JP2705053B2 - Casting method of decorative concrete and template used for casting - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for casting decorative concrete having a design having a matte surface and a glossy surface and having high designability. Also includes a template used for setting. Here, the "mat surface" has a fine unevenness and means a concrete surface having a matte appearance, and the "gross surface" is a smooth surface obtained when a smooth template is used. Means concrete surface. The method of the present invention is particularly meaningful when applied to the production of decorative concrete panels. 2. Description of the Related Art For example, in the production of a concrete panel used for assembling a prefabricated house, in order to obtain a panel having a decorative surface with a picture, one of the conventional techniques is a chemical or mechanical technique. A method of forming a mold using a mold plate having irregularities provided by a method, forming irregularities on the concrete surface by injecting ready-mixed concrete into the mold, and applying a colorant thereon if desired. There is. With this method, only a simple picture can be obtained. Another technique is to spray a mixture of cement, colorant, water and necessary additives with a mortar gun on the surface of wet concrete, but it requires a great deal of labor and always has a certain quality. There is a disadvantage that it is not always possible. SUMMARY OF THE INVENTION An object of the present invention is to replace a part of the concrete surface with a matte surface corresponding to the printing of a pattern provided on a template, in place of the above-described conventional technology. An object of the present invention is to provide a method of placing decorative concrete, in which a decorative concrete having a constant quality and a high design quality is always obtained by forming a portion on a gloss surface. It is also an object of the present invention to provide a template used for the above-mentioned casting. Constitution of the Invention [Means for Solving the Problems] As shown in FIG. 1, the method for placing decorative concrete according to the present invention employs an ink containing a UV-curable resin as a substance for suppressing the curing of concrete. Forming is performed by using the template 1 which is provided with the printing 14 and supports the substrate sheet 13 having a smooth surface in a portion where there is no pattern printing on the substrate 11 so that the side of the pattern printing 14 is on the surface. , As shown in FIG.
The ready-mixed concrete 2A is poured into the formwork, and as shown in FIG. 3, the concrete is hardened while suppressing the hardening of the portion in contact with the pattern print 14, and the hardening is performed by removing the formwork. The suppressed portion is formed on the mat surface 3 and the other portions are formed on the gloss surface 4. The template 1 used for casting the decorative concrete of the present invention
As shown in FIG. 1, a pattern printing 14 is performed with an ink containing a substance that suppresses the hardening of concrete, and a base sheet 13 having a smooth surface in a portion where no pattern printing is performed is provided. It is attached on the plywood 11 so that it is on the surface. The base sheet is a plastic film such as polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyethylene terephthalate, polycarbonate, nylon, polystyrene, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, ionomer, etc. Are preferred. In addition, metal foils such as iron, aluminum and copper, paper sheets, and laminated materials of these foils or paper sheets and plastic films can also be used. Its surface is
Of course, the surface must be glossy and smooth, but the degree only needs to be 10 or more at a 60-degree incident gloss level. In a modified embodiment, an embossed base sheet is used as a printed base sheet. The emboss may be provided by a mechanical method. Alternatively, a sheet provided with a foamable resin layer may be printed with a pattern, heated and foamed, and then mechanically embossed. Further, a sheet provided with a foamable resin layer may be printed with a pattern, and a foam inhibitor may be subjected to pattern printing and embossed by a chemical method of foaming by heating. In this embodiment, if desired, embossing is applied in synchrony with the printing of the picture. In another aspect, as a substrate sheet on which a picture is printed, an ink containing a UV-curable resin as a substance for suppressing curing of concrete was applied to the embossed projections of the embossed substrate sheet by topping. Use things. Alternatively, an ink in which the ink is applied to the concave portion of the emboss by wiping is used. In still another modification, the method includes a step of applying a paint to the surface of the concrete after casting, and such a case is also included in the present invention. Although many substances that suppress the hardening of concrete are known, in the present invention, an ultraviolet curable resin is used. The ultraviolet curable resin has a function of reacting with calcium hydroxide generated in the early stage of the hydration reaction of concrete to take it out of the system. Thereby, the progress of the subsequent hydration reaction is hindered, and the hardening is suppressed. Examples of UV-curable resins include acrylates such as 1,6-hexanediol diacrylate, neopentyl glycol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerythritol tetramethacrylate, α-α-
For phthalates such as tetraacryl-bistrimethylolpropane tetrahydrophthalate, α-α-dimethacryl-bisdiethylene glycol phthalate, tolylene diisocyanate, isophorone diisocyanate, etc.
-A compound obtained by reacting hydroxyethyl acrylate (HEA), a compound obtained by reacting hexanediol and isoolone diisocyanate with HEA, a diacrylate of bisphenol A-diglycidyl ether, trimethylolpropane polyglycidyl ether polyacrylate, spiroglycol diglycidyl Examples include ether diacrylate, silcon acrylate, and trisacryloyloxyethyl isocyanurate. The printing of the picture can be performed by any printing method such as gravure, gravure offset, and offset. For the topping and wiping, any means such as a conventional roll coat, gravure coat, reverse coat and the like can be used. As a paint to be applied to the concrete surface after casting,
Acrylic and fluorine-based paints having excellent weather resistance are suitable. In addition, an epoxy-based or polyurethane-based paint can be used. If a coloring agent is added to this paint, the effect of contrast between the mat surface and the gloss surface of the concrete surface is further enhanced. The amount of the colorant is preferably 5 parts by weight or less based on the resin, and if it is more than 5 parts, the matte and gloss effects are lost. As a coating method, any means such as spraying, roll coating and brush coating can be used. In order to support a substrate sheet on which a pattern is printed on a substrate, particularly a plywood, it is desirable to provide an adhesive layer 12 as shown in FIGS. As the adhesive, polyurethane, urea resin, melamine resin, polyvinyl acetate, ethylene-vinyl acetate copolymer or the like is used. In order to form a template, an adhesive is applied to the plywood, a substrate sheet on which a pattern is printed and a mirror plate are stacked in this order, and hot press molding is performed. The concrete casting method of the present invention can be applied to on-site casting or to panel production in a factory. [Operation] The portion of the pattern printing 14 on the template 1 shown in FIG. 2 contains a substance that suppresses the hardening of the concrete, and the surface of the ready-mixed concrete 2A that contacts the portion suppresses the hardening. Is done. On the other hand, in the other portions in contact with the base material sheet 13, the ready-mixed concrete 2A is hardened. After the concrete is hardened, as shown in FIG. 3, when the template 1 is removed from the hardened concrete 2B, the concrete 5 on the hardened surface is peeled off while adhering to the picture printing portion 14, and the hardening of that portion is performed. Concrete 2B is formed on the mat surface 3. On the other hand, the hardened concrete 2B in the portion of the base sheet 13 has a gloss surface 4. In the embodiment in which the embossed base sheet is used and the embossed portion of the base sheet is applied by topping or wiping, the design is further enhanced by the synergistic effect of the embossed irregularities and the matte surface and the gloss surface. The nature increases. Even in a mode in which the paint is applied to the surface of the concrete after casting, the mat surface has a large amount of paint absorption and is finished in a dark color, and the gloss surface has a small amount of paint absorption,
Finished in pale color, the contrast becomes stronger. Example 1 A 100 μm-thick polyester film “T-60” (Toray) was coated on its surface with an ultraviolet curable ink “Seika Beam PH”.
Using "C" (Dainichi Seika), a pattern was printed by gravure printing, and irradiated with a high-pressure mercury lamp of 160 W / cm for 1 second to cure the ink. Next, the rear surface of the above-mentioned film was bonded on a plywood having a thickness of 12 mm via an epoxy resin adhesive to produce a template. Using the template, a mold for manufacturing a concrete panel was assembled, and mortar in a ratio of cement: sand = 3: 1 was poured. After curing for 4 days, the mold was removed and dried at room temperature for 3 days. A decorative concrete panel with high design properties was obtained, in which the surface of the concrete corresponding to the printing of the pattern was a matte surface and the other surface was a gloss surface. Example 2 Polyester film “T-60” with a thickness of 25μ (Toray)
The decorative concrete panel was formed in the same manner as in Example 1 except that embossing was performed, and only the protrusions were roll-coated with an ultraviolet curable ink “Seika Beam PHC”. In the obtained decorative concrete panel, the concave portion was a mat surface and the other surfaces were gloss surfaces. Example 3 A decorative concrete panel was formed in the same manner as in Example 1. When the water-soluble acrylic resin (Dainippon Paint) was spray-applied to the obtained decorative concrete panel, the concrete surface corresponding to the pattern printing became a dark matte surface, and the other surfaces became a light-colored gloss surface. . Effect of the Invention According to the method for casting decorative concrete using the template of the present invention, the surface of concrete corresponding to the printing of the pattern provided on the template can be formed on the mat surface, and the other surface can be formed on the gloss surface. A highly decorative decorative concrete can be cast.
This method is particularly advantageous for the production of decorative concrete products, such as prefabricated house panels, which are required to always have a constant quality. Since the preparation of the template can be performed by simple operations of printing and lamination, decorative concrete having an arbitrary pattern can be easily manufactured at low cost. In the embodiment in which the embossing is performed, the embodiment in which the embossed portion is topped or wiped, and the embodiment in which the paint is applied to the surface of the concrete after casting, a decorative concrete surface having a higher design quality can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic cross-sectional view showing the configuration of a template used for placing decorative concrete of the present invention. 2 and 3 are cross-sectional views similar to FIG. 1 showing the production of concrete panels according to the method of the present invention, and FIG. 2 shows a state where ready-mixed concrete is poured into a mold. FIG. 3 shows a state where the mold is removed. 1 ... template 11 ... board (plywood), 12 ... adhesive layer 13 ... base sheet, 14 ... pattern printing 2A ... ready-mixed concrete, 2B ... hardened concrete 3 ... matte surface, 4 ... … Gross surface 5 …… Concrete on uncured surface

Claims (1)

(57) [Claims] Print a pattern with an ink containing a UV curable resin as a substance that suppresses the curing of concrete, and place a base sheet with a smooth surface on the part without the pattern print on the substrate so that the side of the pattern print is on the surface A mold is formed by using the supporting template, and fresh concrete is poured into the mold, and the concrete is hardened while suppressing the hardening of the portion in contact with the printing of the pattern, and the mold is formed. A method of placing decorative concrete, characterized in that a portion where hardening is suppressed by removing the above is formed on a mat surface and a gloss surface is formed on other portions. 2. 2. The method for placing decorative concrete according to claim 1, wherein a substrate sheet on which a picture is printed is embossed by a mechanical method. 3. Claims to use, as a substrate sheet on which a pattern is printed, a sheet on which a foamable resin layer is provided, on which a pattern is printed, heated and foamed, and then subjected to embossing by a mechanical method. 2. The method for casting decorative concrete according to claim 1. 4. As a base sheet with a printed pattern, a sheet with a foamable resin layer printed with a pattern, and a foam inhibitor is pattern-printed and embossed by a chemical method of heating and foaming. 2. The method for placing decorative concrete according to claim 1, wherein the method comprises: 5. 5. The method according to claim 2, wherein the embossing is performed in synchronization with the printing of the picture. 6. As the substrate sheet on which the pattern is printed, a sheet obtained by applying an ink containing a UV-curable resin as a substance that suppresses concrete curing to the embossed projections of the embossed substrate sheet by topping is used. The method for placing decorative concrete according to any one of claims 2 to 4. 7. A patent that uses an ink containing a UV curable resin as a substance that suppresses concrete hardening applied to the embossed recesses of the embossed base sheet by wiping as a substrate sheet with a printed pattern The method for placing decorative concrete according to any one of claims 2 to 4. 8. The method for placing decorative concrete according to any one of claims 1 to 7, further comprising a step of applying a paint to the surface of the concrete after placing. 9. A template used for casting decorative concrete, in which a base sheet on which a pattern is printed with an ink containing a UV-curable resin as a substance that suppresses the curing of concrete is adhered to plywood.