JP4294309B2 - Method for producing lightweight cellular concrete panel - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a lightweight cellular concrete panel (hereinafter referred to as an ALC panel) having a decorative surface and a method for producing the same.
[0002]
[Prior art]
The ALC panel is a lightweight ready-made panel reinforced with a reinforcing reinforcing bar or the like, and is known as a large panel having a width of 60 cm and a length of several meters, for example. This ALC panel has the characteristics that it is economical, lightweight, fireproof and heat-insulating, and excellent in workability. In the building industry, it is a private house, a house with a store, a roof of a building, a floor, an outer wall, a partition material, etc. It is often used as.
[0003]
However, although the ALC panel is a material excellent in various properties as described above, in terms of production efficiency, it is generally produced as a panel having a flat flat surface, so that it is poor in design when used as an outer wall material. ALC panels are painted for construction, waterproofing, acid resistance, etc. at the construction site because the material itself has water absorption, and calcareous raw materials are used during production. It is common.
In order to overcome these problems, a method of forming a design groove on the surface of the ALC panel (Patent Document 1: Japanese Patent Laid-Open No. 58-160106, Patent Document 2: Japanese Patent Laid-Open No. 59-167203), A method of forming a recess on the surface of an ALC panel by a shot blast method (Patent Document 3: Japanese Patent Laid-Open No. 63-25284) has been proposed. However, the design obtained by these techniques has problems such as being limited to mechanical and uniform design, and when used as an outer wall of a building, painting is required at the construction site.
[0004]
In addition, methods for producing colored wall plates with two different colors (Patent Document 4: Japanese Patent Laid-Open No. 55-75978 and Patent Document 5: Japanese Patent Laid-Open No. 2-252675) have been proposed. Since the engraving method is based on the cutting means, there is a problem in appearance such that the obtained design is limited to a monotonous one such as a block tone or a striped pattern.
Further, a method of applying a slurry of a mortar composition having good adhesion to ALC and having similar expansion and contraction coefficients to the surface of the ALC panel and polishing the surface after surface curing (Patent Document 6: JP-A-11-11 No. 278,962) has been proposed, but it has problems that the obtained ALC panel is limited to a smooth one, and that it is necessary to perform a schiller treatment or the like in order to provide waterproof performance during construction.
[0005]
[Patent Document 1]
JP 58-160106 A [Patent Document 2]
JP 59-167203 A [Patent Document 3]
JP 63-25284 A [Patent Document 4]
JP-A-55-75978 [Patent Document 5]
Japanese Patent Laid-Open No. 2-252673 [Patent Document 6]
Japanese Patent Laid-Open No. 11-278962
[Problems to be solved by the present invention]
The present invention was devised to solve the above problems, and provides a method for producing a decorative ALC panel in which a decorative layer is laminated on the surface of an ALC panel excellent in design, waterproof performance, and durability. Objective.
[0007]
[Means for Solving the Problems]
That is, the present invention has achieved the above-described problem, and is as follows.
(1) On the surface of the ALC panel, with respect to 100 parts by weight of Portland cement, 140 to 1000 parts by weight of the aggregate powder raw material and solid latex equivalent weight of 10 to 40 parts by weight of acrylic latex emulsified with a nonionic dispersant after the mortar composition was applied consisting of parts, and surface processing the mortar composition compressive strength 0.2~10kg / cm ² stream in a semi-cured state, the water flow, pressing, sculpture, with hit the take Kino physical means A method for producing an ALC panel, characterized by laminating as a decorative layer.
(2) The method for producing a lightweight cellular concrete panel according to claim 1, further comprising adding 0.1 to 20 parts by weight of a powder coloring pigment to the mortar composition according to (1).
[0008]
Hereinafter, the present invention will be described in detail.
First, the example of this invention is typically shown in FIGS.
The ALC panel 1 used for the base of the present invention refers to the one obtained by the following manufacturing method.
For example, mortar slurry in which water, foaming agent, etc. are added to calcareous raw material, siliceous raw material is poured into a mold with a large number of reinforcing bars, and a large block of foam-like form is semi-cured during curing. In this state, it was cut with a piano wire and cured by autoclaving.
The ALC panel 1 as used in the present invention includes any size and shape, and is cut into a predetermined shape by the shape of a reinforcing bar or cutting, a flat used as an outer wall material of a building, or a partition material. Examples of the panel include L-shaped and R-shaped corner panels used for the outer corner and the corner of the outer wall, those having no design groove on the panel surface, and those having a design groove.
[0009]
The mortar composition 2 used in the present invention is preferably a composition comprising Portland cement, aggregate, acrylic latex emulsified with a nonionic dispersant, and a powder coloring pigment to which an appropriate amount of water is added. It is not limited.
The aggregate is generally made suitable for the physical properties of the ALC panel 1 used as the base, but for example, silica powder, calcium carbonate, ALC powder, quartz sand, obsidian perlite, clay mineral, etc. Good, preferably ALC powder, obsidian perlite. The aggregate particle size is preferably 1.2 mm or less, and if it is larger than 1.2 mm, it adversely affects the coating method described later.
[0010]
The amount of aggregate added is preferably 140 to 1000 parts by weight.If the amount is less than 140 parts by weight, the mortar composition surface is liable to crack because of increased curing and drying shrinkage. The strength equivalent to ALC cannot be obtained.
As the acrylic latex emulsion, an acrylic latex emulsified with a nonionic dispersant is suitable. Even if the same acrylic latex emulsion is used, for example, an acrylic latex emulsified with an anionic dispersant having a functional group such as carboxylic acid is used as a cement. The calcium ion in the inside decreases, delays hardening, and cracks occur.
[0011]
When the amount of the acrylic latex emulsified with the nonionic dispersant is more than 40 parts by weight in terms of solid content, the hydration of the cement is hindered and the setting time is significantly increased. If it is less than 10 parts by weight in terms of solid content, the adhesion with ALC is remarkably lowered, and sufficient waterproof performance cannot be obtained for the mortar composition itself.
The amount of the acrylic latex is preferably 35 parts by weight or less with respect to 100 parts by weight of Portland cement, and is preferably added in an amount of 5% by weight or more based on the total solid content. If it exceeds 35 parts by weight with respect to Portland cement, the hydration of the cement will be hindered, and the hardening formation time will be significantly increased. If it is less than 5% by weight with respect to the total solid content, the waterproof performance and the adhesion performance with lightweight lightweight concrete will be lowered.
[0012]
As the coloring pigment, inorganic powder pigments such as Bengala, nickel titanium yellow, yellow iron oxide, yellow lead, ultramarine, bitumen, cobalt blue, carbon black, titanium oxide, cobalt green and the like can be used. Other paste pigments can be used, but depending on the type of surfactant used to disperse the powder pigment, there is a risk of delaying the setting of the cement. Preferably, an inorganic powder pigment having excellent weather resistance is used.
The addition amount of the color pigment is preferably 0.1 to 20 parts by weight, and an excellent coloring effect is exhibited in this range.
[0013]
Further, when dripping occurs after the mortar composition is applied to the ALC panel, it is better to give the mortar composition thickening, for example, a small amount of methyl cellulose or the like is preferably added.
Moreover, the application method of the mortar composition 2 is performed by trowel coating, pouring, spray for coating, universal gun, etc., but it is generally determined from the design properties, productivity, manufacturing cost, etc. of the ALC panel. . If the mortar composition has a high viscosity and is applied by hand, the trowel is good and the viscosity of the paint is low.When using a mortar composition that can be applied by machine, pouring or spraying should be selected. good.
[0014]
The surface treatment of the present invention is performed by physical means such as air flow, water flow, pressing, engraving, scratching, etc., when the mortar composition is semi-cured, and mainly the shape of the decorative layer to be obtained Selected by.
For example, when obtaining a decorative layer having an arbitrary shape, pressing and engraving are suitable. The pressing is performed by applying a compressive force to the mortar composition 2 using a design roller 10 having an arbitrary shape as shown in FIG. In the engraving, the mortar composition 2 having an arbitrary shape using a design mold 14 as shown in FIG.
[0015]
In order to give a gentle natural uneven pattern, an air flow or a water flow is suitable. The airflow is subjected to surface processing by jetting a gas such as air with a tool to which a jet nozzle 5 or the like as shown in FIG. 1 is connected and directly colliding with the mortar composition 2. Further, the surface of the water stream is processed by spraying water with a tool connected to a spray nozzle 8 or the like as shown in FIG. 3 and spraying or colliding with the mortar composition 2.
In the case of obtaining a scratch pattern, surface processing by scratching is suitable, and surface processing can be performed by scratching the mortar composition 2 with a scratching tool 16 in which protrusions as shown in FIG. 9 are arranged.
[0016]
The compressive strength of the mortar composition 2 referred to in the present invention is a physical property value that can be measured during the period from the start to the completion of curing after being applied to the surface of the ALC panel 1, and its optimum value. Is determined by the processing method of the mortar composition 2, the shape of the decorative layer, productivity, production cost, and the like.
For example, when an uneven pattern is obtained by an air flow, the mortar composition 2 is preferably carried out when the compressive strength of the mortar composition 2 is 0.2 to 1.0 kg / cm ² , but preferably 0.3 to 0.6 kg / cm ^2. It had better be carried out in the range of cm ^2. This is because if less than 0.3 kg / cm ^2, more likely the mortar composition is scattered around ALC panel, also exceeds 0.6 kg / cm ^2, is required a large amount of air flow, production efficiency decreases, This is because the manufacturing cost increases.
[0017]
When the uneven pattern is obtained by a water flow, the mortar composition 2 is preferably carried out when the compressive strength of the mortar composition 2 is 0.2 to 10 kg / cm ² , but preferably in the range of ^{2 to} 5 kg / cm ² . Is good. This is because when the amount is less than 2 kg / cm ² , the mortar composition immediately has fluidity due to the water flow, and it becomes difficult to form an uneven pattern. When the amount exceeds 5 kg / cm ² , a large amount of water flow This is because production efficiency decreases and manufacturing costs increase.
When the decorative layer is formed by pressing, it is preferably performed at a time of 0.2 to 10 kg / cm ² , but preferably 0.5 to 5 kg / cm ² . If this is less than 0.2 kg / cm ² , the mortar composition 2 may be too soft and lose its shape after processing, and if it exceeds 5 kg / cm ² , the required pressure increases. This is because workability is lowered.
[0018]
When the decorative layer is formed by engraving, it is preferably performed at a time of 0.2 to 3 kg / cm ² , but preferably 0.5 to ² kg / cm ² . This is because if it is less than 0.5 kg / cm ² , the molded mortar composition 2 is too soft and easily deforms, and if it exceeds ² kg / cm ² , the mortar composition is too hard. This is because it becomes difficult to mold.
When the decorative layer is formed by scratching, it is preferably carried out at a time of 0.2 to 5 kg / cm ² , but preferably 0.5 to ³ kg / cm ² . This is because, if it is less than 0.5 kg / cm ² , the molded mortar composition is too soft and the scratch mark tends to return to its original shape, and if it exceeds 3 kg / cm ² , the mortar composition This is because the object 2 is too hard to easily form a scratch mark.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Next, the present invention will be described in more detail with reference to examples.
A mortar composition was applied to one surface of the ALC panel having a large area, and when the compressive strength of the mortar composition reached a predetermined value, arbitrary surface processing was performed, and the design properties of the fabricated samples were evaluated.
The mortar composition was sprayed with a universal gun so that the coating amount was 8 kg / m ^{2 on the} ALC surface.
[0020]
[Example 1]
ALC panel 1 as shown in FIG. 1 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), Bengala After applying a mortar composition 2 consisting of 5 parts by weight, 1 part by weight of methylcellulose and an appropriate amount of water, the spray nozzle shown in FIG. 1 was used when the compressive strength of the mortar composition 2 was 0.5 kg / cm ² . 5, the air flow 6 collided with the mortar composition 2 to obtain an ALC panel FIG. 2 in which a decorative layer having a natural uneven pattern was laminated.
As a result, it was confirmed that the decorative layer had a rock-like design.
[0021]
[Example 2]
ALC panel 1 as shown in FIG. 3 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), oxidation After applying a mortar composition 2 composed of 5 parts by weight of titanium, 1 part by weight of methylcellulose and an appropriate amount of water, the injection nozzle shown in FIG. 3 was used when the compressive strength of the mortar composition 2 was 2.0 kg / cm ² . By making the water flow 9 collide with the mortar composition 2 in 8, an ALC panel FIG. 4 in which a decorative layer having a natural uneven pattern was laminated was obtained.
As a result, it was confirmed that the decorative layer had a rock-like design.
[0022]
[Example 3]
An ALC panel 1 as shown in FIG. 5 has 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), cobalt After applying a mortar composition 2 consisting of 5 parts by weight of blue, 1 part by weight of methylcellulose, and an appropriate amount of water, the design roller shown in FIG. 5 was used when the compressive strength of the mortar composition 2 was 2.0 kg / cm ² . By pressing the mortar composition 2 from 10 on the surface, an ALC panel FIG. 6 in which a decorative layer having the same shape as the design roller 10 was laminated could be obtained.
As a result, it was confirmed that the decorative layer had a sandstone-like design.
[0023]
[Example 4]
ALC panel 1 as shown in FIG. 7 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), carbon A mortar composition 2 composed of 5 parts by weight of black, 1 part by weight of methylcellulose, and an appropriate amount of water is applied to a design mold 14 as shown in FIG. 7 when the compressive strength of the mortar composition 2 is 1.0 kg / cm ² . An ALC panel diagram in which a decorative layer having a design like a stone is laminated by pasting the mortar composition 2 on the surface of the ALC panel 1 and processing the molded mortar composition 2 in advance. I was able to get 8.
As a result, it was confirmed that the decorative layer had a stone-pasting design.
[0024]
[Example 5]
An ALC panel 1 as shown in FIG. 9 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), carbon After applying a mortar composition 2 composed of 5 parts by weight of black, 1 part by weight of methylcellulose, and an appropriate amount of water, the mortar composition 2 is shown when the compressive strength of the mortar composition 2 is 2.0 kg / cm ² . By scratching with the scratching tool 16 as shown in FIG. 9, the ALC panel FIG. 10 in which the decorative layer containing the scissor-like scratch 17 was laminated was obtained.
As a result, it was confirmed that the decorative layer had a scratch-like design.
[0025]
[Comparative Example 1]
ALC panel 1 as shown in FIG. 1 is composed of 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), Bengala After applying a mortar composition 2 comprising 5 parts by weight, 1 part by weight of methylcellulose, and an appropriate amount of water, the spray nozzle 5 shown in FIG. 1 was used when the compressive strength of the mortar composition was 0.05 kg / cm ² . The air flow 6 was made to collide with the mortar composition 2.
As a result, the mortar composition 2 was scattered around the ALC panel 1, and a decorative layer having a desired shape was not obtained.
[0026]
[Comparative Example 2]
An ALC panel 1 as shown in FIG. 5 has 100 parts by weight of ordinary Portland cement, 40 parts by weight of ALC powder, 100 parts by weight of obsidian perlite, 30 parts by weight of acrylic latex emulsified with a nonionic dispersant (in terms of solid content), cobalt After applying a mortar composition 2 consisting of 5 parts by weight of blue, 1 part by weight of methylcellulose, and an appropriate amount of water, the design roller shown in FIG. 5 was used when the compressive strength of the mortar composition 2 was 0.02 kg / cm ² . 10, the mortar composition 2 was pressed from the surface.
As a result, the pressed mortar composition 2 was deformed, and a decorative layer having a desired shape was not obtained.
[0027]
【The invention's effect】
According to the present invention, since the surface-treated mortar composition is laminated as a decorative layer on the surface of the ALC panel, a manufacturing method for obtaining an ALC panel excellent in design, waterproof performance, and durability is provided. In addition, since it can be constructed as a final finished panel, it is possible to omit construction such as painting that is usually performed at the construction site, shortening the work period and improving workability.
As described above, the present invention solves all the problems of the conventional ALC panel and ALC panel manufacturing technology, and fully responds to recent needs of the building market such as differentiation, individualization, and high added value. It is possible.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a state in which a semi-cured mortar composition is surface-treated with an air stream.
2 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 1. FIG.
FIG. 3 is a cross-sectional view illustrating a state in which a semi-cured mortar composition is surface-treated with a water stream.
4 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 2. FIG.
FIG. 5 is a cross-sectional view showing a state where a semi-cured mortar composition is surface-treated by pressing.
6 is a cross-sectional view of an ALC panel whose surface has been processed by the method of Example 3. FIG.
FIG. 7 is a cross-sectional view showing a state in which a semi-cured mortar composition is surface processed by engraving.
8 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 4. FIG.
FIG. 9 is a cross-sectional view showing a state in which the surface of a semi-cured mortar composition is scratched.
10 is a cross-sectional view of an ALC panel whose surface is processed by the method of Example 5. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ALC panel 2 Mortar composition 3 Concavity and convexity 4 Air supply hose 5 Jet nozzle (for gas)
6 Airflow 7 Liquid supply hose 8 Jet nozzle (for liquid)
9 Water Flow 10 Design Roller 11 Design Roller Direction 12 Design Roller Pressing Direction 13 Design Roller Direction 13 Design Roller Direction 15 Design Form 15 Pressing Direction 16 Design Scratching Tool 17 Peeling Scratch

Claims (2)

10 to 40 parts by weight in terms of solid content of acrylic latex emulsified with 140 to 1000 parts by weight of aggregate powder and nonionic dispersant with respect to 100 parts by weight of Portland cement on the surface of lightweight cellular concrete panel after the mortar composition was applied consisting of, and surface processing the mortar composition compressive strength 0.2~10kg / cm ² stream in a semi-cured state, the water flow, pressing, sculpture, with hit the take Kino physical means, A method for producing a lightweight cellular concrete panel, characterized by laminating as a decorative layer. The method for producing a lightweight cellular concrete panel according to claim 1, further comprising adding 0.1 to 20 parts by weight of a powder coloring pigment to the mortar composition according to claim 1.

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