JP3291180B2 - Method for producing sheet-like material and method for producing concrete product using the same - 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 of manufacturing a sheet material with a decorative stone for fixing a decorative stone on the surface of a concrete product, and a method of manufacturing a concrete product having the decorative stone fixed on the surface using the same. More specifically, the present invention relates to a sheet-like material with a decorative seed that can hold a decorative seed in an arbitrary shape and that can easily fix the decorative stone to the surface of a concrete product. The present invention relates to a method for manufacturing a concrete product.

[0002]

2. Description of the Related Art Conventionally, as a method of exposing decorative stones such as natural stones and glass beads to the surface of concrete and having a beautiful appearance, a method of fixing the decorative stones to the surface of concrete using a joint formation material is known. And a washing method using a mortar kneaded with a cosmetic seed stone as an aggregate.

[0003] As a method of fixing the decorative seed stone on the surface of concrete, decorative stones are laid in a concrete formwork, filled with a joint forming material in the gaps, and then concrete is poured and cured. After the hardened concrete is removed from the hardened concrete, the joint forming material is removed. However, with this method, it is difficult to fix the cosmetic seed stone having a small particle size uniformly and firmly, and therefore, a washing-out method is widely used.

[0004] As a washing method, concretely, a mortar into which a cosmetic stone is kneaded as an aggregate is poured under or on a concrete base material, and a part of the mortar is washed with water while the mortar is not cured. , A method of exposing a part of the aggregate, delaying the hardening of the mortar surface kneaded with cosmetic stone as an aggregate using a retarder or delay paper, etc., after the inside of the mortar is hardened, the unhardened mortar surface Washing with water or high-pressure water to expose a part of the aggregate.Pour mortar into which a decorative stone is kneaded as an aggregate under or above the concrete base material, and after the mortar hardens, a part of the mortar (Surface portion) is pickled, and a method of exposing a part of the aggregate is exemplified.

[0005] In these washing methods, (1) mortar is washed with water or pickled, so that a large amount of an inorganic suspension containing heavy metals is generated and requires treatment. (2) Yield of cosmetic stone (3) It is difficult to control the dispersion state of the cosmetic stone, and the finished state cannot be confirmed until after washing out. There are drawbacks such as the high frequency of non-defective products, (4) the time required for washing out work and poor workability, and (5) the need for advanced technology to perform complicated decorative finishing.

On the other hand, Japanese Patent Publication No. 6-86044 discloses that
A method is described in which paraffin is used as a joint forming material and the decorative material is fixed to the concrete surface.However, although the paraffin can be uniformly filled in the gaps between the decorative materials by heating and pouring into a mold, after curing, Since it has no elasticity, it is easily broken, and it is difficult to handle as an independent sheet holding a decorative material. In addition, it is difficult to remove paraffin, and it has been proposed to remove by heating and re-fluidizing. However, according to this, a large energy is required for removal, and furthermore,
Workability is also poor.

In order to avoid these problems, in recent years,
A sheet in which a cosmetic seed stone is fixed to a flexible base sheet with a hot melt adhesive has been proposed, but (1) the base sheet has no elasticity and lacks shape following properties, and (2) a hot melt adhesive However, there is a problem that the cosmetic seed is shifted due to heating, and (3) a desired exposure state of the cosmetic seed cannot be achieved due to the limitation of the amount of the adhesive applied.

[0008] That is, in the conventional manufacturing method, a concrete product in which the decorative stone was exposed on the surface with a desired design and the decorative stone was firmly fixed could not be obtained.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of the above facts, and has a decorative stone fixed on a surface thereof with a desired design, and the decorative stone is exposed to a desired design on a surface of a concrete product. It is possible to manufacture a sheet-like material that can be easily fixed in a state, and furthermore, a method for manufacturing a sheet-like material with a decorative seed stone in which a material for forming the sheet-like material is recyclable, and using the sheet-like material thus obtained. It is another object of the present invention to provide a method of manufacturing a concrete product in which a decorative seed stone is fixed on a surface in a desired design and exposed state.

[0010]

The method for producing a sheet-like material according to the present invention is a method for producing a sheet-like material with a decorative stone for fixing a decorative stone to the surface of a concrete product,
(1) a step of disposing a decorative seed stone and a decorative seed stone holding depth adjusting material for exposing at least a part of the decorative seed stone on a sheet; and (2) a number average molecular weight of 40. , 0
A thermoplastic high-molecular organic material having a hard block having a crystal structure, an aggregated structure, etc. of at least 00, and a soft block having an amorphous structure, etc. together with a low-molecular compound having a number average molecular weight of 5,000 or less And a high molecular weight blended material obtained by mixing a mixture of both materials having a volume fraction of the high molecular weight organic material of 30% or less with a high shear force. Is a step of heating and melting a sheet-forming thermoplastic material having a three-dimensional continuous network skeleton structure, and injecting it into the mold.
(3) removing the mold after the sheet-forming thermoplastic material is cured.

[0011] A second method for producing a sheet-like material of the present invention is a method for producing a sheet-like material with a decorative stone for fixing the decorative stone to the surface of a concrete product,
(1) A mold having a number average molecular weight of 40,000 or more
Where hard blocks such as crystal structure and aggregate structure are easily formed
Together with soft blocks such as amorphous structures
Thermoplastic organic materials and number average molecules
A low molecular weight material having an amount of 5,000 or less as a main component, and a content ratio of the high molecular weight organic material is less than the content ratio of the low molecular weight material. A step of heat-melting and injecting a thermoplastic material for forming a sheet having a three-dimensional continuous network skeleton structure, injecting and curing to form a thermoplastic material sheet; and (2) forming a thermoplastic material sheet on the cured thermoplastic material sheet in advance. (C) disposing a decorative seed heated to a temperature higher than the softening temperature of the sheet-forming thermoplastic material, cooling the decorative seed to room temperature, and holding the decorative seed on the sheet; Removing the sheet-forming thermoplastic material holding the decorative seed stone.

Further, the method for manufacturing a sheet-like material may include a step of pressing the decorative seed stone to a desired depth after disposing the heated decorative seed stone.

The sheet-forming thermoplastic material (hereinafter referred to as a sheet material as appropriate) used herein is composed mainly of a high-molecular-weight organic material and a low-molecular-weight material, and the content of the high-molecular-weight organic material is a low-molecular-weight material. , Wherein the high molecular organic material is composed of a polymer blend material having a three-dimensional continuous network skeleton structure.

Furthermore, in the manufacturing method of each sheet of the present invention, the above-described polymeric blend material number average molecular weight of 40,000 or more thermoplastic polymeric organic material Sutaira
A low molecular weight material having an average molecular weight of 5,000 or less as a main component,
In addition, a difference in solubility parameter between the thermoplastic high molecular weight organic material and the low molecular weight material is 3.0 or less.

The high-molecular organic material may be a hydrogenated product of a butadiene polymer, a hydrogenated product of a butadiene-styrene copolymer, a hydrogenated product of a styrene-butadiene-styrene block copolymer, polybutadiene and butadiene-polymer.
A hydrogenated product of a block copolymer with a styrene random copolymer, a block copolymer in which crystalline ethylene is linked to one or both terminals of an ethylene / butylene copolymer, and an ethylene-propylene rubber It is preferable that at least one kind is used.

This sheet-forming material has a melting temperature of 70 to 120 ° C. by using the high-molecular organic material as described above and adjusting the type and the amount of the low-molecular material to be used together.
Can be prepared.

Further, the method for producing a concrete product of the present invention is a method for producing a concrete product having a decorative seed stone fixed on a surface thereof. Arranging the held sheet-like material in a concrete casting mold; and (2) casting concrete in the concrete casting mold.
(3) a step of curing the cast concrete until it hardens and develops a desired strength; and (4) a step of removing the sheet-like material adhered to the surface after the concrete is cured and cured. It is characterized by.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

In order to manufacture a sheet-like material having a cosmetic stone on its surface, first, (1) a cosmetic stone and at least a part of the cosmetic stone are exposed on a sheet in a mold. The cosmetic seed stone holding depth adjusting material is arranged. A general-purpose concrete molding mold or the like can be used as the mold at this time.

The cosmetic seed stone holding depth adjusting material may be a fluid material or a solid material as long as the material does not allow the sheet material to enter.

When the cosmetic seed holding depth adjusting material is a fluid material, the cosmetic seed is placed first. That is, first,
A decorative stone is placed on the bottom of the form according to a desired design.

There are no particular restrictions on the stone used as a decorative stone, and natural stones such as bean stones and cobblestones, artificial stones having any particle size and color, glass, and the like can be adapted to the use of concrete products. Beads and the like can be selected and used, and a desired design using these can also be formed.

When placing the decorative seed stone in the mold, it is preferable to wet it with water or the like in advance from the viewpoint of improving workability.

Next, in the concrete formwork, a decorative stone holding depth adjusting material (hereinafter referred to as a depth adjusting material as appropriate) up to a predetermined position in order to bring the decorative stone into a desired exposed state. ).

The part of the decorative stone that is partially exposed from the depth adjusting material is held in the sheet-like material, and the part buried in the depth adjusting material is fixed in concrete, so that the adhesive strength is increased. From the viewpoints of design and design, the arrangement amount (arrangement height) of the depth adjusting material can be determined. The preferred depth varies depending on the shape, material, weight, etc. of the cosmetic stone, but in the case of natural stones such as bean stones and cobblestones, and glass beads, the depth of the depth adjusting material is the height of the cosmetic stone. 1/2 to 2
It is preferably about / 3 from the viewpoint of adhesion strength.

Further, as the fluid material, the specific gravity of the above-mentioned sheet material in a molten state is about 0.8 to 0.9, so that the specific gravity of the material is limited to a value exceeding this range. Non-affinity materials that do not mix with the material for use are preferred. For example, water, hot water, etc. have a specific gravity of 1.0
Since the sheet material is a hydrophobic material and both materials have no affinity, they can be suitably used.

When a solid material is used as the depth adjusting material, the bottom of the mold is uniformly filled with the depth adjusting material in advance, and the decorative seed is inserted to a desired depth and then placed. I do.

As the solid material, a material that can be disposed without gaps between the decorative stones in the mold, for example, a material that can be plastically deformed, such as clay, is preferable.

The material for adjusting the depth is not limited to the above-mentioned materials, but may be a material such as concrete or gypsum, which hardens after the decorative stone is placed and becomes solid.

Thereafter, (2) a polymer blend material containing a high-molecular-weight organic material and a low-molecular-weight material as main components and having a content of the high-molecular-weight organic material smaller than that of the low-molecular-weight material is placed in the mold. The high-molecular-weight organic material is formed by heating and melting a thermoplastic material for forming a sheet having a three-dimensionally continuous network skeleton structure, and is injected to a predetermined position.

In the case where the depth adjusting material is a flowable material, the specific gravity is greater than that of the sheet material that has been melted and is in a fluidized state, and the fluidity is incompatible with the sheet material. Since it is a substance, if the sheet material is gently injected from the upper part of the mold, these materials will not mix, and the upper part will be in a fluid state according to the specific gravity. To form

When the depth adjusting material is a solid material, the decorative seed stone and the depth adjusting material are in close contact with each other, so that the sheet material does not flow along the solid depth adjusting material, and the material does not flow. As in the case of using the conductive material, two layers are formed, that is, a sheet material in the upper part in a fluidized state and a lower part of the filled solid depth adjusting material in the lower part.

Since the sheet material melted in an oily state has a good shape followability, the material is uniformly filled into the details of the uneven portion of the decorative seed, and the decorative seed can be held stably. Since it is in close contact with the decorative seed, it is possible to prevent the concrete from adhering to the exposed portion of the final product of the decorative seed.

When the sheet material is injected into the form, a lath material serving as a core material and a lath material with ribs are provided at positions not in contact with the decorative stone in the sheet material to reinforce the sheet material. , Wire mesh, mesh bars made of reinforcing bars, and the like can also be arranged.

(3) After the sheet-forming thermoplastic material is cured, it is released from the mold and the depth-adjusting material is removed to obtain a sheet having a decorative seed stone.

The sheet material used here becomes a low-viscosity fluid state (oil-like) when melted by heating as described above, and becomes a solid state at room temperature. Therefore, curing can be carried out by leaving it at room temperature. Alternatively, the mold may be positively cooled and cured, for example, by placing the mold in a low-temperature storage.

After confirming the curing of the sheet-forming thermoplastic material, the sheet-like material having the decorative stone on its surface is removed from the mold, and if there is any depth adjusting material remaining on the sheet-like material surface, Remove it.

When the depth adjusting material is a solid material such as clay, the material can be reused after removing impurities such as dust. However, when the adhesion of dust and the like is not remarkable, the thickness of the material in the mold is reduced. Can be reused as it is.

Next, a method for producing the second sheet-like material of the present invention will be described. First, (1) a high-molecular-weight organic material and a low-molecular-weight material are used as the main components, and a high-molecular-weight organic material and a low-molecular-weight material are used. The high-molecular organic material is formed by heating and melting a thermoplastic material for forming a sheet having a three-dimensional continuous network skeleton structure, injecting it to a predetermined position, and curing to form a sheet made of the thermoplastic material. .

As the mold used at this time, a general-purpose concrete molding mold or the like can be used.

When the sheet material is injected into the mold, a lath material serving as a core material and a lath material having ribs are provided at positions not in contact with the decorative seeds in the sheet material to reinforce the sheet material. , Wire mesh, mesh bars made of reinforcing bars, and the like can also be arranged.

The sheet material melted in the oily state is as follows:
Since the fluidity is good, it is possible to form a sheet that is uniformly filled in the mold and has a uniform thickness. Also,
As described above, the sheet material becomes an oily fluid state by heating, but becomes a solid state at room temperature. Therefore, the sheet material can be cured by leaving it at room temperature. In addition, to improve workability, put the formwork in a low-temperature cabinet,
It may be hardened by actively cooling.

In this step, a sheet of a desired thickness made of a sheet material is formed in a concrete forming mold, and the already processed sheet-like thermoplastic material is laid in the concrete forming form. Alternatively, a method in which a small pellet-like or powdery sheet material previously placed in a mold is melted by the heat of the decorative stone to form a uniform sheet-like material may be employed. .

(2) On the cured sheet material, a decorative seed stone previously heated to a temperature higher than the softening temperature of the sheet material is placed. The cosmetic seed may be uniformly arranged on the entire surface of the sheet, or may be partially arranged according to a predetermined desired design.

The heating of the cosmetic seed stone is performed, for example, by using a hot air drier,
It can be performed using a high-temperature steam curing tank, a hot water bath, or the like.

When the heated cosmetic stone is placed on the hardened sheet, the temperature of the cosmetic stone softens the portion of the sheet that contacts the cosmetic stone, and the cosmetic stone sinks into the sheet. Since the thickness of the sheet is determined in consideration of the exposed state of the decorative seed as described above, a part of the decorative seed is exposed from the sheet.

At this time, the cosmetic stone may be sunk by its own weight without applying pressure, or may be sunk by pressing to a predetermined position. By performing the pressing, the exposed height of the decorative seed and the concrete joint depth can be adjusted to be constant, and even when the heating temperature of the decorative seed is low, the decorative seed can be buried in a desired position. It has the advantage that.

Thus, while the cosmetic stone is partially submerged in the sheet, the cosmetic stone is cooled to room temperature, and the cosmetic stone is held on the sheet-forming thermoplastic material. The cooling of this cosmetic stone may be performed by leaving it at room temperature,
Active cooling may be used.

Next, (3) the sheet-forming material holding the cosmetic stone is removed from the mold to obtain a sheet material with cosmetic stone.

The thermoplastic material for forming a sheet used in each of the production methods of the present invention mainly contains a high molecular weight organic material and a low molecular weight material. The high molecular weight organic material has a number average molecular weight of 20, 000 or more, especially 30,000 or more,
In particular, a thermoplastic polymer organic material having a molecular weight of 40,000 or more is preferable. For example, various thermoplastic elastomers such as styrene (butadiene styrene, isoprene styrene, etc.), ester, amide, urethane, and the like; Addition, other modified products, styrene,
ABS type, olefin type (ethylene type, propylene type,
Ethylene propylene, ethylene styrene, propylene styrene, etc.), vinyl chloride, acrylate (methyl acrylate, etc.), methacrylate (methyl methacrylate, etc.), carbonate,
Acetal type, nylon type, halogenated polyether type (chlorinated polyether type, etc.), halogenated olefin type (ethylene tetrafluoride type, fluorinated ethylene chloride type, fluorinated ethylene propylene type, etc.), cellulose type (acetyl cellulose) Thermoplastic resins such as vinylidene-based, vinylbutyral-based, and alkylene oxide-based (such as propylene oxide-based)
And modified rubbers of these resins.

Specific examples of the thermoplastic high molecular organic material include those having both a portion which easily forms a hard block such as a crystal structure and an aggregated structure and a soft block such as an amorphous structure. Preferably, specifically, the following are mentioned.

A block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer.

A block copolymer of polybutadiene and polystyrene, or a block copolymer of polyethylene / butylene and polystyrene obtained by hydrogenating a block copolymer of polybutadiene or an ethylene-butadiene random copolymer and polystyrene .

A block copolymer in which crystalline ethylene is linked to one end or both ends of an ethylene / butylene copolymer.

[0055] Ethylene-propylene rubber. Of these, a block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer is particularly preferred.

These various kinds of thermoplastic polymer organic materials are mainly used alone, but two or more kinds thereof may be used by blending.

On the other hand, the low-molecular material has a viscosity at 100 ° C. of 5 × 10 ⁵ centipoise or less, particularly 1 × 1 ⁵ centipoise.
0 ⁵ centipoise or less, and from the viewpoint of molecular weight, the number average molecular weight of the low molecular weight material is 20,
Less than 000, in particular less than 10,000, especially 5,000
It is preferably 0 or less. Usually, a liquid or liquid material at room temperature is suitably used as such a low molecular material. Further, any of hydrophilic and hydrophobic low-molecular materials can be used, but from the viewpoint of peelability from decorative stones and concrete, hydrophobic low-molecular materials are preferable.

Although the low molecular material is not particularly limited,
The following are preferably exemplified. Softeners: Softeners for various rubbers or resins, such as mineral oils, vegetable oils, and synthetic oils. Examples of the mineral oils include aromatic, naphthenic, and paraffinic process oils. Vegetable oils include castor oil, cottonseed oil, sweet oil, rapeseed oil, soybean oil, palm oil, palm oil,
Peanut oil, wood wax, pine oil, olive oil and the like.

Plasticizers: Various ester plasticizers such as phthalic acid ester, phthalic acid mixed ester, aliphatic dibasic acid ester, glycol ester, fatty acid ester, phosphoric acid ester, stearic acid ester, epoxy plasticizer, etc. Plasticizers for plastics or phthalates, adipates, sebacates, phosphates,
NBR plasticizers such as polyethers and polyesters.

Tackifiers: Various tackifiers (tackifiers) such as coumarone resins, coumarone-indene resins, phenol terpene resins, petroleum hydrocarbons, and rosin derivatives.

Oligomers: crown ether, fluorine-containing oligomer, polyisobutylene, xylene resin, chlorinated rubber, polyethylene wax, petroleum resin, rosin ester rubber, polyalkylene glycol diacrylate,
Various oligomers such as liquid rubbers (polybutadiene, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone oligomers, and poly-α-olefins.

Lubricants: hydrocarbon lubricants such as paraffin and wax; fatty acid lubricants such as higher fatty acids and oxy fatty acids; fatty acid amide lubricants such as fatty acid amides and alkylene bis fatty acid amides; fatty acid lower alcohol esters; fatty acid polyhydric alcohol esters , Ester lubricants such as fatty acid polyglycol esters, fatty alcohols,
Various lubricants such as alcoholic lubricants such as polyhydric alcohol, polyglycol and polyglycerol, metal soaps, and mixed lubricants.

In addition, latex, emulsion, bituminous composition, clay, inorganic silicone oil, phosphazene and the like are also suitable as low molecular weight materials.

Further, organic solvents such as hydrocarbons, halogenated hydrocarbons, alcohols, phenols, ethers, acetals, ketones, fatty acids, esters, nitrogen compounds and sulfur compounds, and petroleums , Water, an aqueous solution and the like can be used in combination to adjust the physical properties.

These low molecular weight materials may be used alone or in combination of two or more. In the present invention, in order to obtain a polymer blend material containing a large amount of the low molecular weight material with a large amount of the low molecular weight material and a smaller amount of the high molecular weight organic material, each of the low molecular weight material and the high molecular weight organic material is used. A difference in solubility parameter value δ = (ΔE / V) ^1/2 (ΔE = molar evaporation energy, V = molar volume) of 3.0 or less;
It is preferable to select both materials so as to be preferably 2.5 or less. If this difference exceeds 3.0, it is difficult to maintain a large amount of low molecular weight material due to the compatibility of the two materials, which hinders the lowering of the elasticity of the obtained polymer blend material. It is not preferable because it easily occurs.

The sheet material must have optimal shear, tensile strength and elongation characteristics, as described later, in order to be free from cracks after curing and to be easily separated from concrete products. For this reason, it is necessary for the polymer organic material constituting the polymer blend material of the sheet material to form a three-dimensional continuous network skeleton structure, and the average diameter of the network skeleton is 50 μm or less, preferably 30 μm or less, average cell (mesh) diameter is 500 μm
Or less, preferably 300 μm or less, and the volume fraction of the high-molecular-weight organic material is defined as [volume of high-molecular-weight organic material / (volume of high-molecular-weight organic material + volume of low-molecular-weight material)] × 100 (%) , The volume fraction of the high-molecular organic material is 30% or less,
In particular, it is desirable to be 25% or less.

The polymer blend material can contain a predetermined amount of a high molecular organic material and a low molecular material, and if necessary, other compounding agents, so that the high molecular organic material can form a three-dimensional continuous network skeleton structure. It can be obtained by mixing under mixing conditions. In this case, it has a uniform three-dimensional continuous network skeleton structure made of a high-molecular-weight organic material, low bleeding of a low-molecular-weight material, and a high-quality material that satisfies the aforementioned characteristics. In order to obtain a molecular blend material, it is preferable to use a high-shear mixer as the mixer, and in particular, a mixer capable of providing a high shear force and a high shear rate between a fixed wall and a rotating rotor. , The distance (clearance) between the fixed wall and the rotating part (rotor) is t (m), and the rotating peripheral speed of the rotor is v
(M / sec) and the shear rate of the rotor as V,
When V = v / t (sec ^-1 ), V ≧ 5.0 × 10 ² (sec ⁻¹ ), preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ), and more preferably V ≧ 2. It is advantageous to use a special high-shear mixer that satisfies 5 × 10 ³ (sec ⁻¹ ), more preferably V ≧ 5.0 × 10 ³ (sec ⁻¹ ).

The polymer blend material according to the present invention is not particularly limited, such as a normal bulk, gel, foam, etc., but is in a gel state, in particular, a three-dimensional continuous uniform material made of a thermoplastic polymer organic material. Those in a gel state having a network skeleton structure are particularly effective for the present invention.

As the material for the sheet, a high-molecular organic material as described in the above (1) to (4) is used, and by adjusting the kind and blending amount of the low-molecular material, the melting temperature becomes, for example, 70.
Although it is possible to prepare a material having a melting temperature of 100 to 120 ° C., it is preferable to use a material having a melting temperature of 100 to 120 ° C. in consideration of the case where the curing of concrete is performed by heating.

Examples of the method for heating the sheet material include a method in which the material is placed in a container, and the container is heated by a direct fire, a heater, a method in a dryer, a method in a microwave oven by microwave, a method in steam. A method of heating, a method of heating with a sand bath, an oil bath, and the like are mentioned, and there is no particular limitation. However, it is preferable to employ a method of heating with steam from the viewpoint that temperature control is reliable and uniform heating can be performed. .

As the physical properties of this sheet material after curing, the tensile strength evaluated by a tensile test according to JIS K6301 is 0.5 kg / cm ² or more, and the elongation at break is 30 kg / cm ^2.
The content of 0% or more is preferable from the viewpoint of workability when the sheet-like material is peeled off after the decorative seed stone is fixed on the surface of the concrete product.

Next, a method of manufacturing a concrete product using the sheet obtained by these manufacturing methods will be described.

The concrete product having the decorative seed stone fixed on the surface thereof is obtained by: (1) placing the sheet-like material having the decorative seed stone on at least a part of the surface obtained by each of the above-described manufacturing methods in a concrete casting mold; (2) Concrete is cast into the concrete casting formwork.

The concrete to be cast here can be arbitrarily used in accordance with the purpose of use of the concrete product. Also, the casting method can be performed by a conventional method. That is, ordinary cement concrete, prestressed concrete (PC), lightweight cellular concrete, or the like can be used. In the case of manufacturing a concrete product of a fixed shape such as a flat plate or an L-shaped retaining wall, a reinforcing material is put in advance to manufacture. You can also.

Thereafter, (3) curing is performed until the cast concrete hardens and develops the desired strength.
The curing may be normal temperature curing or high temperature curing.

From the viewpoint of workability, high-temperature curing is preferable.
Since the temperature of steam curing which is usually performed is 60 to 70 ° C., if a material having a melting temperature of 100 to 120 ° C. is used, the thermoplastic material constituting the sheet material can be used even when high temperature steam curing is performed under normal conditions. Does not affect

When high-temperature curing other than steam curing is performed, it is preferable from the viewpoint of finishability that the upper limit of the heating temperature be around the melting temperature of the sheet material in order to prevent deformation of the sheet material.

(4) After the cast concrete has hardened, it is released from the mold, and the sheet-like material adhered to the surface is peeled off to obtain a concrete product having a decorative seed stone fixed on the surface.

The sheet material holds the low-molecular material in a three-dimensional continuous uniform network skeleton structure made of a thermoplastic high-molecular organic material, and when the hydrophobic low-molecular material is held, the entire material is used. A concrete product that is hydrophobic, has good mold release from concrete and decorative stones, and has no decorative stones or concrete remaining on the surface of the sheet-like material, and the decorative stones are fixed to the surface with the desired design Can be obtained. Therefore, there is no need for pretreatment such as application of a release agent or posttreatment such as removal of concrete remaining on the sheet surface.

Further, the sheet material is a rubber-like elastic body in which the entire material is held by a polymer network skeleton structure, is capable of elastic deformation, has sufficient strength against tensile stress, and has a large area at one time. It is possible to peel off.
Therefore, without damaging the molded sheet,
The sheet material can be easily peeled off, and the decorative stone attached to the surface of the concrete product can be easily separated from the sheet material, and the workability is good.

Further, the sheet material melted in an oily state is uniformly filled in a mold due to its good fluidity, and the surface of the formed sheet-like material is smooth, and the surface of the sheet-like material is not easily mixed with the cosmetic stone. Since the adhesion is also good, the surface of the concrete joint part of the obtained concrete product is smooth,
In addition, concrete does not enter the gap between the sheet material and the decorative stone, and no concrete adheres to the surface of the decorative stone fixed on the concrete product surface, producing a concrete product with excellent appearance. can do.

The sheet-forming thermoplastic material peeled off from the surface of the concrete product is heated and melted, so that the contaminant, such as peeling agent, cement, sand, water, dust and the like, precipitates. can do.
Therefore, it is easy to use (recycle) again.

According to the method for producing a concrete product using the sheet-like material obtained by the production method of the present invention, in addition to a concrete plate, a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a concrete block for a sidewalk, concrete It is possible to easily manufacture a concrete product having a decorative seed stone fixed on a surface of a fence or the like with an arbitrary design. The use of the concrete product is not particularly limited, and examples thereof include those for construction (decorative panels for interior and exterior of buildings, floors, etc.), for civil engineering (road pavement, decorative panels for wall surfaces, etc.), and the like.

[0084]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples.

FIGS. 1A to 1C are schematic sectional views sequentially showing a method for manufacturing the sheet-like material 10 with decorative stones of Example 1 using the depth adjusting material.

FIG. 1A shows a decorative seed 1 in a mold 12.
FIG. 1B shows a state in which a clay 16 which is a depth adjusting material is arranged so that a part of the decorative seed stone 14 is exposed, and FIG.
Shows a state in which the sheet-forming thermoplastic material 18 in a molten state is further injected.

FIG. 1 (C) shows the state taken out of the mold 12.
1 shows a sheet-like material 10 with a decorative seed stone comprising 18 layers of a sheet-forming thermoplastic material holding a decorative seed stone 14 on the surface.

FIGS. 2A to 2C are schematic sectional views sequentially showing a method of manufacturing the concrete product 20 having the cosmetic seed stone fixed to the surface thereof according to the second embodiment.

FIG. 2A shows a concrete casting form 2.
2 shows a state in which a sheet-like material 10 made of a sheet-forming thermoplastic material 18 holding a decorative seed stone 14 is arranged in 2,
FIG. 2 (B) shows a state in which concrete 24 is poured into the formwork 22. FIG. 2 (C) shows a state in which the cured concrete 24 is released from the mold and the sheet-forming thermoplastic material 18 is removed from the surface. It shows a state in which it is peeled off.

FIGS. 3A to 3C are schematic cross-sectional views showing in order a method of manufacturing the sheet-like material 26 with decorative seeds according to the fourth embodiment in which decorative stones are arranged on a sheet.

FIG. 3A shows a state in which a sheet-forming thermoplastic material 18 in a molten state has been injected into the mold frame 12, and FIG. FIG. 3 shows a state in which the heated cosmetic stone 14 is arranged, and FIG.
(C) shows the sheet-like material 26 in which the decorative seed stone 14 is held in the cured 18 layers of the sheet-forming thermoplastic material. (Example 1) (1) Preparation of thermoplastic material A for sheet formation As raw materials, polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, was used. Block copolymer (high molecular weight organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 15 vol%, low molecular weight alkylbenzene (softening agent) (Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight: 335, SP value: 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co., Ltd .: molecular weight: 426, SP value: 8.4) 42.5% by volume)
And a high-shear type special mixer ("TK. Auto Homomixer" manufactured by Tokushu Kika Kogyo Co., Ltd.) for 30 rpm.
The mixture was mixed under a mixing condition of 00 rpm, a shear rate of 1.0 × 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance. did. When a section of the polymer blend material was cut out and confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average diameter of skeleton of 5 μm, average diameter of cell of 15 μm) composed of a thermoplastic polymer organic material was formed. It was confirmed that. In addition, Asker-C hardness of this polymer blend material is 10 and tensile strength is 3 kg /
cm ² , elongation at break 1500%, compression set (7
(0 ° C., 22 hours) was 30 and the melting temperature was 120 ° C. (2) Manufacture of a sheet-like material After the clay 16 as a depth adjusting material is uniformly arranged on the bottom of the mold 12, a bean stone 14 having an average particle diameter of 10 mm
Of the sheet-forming thermoplastic material A18 is heated and melted at 170 ° C., and is gently poured into the mold frame 12, and the bean stone 1
After the sheet material A18 was uniformly filled during the period 4, the sheet material was left to stand at room temperature, and the sheet-forming thermoplastic material A18 was cooled and hardened.

After the sheet material A18 is cured, the mold 1
2 was released from the mold 2 to obtain a sheet-like material 10 having a bean stone 14 as a cosmetic seed stone on the surface. (Example 2) (3) Manufacture of concrete product The sheet-like material 10 holding the bean stone 14 on the surface obtained in Example 1 was placed on the bottom of the concrete casting formwork 22 at the bottom of the bean stone 14.
Was laid so that the side holding the was up.

[0093] Concrete 24 was cast into the concrete casting formwork 22 by a conventional method, steam-cured at about 70 ° C for 3 hours to harden the concrete 24, and then released from the mold.

Then, the sheet 10 made of the sheet-forming thermoplastic material A18 was peeled off from the surface.

In the sheet-like material 10, the portion of the sheet-forming thermoplastic material A 18 is easily formed into a single sheet from the exposed surface of the bean stone 14 fixed to the surface of the concrete joint and the concrete product 20. Cleanly removed,
No cutting on the way or residue on the surface of the concrete product 20 or the bean stone 14 was observed.

In the obtained concrete product 20, the bean stone 14 is securely fixed on the surface, and there is no detached stone.
No concrete adhesion was observed on the surface of the bean stone 14, and the surface of the concrete joint formed between the bean stones 14 was smooth, and the concrete product 20 was excellent in appearance.
Could be manufactured.

Further, the sheet-forming thermoplastic material A18 peeled off from the surface of the concrete product 20 was heated and melted to easily remove impurities, and could be reused (recycled). (Example 3) (1) Preparation of thermoplastic material B for sheet formation As raw materials, polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, was used. Block copolymer (high molecular weight organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 10% by volume and alkylbenzene (softening agent)
(Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight 335, SP
Value 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co .: molecular weight 426,
SP value 8.4) 42.5% by volume, and further 5% by volume of higher fatty acid amide (oleic acid amide Armoslip: manufactured by Lion) were added, and a special high-shear mixer ("TK Auto Homo") was added. Mixer ”Tokushu Kika Kogyo Co., Ltd.
3,000 rpm, shear rate 1.0 ×
The mixture was mixed under a mixing condition of 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance. When a section of this polymer blend material was cut out and confirmed by an optical microscope, a three-dimensional continuous network skeleton structure (average skeleton diameter of 3 μm, average cell diameter of 18 μm) made of a thermoplastic organic polymer material was formed. It was confirmed that. The Asker-C hardness of this polymer blend material is 1
0, tensile strength 3 kg / cm ² , elongation at break 150
0%, compression set (70 ° C., 22 hours) was 30, and melting temperature was 120 ° C. (2) Manufacture of a sheet-like material Clay, which is a depth adjusting material, is uniformly filled into a mold to a depth of 5 mm, and a bean stone having an average particle diameter of 10 mm is placed therein. It was arranged so that the degree was exposed. Then, the sheet-forming thermoplastic material B heated and melted at 170 ° C. is gently poured into a mold, and the sheet material B is uniformly filled between the bean stones. The forming thermoplastic material B was hardened by cooling.

After the sheet material B was cured, the sheet material was released from the mold to obtain a sheet-like material having a bean stone as a cosmetic stone on the surface.

Thereafter, the clay remaining in the mold was taken out, and impurities such as dust and dirt were removed and reused.
Here, when the adhesion of dust and the like is not remarkable, the clay surface in the mold can be made uniform and reused as it is.

A concrete product was manufactured in the same manner as in Example 2 using the sheet-like material obtained here, but a concrete product having a bean stone fixed on the surface as in Example 1 was easily obtained. Was completed. Further, the sheet-forming thermoplastic material B peeled off from the concrete surface could be reused similarly to the sheet-forming thermoplastic material A.

Example 4 (1) Preparation of Sheet Forming Thermoplastic Material C As a raw material, a high molecular weight organic material, polyethylene, was present at both ends and a block copolymer containing ethylene-butylene at the center (high Molecular organic material) (number average molecular weight 280,000:
90% by volume of paraffin oil (softening agent) (PW-32: manufactured by Idemitsu Kosan Co., Ltd .: molecular weight 405: SP value of 7.9), which is a low molecular weight material, is added to 10% by volume of SP value 8.0) and a high shearing type. Mixing conditions using a special mixer ("TK Auto Homomixer" manufactured by Tokushu Kika Kogyo Co., Ltd.) at a rotation speed of 3000 rpm, a shearing speed of 1.0 × 10 ⁴ sec, a mixing temperature of 180 ° C. and a mixing time of 40 minutes. To obtain a polymer blend material having a uniform appearance, which was used as a sheet-forming thermoplastic material C. Also, cut out a section of this polymer blend material,
When confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average skeleton diameter of 5 μm) made of a thermoplastic polymer organic material was confirmed.
m, the average cell diameter was 15 μm). In addition, Asker of this polymer blend material
The C hardness was 2, the tensile strength was 1.2 kg / cm ² , the elongation at break was 970%, the compression set (70 ° C., 22 hours) was 50, and the melting temperature was 110 ° C. (2) Production of sheet-like material The sheet material 18 was injected into the mold 12 so as to have a depth of 3 mm, and was cured at room temperature to form the sheet-like material 14 in the mold 12.

The soybean stone 14 having an average particle size of 10 mm as a cosmetic seed stone was heated to 100 ° C. in a drier and kept at that temperature for 1 hour to equalize the heat. This bean stone 14 was placed on the cured sheet material 18 described above.

In the sheet 18 in the frame 12, the bean stone 1
The portion in contact with 4 was softened by the heat, and the bean stone 14 began to sink into the sheet 18. At this time, 0.00
The bean stone 14 was pressed at a pressure of 7 kgf / cm ² , and was allowed to cool to room temperature as it was.

The bean stone 14 was held on the sheet 14 with about 70% of its height exposed. This was released from the mold frame 12 to obtain a sheet-like material 26 having a bean stone 14 as a cosmetic seed stone on the surface.

A concrete product having a bean stone 14 fixed on the surface could be easily manufactured in the same manner as in Example 2 except that the sheet-like material 26 was used.

The cured sheet-forming thermoplastic material C was easily and completely peeled off as a single sheet from the surface of the concrete joint and the exposed portion of the bean stone, and no adhesion of the sheet material to the surface of the concrete product was observed. In addition, the bean stone was completely fixed on the concrete surface, and no adhesion of concrete was observed on the bean stone surface, and the formed joints were smooth and a concrete product excellent in appearance was obtained.

After the production of the concrete product, the sheet-forming thermoplastic material C peeled from the concrete surface is heated and melted similarly to the sheet-forming thermoplastic material A, whereby impurities are easily removed and reused (recycled)
Was possible.

[0108]

As described above, according to the production method of the present invention, a decorative stone is fixed on a surface of a concrete product with a desired design, and the decorative stone is exposed on a surface of a concrete product with a desired design. It is possible to manufacture a sheet material that can be fixed easily, and furthermore, the material of the sheet material can be recycled,
Further, according to the manufacturing method using the sheet-like material thus obtained, there is an excellent effect that a concrete product having a decorative seed stone fixed on the surface in a design and exposed state can be easily manufactured.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic cross-sectional view sequentially showing a method for manufacturing a sheet-like material with a cosmetic stone in Example 1, and FIG. 1 (A) is a cosmetic stone and a part of the cosmetic stone arranged in a mold. Shows a state in which the clay and the clay are arranged so as to be exposed. (B) shows a state in which a thermoplastic material for sheet formation is further injected into the mold. (C) shows a sheet-like material with a decorative seed stone obtained by demolding.

FIG. 2 is a schematic sectional view sequentially showing a method of manufacturing a concrete product having a cosmetic seed stone fixed to a surface thereof according to a second embodiment. FIG. 2 (A) is a sheet with a cosmetic seed stone in a concrete casting mold. (B) shows a state where concrete is poured into a concrete formwork,
(C) shows a state where the sheet-like material is peeled off from the surface after the cured concrete is released from the mold.

3A to 3C are schematic cross-sectional views sequentially illustrating a method for manufacturing a sheet-like material with a decorative stone according to Example 4, and FIG. 3A is a diagram in which a molten sheet-forming thermoplastic material is injected into a mold. (B) shows a state in which a pre-heated cosmetic stone is placed on the cured sheet material, and (C) shows
Shows a sheet-like material with a decorative seed stone obtained by demolding.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 sheet-like material with decorative seed stone 12 formwork 14 peastone (decorative seed stone) 16 clay (material for adjusting cosmetic stone holding depth) 18 thermoplastic material for sheet formation 20 concrete product 22 concrete casting formwork 24 concrete 26 Sheets with cosmetic stones

Continuing from the front page (72) Inventor Hiroaki Suzuki 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Masao Kusano 7 Minamienkajima, Taisho-ku, Osaka-shi, Osaka −55 Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Shusuke Harada 7-1-55 Minami Enkajima, Taisho-ku, Osaka City, Osaka Prefecture Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Tetsuo Kobayashi Osaka Prefecture 7-1-55, Minami-enkajima, Taisho-ku, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (56) References JP-A-3-205103 (JP, A) JP-A-5-147013 (JP, A) (58) Field surveyed (Int.Cl. ⁷ , DB name) B28B 1/16 B28B 1/14

Claims (6)

(57) [Claims] 1. A method for producing a sheet-like material with a decorative stone for fixing the decorative stone to the surface of a concrete product, comprising: (1) a decorative stone and at least one of the decorative stones in a formwork; (2) a step of arranging a decorative seed stone holding depth adjusting material for exposing a part on the sheet; and (2) forming a hard block having a number average molecular weight of 40,000 or more, such as a crystal structure or an aggregated structure. Part and a thermoplastic polymer organic material having a soft block having an amorphous structure or the like together with a number average molecular weight of 5,000.
0 or less low molecular weight material as the main component, and high molecular weight organic material
It is constituted by using a polymer blend material obtained by mixing a mixture having a volume fraction of 30% or less with a high shear force,
A step of heating and melting a sheet-forming thermoplastic material in which the high-molecular-weight organic material has a three-dimensional continuous network skeleton structure and injecting it into the mold; (3) the sheet-forming thermoplastic material is Removing the mold after curing. 2. A method for producing a sheet-like material with a decorative stone for fixing the decorative stone to the surface of a concrete product, comprising: (1) a crystal having a number average molecular weight of 40,000 or more in a mold; The main component is a thermoplastic high molecular weight organic material that has a portion that easily forms a hard block, such as a structure or a cohesive structure, and a soft block, such as an amorphous structure, and a low molecular weight material with a number average molecular weight of 5,000 or less. And a heat-forming sheet for forming a sheet, wherein the high-molecular-weight organic material is formed using a polymer blend material having a lower content than the low-molecular-weight material, and the high-molecular-weight organic material has a three-dimensional continuous network skeleton structure. A step of heating and melting the thermoplastic material, injecting it, and curing it to form a thermoplastic material sheet; (2) softening the thermoplastic material for sheet formation on the cured thermoplastic material sheet in advance; After placing the decorative species stone which has been heated to a high temperature than degrees, cosmetic species stone was cooled to room temperature,
A method of manufacturing a sheet-like material, comprising: a step of holding a decorative seed stone on the sheet; and (3) a step of releasing the sheet-forming thermoplastic material holding the decorative seed stone. 3. The method for producing a sheet-like material according to claim 2, further comprising a step of pressing the decorative seed stone to a desired depth after disposing the heated decorative seed stone. 4. A polymer blend material comprising a thermoplastic polymer organic material having a number average molecular weight of 40,000 or more and a low molecular material having a number average molecular weight of 5,000 or less as main components, and wherein the thermoplastic polymer 4. The method according to claim 1, wherein a difference in solubility parameter between the organic material and the low molecular weight material is 3.0 or less. 5. The high-molecular organic material is a hydrogenated product of a butadiene polymer, a hydrogenated product of a butadiene-styrene copolymer, a hydrogenated product of a styrene-butadiene-styrene block copolymer, polybutadiene and butadiene-styrene. 1 selected from a hydrogenated product of a block copolymer with a random copolymer, a block copolymer in which crystalline ethylene is linked to one or both ends of an ethylene / butylene copolymer, and ethylene-propylene rubber The method for producing a sheet-like material according to claim 1, wherein the number is at least one kind. 6. A method for producing a concrete product having a decorative stone set on a surface thereof, comprising: (1) a sheet-like material obtained by the method according to any one of claims 1 to 3, wherein the surface holds the decorative stone. (2) a step of placing concrete in the concrete casting formwork; and (3) a step in which the poured concrete hardens and has a desired strength. A method for producing a concrete product, comprising: curing the concrete until it develops; and (4) removing the sheet-like material attached to the surface after curing the concrete.