JPH03242388A - Production of brick panel - Google Patents

Abstract

PURPOSE:To prevent cracks of bonded brick panel and to simplify a production process by bonding plural inorganic brick-like materials having a special specific gravity with a fiber-containing adhesive while providing given joint width, integrating and cutting the integrated materials in parallel to the surface of the brick-like materials. CONSTITUTION:Plural brick-like materials 1 comprising an inorganic burnt material or hydraulic inorganic substance having 0.5-2.0 specific gravity are bonded and integrated with a fiber 3-containing adhesive 4 while providing given joint width 2 and cut in parallel to the surface of the brick-like materials 1 to give a brick panel A. The following method can also be adopted. Namely, the sides 5 of the plural brick-like materials 1 comprising the inorganic burnt material or hydraulic inorganic substance having 0.5-2.0 specific gravity are bonded through a sheetlike material 6 having fluffs 7 such as nonwoven fabric or rope composed of fibers with an adhesive 4 in given arrangement, integrated and cut in parallel to the surface.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing a decorative panel that has an appearance similar to that of piled up bricks.

(Prior art and its problems) Conventional brick panels are made by joining thin brick pieces formed one by one in advance, side to side, and arranging a facing material etc. as appropriate on the back side.

However, in the above manufacturing method, thin brick flakes must be made from the beginning or brick blocks must be formed and then cut out to form thin brick flakes.
The former method is complicated to manufacture, and the latter method has the disadvantage that the material is brittle and tends to crack or chip when cut, resulting in poor yield.

Furthermore, since it is not possible to bond by applying lateral pressure, there are gaps between the joints even after bonding, and the strength is low.

Furthermore, there was also a drawback that the thickness of the brick flakes varied and the surface smoothness of the bonded panel was poor.

Therefore, attempts have been made to form brick-like objects into a desired arrangement by gluing them, and then cutting them from the surface of the brick-like objects to form brick panels. When larger sizes were used, the cracks became even more severe, and the manufacturing yield was extremely poor, making it impossible to put them into practical use.

(Objective of the present invention) The present invention was made in view of the drawbacks of the conventional example, and
The purpose of this is to manufacture brick panels that solve various problems such as cracking caused by pre-mechanizing block-shaped bricks and cutting them parallel to the surface, which greatly simplifies the manufacturing process. We are here to provide you with a method.

(Means for Solving the Problems) In order to achieve the above object, the method for producing a brick panel (^) according to the present invention is as follows in claim (1): A plurality of brick-like objects (1) made of fired bodies or hydraulic inorganic materials are glued together with a fiber-containing adhesive (4) with a predetermined joint width. Cut parallel to the surface.

In claim (2), the following technical means is adopted, and in claim (2): ■ side faces (5) of a plurality of brick-like objects (1) made of inorganic fired bodies or hydraulic inorganic bodies having a specific gravity of 0.5 to 2.0; are bonded together in a desired arrangement with an adhesive (4) through a sheet body (6) having fluff (7) such as a nonwoven fabric or a net made of fibers (3), and after that, the surface Cut parallel to.

Further, in claim (3): ■ In the method for manufacturing a brick panel (^) according to claim (1) or (2), the hardness of the adhesive (4) is adjusted to Shape (1)
■The surface of the brick-like panel obtained by cutting is ground by shot blasting or brushing.

We are using technical means to do so.

(Function) ■In the first embodiment, the fiber-containing adhesive (4) is applied to the side surface (5) of the brick-like object (1), and the brick-like object (1) is placed on the mold material (11) in a desired arrangement. are assembled, and the brick-like material (1) is pressed and hardened from the side using a pair of frame members (9).

As a result, first, the fibers in the adhesive (4) enter into the unevenness (5') of the side surface (5) of the brick-like object (1) together with the adhesive (4), and bond with the brick-like object (1). The fibers (3) in the adhesive (4) form a brick-like shape when they are pressed from the sides when fixed. It is generally layered on the side surface (5) of the object (1), and absorbs vibrations and shocks during cutting with a saw, which will be described later, to prevent cracking and chipping of the brick-like object (1). I can do it.

■ After bonding and fixing the brick-like object (1) with the fiber-containing adhesive (4) in this way, use a diamond-blade circular saw, band saw, etc. to cut parallel to the surface of the brick-like object (1). Cut to form thin brick panels (^).

This results in a brick panel (^) with a uniform thickness,
Even if it accumulates, it will not crack or warp due to local load concentration, and is easy to pack and transport.

■Finally, grind by shot blasting, sandblasting, or brushing to create joints that are softer than the brick parts (
2) Form the resin portion into a concave shape. As a result, the soft joints (2) are largely removed, creating a three-dimensional appearance.In addition, unevenness is also formed on the surface of the brick flakes (8), giving the brick an appearance rich in naturalness and solidity. panel(
^) becomes.

■Also, in the second embodiment, instead of the fibers (3), a sheet body (6) such as a nonwoven fabric or a net is used, which is made of glass fiber, resin fiber, etc. ) and the side surface (5) of the brick-like object (1) during crimping.
) into the unevenness (5 degrees) together with the adhesive (4), firmly adhering the brick-like object (1) and the adhesive (4), and reinforcing the easily breakable brick-like object (1). In addition, the sides (5
) The sheet body (6) disposed approximately parallel to the blade absorbs vibrations during cutting more reliably.

(Example) Hereinafter, the present invention will be described in detail according to illustrated embodiments.

FIG. 1 is a perspective view showing an embodiment of the present invention. The brick-like material (1) used is made by crushing and kneading clay, silica stone, rouseki, silicate clay, fireclay, etc., and forming it into a block shape. It is then fired. Specific gravity is 0.5~ so that it can be cut.
It is set to 2.0. Preferably, the specific gravity is 1.0 to 1.
．． It is 8.

In addition, fine aggregates such as perlite and sand whose main component is cement, and foamed aggregates are kneaded with water and hardened by hydration, and molded, and water glass binders are foamed with alumina or charcoal. It may be formed into a brick-like shape, and the specific gravity is set to 0.5 to 2.0 so that it can be cut as described above.

If the specific gravity is less than 0.5, compression cracking will occur due to cutting resistance, and the cut surface will not be smooth.
If it exceeds 0, it will be difficult to industrially cut the block-shaped brick-like object (1) with good productivity even if a carbide blade such as a diamond cutter is used.

The shape is a rectangular block, and the cut surface determines the external appearance, so it is generally the same size as a normal brick or tile. The width can be increased. Further, the depth is not particularly limited either.

In addition, if a urethane, epoxy, or acrylic resin liquid with good permeability and a solid content of 5 to 50% is applied in advance to at least the side surface (5) that is the adhesive surface of the brick-like object (1), the side surface (5) The resin liquid penetrates into the material and strengthens it, making it even more difficult to crack or chip when cutting.

It is also effective for preventing cracking to impregnate the inside of the brick-like material (1) with resin liquid within a range that does not impede cutting suitability.

For the adhesive (4), cement mortar is used for brick panels (^) where fire resistance is required, and natural rubber, synthetic rubber, epoxy resin, etc. are used for applications where quick curing and workability are required. Synthetic resins such as silicone resins, acrylic resins, urethane resins, and resin mortar made by appropriately mixing cement and synthetic resins can be used as appropriate depending on the purpose.

When gluing, use a material with good durability and small flow in order to maintain the specified joint width. If you specify it numerically, it is 1,000-6,000 cps for resin-based products and 5 for cement-based products.
．． It is sufficient if it is 0OOcps or more.

The fibers (3) mixed into the adhesive (4) are, for example, synthetic fibers such as glass fibers, carbon fibers, and polypropylene, and have an average fiber length of 1 to 30 mm. This is because when the joint width is set to 0.5-51I1ml, the fibers (3) mixed into the adhesive (4) are
5), and the fiber length is specified to be longer than the joint width. Fiber (3) to adhesive (4)
The mixing rate is 1 to 30%.

As shown in Fig. 1, the fiber-containing adhesive (4) is applied to the side surfaces (5) of a plurality of brick-like objects (1), and the brick-like objects (1) are placed on the mold material (11) in a desired arrangement. are assembled, and the brick-like material (1) is pressed and hardened from the side using a pair of frame members (9). At this time, the joint width is 0.5 as described above.
-51, and the fibers (3) in the adhesive (4), which are longer than the joint width, are oriented along the joint (2).

After bonding and fixing the brick-like object (1) with the fiber-containing adhesive (4) in this way, use a diamond-blade circular saw, band saw, etc. to cut the brick-like object (1) parallel to the surface of the brick-like object (1). Cut to form thin brick panels (^).

In addition, if the joints (2) of the brick panel (^) run in a straight line, they are likely to break from the joints (2), so as shown in Figures 2 to 5, the arrangement is such that the joints (2) do not pass through at least in one direction. desirable.

The second embodiment uses a nonwoven fabric, a net, etc. made of synthetic fibers similar to fibers (3) mixed in the adhesive (4), such as glass fibers, carbon fibers, or polypropylene, instead of fibers (3). A sheet body (6) is used.

In this case, the ends of the fibers of the sheet body (6) such as non-woven fabric or net become fluffy and enter the adhesive (4) layer, and when crimped, the adhesive ( 4
) and reinforce the easily breakable brick-like material (1).

When assembling the brick-like object (1), it may be applied along with the adhesive (4) sequentially to the side surface (5), but a pattern for assembling the brick-like object (1) is formed in advance, and the brick-like object is assembled according to the pattern. The most productive method is to place a sheet (6) between the object (1) and its side surface (5), and then pour the adhesive (4) into the joint (2) between the brick-like objects (1). Good and desirable.

The rest is the same as the first embodiment.

In the third embodiment, the surface of the brick panel (^) formed in the first and second embodiments was subjected to short blasting or sandblasting, either as it was or after the joint (2) surface portion was thermally degraded by burner burning or the like. Or grind it by brushing etc.
The resin part of the joint (2), which is softer than the brick part, is formed into a concave shape to form a three-dimensional brick-like appearance.

Therefore, as the resin for the joint 2), a resin whose hardness when hardened is softer than that of the brick-like material (1) from among the above-mentioned types is selected.

(Example 1) Clay-based material with specific gravity of 1.8 and dimensions of 230xllO
10 brick-like objects (1) of X 70mm, size 115
Prepare four pieces of xllOx701III, and use a shape material that can be positioned vertically with the 1101 side vertically and with a joint width of 1mm (
11) Cement mortar (Portland cement: sand: water = 1: 2: 0.45 fl. 180 fl.
Using an L-shaped formwork (9) as shown in FIG. 1, the side surface (5) of the brick-like structure was clamped using the L-shaped mold (9) as shown in FIG. 1, and lateral pressure was applied to integrate it.

After the resin of joint (2) hardens, the side of 110I is vertically 15m.
A brick panel (^) was formed by cutting with a diamond saw parallel to the surface to a thickness of m.

(Example 2) After preparing the above-mentioned brick-like objects (1) and arranging the brick-like objects (1) using the above-mentioned formwork (9), a glass nonwoven fabric was inserted between the brick-like objects (1). The upper part of the nonwoven fabric was fixed, and an epoxy resin having a viscosity of 2,000 cps was poured into the joints (2) without bending the glass nonwoven fabric, followed by curing. The following operations are similar to those in the first embodiment.

(Example 3) The brick panel (^) formed in Example 2 was ground by shot blasting so that the resin joints (2) were recessed by 211 m. As a result, the brick parts also had fine irregularities, giving them the appearance of having been used for many years.

(Effects) As described above, in the first embodiment of the present invention, a plurality of brick-like objects are bonded together with a fiber-containing adhesive with a predetermined joint width. The adhesive can be cured by applying lateral pressure using the wide sides of a large brick-like object, and the fibers penetrate into the unevenness of the sides of the brick-like object, ensuring a secure bond. This can prevent the occurrence of eyesores and variations in adhesive strength.Secondly, the fibers mixed in the filling adhesive between the brick-like objects are pressed against the sides of the brick-like objects by pressing from the side. On the other hand, it is mostly layered in adhesive, absorbing the vibrations and shocks that occur in the vertical direction when cutting perpendicular to the side of the brick, and reinforcing the fragile brick-like material to prevent cracking. It can prevent chipping.

Thirdly, since the brick-like objects are glued together and then cut parallel to the surface, there is little variation in the thickness of the brick flakes that make up the brick panel, and even if they are piled up, the load will concentrate on some parts and cause them to crack. It also has the advantage of not bending or warping, and is easy to pack and transport.

Further, in the second embodiment, in addition to the above-mentioned effects, the side surfaces of the brick-like object are bonded and fixed in a desired arrangement with an adhesive through a sheet body having fluff such as a nonwoven fabric made of fibers or a net. Therefore, the sheet body having fluff can be arranged parallel to the side surface of the brick-like object in advance, and the vibration absorption effect during cutting becomes more reliable.

Furthermore, in the third embodiment, the hardness of the adhesive is made smaller than the hardness of the brick-like material, and the surface of the brick-like panel obtained by cutting is ground by shot blasting or brushing, so that the hardness of the adhesive is smaller than that of the brick flakes. The resin joints are largely shaved off, creating a three-dimensional appearance. Furthermore, as mentioned above, it is possible to form irregularities on the surface of the brick flakes, and in combination with the recessed joint portions, it is possible to create a brick panel with an appearance rich in naturalness and solidity.

[Brief explanation of drawings]

Fig. 1 - Exploded perspective view showing a manufacturing example of the present invention Figs. 2 to 5 -
...A perspective view of a preferable case of a brick panel manufactured according to the present invention An enlarged cross-sectional view of a joint portion of the first embodiment of the present invention An enlarged cross-sectional view of a joint portion of a second embodiment of the present invention (^・Brick panel ( Brick-like material (2)... Joint (3... Fiber (4)... Adhesive (5...
・Side surface (6)... Sheet body (7... Fluff (8)... Brick thin piece (9... L formwork material (11)... Template Figure 6 Figure 7 Figure 2 Figure 3 Figure 4 Figure 5 Figure 1!!!I Brick panel... Brick-like material Fiber side... Fuzz... Formwork material... Joint adhesive... Sheet body... 1 piece of brick)...Template Figure 6

Claims (3)

[Claims] (1) After a plurality of brick-like objects made of inorganic fired bodies or hydraulic inorganic bodies with a specific gravity of 0.5 to 2.0 are bonded together with a fiber-containing adhesive with a predetermined joint width, the bricks are A method for manufacturing a brick panel characterized by cutting parallel to the surface of a shaped object. (2) Glue the sides of a plurality of brick-like objects made of inorganic fired bodies or hydraulic inorganic bodies with a specific gravity of 0.5 to 2.0 through a fluffy sheet body such as a nonwoven fabric made of fibers or a net. A method for manufacturing a brick panel, which comprises gluing and integrating the panels in a desired arrangement, and then cutting them parallel to the surface. (3) In the method for manufacturing a brick panel according to claim (1) or (2), the hardness of the adhesive is lower than the hardness of the brick-like material, and the surface of the brick-like panel obtained by cutting is subjected to shot blasting or brushing. A method for manufacturing a brick panel characterized by grinding.