JP3261894B2 - Surface coloring method for concrete products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for coloring a surface of a concrete product, which is capable of producing a concrete product having the same appearance as natural stone on the surface.

[0002]

2. Description of the Related Art Conventionally, for example, a concrete product with a surface pattern has been used as a building material for decorating an outer wall of a building. This is one in which colored makeup is applied to the surface so as to have the same appearance as natural stone. As a method for producing such a surface-patterned concrete product (surface-coloring cosmetic method), for example, the production method proposed by the present inventor can be mentioned (Japanese Patent Laid-Open No. 5-253909). This manufacturing method will be described with reference to the drawings.
As shown in FIG. 1A, a decorative mat 1 having a transfer surface 2 having an uneven shape is laid on the ground so that the transfer surface 2 faces upward. Then, as shown in FIG.
Is applied with a special adhesive whose adhesive strength is reduced by moisture in concrete to form an adhesive layer 3a. Next, as shown in FIG. 3C, the coloring material 4a is sprayed on the adhesive layer 3a. This scattering is based on the free fall of the coloring material 4a, and the coloring material 4a is buried in the adhesive layer 3a by its own weight. Next, FIG.
As shown in the figure, a formwork 7 is attached around the decorative mat 1 to form a concrete casting space, in which a concrete material 6a is cast with the transfer surface 2 of the decorative mat 1 as a contact surface. And cure and harden. At the time of this casting,
Due to the moisture in the concrete, the adhesive strength of the adhesive layer 3a is reduced, and the coloring material 4a is transferred to and embedded in the concrete surface. Then, as shown in FIG. 4E, by peeling the hardened concrete 6 from the decorative mat 1, a concrete product having a colored uneven pattern formed on the surface can be obtained.

[0003] A concrete product with a surface pattern manufactured in this manner can exhibit the same appearance as natural stone by selecting the degree of the uneven pattern, the type of coloring material, and the like. This makes it possible to provide a low-cost and effective appearance decoration to the building.

[0004]

Such concrete products with a surface pattern have been manufactured each time at a construction site or the like, but because of the various advantages described above, the demand for them is increasing. Recently, mass production at factories has been considered. However, the conventional method of coloring the surface of a concrete product is not limited to the above-mentioned method proposed by the present inventor, and is a mode in which a concrete material is cast in a state where a decorative mat is laid horizontally (hereinafter referred to as “lateral casting method”).
), Which hinders the transition to factory production. In other words, in the horizontal casting method, a large area is occupied in order to lay the decorative mat horizontally, and in a factory where the construction site is limited, it is difficult to perform many processes at once. In addition, in the horizontal casting method, since the concrete product is peeled from the decorative mat by lifting the concrete product from the decorative mat, it is necessary to use a special machine such as a crane, and the manufacturing operation is complicated. Has become. Furthermore, the conventional method for coloring the surface of concrete products is technically limited only to the horizontal casting method, and thus may not be able to cope with recent remarkable advances in technical development in the field of construction. For this reason,
There is a demand for new technology development different from the conventional method.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a novel method of coloring a surface of a concrete product applicable to factory production.

[0006]

Means for Solving the Problems In order to achieve the above object, a method for coloring a surface of a concrete product according to the present invention comprises:
Prepare a decorative mat having a transfer surface, stand the decorative mat so that the transfer surface is substantially perpendicular to the ground, and in this state, apply a high-viscosity adhesive whose adhesive force is reduced by absorbing water to the decorative mat. The transfer surface is coated to form an adhesive layer, and a granular coloring material is sprayed on the adhesive layer on the transfer surface of the decorative mat to be embedded in the adhesive layer. The material is cast, the adhesive force of the adhesive layer is reduced by the moisture of the concrete material, and the granular coloring material embedded in the adhesive layer is transferred and embedded on the concrete surface.

[0007]

That is, the inventor of the present invention has carried out a series of studies mainly on the development of a new technology for producing a concrete product having a textured surface. In this process, the idea of casting concrete while standing a decorative mat so that the transfer surface is substantially perpendicular to the ground was obtained. That is, if the decorative mat is set up, it can be peeled off from the decorative mat without occupying a wide area and without lifting the cured and cured concrete product. Therefore, based on this idea, further research was conducted, and various studies were repeated in order to realize a surface coloring cosmetic method for a concrete product with a decorative mat standing. As a result, with the makeup mat upright,
An adhesive layer is formed using a high-viscosity adhesive whose adhesive strength is reduced when moisture is absorbed on the transfer surface, and a granular coloring material is sprayed on the adhesive layer and embedded in the adhesive layer. By adopting it, it has been found that the granular coloring material can be promptly transferred and buried on the concrete surface, and that it is possible to produce a concrete product having the same appearance as natural stone, and the present invention has been achieved. According to the present invention, it is possible to provide a novel surface coloring cosmetic of a concrete product, solve the problems of the conventional method, and enable mass production in a factory.

Next, the present invention will be described in detail.

The surface coloring method for a concrete product according to the present invention uses a decorative mat, a special adhesive, and a granular coloring material so that the transfer surface of the decorative mat is substantially perpendicular to the ground. This is a method in which concrete is cast in a state where a mat is set up (hereinafter referred to as "vertical casting method").

As the above-mentioned decorative mat, a decorative mat having an uneven transfer surface is usually used. As this decorative mat, one made of hard urethane foam resin or paper is used.

The above-mentioned special adhesive is a highly viscous adhesive having a function of reducing the adhesive strength due to moisture. Examples of such an adhesive include a methylcellulose adhesive, a polyvinyl alcohol adhesive, water glass,
Two-part acrylic adhesives are listed. The viscosity of the adhesive (viscosity at 20 ° C., hereinafter the same) is 800
0 mPa · s or more, preferably 8000 to 15000 m
Pa · s. If an adhesive layer is formed by using an adhesive having such a function, when concrete is poured, the adhesive force of the adhesive layer is reduced by moisture in the concrete, and the adhesive layer is buried therein. The granular coloring material is quickly transferred to and embedded in the concrete surface. And, if the high-viscosity adhesive as described above is used, even when the decorative mat is set up so that the transfer surface is substantially perpendicular to the ground, no dripping of the adhesive occurs and the uniformity is obtained. It is possible to form a thick adhesive layer.

Next, as the above-mentioned granular coloring material, those conventionally used can be mentioned. For example, coloring pigments, coloring ceramic particles, and coloring glass particles formed into granules can be used. The average particle size of the granular coloring material is preferably from 70 μm to 2 mm, particularly preferably from 70 to 500 μm. Further, as will be described later, in the present invention, two or more, preferably three or more types of granular colorants can be used simultaneously in spray coating of the granular colorant.

It is preferable to use natural stone crushed stone together with the granular coloring material. The natural stone crushed stone is preferably incorporated into the granular coloring material in an amount of at least 10% by weight (hereinafter abbreviated as “%”) based on the total weight of the granular coloring material and the natural stone crushed stone. The average particle size of the crushed natural stone is usually 500 to 2000 μm, preferably 500 to 2000 μm.
1000 μm. Thus, when natural stone crushed stone is used in combination, it becomes possible to form a colored pattern more similar to the appearance of natural stone on the surface of the concrete product.

An example of the method for coloring the surface of a concrete product of the present invention using the decorative mat and various materials will be described with reference to the drawings.

That is, first, as shown in FIG. 1A, a decorative mat 1 having an uneven transfer surface 2 is prepared, and this is set up so that the transfer surface 2 is substantially perpendicular to the ground.

Next, as shown in FIG. 1B, a predetermined adhesive is applied to the transfer surface 2 of the decorative mat 1 to form an adhesive layer 3. This coating is preferably performed by spray coating using a spray nozzle 5a as shown in FIG. When applying the adhesive, as described above, since a high-viscosity adhesive is used, even when the decorative mat is set up, no dripping of the adhesive occurs and the adhesive layer 3 having a uniform thickness is formed. Can be formed. The thickness of the adhesive layer 3 is usually 100 μm
１1 mm, preferably in the range of 200-400 μm. The adhesive layer 3 may have an adhesive force (measured by a Douglas-type tack meter according to JIS Z 0237, the same applies hereinafter) of 9 points or more in order to securely hold the granular coloring material. preferable. The air pressure at the time of spraying the adhesive is usually 2.
0 kg / cm ² or more.

Then, as shown in FIG. 1 (C), a granular coloring material 4 is sprayed on the adhesive layer 3 of the decorative mat 1 and embedded in the adhesive layer 3. The spraying of the granular coloring material 4 is performed by, for example, a dry spraying method using a spray nozzle 5b. As shown in FIG. 5, the spray nozzle 5b includes a container 8 for storing the granular coloring material 4, and the bottom of the container 8 communicates with the spray nozzle body 9. Then, as shown in the drawing, when the air flows in the nozzle body 9, the granular coloring material 4 is sucked into the nozzle body 9 and is ejected from the nozzle tip port 10 together with the air. The air pressure at this time is preferably 2.0 kg / cm ² or more. According to such a dry spraying method, the spraying method can be applied to a granular coloring material having an average particle size of 70 μm or more. Further, according to the dry spraying method, it is possible to simultaneously spray two or more kinds of granular coloring materials. Therefore, according to the present invention, it is possible to embed all the necessary types of granular coloring materials in the adhesive layer by a single spraying process, so that the working efficiency is high. In addition, as long as the granular coloring material is securely held by the adhesive layer, the embedding of the granular coloring material in the adhesive layer is not limited to a state in which the granular coloring material is completely embedded, but also a part thereof. It may be in a semi-buried state exposed to the outside.

Next, as shown in FIG. 2 (D), the concrete material 6a is cast, cured and hardened so that the transfer surface of the decorative mat 1 becomes the contact surface. In the figure, 7
Indicates a mold. At the time of the casting or the like, the adhesive force of the adhesive layer is reduced due to the moisture in the concrete, and the granular coloring material 4 is transferred and embedded on the concrete surface. Next, as shown in FIG. 2 (E), by peeling the hardened concrete from the decorative mat 1, a concrete product 6 having a colored pattern formed on the surface can be obtained.

As described above, the surface coloring method for a concrete product of the present invention mainly comprises the step of forming an adhesive layer using a special adhesive and the step of spraying a granular coloring material. With this configuration, it is possible to apply the concrete vertical placing method and solve the problems of the conventional method. This is the most important feature of the present invention.

In the present invention, the progress up to the above configuration is as follows. That is, at the beginning of the research on the present invention, instead of the method having the above-described configuration, an adhesive and a coloring material were preliminarily mixed, and the mixture was sprayed on a transfer surface of a decorative mat to form an adhesive layer and an adhesive for the coloring material. The method of burying in the layer at the same time was examined. The reason is that, according to this method, the steps can be simplified and the operation can be automated because the spraying method is employed. However, this method needs to solve various problems described below.

First, the method of mixing and spraying an adhesive and a coloring material has a problem that the coloring material is limited to those having an extremely small particle size (average particle size: 20 μm or less). is there. This is because when a colorant having a general size is used, the viscosity of a mixture of the colorant and the adhesive becomes high, and spray coating cannot be performed. However, since the fine coloring material has poor biteability to the concrete surface, migration and embedding on the concrete surface is not sufficient, and a problem occurs that the surface pattern of the obtained concrete product is easily lost. In addition, when a colored pattern is formed on a concrete product using a minute coloring material, the colored pattern becomes uniform as if a paint was applied, and there is a problem that a spot-like color pattern unique to natural stone is not obtained. In addition, in order to obtain a multi-color expression such as natural stone, it is necessary to prepare a mixture for each granular coloring material of each color type and separately spray-coat (superimpose) these. It becomes complicated.

Thus, the adhesive and the colorant are mixed,
The method of spray-coating this mixture onto the transfer surface of a decorative mat has various problems. However, since this method can be expected to have the advantages described above, the inventor of the present invention solves the above-mentioned various problems by further detailed examination, and improves and develops the present invention. It has been reached. That is, as described above, the present invention makes it possible to apply the spraying method by making the step of forming the adhesive layer and the step of embedding the granular coloring material in this adhesive layer separate steps. This makes it possible to use a granular coloring material having an average particle size of not less than a certain value (not less than 70 μm). Therefore, the surface coloring cosmetic of the concrete product of the present invention can embed the granular coloring material in the adhesive layer by a single spraying process, and transfer the granular coloring material to the concrete surface. Burying can be performed reliably. For this reason, the surface-patterned concrete product obtained by the present invention has a high production efficiency, and is buried in a state where the granular coloring material has sufficiently penetrated the surface, and this surface pattern is also similar to natural stone. It becomes a natural spot-like color pattern.

[0023]

As described above, according to the method for coloring a surface of a concrete product of the present invention, the decorative mat is set up so that the transfer surface is substantially perpendicular to the ground, and a special adhesive is applied to the transfer surface. After applying an agent to form an adhesive layer, a granular colorant is sprayed onto the adhesive layer to bury the adhesive layer, and a concrete material is poured using the transfer surface as a contact surface, thereby forming a concrete vertically. Is applicable. For this reason, the surface coloring method for concrete products of the present invention does not occupy a large area, and the concrete products can be easily removed from the decorative mat. Further, according to the present invention, since the spraying is used as a main method, the steps can be automated. Therefore, by applying the present invention, it becomes possible to mass-produce a concrete product with a surface pattern in a factory, and it is possible to reduce the cost. Further, the surface coloring method for concrete products to which the vertical placing method is applied is a novel technique, and can appropriately cope with the increasingly complicated construction field.

Next, an embodiment will be described.

[0025]

Example 1 A concrete product with a surface pattern was produced by the method described above. That is, first, as shown in FIG. 1 (A), a decorative mat 1 made of rigid urethane foam was prepared. The interior of the rigid urethane foam decorative mat 1 is a foam layer, and the transfer surface 2 is a dense integral skin layer. Then, as shown in FIG. 1 (B), a polyvinyl alcohol adhesive (viscosity: 8000 mPa · s) is sprayed on the transfer surface 2 of the decorative mat 1 under the condition of an air pressure of 2 kg / cm ² to form the adhesive layer 3. It was formed with a thickness of 200 μm. In forming this adhesive layer,
No dripping of the adhesive occurred, and an adhesive layer having a uniform thickness could be formed. The adhesive strength of the adhesive layer 3 was 9 points. Next, as shown in FIG. 1 (C), a granular coloring material 4 having an average particle diameter of 2000 μm (obtained by high-speed rotation mixing of a coloring pigment and cement particles) is added to the adhesive layer 3. Air pressure 2kg / c
m ² and buried in the adhesive layer 3. The color type of the granular coloring material 4 is a rust type. Then, as shown in FIG. 2 (D), a filling space was formed using the decorative mat 1 and the formwork 7, and a concrete material 6a was poured into this space, and then cured and cured. From this casting to curing and curing, the granular coloring material 4 embedded in the adhesive layer 3 was transferred and embedded on the concrete surface due to a decrease in the adhesive strength of the adhesive layer 3 due to moisture in the concrete. Then, as shown in FIG. 2 (E), the concrete product 6 was peeled from the decorative mat 1 to obtain a desired concrete product with a surface pattern. This concrete product had a granite pattern on its surface.

[0026]

Example 2 A natural stone crushed stone (average particle size 2000 μm) was blended together with the granular coloring material at a ratio of 10% to the whole of the granular coloring material and the natural stone crushed stone. Otherwise,
A concrete product with a surface pattern was produced in the same manner as in Example 1 above. This concrete product had a granite pattern on its surface.

[Brief description of the drawings]

FIG. 1A is an explanatory view showing a state in which a decorative mat is set up, FIG. 1B is an explanatory view showing a state in which an adhesive layer is formed on a transfer surface of the decorative mat, and FIG. () Is an explanatory view showing a state in which a granular coloring material is sprayed on the adhesive layer.

FIG. 2D is an explanatory view showing a state where concrete is cast using a decorative mat and a formwork, and FIG.
It is explanatory drawing which shows the state which peels a concrete product from the said decorative mat.

FIG. 3A is an explanatory view showing a state in which a decorative mat is laid on its side, and FIG. 3B is an explanatory view showing a state in which an adhesive layer is formed on a transfer surface of the decorative mat; (C)
FIG. 4 is an explanatory view showing a state in which a coloring material is sprayed on the adhesive layer.

FIG. 4D is an explanatory view showing a state in which concrete is poured while the decorative mat is laid down, and FIG.
It is explanatory drawing which shows the state which peels a concrete product from the said decorative mat.

FIG. 5 is a sectional view of an example of a spray nozzle used for spraying a granular coloring material in the present invention.

────────────────────────────────────────────────── ─── Continued on the front page (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 11/00-19/00 E04F 13/14 102 E04F 13/08

Claims (5)

(57) [Claims] 1. A decorative mat having a transfer surface is prepared, and the decorative mat is erected such that the transfer surface is substantially perpendicular to the ground. Is applied to the transfer surface of the decorative mat to form an adhesive layer, and the adhesive layer of the decorative mat transfer surface is sprayed with a granular coloring material and embedded in the adhesive layer,
A concrete material is poured with the transfer surface as a contact surface, the adhesive force of the adhesive layer is reduced by the moisture of the concrete material, and the granular coloring material embedded in the adhesive layer is transferred and embedded on the concrete surface. The cosmetic coloring method for concrete products. 2. The method according to claim 1, wherein the granular colorant has an average particle size of 70 μm or more. 3. The method for coloring a surface of a concrete product according to claim 1, wherein natural stone crushed stone is sprayed together with the granular coloring material on the adhesive layer formed on the transfer surface of the decorative mat. 4. The method for coloring a surface of a concrete product according to claim 1, wherein a granular coloring material of three or more colors is sprayed. 5. The high viscosity adhesive has a viscosity of 8000 mPa.
The surface coloring cosmetic method for a concrete product according to any one of claims 1 to 4, which is at least s.