JP2571474B2 - Lightweight foam concrete board with surface decoration and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight foamed concrete board with surface decoration used for floors, roofs, walls and the like of buildings and a method for producing the same.

[0002]

2. Description of the Related Art In general, a lightweight foam concrete board (hereinafter abbreviated as "ALC board") is a prefabricated house, which is considered to be lightweight, excellent in heat insulation and fire resistance, and excellent in workability such as nailing and sawing. It is widely used as a fire-resistant coating, including floors, roofs, and walls of high-rise buildings. Recently, it has been practiced to enhance the aesthetic appearance of the inner and outer walls of a building by using a surface of the ALC plate with a concavo-convex pattern. Makeup with crushed stones and the like has been performed.

When the above-described makeup is applied to the surface of an ALC plate with a decorative surface, it is not preferable from the technical and design standpoints to attach natural crushed stone or the like directly to the foamed uneven surface of the ALC plate. For this reason, as shown in FIG. 6, a non-foamed skin layer 2 is usually formed by spraying a resin solution (urethane resin solution or the like) containing crushed stones 3 on the surface of the ALC plate 1 with a decorative surface having irregularities. Using the foamed skin layer 2 as a binder, crushed stones 3 are held on the surface of the ALC plate as shown in FIG.

[0004]

However, in the above-mentioned method, the crushed stone 3 or the like is contained in the resin solution so that the ALC plate 1
Although it depends on the structure of the nozzle used for spraying because it is sprayed and supplied to the surface, usually large crushed stones 3 cannot be sprayed. In addition, since the crushed stones 3 are held by the thin non-foamed skin layer 2, the holding strength of the crushed stones 3 is weak, and the crushed stones 3 easily fall off from the non-foamed skin layer 2. . For this reason, the particle size of crushed stones and the like used for makeup is generally limited to 3 mm or less, and in reality, it is impossible to provide a decorative pattern having a design that gives a novel impression.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a surface-decorated ALC plate using a large crushed stone or the like as a decorative material, and a method for producing the same.

[0006]

In order to achieve the above-mentioned object, the present invention relates to an ALC plate, in which the surface of an ALC plate is transferred and formed on an uneven pattern surface or a smooth surface, and a surface layer portion including the transfer formed surface is formed as a non-foamed layer. A first aspect of the present invention is a surface-coated ALC plate formed and embedded with a granular decorative material having an average particle size of 5 mm or more in a dispersed state in the non-foamed layer. A concrete molding mat made of foamed resin having a surface portion including a surface formed on an integral skin layer is prepared, and the concrete molding mat is vacuum suctioned to a bottom portion with the shaping surface facing upward. Laid in a concrete molding form with means, on which,
After spraying a granular decorative material having an average particle size of 5 mm or more, a lightweight foamed concrete material is cast, and a lightweight foamed concrete material is formed while vacuum-sucking the inside of the mold by the vacuum suction means. This is the second point.

[0007]

In other words, the present invention relates to a method of applying a decorative material such as
As a method of supplying to the board surface, instead of spray coating a resin liquid containing crushed stones or the like, at the time of forming the ALC board, a cosmetic material having an average particle size of 5 mm or more is sprayed on a shaping surface of mat used for forming. In this state, a lightweight foamed concrete material is cast and molded while vacuum suction is applied, so that the surface layer portion including the transfer-formed surface of the ALC plate is made a non-foamed layer, and this layer holds the decorative material. Things. According to the present invention, the thickness of the non-foamed layer can be arbitrarily set according to the conditions of vacuum suction, so that the non-foamed layer has a large particle size as described above, even though the particle size of the decorative material is large as described above. Since the layer can be thickened and a cosmetic material can be embedded in this portion and firmly held, a large variety of decorative materials can be used to provide a variety of unprecedented makeup.

[0008]

Next, the present invention will be described in detail based on embodiments.

FIG. 1 shows an embodiment of an ALC plate with a decorative surface according to the present invention. The ALC board 10 with surface decoration has an uneven pattern formed on the surface, and the surface layer of the uneven pattern portion (the portion demarcated by the dashed line P in the figure) is the non-foamed layer 11. In the non-foamed layer 11, a decorative material 12 (having an average particle size of 5 mm or more) such as crushed natural stone is embedded in a dispersed state with a part thereof exposed on the surface. As described above, since the large-sized decorative material 12 is dispersedly exposed on the surface of the concave-convex pattern portion, the ALC plate is made of concrete even though the main material is concrete.
At first glance, it has a natural stone appearance. Moreover, the cosmetic material 12 exposed on the surface is larger than ever before (larger than 3 mm).
It gives a fresh impression.

The above-described ALC board 10 with decorative surface can be manufactured, for example, as follows. That is, first, a mat 24 for concrete molding is manufactured using a mold having an upper mold 21 and a lower mold 22 as shown in FIG. A concave and convex pattern for transfer is formed in the lower mold 22,
A foamable resin liquid (for example, (urethane resin liquid)) having a predetermined composition is cast into the lower mold 22 and the mold is clamped, and then heated to 40 to 60 ° C. to foam the resin liquid.
At this time, a portion of the generated air bubbles that contacts the concave and convex pattern portion for transfer of the lower mold 22 is compressed and collapsed (disappears) by the internal pressure in the mold, so that the integral skin layer 25 is formed. It is formed. After curing and curing in this state, the mold is removed to obtain a concrete molding mat 24 as shown in FIG. The integral skin layer 25 desirably has both heat resistance, air permeability, and flexibility. Specifically, the integral skin layer 25 withstands a high temperature of 150 ° C. or more, has a large number of communication holes having a diameter of 3 μ or more, and has a random shape. And a material having a 90 ° bendability is preferable. And the thickness of this integral skin layer 25 is
It is preferable to set it to 0.1 to 30 mm. It is desirable that the irregularities on the surface of the integral skin layer 25 have a height difference of 1 mm or more.

Next, the concrete molding mat 2
4 is laid in a formwork 26 as shown in FIG. The formwork 26 has a bakium tank 27 at the bottom and a frame 28 attached to the top. Communication holes 27a are formed at a predetermined interval on the upper surface of the vacuum tank 27 so as to communicate with an internal space surrounded by the frame 28. On the other hand, a joint 29 is fitted into the bottom surface of the vacuum tank 27, and a vacuum pump (not shown) is connected to the joint 29.

The decorative material 12 used for decorative finishing is sprayed on the concrete molding mat 24 in the formwork 26. As the decorative material 12, a large particle having an average particle diameter of 5 mm or more is used. And the cosmetic material 12 when spraying
It is preferable that the interval between the two is at least 0.5 mm, although it depends on the size of the decorative material 12. Cosmetic material 12
This is because, when they overlap with each other, the lightweight foamed concrete material does not sufficiently enter the surroundings of each of the decorative materials 12, and the holding strength of the decorative materials 12 is weakened, so that the decorative materials 12 easily fall off.

Next, as shown in FIG. 5, a lightweight foam concrete material 30 having a predetermined composition is cast, a vacuum pump is operated, and vacuum suction is performed as shown by an arrow in the mold 26. The concrete material 30 is foamed. At this time, a portion of the generated bubbles that comes into contact with the uneven pattern portion of the molding mat 24 is pressed against the surface of the molding mat 24 by vacuum suction from below and collapsed, and the non-foamed layer 11 is crushed.
Is formed. Then, the decorative material 12 is firmly held by the non-foamed layer 11. In this state, curing and hardening are performed according to a usual method, and the mold is removed to obtain an ALC board with a surface decoration as shown in FIG. Alternatively, curing and curing may be performed in an autoclave after demolding.

In the above-mentioned manufacturing method, the decorative material 12 used for decorative finishing is made of the non-foamed layer 1 of lightweight foamed concrete.
Since the particles are held firmly by the method 1, even though they have an average particle diameter of 5 mm or more, which is larger than the conventional one, they are sufficiently retained without falling off. Therefore,
There is no upper limit on the particle size of the decorative material 12, and a large one can be used. However, as the particle size of the decorative material 12 increases, the thickness of the non-foamed layer 11 holding the decorative material needs to be increased, and in order to increase the thickness, the vacuum suction must be performed strongly. For example, when the decorative material 12 having an average particle size of 5 to 10 mm is used, it is preferable to set the thickness of the integral skin layer 25 to about 5 to 10 mm. , Vacuum suction, vacuum degree 700 ~ 760mmHg, suction time 5 ~
It is necessary to perform under the condition of 15 minutes.

Various kinds of materials such as crushed natural stones, artificial ceramics pieces, tile pieces and the like can be used as the decorative material 12 used for the decorative finishing, and various metal pieces and wood pieces can be used instead of the crushed stones. Etc. can be used. That is, any material may be used as long as it adds decorativeness to the surface of the ALC plate. As described above, it is necessary to use an average particle size of 5 mm or more from the viewpoint of the difference from the conventional product.
Thus, a design with a strong impression can be obtained.

Further, in the above-described embodiment, the surface of the ALC plate is formed on the uneven pattern surface, but it is not particularly necessary to shape the uneven pattern surface, and for example, it may be formed on a smooth surface. However, in this case, as the molding mat 24,
A transfer surface having a smooth surface is used.

[0017]

As described above, according to the present invention, at the time of forming an ALC plate, a decorative material having an average particle size of 5 mm or more is sprayed on a transfer surface of a mat for concrete molding, and in this state, a lightweight foamed concrete material is placed thereon. Is cast and molded under vacuum suction, so that the surface layer portion including the transfer forming surface is made into a non-foamed layer, and the decorative material is embedded and held in this layer. Therefore, according to the present invention, the thickness of the non-foamed layer can be appropriately set according to the degree of the vacuum suction. It can be held firmly in the layer. For this reason, it is possible to obtain a decorative ALC board with a large-sized decorative material, which cannot be obtained by the conventional method, and it is possible to make a building or the like having a novel design appearance using this.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of an ALC board with a decorative surface according to the present invention.

FIG. 2 is an explanatory view of how to make a mat for concrete molding used in manufacturing the above-mentioned example product.

FIG. 3 is a sectional view showing the concrete molding mat.

FIG. 4 is an explanatory diagram of a method of manufacturing the product of the embodiment.

FIG. 5 is an explanatory diagram of a method of manufacturing the product of the example.

FIG. 6 is an explanatory diagram of how to make a conventional ALC board with surface decoration.

FIG. 7 is a cross-sectional view showing the above-mentioned conventional ALC board with decorative surface.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ALC board with a surface decoration 11 Non-foamed layer 12 Decorative material 24 Mat for concrete molding 25 Integral skin layer 26 Formwork 27 Back tank 27a Communication hole

Claims (2)

(57) [Claims] 1. The surface of a lightweight foam concrete board is transferred and formed on a textured surface or a smooth surface, a surface layer including the transfer formed surface is formed on a non-foamed layer, and the average particle size is formed in the non-foamed layer. A light-weight foamed concrete board with surface decoration, wherein a granular decorative material of 5 mm or more is embedded in a dispersed state. 2. A concrete molding mat made of a foamed resin having a surface portion including an uneven surface or a smooth surface which is a shaping surface formed on an integral skin layer is prepared. With the mold surface facing upward, it was laid in a concrete molding mold provided with vacuum suction means on the bottom part, and a granular decorative material having an average particle size of 5 mm or more was sprayed thereon. Thereafter, a lightweight foamed concrete material is cast, and the lightweight foamed concrete material is formed while vacuum-sucking the inside of the mold by the vacuum suction means.