JP4119009B2 - Method for producing artificial stone - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for producing a pseudo stone, and more particularly to a method for producing a pseudo stone plate having a surface very similar to a rough (porous) natural stone, which is used as a stone plaster on a wall surface or a floor surface.
[0002]
[Prior art]
2. Description of the Related Art In recent years, buildings and civil engineering structures and the like are required to nurture and enhance the natural tone or heavy atmosphere, and natural stone materials or pseudo stone materials are frequently used for forming wall surfaces and floor surfaces. However, natural stone materials are becoming more expensive due to resource depletion and the like, and there are difficulties in construction, and construction with natural stone is becoming more expensive. On the other hand, artificial stones (artificial stones) resembling natural stones are cheaper than natural stones and are excellent in workability, and in recent years, artificial stones have been frequently used instead of natural stones.
[0003]
Conventionally, for example, a stone with a rough surface made of Ryukyu limestone called “travertine” has been proposed. As its manufacturing method, a method of forming with white Portland cement using travertine grains generated in the processing process of travertine as an aggregate (Japanese Patent Laid-Open No. 8-2958), and laying by spraying granular or massive soil on a mold However, a method for forming a surface state very similar to travertine by filling cement concrete raw material thereon and removing the soil adhering to the surface after solidification has been proposed by the present applicants (Japanese Patent Laid-Open No. Hei 9). -255455).
[0004]
[Problems to be solved by the invention]
Of the conventionally proposed methods for producing pseudo stones, the latter method is a natural stone by removing soil adhering to the cement concrete surface irregularly and removing the soil adhering to the surface after demolding. A close expression can be obtained. However, when obtaining a thin flat plate for use as a floor or wall material, the concrete layer is formed with a thin formwork for the flat plate, and the concrete layer is formed thin. There is a drawback that sufficient strength cannot be obtained.
[0005]
Therefore, the present invention has been developed to overcome the above-mentioned problems of conventional pseudo stone manufacturing technology, and has an expression that closely resembles that of natural stone such as travertine and has a desired strength. It is an object of the present invention to provide a method for producing a pseudo stone capable of easily and efficiently obtaining a thin pseudo stone plate-like body.
[0006]
[Means for Solving the Problems]
The method for producing a pseudo stone according to the present invention that solves the above-described problems is a method for producing a pseudo stone material using a cement material as a solidifying material, and having a predetermined thickness comprising a soil spray layer in which soil is sprayed in a mold and a cement material. Laminate forming step of alternately laminating cement layers to form a laminate, compacting step of vibrating or pressing the laminate to compact the cement layer, demolding after solidifying cement material, and laminating the laminate A slicing step to obtain a plate-like body by thinly slicing the soil-spreading layer on at least one side so that the soil-spreading layer is exposed, and a soil removing step to remove the soil exposed on the surface of the plate-like body Is.
[0007]
If the thickness of the cement layer is formed to be twice the thickness of the plate-like body to be manufactured, the slicing step includes slicing the intermediate thickness portion of the cement layer and the soil spreading layer portion, respectively. Thus, it is possible to efficiently obtain a plate-like body in which the earth spreading layer is exposed on one side. On the other hand, when the thickness of the cement layer is formed to be the thickness of the plate-like body to be manufactured, the slicing step exposes the earth spreading layer on both sides by slicing the soil spreading layer portion, respectively. A plate-like body can be obtained.
[0008]
In addition, another method for producing a pseudo stone according to the present invention that solves the above-described problem is a method for producing a pseudo stone using a cement material as a solidifying material.
A plate-like body is formed by an earth-spreading layer forming step for forming an earth- spreading layer by arbitrarily sprinkling granular or massive earth and a cement layer forming step for forming a cement layer with a predetermined thickness. And a partition plate insertion step of inserting a partition plate on the cement layer. The plate body formation step and the partition plate insertion step are alternately repeated, and the soil is placed in the mold. Laminate forming step of alternately laminating plate-like bodies and partition plates composed of a spraying layer and a cement layer to form a laminate, and compacting step of compacting the cement layer by vibrating or pressing the laminate Characterized by comprising a partition plate removing step for obtaining a plate-like body by removing the partition plate after demolding after solidifying the cement material, and an earth removing step for removing the earth on the surface of the plate-like body It is. In this case, a slicing process is not required. By the above method, an artificial travertine plate-like body closer to natural stone can be obtained at low cost.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1: has shown the flowchart of embodiment which concerns on the manufacturing method of the pseudolite of this invention. In the present embodiment, as shown in FIG. 2, as shown in FIG. 2, the earth spraying in which the earth is sprayed in the columnar mold 10 in the laminate forming process 1 including the earth spreading layer forming process 2 and the cement layer forming process 3. The laminated body 13 is formed by alternately laminating the layers 11 and the cement layers 12 made of a cement material having a predetermined thickness. The earth spreading layer is for forming irregularities and porous textures that are very similar to natural stones on the surface of the plate-like body, and according to the surface properties of the target natural stone, the desired granular or massive soil and its It is formed by selecting the particle size and spreading earth at an arbitrary density on the mold bottom and / or the cement layer. The cement layer 12 is formed by filling a cement material obtained by kneading cement (solidifying material), aggregate, and water so as to have a desired plate-like thickness or twice the thickness (FIG. 2). In the embodiment shown in FIG. 2, the thickness is twice as large).
[0010]
Next, while the cement material of the laminated body 13 is not solidified, the cement layer is compacted by vibrating the frame body 10, that is, the laminated body formed in the mold (consolidating step 4). The compaction is not necessarily limited to the case where the laminated body is vibrated, and may be performed by pressing with a press from above in the laminated state. By compacting the concrete, the concrete becomes dense and the strength is improved, and a sufficient strength can be ensured even if the concrete is sliced.
[0011]
After the compaction step, the concrete laminate 13 is obtained by demolding at a stage where the cement material is sufficiently solidified to sandwich the earth spray layer. The concrete laminate 13 is sliced in parallel from the middle position of the earth spreading layer 11 and the middle thickness position 15 of the cement layer 12 indicated by the one-dot chain line in FIG. Is obtained (demolding / slicing step 5). In this embodiment, the thickness of the cement layer is formed to be twice that of the plate-like body. However, if the thickness of the cement layer is formed to a desired thickness of the plate-like body in the laminate forming process, It is sufficient to slice from only the spray layer. In the case of the present embodiment, since the earth is attached to one side of the obtained plate-like body, the earth is washed away by blowing water or removed by blowing air (earth removing step 6). . By removing the earth, the place where the earth has adhered forms irregularities on the cement layer surface as shown in Fig. 3, and expresses a natural porous texture. You can get a body. And since the obtained plate-shaped body is fully compacted, even if it is a thin plate, it has sufficient strength and can be used as a stone material for masonry work such as a wall surface or a floor surface.
[0012]
The soil forming the soil spreading layer 11 may be any soil as long as it does not easily dissolve in the kneaded cement material and can be easily removed from the cement layer surface after solidification. The particle size is adjusted to have a suitable particle size or mass. Red soil is distributed nationwide, especially red soil distributed in Okinawa Prefecture is called Kunigami merger, most of which is viscous, has very fine particles and weak adhesion, so it is very soluble in water. Therefore, it can be easily washed away from the cement layer surface. On the other hand, the fine particles of red soil adhering to the cement surface penetrate into the cement layer and remain inside the cement layer. .
[0013]
However, the earth is not necessarily limited to red soil or pure clay, but may be fine particles or lumps other than other soil or soil, such as coral powder, as long as it can be easily removed from the cement layer surface after solidification. May be. In addition, the particle size is appropriately adjusted according to the surface properties of the cement layer. In the above-described embodiment, the soil is spread moderately on the bottom of the first formwork to form an earth-spreading layer, and the cement material is put thereon. In this manner, the cement material may be added to form a cement layer, and the first earth spray layer may be formed thereon.
[0014]
4 and 5 show an embodiment of a method for producing a pseudo stone according to the invention described in claim 4. The difference between the present embodiment and the above embodiment is that a partition is formed by inserting a partition plate between a single plate-like body composed of an earth spreading layer and a cement layer, and after demolding, the partition plate By removing, each plate-like body can be obtained without slicing. That is, in the present embodiment, a plate-like body that forms a single plate-like body by an earth-spreading layer forming step 21 that arbitrarily sprinkles granular or massive earth and a cement layer-forming step 22 that forms a cement layer. The body forming step 23 is performed, and the partition plate inserting step 24 is provided between the plate-like body forming steps 23, and the laminate forming step 20 is configured by repeating the process, and the earth is formed in the mold 26 via the partition plate 25. A laminated body 29 is obtained by alternately laminating plate-like bodies and partitioning plates composed of the spraying layer 27 and the cement layer 28.
[0015]
Next, the laminate is vibrated or pressed to compact the cement layer (compacting step 30), and after the cement is solidified, the mold is removed and the partition plate is removed (demolded partition plate removing step 31). A thin plate-like body separated individually is obtained. Then, by removing the earth on the surface of the plate-like body in the earth removing step 32, a pseudo stone whose surface is very similar to natural stone can be obtained as in the above embodiment.
[0016]
In the above embodiment, the partition plate 25 is not necessarily limited to a flat plate. For example, by using a curved bent plate or a corrugated partition plate, the obtained pseudo stone plate-like body has a curved shape or a wave shape. A bent shape is obtained. Accordingly, the pseudo stone plate-like body of the present invention defined in the claims is not necessarily limited to a flat plate-like body, but a plate-like body bent into an arbitrary shape or a special pattern shape, etc. It is to be included. Moreover, in the said embodiment, although the plate-shaped body has shown the case where it forms in a rectangular shape, it does not necessarily need to be a rectangular shape, and by changing a form shape suitably, it is a plate shape of circular shape or other arbitrary shapes. You can get a body.
[0017]
【Example】
Next, an example of the present invention according to the embodiment shown in FIGS. 1 and 2 will be described.
First, powdery or massive red soil is randomly scattered on the bottom of the mold 10 having a predetermined thickness (depth). The red soil used was a lump that had a particle size of about 2 to 10 mm through a sieve. Then, an appropriate amount of concrete material (white Portland cement 1 weight ratio: coral (Ryukyu limestone) powder 2 weight ratio: water 0.5 weight ratio kneaded) is added so that the thickness after molding becomes a predetermined plate thickness. Then smooth out. Sprinkle the soil randomly on it. Then, the same amount of the concrete material as that of the previous time is charged, leveled on a flat surface, and soil is further randomly distributed on the surface as in the previous time. Thereafter, the same operation is repeated until the formwork is full.
[0018]
When the filling of the mold is completed, the entire mold is vibrated with a vibrator to perform sufficient compaction. At that time, because the concrete weight deeply filled in the mold is heavy, the compaction effect by vibration is high and the concrete is sufficiently compacted. By demolding after solidification, it is possible to obtain a multi-layered concrete stone material in which a red clay layer is sandwiched in the middle and red soil is adhered to the demolding surface corresponding to the mold bottom.
[0019]
By slicing the obtained concrete column (laminate) with a cutter from the portion with the red soil spray layer and the intermediate thickness portion of the concrete, a plate-like body with a desired thickness having the red soil spray layer on one side can be obtained. it can. The red soil is washed away by spraying high-pressure water with a spray nozzle onto the red soil adhesion surface of the obtained plate-like body. The obtained plate-like body is moderately uneven by the adhesion of red soil, creating a natural pattern, and becomes a plate-like body rich in expression. In addition, after red soil removal, the color becomes slightly red and has the same color and pattern as the surface of travertine. This is because red soil is very fine and the fine particles permeate into the solidified material and become red and cannot be easily removed by washing with water. Even if the plate is thin, the concrete is sufficiently compacted, so that a high-quality artificial travertine having sufficient strength and very similar to travertine can be obtained.
[0020]
【The invention's effect】
As described above, according to the first to fifth aspects of the present invention, the place where the earth is attached forms unevenness on the cement layer surface to express a natural porous texture, and is a pseudo stone that closely resembles natural stone. A plate-like body can be obtained. And since the obtained plate-shaped body is fully compacted, even if it is a thin plate, it has sufficient strength and can be used as a stone material for stonework such as a wall surface or a floor surface. In addition, since an inexpensive earth is used for forming a natural stone pattern, the raw material is inexpensive and can be manufactured at a low cost by a simple process without requiring skill. In particular, it is effective for producing a travertine pseudolithic plate.
[0021]
Furthermore, according to the invention described in claim 4, since it can be separated into a plate-like body simply by removing the partition plate, a slicing step is not required and the production can be performed more easily.
[Brief description of the drawings]
FIG. 1 is a flowchart of a method for producing a pseudolite according to an embodiment of the present invention.
2A and 2B are schematic views of a laminated body in an intermediate process, where FIG. 2A is a perspective view and FIG. 2B is a front view.
FIG. 3 is a schematic view of a pseudolite obtained by the present invention, in which (a) is a perspective view and (b) is an enlarged cross-sectional view.
FIG. 4 is a flowchart of a method for manufacturing a pseudo stone according to another embodiment of the present invention.
FIG. 5 is a schematic cross-sectional view showing an intermediate process.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1,20 Laminate formation process 2,21 Earth spreading layer formation process 3,22 Cement layer formation process 4,30 Compaction process 5 Demolding and slicing process 6,32 Earth removal process 10,26 Formwork 11,27 Earth spreading layer 12, 28 Cement layer 13, 29 Laminate 16 Plate-like body 17 Concavity and convexity 23 Plate-like body forming step 24 Partition plate inserting step 25 Partition plate

Claims (5)

In a method for producing pseudo stone material using cement material as a solidification material, a layered product is formed by alternately laminating a soil spraying layer in which a soil is sprinkled in a mold and a cement layer of a predetermined thickness made of cement material. A body forming process, a compacting process in which the laminated body is vibrated or pressed to compact the cement layer, and demolding after the cement material is solidified so that the soil spreading layer is exposed on at least one side of the laminated body A pseudo stone manufacturing method comprising a slicing step of thinly slicing a plate-like body and an earth removing step of removing earth exposed on the surface of the plate-like body. The cement layer is formed to be twice as thick as the plate-shaped body to be manufactured. The method for producing pseudolite according to claim 1, wherein: 2. The pseudo stone according to claim 1, wherein the cement layer is formed to have a thickness that is equal to a thickness of a plate-like body to be manufactured, and in the slicing step, the earth-spreading layer portion is sliced to obtain a plate-like body. Manufacturing method. In the method of manufacturing pseudo stones using cement as a solidifying material,
A plate-like body is formed by an earth-spreading layer forming step for forming an earth- spreading layer by arbitrarily sprinkling granular or massive earth and a cement layer forming step for forming a cement layer with a predetermined thickness. And a partition plate insertion step of inserting a partition plate on the cement layer. The plate body formation step and the partition plate insertion step are alternately repeated, and the soil is placed in the mold. Laminate formation process for forming a laminate by alternately laminating plate-like bodies and partition plates composed of a spray layer and a cement layer ,
A compacting step for compacting the cement layer by vibrating or pressing the laminate, a partition plate removing step for obtaining a plate-like body by removing the partition plate after demolding after solidifying the cement material,
A method for producing pseudo-stone, comprising an earth removing step for removing earth on the surface of the plate-like body. The method for producing pseudo stone according to any one of claims 1 to 4, wherein the pseudo stone is an artificial travertine plate.

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