JPH0250843B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing artificial stone having a stone pseudo surface.

In general, the manufacturing method for what is called artificial stone is, for example, by applying several types of crushed stone and white cement using natural stone on the surface of a base material such as concrete or mortar.
After applying a mixture of sand, pigment, water, etc. and drying it, or after drying the mixture itself, the surface is polished or polished in the same way as natural stone. something is known.

However, in the above method, the displayed ring of crushed stone is clearly divided and the crushed stone appears to be exposed only on the surface, so it can be seen at a glance that it is an artificial stone. In addition, this method requires at least a step such as polishing or dabbing, and it is also possible to apply the crushed stone mixture to the surface of the base material.
Also, it was rarely used as a stone material, except for special applications.

In addition, the present applicant has filed patent application No. 57-124105, 57-
In 197944, we proposed a method for constructing a stone pseudo surface that is similar to natural stone, but these methods cannot be applied to walls that have already been formed,
This was an attempt to create a pseudo stone surface on the surface of a floor, etc., and as a final finish, the surface still had to be polished.

The present invention is based on the above-mentioned technical background and provides a new method for manufacturing artificial stone that eliminates the conventional drawbacks. The coated body is applied to the inner surface by a spraying means so as to form an irregular irregular pattern of heights and heights, and is slightly dried and solidified to form a first layer, and then, on the surface of the first layer,
A coated body of a different color from the above coated body is coated by spraying means so that the uneven pattern is polymerized or has intricate heights, and is slightly dried and solidified to form a second layer. A stone pseudo surface is formed by sequentially forming the third and subsequent layers of different colors by the same means (first invention), or on top of these, from the first layer to the final layer, by the same method as above. After that, muddy concrete, mortar, etc. are poured into the remaining part of the formwork to dry and solidify, and the frame is removed to form a pseudo stone surface (second invention). The point is that the beautiful stone pattern, which is partially scattered, is made to appear.

Embodiments of the present invention will be described below with reference to the drawings.

The shape of the formwork 1 used in the present invention is as follows:
A box-shaped one with at least a flat bottom is sufficient, but it is easy to spray, remove the frame, etc., and it is also possible to obtain plate-shaped or square-shaped stones, which are often used as stone materials. It is preferable that each surface is a flat surface. Further, the formwork 1 may be either an integral type or a split type, but it is well known that in the case of an integral type, a punching allowance is provided in consideration of ease of removing the frame. Next, as for the material of the formwork 1, metal, plastic, wood, etc. can be used, but a metal material with a smooth surface and high strength is preferable. By the way, even if the inner surface of the formwork 1 is smooth, in order to make it easier to remove the frame and to prevent chipping, flaws, etc. from occurring on the stone surface, a mold release agent, for example, is applied to the inner surface of the formwork 1.
Of course, it is also possible to apply Homa oil, silicone oil, etc.

The spraying means used in the present invention is a common method used in the painting field, which is also called spray painting or spray painting, and a spray gun is used as the equipment, and a spray gun with a relatively large diameter is suitable.

Next, the coated body used in the present invention is preferably one that has an appropriate viscosity when sprayed and has as high a hardness as possible after drying. For example, synthetic resin paints such as acrylic resin paints and epoxy resin paints, or cements made by mixing white cement or other Portland cement with desired pigments and kneading them with water to make them easy to spray and have a suitable viscosity. Examples include paints based on paints, and those mixed with fine grains of sand.

Next, a method for manufacturing an artificial stone having a stone pseudo surface according to the first invention will be described with reference to the drawings.

The formwork 1 used in the present invention is a rectangular tray-shaped formwork 1 made of iron plate, aluminum plate, etc.
(see FIG. 1), first, a release agent such as silicone oil or homa oil is applied to the inner surface of the mold 1 to form a first coating layer 2 on at least the bottom surface.

Here, a spray gun is used for this formation,
Air pressure is 4~8Kg/ ^cm2 , nozzle diameter is 2~
A diameter of 10 mm is used, and a white cement-based paint, for example, is used as the coating body. Spraying follows the usual method, but the moving speed of the spray gun, air pressure, nozzle diameter, etc. are selected empirically after considering the surface pattern of the target stone.

In this way, the first coating layer 2 coated on the bottom surface of the formwork 1 displays a three-dimensional irregular pattern of irregular shapes such as height, size, etc. If you look at this state from the bottom side, you can see that the size of the coated body varies, and there are parts where the coated body is very thinly coated, so there are various patterns of shading ( (see Figure 2) is exposed.

Next, after the first coating layer 2 is slightly dried and solidified, a second coating layer 3 is formed on the surface thereof by the same spraying means. The coated body of this second coated layer 3 is:
For example, use a butter-colored one.

The second coating layer 3 thus coated is similar to the first coating layer 3.
An irregular uneven pattern is superimposed on the irregular uneven pattern of coating layer 2, and if this state is viewed from the bottom side, the first coating layer has a mixture of sizes and shading. The coated bodies of the second coated layer 3 are coated with different sizes and shadings so as to fill in the uncoated portions of the second coated layer 3 (see FIG. 3).

Next, a third coating layer 4 and a fourth coating layer 5 are sequentially formed by the same means. Looking at this final state from the bottom side, based on the scattering of the coated bodies of the first coated layer 2 with different sizes and shades, other coated bodies are
A complementary filling pattern (see FIGS. 4 and 5) can be seen to fill in this scattering. The coated bodies of the third and fourth coated layers 4 and 5 are, for example, yellowish brown or dark brown.

At this time, the number of the coating layers may be 2 or more, and in this description, 1 to 4 layers are used, but in reality, 5 to 7 layers are preferable from the viewpoint of appearance. In addition, the colors of the coating bodies used in the first to fourth coating layers are those whose lightness decreases as the layers go up, but this is just one example and is not limited to this in any way. Rather, the color of the coated body of each coated layer can be freely selected.

In addition, the "layers" expressed in the above explanation are not clearly distinguished between layers like so-called geological strata, and as mentioned earlier, each coating layer is in a state of overlapping or a complicated state of uneven heights. Formwork 1 as shown in Figure 5
The second to fourth coating layers 3 to 5 are partially exposed around the top layer 2 when viewed from the bottom side.

After forming the first to fourth coating layers 2 to 5 on the inner surface of the formwork 1 in this way, muddy concrete, mortar, etc. is poured into the remaining part of the formwork 1, dried and solidified, and the frame is removed. , it is possible to obtain artificial stone with a beautiful natural stone pattern in which the applied layers do not form clear outlines on the surface but are scattered. still,
Of course, when pouring concrete or the like, vibration may be applied to the formwork 1 in order to densely fill the concrete or the like.

Next, the second invention will be explained. This invention is based on the first to fourth coating layers 2 described in the first invention.
-5 is first formed on the inner surface of the formwork 1, and then in the same manner, the first to fourth coating layers are formed on the fourth coating layer, which is the final layer, to form a stone pseudo surface. After that, concrete mud, mortar, etc. are poured into the remaining part of the formwork, allowed to dry and solidify, and the formwork is removed.

The invention is as described above. Since the coating body was applied by spraying means without using a natural frame stone, the surface of the artificial stone according to the present invention has an appearance similar to that of natural stone. In addition, the color of the coating body and the number of coating layers can be freely selected, and the diameter of the nozzle used during spraying can be changed, so the color of the stone pattern can be changed.
You can freely change the size and offer a wide variety of items.

Furthermore, by using a mold with a smooth surface as the formwork 1, the surface of the artificial stone according to the present invention will also be smooth, and the finishing polishing step that was conventionally required can be omitted. Of course, if a smoother surface is required, finishing polishing may be performed, and furthermore, a transparent finishing coating may be applied to make the surface glossy.

Furthermore, if the first to fourth coating layers 2 to 5 are formed in two stages as in the second invention, even if the first stage is weathered, worn out, missing, etc., the internal concrete etc. Never exposed, forever beautiful.
It continues to reveal the natural stone pattern.

By the way, according to the present invention, the stones can be prepared in advance and can therefore be manufactured in a factory or the like, so it is also possible to produce them in large quantities at low cost.

[Brief explanation of the drawing]

Figure 1 is a perspective view of a rectangular tray-shaped formwork, Figures 2-
FIG. 5 shows a plan view of the first to fourth coating layers viewed from the bottom side of the mold. 1... Formwork, 2... First coating layer, 3... Second coating layer,
4...Third coating layer, 5...Fourth coating layer.

Claims (1)

[Scope of Claims] 1. The coating material is applied to the inner surface of a box-shaped formwork whose bottom surface is at least flat by spraying means so as to form an irregular uneven pattern of heights and heights, and is slightly dried. solidify to form a first layer;
On the surface of the layer, a coated body having a different color from the coated body is applied by spraying means so that the uneven pattern is polymerized or has intricate heights, and is slightly dried and solidified to form a second layer. , After forming a stone pseudo surface by sequentially forming the third and subsequent layers of different colors using the same method on the second layer, pour concrete, mortar, etc. into the remaining part of the formwork and dry and solidify. A method for manufacturing an artificial stone having a stone pseudo-surface that reveals a beautiful stone pattern in which each painted layer is partially scattered on the surface by removing the frame. 2. Apply the coating material to the inner surface of a box-shaped formwork with at least a flat bottom surface using a spraying means so as to form an uneven pattern of irregular shapes such as height, height, size, etc., and dry and solidify it slightly. A layer is formed, and then a coated body having a different color from the coated body is applied to the surface of the first layer using a spraying means so that the uneven pattern is polymerized or has a concave and convex pattern, and is slightly dried and solidified. Then, on the second layer, the third and subsequent layers of different colors are sequentially formed by the same method to form a stone pseudo surface, and then the first layer to the final layer are added on top of these. After forming in the same manner as above,
By pouring muddy concrete, mortar, etc. into the remaining part of the formwork, allowing it to dry and solidify, and then removing the formwork, a beautiful stone pattern with partial scattering of each coating layer is revealed on the surface. A method for manufacturing artificial stone having a stone pseudo surface.