JP4843763B2 - Pattern forming method for concrete surface and decorative mat used therefor - Google Patents

Description

  The present invention relates to a pattern forming method for a concrete surface and a decorative mat used therefor.

  When forming a natural stone-like concavo-convex pattern on the concrete surface, use a decorative mat (decorative formwork) with a concavo-convex pattern transfer surface, transfer the concavo-convex pattern transfer surface to the concrete surface, and color the concrete surface How to do it.

The method is performed as follows, for example. That is, the colored granular material is fixed on the uneven pattern transfer surface of the decorative mat in advance using a water-soluble adhesive (an adhesive whose adhesive strength is reduced by moisture, alkali components, etc. in the concrete material). When the concrete material is placed, the uneven pattern of the decorative mat is transferred to the concrete surface, and at the same time, the colored granular material is transferred and embedded in the surface of the concrete material being hardened (the adhesive is water in the concrete material). And the concrete surface is colored with this colored granular material. Examples of the water-soluble adhesive used in this method include those whose main component is polyvinyl alcohol (Patent Document 1), water-soluble urethane resins (Patent Document 2), and the like.
JP-A-6-71623 JP 2006-256058 A

  However, in the water-soluble adhesives of Patent Documents 1 and 2, depending on the concrete placement conditions (such as the uneven shape of the uneven pattern transfer surface) and the construction environment (temperature, etc.), the water solubility varies, and as a result, Some of the colored granular materials did not migrate to the concrete surface, or color defects occurred. In addition, when the colored granular material moves to the concrete surface, the water-soluble adhesive adheres to the surface of the colored granular material, and the organic material of the water-soluble adhesive deteriorates over time. The color of was unclear.

  This invention is made | formed in view of such a situation, The objective is to provide the pattern formation method with respect to the concrete surface excellent in the transferability of a colored granular material and the expression of the color, and a decorative mat used therefor.

In order to achieve the above object, the present invention includes a decorative mat base material on which a concavo-convex pattern transfer surface is formed , an adhesive layer formed on the surface of the concavo-convex pattern transfer surface, the adhesive force of which decreases due to water absorption , Prepare a decorative mat consisting of colored granular materials adhered and fixed to the surface of the adhesive layer , and place the concrete material with the uneven pattern transfer surface of the decorative mat as a contact surface to the concrete surface. The pattern forming method for a concrete surface, wherein the adhesion of the adhesive layer is reduced and the colored granular material is transferred and embedded in the concrete surface, and the concrete surface is formed on the concavo-convex pattern surface by transferring the concavo-convex pattern transfer surface. the decorative mat base material is made of polystyrene foam, the adhesive layer is mainly composed of sodium silicate perfluoroalkyl compound Contact A water-soluble inorganic layer formed by using an inorganic composition containing fine diethyl phthalate, and the first aspect a pattern forming method for the concrete surface.

The present invention also provides a decorative mat substrate having a concavo-convex pattern transfer surface, an adhesive layer formed on the surface of the concavo-convex pattern transfer surface, the adhesive force of which decreases due to water absorption, and the adhesive layer surface. A decorative mat comprising a fixed colored granular material, wherein the decorative mat substrate is made of polystyrene foam, and the adhesive layer contains sodium silicate as a main component and a perfluoroalkyl compound and diethyl phthalate. A second aspect is a decorative mat that is a water-soluble inorganic layer formed using an inorganic composition.

  In the pattern formation method for the concrete surface, the inventors of the present invention have made extensive studies in order to improve the migration of colored particulates and the color development. As a result, when the adhesive layer formed on the uneven pattern transfer surface of the decorative mat is a water-soluble inorganic layer formed using an inorganic composition mainly composed of sodium silicate, it has been found that the intended purpose is achieved. The present invention has been reached.

  That is, the specific water-soluble inorganic layer (adhesive layer) formed on the concave / convex pattern transfer surface of the decorative mat was cast with a concrete material as compared with a conventional adhesive layer made of polyvinyl alcohol or water-soluble urethane resin. At this time, it becomes easy to peel off from the decorative mat due to moisture in the concrete material. Moreover, even if there is a portion that does not come into contact with the concrete material due to the presence of air pockets or the like due to the concavo-convex shape of the concavo-convex pattern transfer surface, the specific water-soluble inorganic layer is not separated from the concrete material around the portion. Moisture penetrates into and peels off, covering the concrete material such as the lower side of the air pocket, and transferring the colored particulate matter. For this reason, the whole is patterned and the concrete surface part which is not patterned is not scattered. Thus, the pattern formation method for the concrete surface of the present invention is excellent in the migration property of the water-soluble inorganic layer and hence the migration property of the colored particulate matter. In addition, when the concrete material is placed, the water-soluble inorganic layer moves to the concrete surface together with the colored particles (however, since the water-soluble inorganic layer is water-soluble, a part of the water-soluble inorganic layer is contained in the concrete material). The water-soluble inorganic layer covers the colored particulate matter on the concrete surface. And this water-soluble inorganic layer acts as a protective layer, and prevents the color change of a colored granular material with time. Moreover, since the water-soluble inorganic layer is transparent and made of an inorganic material, it does not cause discoloration or color dullness due to deterioration of the resin such as an organic material. Also excellent in properties.

  In the pattern formation method for the concrete surface of the present invention, the decorative mat used is formed on the uneven pattern transfer surface using an inorganic composition containing sodium silicate as a main component, and is a transparent water-soluble inorganic that is easily peeled off by moisture. A layer (adhesive layer) is formed, and a large number of colored particles are distributed through the water-soluble inorganic layer. For this reason, when the concrete material is placed, due to moisture in the concrete material, the specific water-soluble inorganic layer is easily peeled off from the decorative mat, and is transferred to the concrete surface together with the colored particulate matter. Covers the colored particles. As described above, the specific water-soluble inorganic layer is easy to peel off due to moisture and is transparent. Therefore, the pattern forming method for the concrete surface of the present invention is excellent in the migration of the colored particles, Excellent color development. Furthermore, since the water-soluble inorganic layer moves to the concrete surface, the concrete surface can be strengthened and deterioration of the concrete surface (neutralization due to salt damage or acid rain) can be prevented.

  In addition, the decorative mat of the present invention has a pattern formed on the concrete surface of the present invention because a large number of colored particles are distributed on the uneven pattern transfer surface via the specific water-soluble inorganic layer (adhesive layer). When used in the method, it is possible to improve the migration of colored particles and the color development. Furthermore, the water-soluble inorganic layer can be transferred to the concrete surface, whereby the concrete surface can be strengthened and deterioration of the concrete surface (neutralization due to salt damage or acid rain) can be prevented. .

Then, in the invention of the first and second aspect, the decorative mat base material is made of expanded polystyrene, in the inorganic composition, the perfluoroalkyl compound and diethyl phthalate that contained. That is, Styrofoam, usually repel liquids, the perfluoroalkyl compound, acts to prevent repel the inorganic composition of the liquid at the surface of the decorative mat substrate (styrofoam). Also, the diethyl phthalate is dissolved the surface of the decorative mat substrate (styrofoam) and the liquid, which acts to soften the inorganic composition of the liquid on the surface of the decorative mat substrate (styrofoam). Due to the action of these perfluoroalkyl compounds and diethyl phthalate, the water-soluble inorganic layer (adhesive layer) formed using the above inorganic composition has an uneven pattern transfer surface even if the uneven pattern transfer surface is made of polystyrene foam. Are uniformly formed.

  Next, embodiments of the present invention will be described in detail with reference to the drawings.

Pattern forming method for the concrete surface of the present invention, as shown in FIG. 1, the uneven pattern transfer surface 11a of the styrofoam decorative mat base member 11, a large number of colored granules 13 through the adhesive layer 12 is distributed of粧mat 1 was prepared, and the uneven pattern transfer surface 11a of the decorative mat 1, in the contact surface against the concrete surface concrete material Da設by moisture of the concrete material reduces the adhesive force of the adhesive layer 12 Then, the colored granular material 13 is transferred and embedded in the concrete surface, and the concrete surface is made to have a concavo-convex pattern surface by transferring the concavo-convex pattern transfer surface 11a (see FIGS. 2 and 3). In the present invention, the adhesive layer 12 is a water-soluble inorganic layer formed using an inorganic composition containing sodium silicate (water glass) as a main component and containing a perfluoroalkyl compound and diethyl phthalate. As a result, the adhesive layer 12 moves to the concrete surface while maintaining a substantially layer shape. This is a feature of the present invention.

More specifically, the decorative mat 1 includes a styrofoam decorative mat substrate 11 on which a concavo-convex pattern transfer surface 11a is formed, and an adhesive layer formed on the surface of the concavo-convex pattern transfer surface 11a. Inorganic layer) 12 and colored granular material 13 adhered and fixed to the surface of the adhesive layer 12. Work made of the decorative mat substrate 11 is carried out by molding. Thereby, the said decorative mat base material 11 is formed in what has sufficient mechanical strength with respect to the concrete material driven at the time of placement. And the said uneven | corrugated pattern transfer surface 11a is formed in one surface of the decorative mat base material 11, and the back surface (opposite surface) is normally formed in the flat surface. Furthermore, it is preferable that a skin layer having almost no bubbles is formed on at least the uneven pattern transfer surface 11a of the decorative mat substrate 11. This is because the concavo-convex pattern transfer surface 11a has excellent surface smoothness. The shape of the concave / convex pattern transfer surface 11a is not particularly limited in the present invention.

The adhesive layer 12 is coated with an inorganic composition (liquid) containing sodium silicate as a main component and containing a perfluoroalkyl compound and diethyl phthalate on the concave / convex pattern transfer surface 11a of the decorative mat substrate 11 and then dried. Thus, a transparent water-soluble inorganic layer is formed. The thickness of the adhesive layer (water-soluble inorganic layer) 12 is preferably set in the range of 0.05 to 0.8 mm from the viewpoint of the adhesive fixability of the colored granular material 13 and the like. Here, the “water-soluble inorganic layer” means that the adhesive strength with the decorative mat base material 11 is reduced due to the moisture of the placed concrete material, and a part thereof is dissolved, but the shape of the substantially layer is maintained. An inorganic layer that can be transferred to the concrete surface in a state. Moreover, the said main component means what has a big influence on the characteristic of a composition, and means the component which occupies the majority of the whole (inorganic composition).

  The inorganic composition may contain amorphous silicon dioxide (silica far-changing agent). This amorphous silicon dioxide adjusts the viscosity of the liquid inorganic composition, and when the liquid inorganic composition is applied to the concavo-convex pattern transfer surface 11a, the liquid inorganic composition becomes the concavo-convex pattern transfer surface 11a. It works to make it difficult to sag. And from the viewpoint of making the viscosity of the liquid inorganic composition appropriate and improving the formability of the adhesive layer (water-soluble inorganic layer) 12, amorphous silicon dioxide is 1 to 2 with respect to 100 parts by weight of sodium silicate. It is preferably contained within the range of parts by weight.

In this embodiment, we have use those styrofoam as a cosmetic mat base member 11, to the inorganic composition, and is contained perfluoroalkyl compounds (fluorine surfactant) and diethyl phthalate (ester). The reason is as follows. That is, Styrofoam, usually repel liquids, the perfluoroalkyl compound, acts to prevent repel the inorganic composition of the liquid in the decorative mat substrate (styrofoam) 1 1 surface. Also, the diethyl phthalate is dissolved decorative mat substrate (styrofoam) 1 1 surface to the liquid, which acts to soften the inorganic composition of the liquid cosmetic mat substrate (styrofoam) 1 1 surface. Due to the action of these perfluoroalkyl compounds and diethyl phthalate, the adhesive layer (water-soluble inorganic layer) 12 formed using the above-mentioned inorganic composition has a concavo-convex pattern transfer surface 11a of the decorative mat substrate 11 made of polystyrene foam. However, it is because it is uniformly formed on the concavo-convex pattern transfer surface 11a. In this case, from the viewpoint of easily forming the adhesive layer (water-soluble inorganic layer) 12 uniformly, the content ratio of the perfluoroalkyl compound in the inorganic composition is set to 2 parts by weight or less with respect to 100 parts by weight of sodium silicate. The content ratio of diethyl phthalate is preferably set to 5 parts by weight or less with respect to 100 parts by weight of sodium silicate.

  Although it does not specifically limit as said colored granular material 13, The colored crushed granule of a natural stone, a ceramic particle, glass particle, cement powder, etc. are used. The average particle diameter of the colored granular material 13 is usually set in the range of 10 μm to 15 mm, and preferably in the range of 10 μm to 10 mm. As a method for distributing a large number of the colored granular materials 13 to the adhesive layer 12, a large number of the colored granular materials 13 are sprayed on the adhesive layer 12, and the adhesive layer 12 is dried (cured). A fixing method is exemplified.

  Next, an example of the pattern forming method for the concrete surface of the present invention using the decorative mat 1 will be described in detail.

  First, a decorative mat 1 as shown in FIG. 1 is produced by the method described above. Next, as shown in FIG. 2, the concavo-convex pattern transfer surface 11a of the decorative mat 1 and the separately prepared mold 3 are arranged so as to face each other, and the decorative mat 1 and the mold are further arranged. The side opening and the bottom opening are closed with a plate material 4 separately prepared (the side plate material is not shown). Then, the concrete material 2a formed by kneading cement and water is prepared, and this is placed in the gap between the decorative mat 1 and the mold 3 from its upper opening. And the said concrete material 2a is trained and hardened as it is. At that time, due to the moisture of the concrete material 2a, the adhesive strength of the adhesive layer 12 is reduced, and the adhesive layer 12 is easily peeled off from the concave / convex pattern transfer surface 11a of the decorative mat substrate 11, and the adhesive layer 12 is adhered and fixed. The colored particulate matter 13 that has been transferred is embedded in the concrete surface. Then, after the concrete material 2a is completely cured, as shown in FIG. 3, the decorative mat base material 11 and the like are removed to be colored by the colored granular material 13, and together with the colored granular material 13, the adhesive layer 12. The concrete board 2 in which the covered uneven | corrugated pattern surface 21 was formed can be obtained.

  In the pattern forming method for the concrete surface, the adhesive layer 12 formed on the decorative mat 1 is easily peeled off by the moisture of the placed concrete material 2a and transferred to the concrete plate 2. Moreover, even if there is a portion of the air pocket that is not filled with the concrete material and does not come into contact with the concrete material due to the concave and convex shape of the concave and convex pattern transfer surface 11a, the pattern is conventionally transferred to that portion. However, in the present invention, the surface of the concrete plate 2 is exposed, and in the present invention, the adhesive material 12 permeates into the adhesive layer 12 from the concrete material around the portion, and the adhesive layer 12 is peeled off. The lower concrete material is covered and the colored granular material 13 is transferred. From these things, the pattern formation method with respect to the said concrete surface is excellent in the transferability of the contact bonding layer 12, and the transferability of the colored granular material 13 by extension. Moreover, since the said adhesive layer 12 is transparent and consists of an inorganic substance, even if it covers the colored granular material 13 in the uneven | corrugated patterned surface 21 of the produced concrete board 2, it is excellent in the color development property of the colored granular material 13. ing. Furthermore, by covering the concavo-convex pattern surface 21 of the concrete plate 2 with the adhesive layer 12, the concavo-convex pattern surface 21 is strengthened and the concrete plate 2 is protected from deterioration such as neutralization due to salt damage or acid rain. Can do.

  Next, examples will be described together with conventional examples. However, the present invention is not limited to the following examples.

[Preparation of adhesive layer forming materials of Examples 1 to 4 and Reference Examples 1 to 4 ]
Each adhesive layer is prepared by preparing an aqueous solution of sodium silicate (manufactured by Daito Sangyo Co., Ltd.), amorphous silicon dioxide (manufactured by Tosoh Corp.), perfluoroalkyl compound and diethyl phthalate and blending them in the proportions shown in Table 1 below. A forming material was prepared. Further, the viscosity at 25 ° C. was measured using a B-type viscometer, and is shown in Table 1 below.

[Formation Material of Adhesive Layer of Conventional Example 1]
A polyvinyl alcohol adhesive layer (manufactured by Fuki Co., Ltd.) was prepared. Moreover, the viscosity at 25 degreeC was measured similarly to the above, and it showed together in following Table 2.

[Formation material of adhesive layer of Conventional Example 2]
A water-soluble urethane resin adhesive layer (Ohara Palladium Co., Ltd.) was prepared. Moreover, the viscosity at 25 degreeC was measured similarly to the above, and it showed together in following Table 2.

[Production of makeup mat]
A styrofoam decorative mat base material on which a predetermined concavo-convex pattern transfer surface (having a skin layer on the surface layer portion) was prepared. Next, the adhesive layer forming material prepared above was sprayed twice on Examples 1 to 4 and Reference Examples 1 to 4 on the surface of the decorative mat substrate on the uneven pattern transfer surface (the amount of spraying each time: 250 g / m ³ ), and Conventional Examples 1 and 2 were applied by spraying once to form an adhesive layer having a thickness of 0.2 mm. And after spraying many colored crushed stone particles of natural stone within a range of 1 to 3 mm on the surface of each adhesive layer, the adhesive layer was dried. In this way, a decorative mat was produced (see FIG. 1).

[Formability of adhesive layer on styrofoam decorative mat substrate]
In the production of the decorative mat, the state of the adhesive layer when the adhesive layer was formed was visually evaluated. As a result, the case where the adhesive layer was uniformly formed was evaluated as ◯, the portion where there was unevenness was evaluated as Δ, and the case where it was clearly non-uniform was evaluated as ×, and the results are shown in Tables 1 and 2 below.

[Migration of colored particles]
A concrete material (kneaded with cement and water, pH: 12 to 14) was placed with the uneven pattern transfer surface of each decorative mat as the contact surface with the concrete surface. At that time, a vibrator was used to fill concrete well. Next, the concrete material was cured and cured, and then the decorative base material and the like were removed (see FIGS. 2 and 3). And the transfer condition of the colored granular material to the concrete board surface (uneven pattern surface) was evaluated by visual observation. As a result, the transfer rate when the entire surface is colored by the migration of the colored granular material is set to “100%”, and a transfer rate (rough number) exceeding 90% based on this is regarded as having excellent transferability. More than 90% of the samples were evaluated as Δ with the transferability being slightly inferior, and less than 70% were evaluated as × with inferior transferability, and are shown in Tables 1 and 2 below.

[Color expression of colored granular materials]
The expression of the color of the colored granular material transferred to the concrete plate surface (uneven pattern surface) was visually evaluated. As a result, those in which the color of the colored granular material was clearly expressed were evaluated as ○, and those that were expressed by being thinned or whitened were evaluated as ×, and are shown in Tables 1 and 2 below.

From the above results, it can be seen that in Examples 1 to 4 and Reference Examples 1 to 4 , the migration of the colored granular material and the color development are superior as compared with Conventional Examples 1 and 2. In Reference Examples 1 to 4 , since the adhesive layer forming material does not contain at least one of a perfluoroalkyl compound and diethyl phthalate, the adhesive layer can be formed on a foamed polystyrene decorative mat substrate. Although it is inferior, as shown in the above result, it is excellent in the migration of the colored granular material and the expression of its color.

It is sectional drawing which shows one Embodiment of the decorative mat of this invention. It is sectional drawing which shows the pattern formation method with respect to the concrete surface of this invention. It is sectional drawing which shows the pattern formation method with respect to the said concrete surface.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Makeup mat 11a Irregularity pattern transfer surface 12 Adhesive layer 13 Colored granular material

Claims (6)

A decorative mat substrate on which a concavo-convex pattern transfer surface is formed, an adhesive layer formed on the surface of the concavo-convex pattern transfer surface, the adhesive strength of which decreases due to water absorption, and a colored granular material adhered and fixed to the surface of the adhesive layer The decorative mat is prepared by placing a concrete material with the uneven pattern transfer surface of the decorative mat as a contact surface with respect to the concrete surface, and reducing the adhesive force of the adhesive layer by the moisture of the concrete material. It is a pattern forming method for a concrete surface, in which a granular material is transferred and embedded in a concrete surface, and the concrete surface is formed on a concavo-convex pattern surface by transferring the concavo-convex pattern transfer surface, and the decorative mat base material is made of polystyrene foam the adhesive layer is formed using an inorganic composition containing the following as the main component of the following (a) (B) and (C) water Pattern forming method for the concrete surface, characterized in that an inorganic layer.
(A) Sodium silicate.
(B) Perfluoroalkyl compound.
(C) Diethyl phthalate. The content ratio of the component ( B ) in the inorganic composition is set to 2 parts by weight or less with respect to 100 parts by weight of the component (A), and the content ratio of the component ( C ) is 100 parts by weight of the component (A). , the pattern forming method for the concrete surface as claimed in claim 1, wherein it is set to 5 parts by weight or less. The inorganic composition contain the following component (D), the content of the component (D) is set to 100 parts by weight of component (A) in the range of 1 to 2 parts by weight The pattern formation method with respect to the concrete surface of Claim 1 or 2 .
( D ) Amorphous silicon dioxide. A decorative mat substrate on which a concavo-convex pattern transfer surface is formed, an adhesive layer formed on the surface of the concavo-convex pattern transfer surface, the adhesive strength of which decreases due to water absorption, and a colored granular material adhered and fixed to the surface of the adhesive layer A decorative mat comprising: an inorganic composition in which the decorative mat base material is made of polystyrene foam, and the adhesive layer contains the following (A) as a main component and the following (B) and (C): A decorative mat, which is a water-soluble inorganic layer formed by using the decorative mat.
(A) Sodium silicate.
(B) Perfluoroalkyl compound.
(C) Diethyl phthalate. The content ratio of the component ( B ) in the inorganic composition is set to 2 parts by weight or less with respect to 100 parts by weight of the component (A), and the content ratio of the component ( C ) is 100 parts by weight of the component (A). The decorative mat according to claim 4, which is set to 5 parts by weight or less. The inorganic composition contain the following component (D), the content of the component (D) is set to 100 parts by weight of component (A) in the range of 1 to 2 parts by weight The decorative mat according to claim 4 or 5.
( D ) Amorphous silicon dioxide.

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