JP2599251B2 - Decorative aggregate mounting sheet and method of manufacturing decorative aggregate exposed concrete using the sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the production of precast concrete products of various shapes, the surfaces of which have been decorated with decorative aggregates such as natural stones and ceramics, and cast-in-place landscape decorative concretes. TECHNICAL FIELD The present invention relates to a decorative aggregate mounting sheet capable of using a small and high decorative aggregate, and capable of processing a complicated pattern, and a method of manufacturing a decorative aggregate exposed concrete using the same.

[0002]

2. Description of the Related Art As one method of decorating the surface of concrete with decorative aggregates or the like, a construction method called a washing method has been used. In this method, initially, concrete or mortar into which aggregate is kneaded is poured into the formwork, and while they are semi-hardened, the concrete or mortar on the surface is washed away to expose a part of the aggregate. Had been. Also, in recent years, a method has been employed in which concrete or the like into which aggregate is kneaded is poured and then a concrete setting retarder is sprayed on the surface thereof, or a special sheet called a setting delay sheet is placed. . These methods delay the hardening of the surface of concrete or the like, and when the inside hardens, wash the unhardened surface layer to expose a part of the aggregate.

In recent years, as one of the above-mentioned washing methods, there has been proposed a method of manufacturing a molded article having a decorative aggregate exposed on the surface by a form-fixing method in which the aggregate is not kneaded.
(For example, described in JP-A-4-163105). This method
Adhere the super-hardening retarder to the bottom plate surface of the mold and arrange the stones on it, or fix the stone to the plate with the super-hardening retarder attached with adhesive and place the plate on the bottom plate of the mold Then, concrete is poured into a mold, cured, demolded, and the surface of the obtained block is washed away.

The present inventors have previously proposed a special decorative aggregate mounting sheet applicable to the exposure of concrete decorative aggregate and a decorative aggregate exposing method using the sheet and not relying on a washing method. (JP-A-6-134907, JP-A-6-1
No. 34736). In this method, a hot-melt adhesive layer or the like is formed on a flexible base material, and a decorative aggregate mounting sheet in which the decorative aggregate is partially embedded in the adhesive layer is produced. It is a method in which the decorative aggregate is exposed by installing and pouring concrete, curing, and then peeling off the sheet.

[0005]

However, in the method described in the above-mentioned Japanese Patent Application Laid-Open No. 4-163105, a super-hardening retarder is adhered to the bottom plate surface of a hard mold, and decorative aggregates are arranged thereon. However, it is difficult to carry out other than the horizontal plane. In addition, in the method of placing the decorative aggregate on another plate to which the super-hardening retardant is attached and installing the decorative aggregate on the bottom plate surface of the formwork, the plate lacks flexibility, so that it is necessary to manufacture a product having a curved surface or an uneven surface. Was difficult to apply, and there were limitations on the shapes of applicable products. Also, if an adhesive is applied to the entire surface of the delay agent layer and the aggregate is attached, the effect of the delay agent cannot be expected, and the adhesive is attached to each aggregate and adhered to the delay agent layer, An adhesive is applied to the retarder layer in advance according to the aggregate having a non-uniform shape and dimensions, and the aggregate is arranged at a predetermined density in order to force the aggregate to adhere to the aggregate. However, there are problems such as that the work is complicated and productivity is low, and that it is difficult to apply to small decorative aggregates. Furthermore, it has not been easy to apply the above method to decoration of complicated patterns.

When the method described in Japanese Patent Application Laid-Open No. 6-134736 is applied to a large decorative aggregate, the thickness of the hot-melt adhesive layer must be increased. There was a problem that it was difficult to apply the material economically.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the prior art, and to provide a decorative bone which is simple in operation, has good productivity, can use small decorative aggregates, and can process complicated patterns. It is an object of the present invention to provide a material mounting sheet and a method for producing decorative aggregate exposed concrete using the same.

[0008]

SUMMARY OF THE INVENTION An object of the present invention is to provide a thin support comprising a flexible support, a binder layer comprising a hot melt composition formed on the support, and a concrete retarder formed on the binder layer. A decorative aggregate mounting sheet, comprising a configuration in which a decorative aggregate such as natural stone and ceramics is mounted on a support sheet made of layers, and a part of the decorative aggregate is heated and embedded in the binder. Alternatively, on a support sheet composed of a flexible support and a binder layer composed of a hot melt composition kneaded with a concrete setting retarder formed on the support, natural stone,
Mounting a decorative aggregate such as ceramics, heating, to produce a decorative aggregate mounting sheet characterized by comprising a configuration in which a part of the decorative aggregate is embedded in the binder,
And, the decorative aggregate mounting sheet obtained above is attached to a formwork with the decorative aggregate mounting surface inside, and concrete is driven in, or the decorative aggregate mounting surface is brought into contact with the uncured concrete surface. After pressurizing and pressing, curing, demolding, and peeling of the support sheet are performed to expose the decorative aggregate, and then the semi-hardened concrete on the decorative aggregate exposed surface is washed out or mechanically removed to a predetermined depth. The present invention can be achieved by a method for producing a decorative aggregate-exposed concrete, characterized by exposing the decorative aggregate to the concrete.

Materials suitable for the above-mentioned flexible support include plastic films such as polyethylene terephthalate, stretched polypropylene and cross-linked polyethylene;
Also, there are sheets made of various types of paper, nonwoven fabric, cloth, and the like.
Any of these can be used, but a plastic film such as polyethylene terephthalate, which has high mechanical strength and high heat resistance and water resistance, is particularly suitable.

[0010] The hot melt composition includes a styrene-butadiene-styrene block copolymer,
Styrene / isoprene / styrene block copolymer, styrene / ethylene / butylene / styrene block copolymer,
A hot melt composition using an ethylene / vinyl acetate copolymer or the like as an elastomer, particularly a hot melt adhesive or a hot melt adhesive, particularly a hot melt adhesive is suitable.

In the present invention, preferred curing retarders include aminotri (methylenephosphonic acid), pentasodium aminotri (methylenephosphonic acid), other phosphonic acid derivatives, citric acid, hydroxycarboxylic acid and other organic acids. Acids can be mentioned. In particular, 1: 1 to 2:
One mixture is preferred.

In order to adhere the above-mentioned curing retarder on the binder, for example, it is dissolved in styrene / butadiene rubber latex, aqueous solution of polyvinyl alcohol, etc., thinly applied and dried, or depending on the type of curing retarder. Is dissolved in an organic solvent solution such as rubber and applied and dried, or kneaded into a hot melt composition or the like and thinly applied on a binder.

[0013] The decorative aggregate mounting sheet obtained as described above is placed on a formwork with the decorative aggregate mounting surface facing inward, and concrete is poured on this and cured, or uncured concrete is cured. The decorative aggregate is attached to the surface so that the decorative aggregate is in contact with the surface, pressed and cured, the concrete is cured, the mold is removed, and the supporting sheet is peeled off to expose the decorative aggregate. Next, the semi-hardened concrete on the surface is physically washed away or removed to a desired depth by a mechanical method such as shot blasting to finish the decorative aggregate exposure.

[0014]

According to the present invention, there is provided a binder layer made of a flexible hot melt composition on a flexible support, and a decorative aggregate made of natural stone or the like is buried at an appropriate depth using heat in the binder layer. The fact that the mounting sheet can be easily manufactured has already been described in Japanese Patent Application Laid-Open No. Hei 6-134907. Similarly, as shown in FIG. A binder layer 2 such as a melt pressure-sensitive adhesive is formed, a concrete retarder layer 3 is thinly applied thereon, and a decorative aggregate 4 is placed on the retarder layer. When heated, the decorative aggregate sinks into the binder layer by its own weight. At this time, the decorative aggregate is as shown in FIG.
As shown in (B), the thin layer containing the hardening retardant breaks down and sinks, is held firmly in contact with the binder, and does not fall off during operations such as transportation and concrete pouring.

When the setting retarder is kneaded into the hot melt composition, the tackiness or adhesiveness of the hot melt composition is not lost by this, so that when the decorative aggregate is embedded therein, However, the decorative aggregate is held strong enough not to fall off.

When the concrete hardening retardant in the water-soluble polymer thin film comes into contact with the moisture contained in the concrete by pouring it, it melts out of the film and acts on the concrete to delay the hardening thereof. When the setting retarder is contained in a water-insoluble binder or the like, the curing retarder collects at the interface with concrete during curing after the concrete is poured, and the concrete hardens in the same manner as described above. Inhibits. When the concrete is cured at a high temperature, the movement of the setting retarder to the interface is promoted.

The method of heating the binder made of the hot-melt composition to sink the decorative aggregate is that it can process a sheet having a large area at a time, can be applied even if the decorative aggregate has a slightly different size, This method has advantages such as simplicity, and is a highly productive method.

Since the decorative aggregate mounting sheet of the present invention is flexible and holds the decorative aggregate sufficiently strong so as not to fall off, the sheet is applicable to both molding of concrete products and cast-in-place. . In addition, even if the concrete to be applied is not a flat surface but a curved surface, even if it has irregularities, the sheet can be deformed and can be cut and installed as appropriate, so that a decorative surface with a good finish can be created. .

Further, in the decorative aggregate mounting sheet of the present invention, since a binder which can be easily peeled off and removed from the aggregate surface after hardening concrete is used as the binder, the binder remains on the exposed decorative aggregate surface. Nothing. In addition, since the curing retarder is in close contact with, or kneaded into, a tacky or adhesive binder, excess curing retarder and resin holding the curing retarder are removed together with the sheet, resulting in environmental pollution. Cause less risk.

Further, in the present invention, at the stage where the support sheet for mounting the decorative aggregate is peeled off after the concrete is hardened, a part of the decorative aggregate is exposed from the concrete and is kept in a semi-hardened state by a hardening retarder. Removal of the laid concrete surface portion is small and, therefore, the exposed surface finish is good. That is, in the production of decorative aggregate exposed concrete using the decorative aggregate mounting sheet of the present invention, the exposure of the decorative aggregate by embedding the aggregate into the binder layer, and the physical and mechanical Exposure by a typical post-process is used in combination, so that even if the thickness of the binder layer is small, it is possible to sufficiently expose large decorative aggregates.

FIGS. 2 to 4 are conceptual views showing the method of exposing the decorative aggregate according to the present invention, taking a concrete plate as an example. Here, FIG. 2 is a view showing a state where the decorative aggregate mounting sheet is installed on the formwork 5 with the decorative aggregate mounting surface inside, and concrete 6 is poured on the form. FIG.
Fig. 4 is a view showing a state in which after the concrete curing, the mold is removed and the support sheet is removed, and a part of the decorative aggregate is exposed;
FIG. 4 is a view showing a state of a product in which a semi-hardened layer on a concrete surface is further removed to sufficiently expose a decorative aggregate.

[0022]

EXAMPLES The decorative aggregate mounting sheet of the present invention and the method for producing decorative aggregate exposed concrete using the same will be specifically described with reference to examples. Note that the examples given here are only some examples of the present invention, and the present invention is not limited to these examples.

[0023]

Example 1 First, an adhesive hot melt binder based on a styrene / butadiene / styrene block copolymer was applied on a polyester film having a thickness of 50 μm to a thickness of 0.5 mm.
A 600 mm × 600 mm pressure-sensitive adhesive sheet coated to a thickness of 1 mm was prepared. Next, a 1.5: 1 (weight ratio) mixture of aminotri (methylenephosphonic acid) and citric acid 10
A retarder paste in which 0 parts by weight was dissolved in 150 parts by weight of styrene / butadiene rubber latex was applied so that the dry film thickness became about 30 μm, to produce an aggregate support sheet. When the membrane surface is almost dry, sprinkle natural pebbles (decorative aggregate) with an average particle size of about 15 mm on the surface, then put the pebble-mounted sheet in an electric furnace and heat it at 140 ° C for 15 minutes. A decorative pebble-mounted sheet in which a part of was embedded in a binder was produced.

Next, this sheet is placed in a formwork with the pebble mounting surface facing inward, and concrete is poured on the sheet, cured at 60 ° C. for 4 hours to harden the concrete, and then the formwork is placed. The support sheet was peeled off from the pebble surface to expose the pebble portion buried in the binder. Next, the unhardened concrete on the surface was removed by washing to obtain a decorative concrete block in which pebbles were exposed to about 1/3 of the particle diameter.

[0025]

Example 2 On a 50 μm-thick polyester film,
An adhesive hot melt binder based on styrene / butadiene / styrene block copolymer is applied to a thickness of 0.5 mm, and a low melt viscosity based on styrene / isoprene / styrene block copolymer is applied on top of this. Amino tri (methylene phosphonic acid) in 100 parts by weight of hot melt composition
A composition obtained by mixing 20 parts by weight of a 1.5: 1 (weight ratio) mixture of acetic acid and citric acid was laminated at a thickness of 50 μm to produce a decorative aggregate support sheet. In this sheet, a natural stone having an average particle size of about 15 mm was embedded to prepare a decorative aggregate-mounted sheet in the same manner as in Example 1, and then concrete was poured and cured, and finally the support sheet was peeled off. To expose the pebbles buried in the binder.
Next, the semi-hardened concrete on the surface was removed by sandblasting to expose the pebbles to about 1/3 of the particle size, and a decorative concrete block whose surface was decorated with natural stone was obtained.

[0026]

Example 3 First, when a tacky hot melt binder based on a styrene / butadiene / styrene block copolymer was kneaded and produced, aminotri (methylene) was added to 100 parts by weight of the hot melt binder. 20 parts by weight of a 1.5: 1 (weight ratio) mixture of (phosphonic acid) and citric acid were mixed to prepare a hot melt binder containing a concrete setting retarder, and the binder was applied to a 50 μm-thick polyester film having a thickness of 0.5 mm. Coated. In the same manner as in Example 1, a natural stone having an average particle size of about 15 mm was embedded in the obtained sheet to produce a decorative aggregate-mounted sheet.
Next, concrete was poured in and cured, and finally the support sheet was peeled off to expose the pebble portion buried in the binder. Next, the semi-hardened concrete on the surface was removed by sandblasting to expose the pebbles to about 1/3 of the particle size, and a decorative concrete block whose surface was decorated with natural stone was obtained.

[0027]

As described above, in manufacturing decorative aggregate exposed concrete, by adopting the decorative aggregate mounting sheet of the present invention and the method of manufacturing decorative aggregate exposed concrete using the same, the prior art Decorative aggregate mounting sheet and decorative aggregate exposure using the same, which solves the problems which have been described above, is simple in operation, has high productivity, can use small decorative aggregates, and can also process complicated patterns. A method for producing concrete can be provided.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view conceptually showing a method for producing a decorative aggregate mounting sheet.

FIG. 2 is a cross-sectional view conceptually showing a state in which concrete is poured.

FIG. 3 is a sectional view conceptually showing a concrete block when a sheet is peeled off.

FIG. 4 is a sectional view conceptually showing a concrete block after surface finishing.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Support, 2 ... Binder layer, 3 ... Concrete hardening retardant layer, 4 ... Decorative aggregate, 5 ... Formwork, 6 ... Concrete.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B32B 27/14 B32B 27/14 31/18 7148-4F 31/18 (72) Inventor Tetsuya Yamada Tokyo 1-4-3 Kotobukicho, Fuchu-shi, Japan (72) Inventor Eisho Kobayashi 3819 Noto, Tama-ku, Kawasaki City, Kanagawa Prefecture Inside Slion Tech Co., Ltd. (72) Inventor Hiroyuki Enomoto Tama-ku, Kawasaki City, Kanagawa Prefecture 3819 Noborito Inside Sliontec Co., Ltd.

Claims (6)

(57) [Claims] 1. A support sheet comprising a flexible support, a binder layer formed of a hot melt composition formed on the support, and a thin layer containing a concrete setting retarder formed on the binder layer. A decorative aggregate mounting sheet comprising a structure in which decorative aggregates such as natural stones and ceramics are mounted, and a part of the decorative aggregates is embedded in the binder by heating. 2. The thin layer containing the concrete retarder according to claim 1, wherein the thin layer is obtained by applying and drying a polymer solution in which the set retarder is dissolved and dispersed. The decorative aggregate mounting sheet described in the above. 3. The decorative aggregate according to claim 1, wherein the thin layer containing the concrete retarder is a thin layer formed by using a polymer composition into which the hardener is kneaded. Mounting seat. 4. A flexible support, and formed on said support,
On a support sheet constituted by a binder layer made of a hot melt composition into which a concrete setting retarder has been kneaded, a decorative aggregate such as natural stone or ceramics is mounted, and a part of the decorative aggregate is heated to form the binder layer. A decorative aggregate mounting sheet characterized by being embedded in the interior. 5. The decorative aggregate mounting sheet according to claim 1, wherein the hot melt composition is a hot melt adhesive composition or a hot melt adhesive composition. 6. The decorative aggregate mounting sheet according to any one of claims 1 to 4, which is mounted on a formwork with the decorative aggregate mounting surface facing inward, and is driven into concrete, or is mounted on an uncured concrete surface. After pressing the decorative aggregate mounting surface so that it touches, curing, demolding, peeling of the support sheet to expose the decorative aggregate, and then wash off the semi-hardened concrete on the decorative aggregate exposed surface, or machine A decorative aggregate-exposed concrete, characterized in that the decorative aggregate is exposed to a predetermined depth by removing the decorative aggregate.