 where the molding surface 311 of the upper mold device 31 and the molding surface 321 of the lower mold device 32 face each other.

  Next, referring to the molding process shown in FIG. 5, the synthetic resin material 10 supplied from the injection nozzle 33 to the molding space 30 is applied to the base portion 10 by the same pressurization or heat treatment as in a general injection molding process. Molded. The one surface 101 of the molded base portion 10 is provided with the concavo-convex surface 11 along the concavo-convex shape of the molding surface 311.

  Next, referring to the demolding step shown in FIG. 6, the upper mold apparatus 31 is demolded in the direction indicated by the arrow M1, and the lower mold apparatus 32 is demolded in the direction indicated by the arrow M2. 10 is taken out.

  Next, referring to the decoration process shown in FIG. 7, for example, a plurality of types of particulate matter having different colors and particle diameters are sprayed on one surface 101 of the base portion 10 obtained by demolding to form a thin film. The decorative layer 20 is formed, and an uneven shape reflecting the unevenness of the uneven surface 11 is given to the surface 21.

  According to the method of manufacturing a pseudo stone structure described with reference to FIGS. 4 to 7, a pseudo stone structure having all the advantages described with reference to FIGS. 1 and 3 can be manufactured. For example, since the three-dimensional uneven shape of the natural stone material can be efficiently formed on the uneven surface 11 of the base portion 10, it is excellent in mass productivity and manufactured at a low cost as compared with Patent Document 1. The manufacturing method of the pseudo stone structure which can be provided can be provided.

  FIG. 8 is a plan view of a pseudo stone structure according to another embodiment of the present invention, and FIG. 9 is a front sectional view of the pseudo stone structure shown in FIG. 8 and 9, parts having the same configuration as the pseudo stone structure shown in FIGS. 1 to 7 are denoted by the same reference numerals.

  The pseudo stone structure shown in FIGS. 8 and 9 is an embodiment in which the uneven surface 11 of the base portion 10 and the surface 21 of the decorative layer 20 reflecting the unevenness of the uneven surface 11 are divided into two by a route 22. is there. As described with reference to FIGS. 1 to 7, the pseudo stone structure according to an embodiment of the present invention is characterized in that the surface 21 is provided with an uneven shape reflecting the unevenness of the uneven surface 11. is there. Therefore, the shape of the concave / convex surface 11 as a base can be freely set in accordance with, for example, a design required as an interior / exterior decorative board for architecture.

  FIG. 10 is a front view showing a partially broken pseudo stone structure according to still another embodiment of the present invention, and FIG. 11 is an enlarged view showing a part of the pseudo stone structure shown in FIG. . The planar structure of the pseudo stone structure according to one embodiment of the present invention is preferably the same as that shown in FIG. 10 and 11, parts having the same configuration as the pseudo stone structure shown in FIGS. 1 to 9 are denoted by the same reference numerals.

  The pseudo stone structure shown in FIG. 10 and FIG. 11 is an embodiment in the case of being used as a paving board or a paving stone laid by combining a plurality of pieces in a garden, entrance, park, sidewalk, or the like. That is, the base portion 10 is a flat plate having a vertical dimension L of 300 mm, a width dimension W of 600 mm, a height dimension T of 60 mm, and a weight of 6.0 kg. 102 has a rib 12 and a leg 13. The leg 13 is provided with a stopper 130 at a corner. The specific structure of the other surface 102 is a design matter determined in accordance with the application. The decoration layer 20 is provided on the one surface 101 and the side surface 103 of the base portion 10.

  According to the structure described above, the pseudo stone structure shown in FIGS. 10 and 11 has all the advantages described with reference to FIGS. Furthermore, since at least the uneven surface 11 of the pseudo stone structure is covered with the decoration layer 20, the slip resistance coefficient can be appropriately set by adjusting the composition of the decoration layer 20. Therefore, when the pseudo stone structure is used as a paving stone, it is possible to provide a paving stone which is not slippery.

  FIG. 12 is a front view of a pseudo stone structure according to still another embodiment of the present invention, with a part thereof broken away, and FIG. 13 is a front cross-sectional view of the pseudo stone structure shown in FIG. 12 to 13, the same reference numerals are assigned to portions having the same configuration as the pseudo stone structure shown in FIGS. 1 to 11.

  The pseudo stone structure shown in FIGS. 12 to 13 is an embodiment used as a decorative board for interior and exterior of a building like the pseudo stone structure shown in FIGS. It is an embodiment showing a structure that is lighter by being pushed up in the thickness direction T.

  14 to 16 are front cross-sectional views illustrating a method for manufacturing a pseudo stone structure according to another embodiment of the present invention with a part thereof omitted. The pseudo stone structure manufacturing method shown in FIGS. 14 to 16 shows an embodiment using a so-called press molding technique. 14 to 16, the same reference numerals are given to the portions having the same configuration as the pseudo stone structure shown in FIGS. 1 to 13.

  First, referring to FIG. 14, in the molding apparatus used in this manufacturing method, the upper mold apparatus 31 has a molding surface 311, and the molding surface 311 is a three-dimensional surface irregularity formed from a natural stone material such as granite. It has a shape. The lower mold apparatus 32 has a molding surface 321, and the molding surface 321 has a surface structure that follows the uneven shape of the molding surface 311.

  Between the molding surface 311 of the upper mold apparatus 31 and the molding surface 321 of the lower mold apparatus 32, the synthetic resin sheet 20 serving as a decoration layer and the metal material plate 10 serving as a base portion are disposed. The surface 21 of the synthetic resin sheet 20 is preliminarily printed with natural stone-like colors and patterns by a well-known printing technique.

  The metal material plate 10 and the synthetic resin sheet 20 are moved so that the upper die device 31 moves in the pressing direction indicated by the arrow M11, and the lower die device 32 moves in the pressing direction indicated by the arrow M21. Compression molding is performed with the molding surface 321.

  Next, referring to FIG. 15, the synthetic resin sheet 20 and the metal material plate 10 are press-compressed with each other between the molding surface 311 of the upper mold device 31 and the molding surface 321 of the lower mold device 32. As a result, the synthetic resin sheet 20 is molded into the decorative layer 20 and the metal material plate 10 is molded into the base portion 10. In the base portion 10, the concave / convex surface 11 is molded on one surface 101 by the molding surface 311, and the concave / convex shape is also given to the other surface 102 by the molding surface 321. The decorative layer 20 that is pressure-bonded to the base body 10 is also provided with an uneven shape reflecting the unevenness of the uneven surface 11 on the surface 21 by the molding surfaces 311 and 321.

  Next, referring to FIG. 16, the upper mold device 31 is removed in the direction indicated by the arrow M12, the lower mold device 32 is removed in the direction indicated by the arrow M22, and the pseudo stone structure is taken out from the molding apparatus.

  According to the manufacturing method shown in FIG. 14 to FIG. 16, the pseudo stone structure can be manufactured using the existing press working technique. Therefore, for example, compared with Patent Document 1, it is excellent in mass productivity and inexpensive. Can be manufactured.

  In addition, the decorative layer 20 can be made of a natural resin-like color and a synthetic resin sheet on which a pattern or the like is printed in advance by a known printing technique. A pseudo stone structure (see FIGS. 17 and 18) having a pattern can be efficiently provided.

  In addition, in the method for manufacturing the pseudolite structure shown in FIGS. 14 to 16, the base portion 10 is not limited to a metal material, and for example, a flame-retardant material such as wood or ceramic, or a synthetic resin material is used. You can also. 14 to 16 can also be used for the pseudolite structure shown in FIGS. 1 to 3 and FIGS. 8 to 13.

  Although the contents of the present invention have been specifically described above with reference to the preferred embodiments, it is obvious that those skilled in the art can take various modifications based on the basic technical idea and teachings of the present invention. It is.

It is a top view of a pseudo stone structure concerning one embodiment of the present invention. It is a front view which fractures | ruptures and shows a part about the pseudolite structure shown in FIG. It is a figure which expands and shows a part of pseudo-stone structure shown in FIG. It is front sectional drawing which abbreviate | omits one part and shows the manufacturing method of the pseudo stone structure which concerns on embodiment of this invention. It is a figure which shows the process after FIG. It is a figure which shows the process after FIG. It is a figure which shows the process after FIG. It is a top view of the pseudo-stone structure concerning another embodiment of the present invention. It is front sectional drawing of the pseudo stone structure shown in FIG. It is a front view which fractures | ruptures and shows a pseudo stone structure concerning another embodiment of the present invention. It is a figure which expands and shows a part of pseudo-stone structure shown in FIG. It is a front view which fractures | ruptures and shows a part about the pseudo-stone structure which concerns on another one Embodiment of this invention. It is front sectional drawing of the pseudo-stone structure shown in FIG. It is front sectional drawing which abbreviate | omits one part and shows the manufacturing method of the pseudolite structure which concerns on another embodiment of this invention. It is a figure which shows the process after FIG. It is a figure which shows the process after FIG. It is a photograph of the prototype of the pseudolite structure concerning the present invention. It is the photograph image | photographed from another direction about the prototype of the pseudo stone structure shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Base part 101 One surface 11 Uneven surface 20 Decoration layer 21 Surface

Claims (3)

A pseudo stone structure including a base portion and a decoration layer,
The base portion has an uneven surface on one surface,
The decorative layer is configured by attaching a synthetic resin sheet to the uneven surface, and an uneven shape reflecting the unevenness of the uneven surface is given to the surface.
Pseudostone structure. The pseudo-stone structure according to claim 1,
A pseudo stone structure used as an interior / exterior decorative board for architecture or as a paving board. A method for producing a pseudolite structure according to claim 1 or 2,
Processing one surface of the base portion into a concavo-convex shape, forming the concavo-convex surface,
The synthetic resin sheet is adhered to the uneven surface to constitute the decorative layer, and the uneven surface reflecting the unevenness of the uneven surface is imparted to the surface of the decorative layer.
A method for producing a pseudolite structure including a process.