JP6494255B2 - Nonflammable retroreflective material, wall surface construction method, and retroreflective material manufacturing method - Google Patents

Description

  The present invention relates to a nonflammable retroreflective material, a wall surface construction method, and a method of manufacturing a retroreflective material.

For example, Patent Document 1 discloses an optical wide-angle reflective tile for tunnel interior in which a glaze is applied to the surface side having a plurality of granular irregularities formed on the surface of a tile base material, and a raster glaze is further laminated on the glaze. It is disclosed.
Patent Document 2 discloses a road fence provided with a retroreflective element and installed on a road or around the road.
Patent Document 3 discloses an interlocking block in which a polymer coating is sprayed and glass beads are sprayed on the sprayed surface.

JP 2010-255188 A JP 2010-156106 A JP-A-5-43358

  An object of the present invention is to provide a non-flammable retroreflective material that is retroreflected with little in-plane unevenness.

  The nonflammable retroreflective material according to the present invention is a state where a plate-like or block-like nonflammable base material, glass beads, and a plurality of the glass beads are arranged, and a part of each glass bead is exposed. And a fixing layer for fixing the glass beads to the surface of the non-combustible substrate.

  Preferably, the fixed layer is a sintered body obtained by sintering a mixture containing at least a glass having a melting point lower than that of the glass beads and a glaze.

  Preferably, the glass beads are arranged adjacent to each other, and the fixing layer is fixed to the surface of the nonflammable substrate with one third or more of the glass beads exposed.

  Suitably, the said nonflammable base material is tile-shaped ceramics, and the said fixed layer has developed the specific color with the said glaze.

  Moreover, the wall surface construction method according to the present invention is a combination of a retroreflective tile arranged and fixed in a protruding state with glass beads and a non-retroreflective tile that does not retroreflect more than the retroreflective tile. It has the process of producing a panel, and the process of sticking and fixing this produced panel in a tunnel.

  Further, the wall surface construction method according to the present invention includes a step of attaching a retroreflective tile arranged and fixed in a protruding state with glass beads to a wall surface, and a non-retroreflective tile that does not retroreflect more than the retroreflective tile. And adhering to the retroreflective tile.

  Preferably, in the step of pasting the retroreflective tiles, the retroreflective tiles that generate different colors are arranged and pasted.

  The retroreflective material manufacturing method according to the present invention includes a step of preparing a retroreflective sheet in which glass beads are sandwiched between an organic binder layer containing an organic polymer and an inorganic binder layer containing glass; Heating the inorganic binder layer of the reflective sheet in contact with the surface of the nonflammable substrate to sinter at least the inorganic binder layer.

  Preferably, the organic binder layer is a polyethylene film layer, and further includes a step of peeling the organic binder layer from the nonflammable substrate, the inorganic binder layer, and the glass beads, and in the sintering step, The retroreflective sheet from which the polyethylene film layer has been peeled is heated while being in contact with the surface of the non-combustible substrate.

  Preferably, in the step of preparing the retroreflective sheet, an inorganic binder containing glass having a melting point lower than that of the glass beads is applied to the glass beads spread on the sheet and held by the organic polymer. And a step of creating the retroreflective sheet.

  Preferably, the method further includes a step of applying an antifouling agent to the sintered inorganic binder layer and the glass beads.

  Preferably, in the step of applying the inorganic binder, a mixture of glass having a melting point lower than that of the glass beads and glaze is applied.

  Preferably, in the step of sintering, the organic polymer is heated at a temperature at which the organic polymer is burned out, and the glass contained in the inorganic binder layer is melted, and the inorganic binder layer is used as the nonflammable substrate. Sinter.

  It is possible to provide a nonflammable retroreflective material that is retroreflective with little in-plane unevenness.

(A) illustrates a cross section of the retroreflective tile 10, and (B) is a schematic view illustrating the surface of the retroreflective tile 10. It is a figure explaining the manufacturing method of the retroreflection sheet. It is a figure explaining pasting of retroreflective sheet 20, and exfoliation of organic binder layer 210. It is a schematic diagram of the retroreflective tile 10 after sintering. 4 is a flowchart illustrating a tile manufacturing process (S10) of the retroreflective tile 10; It is a figure which illustrates the wall surface 1 on which the retroreflective tile 10 and the non-retroreflective tile 50 were stuck. It is a figure which illustrates the wall surface 1 which stuck the retroreflective tile 10 of a color. It is a figure which shows the result of the reflection luminance test of the retroreflective tile.

(background)
First, the background of the present invention will be described.
Conventionally, since light from the outside does not enter inside the tunnel of an expressway or a general road, lighting fixtures are installed in order to keep the vehicle running safely. However, the installation of lighting fixtures has some limitations because it requires a large amount of money, such as ensuring safety, construction costs, and maintenance of facilities.
Therefore, many attempts have been made to make the tunnel as bright as possible, and glossy tiles with a white surface are used as the interior material. Thereby, the illumination in the tunnel is specularly reflected on the surface of the white tile, and the illumination in the tunnel is effectively utilized.
On the other hand, for a driver of a car traveling in a tunnel, the illuminance necessary for driving cannot be obtained only by lighting in the tunnel, so the headlight is turned on during traveling. The car's headlight also illuminates the tunnel wall and hits the tiles installed. The headlight light incident on the tile surface is specularly reflected and exits at the same angle, so the driver side is not illuminated brightly. For this reason, it is difficult to obtain a gaze guidance effect necessary for driving.
In addition, a white tile has been proposed in which an infinite number of irregularities are formed on the surface of the tile, a white glaze is applied thereon, and the surface is sintered at a high temperature. However, in the case of this proposal, the light hitting the tile surface is irregularly reflected on the tile surface, and a very high luminance cannot be expected. Therefore, it is difficult to expect a gaze guidance effect that shows the situation of the tunnel curved portion to the driver.
Therefore, in this embodiment, a wall surface construction method using the retroreflective tile 10 is proposed.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1A illustrates a cross section of the retroreflective tile 10, and FIG. 1B is a schematic view illustrating the surface of the retroreflective tile 10.
As illustrated in FIG. 1, the retroreflective tile 10 includes a tile 100 as a base material, a fixing layer 110, glass beads 120, and an antifouling agent film 300. The retroreflective tile 10 is an example of a nonflammable retroreflective material according to the present invention.

The tile 100 is a plate-like or block-like incombustible base material. For example, the tile 100 is a block member made of sintered ceramics or concrete. The tile 100 of this example is a ceramic tile.
The fixing layer 110 is a nonflammable binder layer that fixes glass beads to the surface of the tile 100. For example, the fixing layer 110 is a sintered body obtained by sintering an inorganic binder containing a mixture of glass having a lower melting point than glass beads and a glaze. The glass having a melting point lower than that of the glass beads is, for example, powdered glass and is glass that melts at 500 ° C to 700 ° C. A glaze develops a desired color after sintering. The thickness of the fixing layer 110 is 25 μm to 40 μm. The fixing layer 110 of this example is a sintered body in which an inorganic binder layer 220 described later is sintered at 500 ° C. to 600 ° C.
The retroreflective tile 10 uses glass beads having a refractive index of 1.93 as described below. However, since the melting point is as high as 1000 ° C. or higher, the glass is deformed at a temperature of 500 to 600 ° C. where the low melting point glass melts and becomes a binder. Without doing so, the retroreflective function is sufficiently maintained.

The glass beads 120 are, for example, spherical glasses having a refractive index of 1.90 to 2.20. More preferably, the glass beads 120 are glass beads having a diameter of 50 μm to 70 μm, a melting point of 1000 ° C. or more, and a refractive index of 1.93.
The components of the glass bead are barium oxide, silicon oxide, and titanium oxide glass, and have a specific gravity as heavy as 4.2 ± 0.1 and a melting point as high as 1000 ° C. or higher.
In the glass beads having a refractive index of 1.93, light incident from the air is refracted by the glass beads and the focal point is connected to the bottom surface of the glass beads. Since it bounces back from that position at the same angle and exits from the glass beads, it returns to the direction of light irradiation and retroreflects.

The glass beads 120 are fixed to the surface of the tile 100 with one-third or more of the diameter exposed from the fixing layer 110. The glass beads 120 of the present example are fixed to the surface of the tile 100 with half of them exposed. It is desirable that the glass beads 120 fixed to the surface of the tile 100 be exposed so as to have substantially the same height. Thereby, more uniform retroreflection is realized.
Further, the glass beads 120 are arranged as illustrated in FIG. Here, “glass beads are arranged” means a state in which the majority of glass beads are regularly arranged on the tile surface. It is desirable that the glass beads 120 be arranged adjacent to each other and have a high density. By arranging the glass beads 120 in an orderly manner, the surface of the retroreflective tile 10 can be retroreflected uniformly.

  The antifouling agent film 300 is an antifouling agent film formed by applying an antifouling agent and drying it. The antifouling agent film 300 is not essential, but it may be exposed to floating substances such as yellow sand or an acid rain environment such as dust that soars due to exhaust gas in the tunnel, wind pressure, or outdoor exposure walls. The antifouling agent film 300 is preferably formed on the surfaces of the glass beads 120 and the fixing layer 110. The antifouling agent, for example, makes it difficult to be soiled by a coating of silicon oxide ceramic nanoparticles, and also adds acid resistance and wear resistance.

Next, a method for manufacturing the retroreflective tile 10 will be described with reference to FIGS.
FIG. 5 is a flowchart illustrating a tile manufacturing process (S10) of the retroreflective tile 10.
As illustrated in FIG. 5, in step 100 (S100), the manufacturer prepares an organic binder layer in which glass beads are arranged. More specifically, as illustrated in FIG. 2A, the manufacturer forms an organic binder layer 210 on one surface of the protective sheet (polyester sheet 200), and glass beads 120 are formed on the organic binder layer 210. Is prepared (bead sheet). For example, the organic binder layer 210 is composed of an organic binder mainly composed of polyethylene. The manufacturer attaches a polyethylene film having a thickness of 30 μm to one surface of the polyester sheet 200, and in a state where the polyethylene film is melted at 140 ° C. to 150 ° C., the glass beads 120 are dispersed and fixed. This is cooled and fixed. Here, the glass beads 120 to be dispersed have a diameter larger than the thickness of the polyethylene film layer. The polyethylene film layer of this example is an example of an organic binder layer, and holds the glass beads 120 with a relatively weak force such as temporary adhesion. Even if the glass beads 120 pressed against the melted polyethylene film layer are the deepest buried, they abut against the polyester sheet 200 and are positioned on the polyester sheet surface, so that the glass beads 120 are separated from the polyethylene film layer (organic binder layer 210). It will be in a state of protruding beyond a certain level. More preferably, the glass beads 120 protrude substantially uniformly from the polyethylene film layer (organic binder layer 210) by pressing the glass beads 120 firmly against the polyethylene film layer (organic binder layer 210) and abutting against the polyester sheet 200. Placed in the state. Moreover, by trying to adhere more glass beads on the melted polyethylene film, one layer of glass beads is arranged in a high density.
In the present application, a polyethylene sheet attached to the polyester sheet 200 and glass beads embedded in the polyethylene film may be referred to as a bead sheet.

  In step 110 (S110), the manufacturer screen-prints the inorganic binder on the surface of the prepared bead sheet on which the glass beads are arranged (that is, the surface on which the glass beads 120 protrude from the organic binder layer 210). Thus, the inorganic binder layer 220 is formed. Thereby, the retroreflective sheet 20 is completed. More specifically, as illustrated in FIG. 2B, the manufacturer can use a bead sheet (ie, the organic binder layer 210 and the glass beads so that the glass beads 120 protruding from the organic binder layer 210 are covered. 120), an inorganic binder is applied to form an inorganic binder layer 220. The inorganic binder is, for example, a mixture of glass powder having a melting point lower than that of the glass beads 120, glaze, and squeegee oil. The squeegee oil is for kneading powders such as glass powder and glaze into a paste, and vaporizes and disappears without being carbonized after firing.

In step 120 (S120), the manufacturer cuts the completed retroreflective sheet 20 according to the size and shape of the tile 100.
In step 130 (S130), the manufacturer applies an adhesive resin to the surface of the tile 100 and dries it. For example, the adhesive resin is desirably a water-based resin from the viewpoint of workability and safety, and exhibits adhesiveness when dried. The adhesive resin plays a role of bonding the completed retroreflective sheet 20 and the surface of the tile 100, but after bonding, a protective sheet (polyester sheet 200) and a polyethylene film layer attached to one surface Adhesive strength must be stronger than the force when peeling 210 together. This is because if the adhesive force is weak, the completed retroreflective sheet 20 cannot be attached to the tile surface.
Further, it is desirable that this adhesive resin disappears without ash remaining when baked at 500 ° C. or higher. This is because if the ash remains on the adhesion surface, the adhesion between the low melting point glass and the tile 10 becomes weak, the adhesion between the glass beads 120 decreases, and the glass beads 120 may fall off.

In step 140 (S140), as shown in FIG. 3A, the manufacturer attaches the inorganic binder layer 220 of the retroreflective sheet 20 to the surface 230 of the tile 100 on which the adhesive resin is applied.
In step 150 (S150), the manufacturer integrally peels the polyester sheet 200 and the polyethylene film layer (organic binder layer 210) from the retroreflective sheet 20 attached to the tile 100. When the polyester sheet 200 and the polyethylene film layer (organic binder layer 210) are peeled off, the glass beads 120 and the inorganic binder layer 220 are exposed on the surface of the tile 100 as illustrated in FIG.

  In step 160 (S160), the manufacturer heats the tile 100 from which the glass beads 120 and the inorganic binder layer 220 are exposed to 500 ° C. to 600 ° C. for 40 minutes to sinter the inorganic binder layer 220. In the sintered inorganic binder layer 220, as illustrated in FIG. 4, the squeegee oil is burned away, and the low-melting glass powder and the glaze are melted and sintered to become the fixed layer 110. The fixing layer 110 develops a predetermined color and fixes the glass beads 120 to the surface of the tile 100. Even if the organic substance of the organic binder remains on the surface of the glass bead 120 or the inorganic binder layer 220, the organic substance disappears after the heating because it is heated at 500 ° C. to 600 ° C. Thereby, the retroreflective tile 10 comprised only with the nonflammable material is manufactured.

  In step 170 (S170), the manufacturer applies the antifouling agent thinly and uniformly on the surface of the retroreflective tile 10 (the surface on which the glass beads 120 are exposed).

Next, a wall surface construction method using the retroreflective tile 10 will be described. The wall construction method includes a first method in which a plurality of tiles (retroreflective tiles or non-retroreflective tiles) are pasted on the panel in advance, and the panel is installed on the wall. There is a second method of installing
FIG. 6 is a diagram schematically illustrating a wall surface construction example using the retroreflective tile 10.
In the first wall surface construction method, the retroreflective tiles 10 arranged and fixed in a state in which the glass beads 120 protrude and the non-retroreflective tiles 50 that do not retroreflect more than the retroreflective tiles 10 are combined in advance. A wall surface construction method having a panel manufacturing process for manufacturing a panel and a pasting process for pasting and fixing the panel in a tunnel.
There is a strong demand to reduce the time required for on-site construction and to reduce the construction cost as much as possible by preparing a panel of 2 m in length and 1.8 m in width at the factory in advance.
The second wall surface construction method includes a step of pasting and fixing the retroreflective tile 10 to the wall surface and a step of pasting and fixing the non-retroreflective tile 50 adjacent to the retroreflective tile 10. It is. The order of pasting the retroreflective tile 10 and the non-retroreflective tile 50 is not particularly limited, and the non-retroreflective tile 50 may be pasted and fixed first. The non-retroreflective tile 50 is, for example, an existing tile that has no glass beads and is specularly reflected on the surface.
In this example, as illustrated in FIG. 6A, the retroreflective tiles 10 are continuously arranged in the running direction of the wall surface of the road, and non-retroreflective is applied to the upper and lower wall surfaces of the arranged retroreflective tiles 10. The sex tile 50 is spread. As illustrated in FIG. 6B, the retroreflective tile 10 retroreflects incident light from the light source toward the light source. Therefore, the retroreflective tile 10 appears to shine from an observer (for example, a car driver) in the vicinity of the light source. On the other hand, as shown in FIG. 6C, the non-retroreflective tile 50 does not retroreflect and mirror-reflects the light emitted from the light source. It just looks like under normal lighting.
Depending on the retroreflective difference between the retroreflective tile 10 and the non-retroreflective tile 50, a sign or a desired pattern can be drawn on the wall surface.

  Moreover, the retroreflective tile 10 which retroreflects with various colors with the color of a glaze can be manufactured. By combining the multi-color retroreflective tiles 10 and the non-retroreflective tiles 50, it is possible to draw a pattern that retroreflects in a plurality of colors on the wall surface as illustrated in FIG. In this example, the letter “P” is formed by the retroreflective tile 10 </ b> W that retroreflects white, and the surrounding area is surrounded by the retroreflective tile 10 </ b> B that retroreflects blue. Drawn by reflected light.

(Test results)
Next, the test result of the reflection luminance of the retroreflective tile 10 will be described.
FIG. 8 is a diagram showing the result of the reflection luminance test of the white retroreflective tile 10.
As shown in FIG. 8, when the incident angle of light with respect to the surface of the retroreflective tile 10 is changed to 5 °, 30 °, and 40 ° and the reflection luminance of the retroreflection is measured, any incident angle is sufficient. Reflection brightness was obtained. In this test, a retroreflective luminance measuring device NS-I manufactured by Suga Test Instruments Co., Ltd. was used, and measurement was performed with a measurement reference reflector 401 cd / lux / m 2 and an observation angle of 0.2 °.

As described above, according to the retroreflective tile 10 of the present embodiment, retroreflection with little in-plane unevenness is possible, and a beautiful retroreflection pattern can be formed on a wall surface or the like by pasting the tile. Thereby, for example, the tunnel inner wall surface can have a gaze guidance effect in the traveling direction of the vehicle. Such a retroreflective tile 10 reflects the light of the headlight of the own vehicle in the direction of the own vehicle, so that it appears to the driver as if the tile is shining by itself, and the bending of the tunnel and the up / down of the tunnel It is expected to contribute to safe driving and accident prevention by making it easier to grasp road information and giving the driver a psychological sense of security in a dark tunnel.
Further, since the retroreflective tile 10 is made of a nonflammable material, it does not burn even if a fire occurs in the tunnel, and does not cause toxic gas generation. Rather, it can be widely used as a sign for evacuation guidance during a disaster.
Moreover, since the retroreflective tile 10 can be retroreflected with various colors, the range of designs of symbols and characters by retroreflection can be widened.
Moreover, even if an antifouling agent layer is formed on the surface of the retroreflective tile 10, the retroreflective property is not lowered, and contamination with exhaust gas from a passing vehicle is suppressed.

DESCRIPTION OF SYMBOLS 1 ... Wall surface 10 ... Retroreflective tile 20 ... Retroreflective sheet 100 ... Tile 110 ... Adhesion layer 120 ... Glass bead 200 ... Polyester sheet 210 ... Organic binder layer 220 ... Inorganic binder layer 230 ... Adhesive 300 ... Antifouling agent film 50 ... Non-retroreflective tiles

Claims (5)

Preparing a retroreflective sheet in which glass beads are sandwiched between an organic binder layer containing an organic polymer and an inorganic binder layer containing glass;
Heating the inorganic binder layer of the retroreflective sheet in a state in contact with the surface of the non-combustible base material, and sintering at least the inorganic binder layer;
I have a,
The organic binder layer is a polyethylene film layer,
The process of peeling the said organic binder layer from a nonflammable base material, an inorganic binder layer, and a glass bead
Further comprising
In the sintering step, a retroreflective material manufacturing method in which the retroreflective sheet from which the polyethylene film layer has been peeled is heated while being in contact with the surface of the non-combustible substrate . The step of preparing the retroreflective sheet includes
2. The process of applying the inorganic binder containing the glass whose melting | fusing point is lower than the said glass bead to the glass bead spread | laid on the sheet | seat and hold | maintained with the organic substance polymer, The process of creating the said retroreflective sheet | seat is included. The manufacturing method as described in. The manufacturing method according to claim 1, further comprising a step of applying an antifouling agent to the sintered inorganic binder layer and the glass beads. The manufacturing method according to claim 2, wherein in the step of applying the inorganic binder, a mixture of glass having a melting point lower than that of the glass beads and glaze is applied. In the sintering step, the organic polymer is heated to a temperature at which the organic polymer is burned out, and the glass contained in the inorganic binder layer is melted to sinter the inorganic binder layer into the nonflammable substrate. Item 5. The production method according to Item 4.

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