JP2007154450A - Grain-toned block body, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a grain-toned block body which is reduced in weight, and can sufficiently project the texture and massive feeling inherent in a natural stone. <P>SOLUTION: The grain-toned block body A1 is composed of a block molded body 1 made of styrofoam, and a cover layer 2 covering at least part of a surface of the block molded body 1. The cover layer 2 includes colored aggregate pieces 21A, 21B, 21C obtained by crushing a natural stone or an artificial stone. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a stone-tone block body and a method for producing the same.

  2. Description of the Related Art Conventionally, natural stone materials constructed by using natural stones of an appropriate size as they are, or by dividing natural stones into appropriate sizes, are often used as interior / exterior materials for buildings or models of gardens and parks. Such natural stone materials are preferred as having a texture and a weight feeling peculiar to natural products. However, since natural stone is a natural product, the material itself is expensive, and the weight is large, so that the workability is poor and the transportation cost is high.

  In order to cope with the disadvantages of such natural stone materials, stone-tone tiles that simulate natural stones have been proposed. A conventional example of a stone-tone tile is described in Patent Document 1, for example. The stone-tone tile shown in Patent Document 1 includes a plate-like base material and a stone-tone surface layer formed on the base material. A stone-tone panel having this configuration is formed by forming a base material by forming a kneaded material containing ceramic particles into a plate shape, and laminating a stone-tone surface layer on the substrate before the base material is dried. After integrating the base material and the surface layer, the integrated base material and surface layer are obtained by heating and sintering. The stone-tone panel having such a configuration has a texture similar to that of natural stone, but is lighter than natural stone and thus has excellent workability.

  However, in the structure described in Patent Document 1, although it is lighter and has better workability than natural stone, the base material has a plate shape, so it must have a monotonous planar form in appearance. Therefore, it is difficult to bring out the texture and weight peculiar to natural stone. Moreover, in the stone-tone panel described in Patent Document 1, it is necessary to laminate the surface layer before drying the base material, and it is necessary to heat and sinter the base material and the surface layer in the production thereof. The manufacturing process is complicated.

Utility Model Registration No. 3009279

  The present invention has been conceived under the circumstances described above, and it is intended to provide a stone-tone block body that can sufficiently bring out the texture and weight of natural stone while achieving weight reduction. It is an issue. Moreover, this invention makes it the other subject to provide the preparation method of the stone-tone block body which can produce such a stone-tone block body efficiently and appropriately.

  In order to solve the above problems, the present invention takes the following technical means.

  The stone-tone block body provided by the first aspect of the present invention includes a block molded body made of polystyrene foam and a coating layer covering at least a part of the surface of the block molded body. Or the colored aggregate obtained by pulverizing the artificial stone is included.

  According to the stone-tone block body having such a configuration, since the block molded body is formed of foamed polystyrene, further weight reduction can be achieved. Further, the polystyrene foam can be molded, and according to the mold molding, a block molded body having a predetermined shape can be easily obtained. For this reason, for example, it is easily realizable to make a block molded object into the same three-dimensional shape as an actual natural stone by providing an unevenness | corrugation in the surface, giving moderate volume. Then, by covering the block molded body having such a three-dimensional shape with a coating layer containing colored aggregate, it is possible to sufficiently bring out the texture and weight of natural stone.

  In preferable embodiment of this invention, the surface of the said coating layer is made into the uneven surface reflecting the form of the said colored aggregate.

  According to such a configuration, the surface of the coating layer has a texture as if the surface of a natural stone was broken, and the stone-tone block body appears to have been produced using natural stone. Therefore, such a configuration is suitable for sufficiently producing the texture and weight of natural stone.

  In a preferred embodiment of the present invention, the coating layer includes a binder and is formed by spray coating.

  According to such a configuration, the coating layer can be formed by a simple means such as spray coating. Specifically, the coating layer can be easily formed by spraying and adhering a mixed material containing a colored aggregate and a binder onto the surface of the block molded body and solidifying by curing. Further, if the coating layer is formed by spray coating, the surface of the coating layer is in a state in which the colored aggregate is dispersed and fixed between the binders. Therefore, such a configuration is suitable for making the surface of the coating layer an uneven surface reflecting the form of the colored aggregate.

  In a preferred embodiment of the present invention, the colored aggregate includes two or more kinds of different colors.

  According to such a configuration, various types of stone-like surfaces can be easily produced by variously changing the distribution state and content ratio in the coating layer for each type of colored aggregate.

  In a preferred embodiment of the present invention, the coating layer is formed by spraying the surface of the block molded body maintained in an upward horizontal posture.

  According to such a configuration, the binder has fluidity at the beginning of spray coating, but the surface of the block molded body to be sprayed is in an upward horizontal posture, so the binder is colored aggregate. Is hardly flown in the in-plane direction of the surface of the block molded body. Therefore, according to such a configuration, the thickness of the coating layer can be made uniform.

  The method for producing a stone-tone block body provided by the second aspect of the present invention includes a step of preparing a block molded body made of polystyrene foam, and the surface of the block molded body maintained in an upward horizontal posture. And a step of spraying a mixed material containing a colored aggregate obtained by pulverizing natural stone or artificial stone and a binder to form a stone-like coating layer.

  According to such a production method, the stone block body provided by the first aspect of the present invention can be produced efficiently and appropriately.

  Other features and advantages of the present invention will become more apparent from the detailed description given below with reference to the accompanying drawings.

  Hereinafter, preferred embodiments of the present invention will be specifically described with reference to the drawings.

  1 to 3 show a stone block A1 according to the present invention. FIG. 1 is a perspective view of the stone-tone block body A1. FIG. 2 is a vertical cross-sectional view of the stone-tone block body A1. FIG. 3 is a schematic cross-sectional view showing the structure of the stone-tone block body A1.

  As shown in FIGS. 1 and 2, the stone-tone block body A <b> 1 includes a block molded body 1 and a coating layer 2.

  The block molded body 1 has an irregular three-dimensional shape that imitates natural stone, and is made of polystyrene foam. The surface of the block molded body 1 is composed of a flat bottom portion 1a and an irregular surface portion 1b having moderate irregularities.

  The covering layer 2 has a stone-like surface shape and is formed so as to cover the side surface portion 1 b of the block molded body 1. The covering layer 2 includes an infinite number of colored aggregates 21 and a binder 22, and the colored aggregates 21 are dispersed and fixed by the binder 22.

  The colored aggregate 21 is a stone grain having a particle size of about 2 mm or less obtained by pulverizing natural stone or artificial stone, and in this embodiment, the colored aggregate 21 is composed of three types of colored aggregates 21A, 21B, and 21C having different colors. . As raw materials for the colored aggregates 21A, 21B, 21C, for example, natural stones such as black granite (black), red granite (red), north wood stone (grey), rust stone (light brown), serpentine (green), etc. are used. It is done.

  The binder 22 has a synthetic resin solidifying material that is dry-cured and cured in air as a main component, and a thickener, water, and the like are appropriately added. As the solidifying material, for example, an acrylic emulsion is used.

  Next, an example of a method for producing the stone-tone block body A1 will be described.

First, the block molded body 1 is prepared. The block molded body 1 is molded, for example, by injecting polystyrene resin particles (polystyrene beads) containing a foaming agent into a mold formed in a predetermined shape and heating and foaming with steam. The block molded body 1 can also be molded by cutting the expanded polystyrene block obtained by the above method with a blade or the like. The bulk density (specific gravity) of the block molded body 1 molded with polystyrene foam is, for example, about 0.018 to 0.020 g / cm ³ .

  Next, the coating layer 2 is formed on the side surface portion 1 b of the block molded body 1. As shown in FIG. 4, for example, three spray guns 3 are used to form the coating layer 2, and any one of the colored aggregates 21 </ b> A, 21 </ b> B, and 21 </ b> C is mixed with the binder 22 from each spray gun 3. This is done by spraying the material and solidifying it by room temperature curing (spray painting). The above-mentioned mixed material is, for example, 80% of the colored aggregate 21, 16% of the solidified material, and 4% of the thickening material, and an appropriate amount of water or solvent is added thereto.

  More specifically, when forming the coating layer 2, the block molded body 1 is supported by the support body 4 so that a predetermined portion of the side surface portion 1 b is in an upward horizontal posture. Here, the “upward horizontal posture” is not limited to a strict horizontal posture, but means a posture that clearly tilts. In other words, the side surface portion 1b has an irregular surface having irregularities, but the predetermined portion of the side surface portion 1b does not incline on average and may be in a substantially horizontal posture. A kind of colored aggregate is blown out from each spray gun 3 without being mixed with other kinds of colored aggregates, and mixed materials corresponding to the colored aggregates 21A, 21B, and 21C are respectively provided in the predetermined portions of the side surface portion 1b. It adheres randomly within a suitable range.

  Here, at the beginning of spraying the mixed material, the binder 22 has fluidity, but since the predetermined portion of the side surface portion 1b is in an upward horizontal posture, the binder 22 entrains the colored aggregate 21 and There is almost no flow in the in-plane direction of the predetermined part. Therefore, according to such a spray coating method, the thickness of the coating layer 2 can be made uniform.

  When spray coating on the predetermined portion of the side surface portion 1b is completed, the posture of the block molded body 1 is changed so that the other portion of the side surface portion 1b is in an upward horizontal posture, and spray coating is performed on the other portion. (See FIG. 5). By repeating this sequentially, the coating layer 2 is formed over the entire side surface portion 1b of the block molded body 1. Thus, the thickness of the coating layer 2 formed is 2-5 mm, for example. Through the series of steps described above, the stone-tone block body A1 shown in FIGS.

  Next, the operation of the stone-tone block body A1 will be described.

  In the stone-tone block body A1, since the block molded body 1 occupying most of its volume is formed of foamed polystyrene, which is a lightweight material, further weight reduction is achieved. Moreover, since the block molded body 1 is shape | molded with a metal mold | die, the block molded body 1 of a predetermined shape can be obtained easily. That is, it is easy to make the block molded body 1 have a three-dimensional shape similar to a real natural stone by providing irregularities on the surface while having an appropriate volume. And by covering the block molded object 1 which has such a three-dimensional shape with the coating layer 2 containing the colored aggregate 21, the texture and the weight feeling which a natural stone has can be fully brought out.

  In addition, the stone-tone block body A1 has a configuration in which the block molded body 1 is covered with the coating layer 2, so that the overall strength is higher than that of the block molded body 1, and the shape retaining property is excellent. Such a stone-tone block body A1 is suitable for use as an article constituting a garden, a courtyard, a flower bed or the like.

  In the stone-tone block body A1, the coating layer 2 can be formed by a simple means such as spray coating. Moreover, according to spray coating, the surface of the coating layer 2 is in a state in which the colored aggregates 21 are dispersed and fixed between the binders 22 as shown in FIG. Therefore, such a configuration is suitable for making the surface of the coating layer 2 an uneven surface reflecting the form of the colored aggregate 21.

  At the time of spray coating, since the portion to be sprayed is in an upward horizontal posture, the thickness of the coating layer 2 can be made uniform, and as a result, the stone-tone block body A1 maintains a predetermined quality. be able to.

  6 to 10 show other examples of the stone block body according to the present invention. 5 and the subsequent drawings, the same or similar elements as those of the above embodiment are denoted by the same reference numerals as those of the above embodiment, and the description thereof will be omitted as appropriate.

  In the stone-tone block body A2 shown in FIGS. 6 and 7, the block molded body 1 has a substantially rectangular parallelepiped shape. The surface of the block molded body 1 includes a bottom surface portion 1c, a top surface portion 1d substantially parallel to the bottom surface portion 1c, and a side surface portion 1e continuous to the bottom surface portion 1c and the top surface portion 1d.

  The covering layer 2 is formed so as to cover the upper surface portion 1 d of the block molded body 1. As shown in FIG. 8, the covering layer 2 is formed by placing the block molded body 1 on the support base 5 so that the upper surface portion 1d is in an upward horizontal position, and with respect to the upper surface portion 1d of the block molded body 1, for example. This is done by spraying.

  The stone block A2 having such a configuration is suitable for use as an interior / exterior material of a building. If the upper surface portion 1d is formed as a rough irregular surface, it is suitable for faithfully creating a grainy atmosphere. Note that the stone-tone block body A2 may have a configuration in which a member (not shown) such as a resin plate is bonded and fixed to the bottom surface portion 1c for convenience such as attachment to a building.

  In the stone-tone block body A3 shown in FIGS. 9 and 10, the block molded body 1 has a substantially rectangular parallelepiped shape, and a concave portion 1f having a predetermined shape is formed on the upper surface portion 1d. The covering layer 2 is formed so as to cover the upper surface portion 1d and the side surface portion 1e of the block molded body 1. However, the coating layer 2 is not formed on the concave portion 1f by masking or the like when spraying the upper surface portion 1d. And the panel 6 which described the character etc. is engage | inserted by the recessed part 1f.

  The stone-tone block body A3 having such a configuration is suitable for use when, for example, character notation is required in a park that is unified in stone tone, or when a shop name is indicated at the entrance of a Japanese-style inn.

  While specific embodiments of the present invention have been described above, the present invention is not limited to these embodiments, and various modifications can be made without departing from the spirit of the invention.

  Below, the evaluation test performed regarding this invention is demonstrated based on an Example and Comparative Examples 1 and 2. FIG.

In this example, the stone block A2 according to the above embodiment was prepared as a test body, and an evaluation test was performed. In the present embodiment, a rectangular parallelepiped bead foam polystyrene (target dimensions: width 75 mm, length 300 mm, thickness 50 mm) is adopted as the block molded body 1, and spray coating is applied to the upper surface portion 1 d of the block molded body 1. A coating layer 2 was formed. The spray coating was performed by spraying the mixed material composed of the colored aggregate 21 and the binder 22 substantially uniformly over the entire upper surface portion 1d in the upward horizontal posture. The coating amount of the mixed material was 2.0 kg / m ² . In this example, three stone-tone block bodies A2 as test specimens prepared by the above method were prepared, and the width and thickness of each specimen were measured (average of measured values at three locations). The maximum load was determined in accordance with the bending test method for the foamed plastic heat insulating material of JIS A9511. A constant-speed universal testing machine was used for the bending test, and the loading speed was 20 mm / min. In this example, the test was performed with the coating layer 2 facing upward (compression side). The results of the bending test are shown in Table 1.

Comparative Example 1

  In this comparative example, the same block molded body 1 as in the example was used, and no coating layer was formed. In this comparative example, three block molded bodies 1 were prepared as test bodies, and the width and thickness of each test body were measured (average of measured values at three locations), and then the same bending test as in the example. Was done. The results of the bending test are shown in Table 1.

Comparative Example 2

In this comparative example, the same block molded body 1 as in the example was used, and a coating layer was formed by spray coating on the upper surface portion 1d and the bottom surface portion 1c of the block molded body 1. The spray coating was performed by spraying the same mixed material as in the example substantially uniformly onto the upper surface portion 1d and the bottom surface portion 1c in the vertical posture. The coating amount of the mixed material was 2.0 kg / m ² . In this comparative example, three test specimens prepared by the above method were prepared, and for each test specimen, the width and thickness were measured (average of measured values at three locations), and then the same bending test as in the example. Was done. The results of the bending test are shown in Table 1.

  As can be understood by comparing the maximum load of the example shown in Table 1 and the maximum load of the comparative example 1, in the stone block A2 in the example, the maximum load is larger than that of the block molded body 1 of the comparative example 1. It was much bigger. Thereby, it turned out that intensity | strength (bending strength) is significantly raised by the stone-tone block body A2 providing the coating layer 2 compared with the case where the coating layer 2 is not provided.

  Moreover, as can be understood by comparing the maximum load of the example shown in Table 1 and the maximum load of the comparative example 2, the stone block A2 in the example has a maximum load compared to the test body of the comparative example 2. It was big. That is, in the stone-tone block body A2 of the example, the formation range of the coating layer 2 is only on the upper surface portion 1d, and the coating layer is formed on the upper surface portion 1d and the bottom surface portion 1c as in the test body of Comparative Example 2. Although the formation range of the coating layer was about half as compared with the case where the film was formed, the strength (bending strength) was higher than that of the test sample of Comparative Example 2. This is considered to be due to the fact that the thickness of the coating layer 2 of the stone-tone block body A2 was kept uniform by spraying the horizontal posture in the example. On the other hand, in Comparative Example 2, it is considered that the mixed material flowed downward at the beginning of spraying due to the spray coating with respect to the vertical posture, and the thickness of the coating layer became non-uniform.

It is a perspective view which shows an example of the stone-tone block body which concerns on this invention. It is a longitudinal cross-sectional view of the stone-tone block body shown in FIG. It is a schematic cross section which shows the structure of the stone-tone block body which concerns on this invention. It is a partial cross section side view which shows an example of the method of producing the stone-tone block body which concerns on this invention. It is a partial cross section side view which shows an example of the method of producing the stone-tone block body which concerns on this invention. It is a perspective view which shows the other example of the stone-tone block body which concerns on this invention. It is VII-VII sectional drawing of FIG. It is a side view which shows the method of producing the stone-tone block body shown by FIG. It is a perspective view which shows the other example of the stone-tone block body which concerns on this invention. It is XX sectional drawing of FIG.

Explanation of symbols

A1, A2, A3 Stone-tone block body 1 Block molded body 1a, 1c Bottom face (surface of block molded body)
1b, 1e Side surface (surface of block molding)
1d Upper surface part (surface of the block molding)
2 Coating layers 21, 21A, 21B, 21C Colored aggregate 22 Binder

Claims (5)

A block molded body made of polystyrene foam and a coating layer covering at least a part of the surface of the block molded body,
The said coating layer is a stone-tone block body containing the colored aggregate obtained by grind | pulverizing a natural stone or an artificial stone.   The stone-like block body according to claim 1, wherein the surface of the covering layer is an uneven surface reflecting the form of the colored aggregate.   The stone block according to claim 1 or 2, wherein the coating layer includes a binder and is formed by spray painting.   The stone-like block body according to claim 3, wherein the coating layer is formed by spraying the surface of the block molded body maintained in an upward horizontal posture. Preparing a block molded body made of polystyrene foam,
A mixed material containing colored aggregate and binder obtained by pulverizing natural stone or artificial stone is sprayed onto the surface of the block molded body maintained in an upwardly horizontal position to form a stone-like coating layer. Forming, and
A method for producing a stone-tone block body.

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