JPH0392304A - Lightweight cellular concrete decorative panel and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide the new beautiful appearance in the field of light weight aerated concrete (ALC) and protect an ALC matrix against the impact of foreign matters and the like from outside by exposing a number of decorative grains materials on the surface of a panel. CONSTITUTION:Reinforcing bars 4 are imbedded in an ALC matrix 2 and decorative grains materials 3 are embedded only on the surface section of the ALC matrix 2 almost in one line or two lines, and a part of the same is exposed on the surface of the ALC matrix 2. As for said decorative grains 3, provided the gravity is larger than that of ALC raw material slurry at the time of foaming and grain diameter is larger than that of a raw material in said slurry, any kinds of the materials can be applied. For manufacturing, the reinforcing bars 4 are disposed floating above a bottom section in a form 5, and a number of decorative grains 3 are mixed in the ALC raw material slurry known to the public, and agitated therein, injected foamed and solidified to manufacture an uncured panel 6. The same is released from the form, transferred to an autoclave, cured under the high temperature and high pressure vapor and cured completely to manufacture a cured panel 7 with its surface section where a number of decorative grains 3 are disposed uniformly, and finally the surface section of ALC matrix 2 is removed to expose the decorative grains 3.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is based on lightweight aerated concrete (hereinafter referred to as ALC) used for the walls of structures, etc. The surface of the panel is made of granite,
The present invention relates to an ALC decorative panel in which decorative granules such as serpentine or marble are exposed, and a method for manufacturing the same.

[Prior art and problems to be solved by the invention] ALC
In the field of panels, in order to improve the aesthetics of panels, AL has a decorative plate, such as a stainless steel pattern plate, attached to its surface.
Although C panels have already been widely used, no prior art has been found that corresponds to ALC panels with decorative granules exposed on the surface as in the present invention.

However, in the field of non-foamed ordinary concrete panels, some have decorative granules such as granite exposed on the surface. This ordinary concrete panel is made by pouring and forming concrete raw material slurry mixed with decorative granules, and then before the slurry completely hardens, water is sprayed onto the surface to add the decorative granules. The above-mentioned surface was obtained by exposing, so-called washing out.

However, in manufacturing the above-mentioned ordinary concrete panel, if the decorative granules are simply mixed into the concrete raw material slurry and shaped, the difference in specific gravity between the decorative granules and the concrete raw material slurry is small and the concrete Due to the high viscosity of the raw material slurry, the decorative granules are dispersed within the concrete matrix and are not concentrated only on the surface. If the decorative granules are exposed by washing out in this state, the positions of the exposed decorative granules will be non-uniform in the thickness direction.

Therefore, in reality, a concrete raw material slurry containing decorative granules is layered thinly on the surface of an ordinary concrete panel that does not contain decorative granules and is shaped flat, and then the latter concrete matrix is It was manufactured using a method that required many steps and was laborious to wash the materials.

In addition, as another manufacturing method, after completely hardening concrete raw material slurry mixed with a large amount of decorative granules,
It is also possible to perform a removal process such as grinding on the surface of the concrete base material. However, since ordinary concrete becomes very hard when completely hardened, it is difficult to remove it, and a large amount of decorative granules are required, which may lead to an increase in costs.

The purpose of the present invention is to solve the above-mentioned problems, provide a new aesthetic appearance with decorative granules exposed on the surface, improve the strength of the surface part, and eliminate the need to waste decorative granules, making it inexpensive. In addition to providing an ALC decorative panel, the decorative granules are uniformly exposed on the surface of the ALC panel.
To provide a method for easily manufacturing decorative panels.

[A Thousand Steps to Solve the Problem] In order to achieve the above object, the ALC decorative panel of claim 1 includes an ALC base material and an ALC base material that exists only on the surface of the ALC base material and is exposed on the surface. It was combined with a large number of decorative granules.

In the method for manufacturing an ALC decorative panel according to claim 2,
A step of mixing into the ALC raw material slurry a large number of decorative granules having a specific gravity greater than the specific gravity of the slurry at the time of foaming and a particle size larger than the raw material in the slurry, and mixing the decorative granules into the formwork. a step of obtaining an uncured panel in which the decorative granules have settled to the bottom by injecting, foaming and solidifying the ALC raw material slurry; and a step of obtaining a cured panel by curing the uncured panel. ,
The surface of the ALC base material on the bottom side of the cured panel was removed to expose a large number of decorative granules on the surface.

[Function] According to the ALC decorative panel of claim 1, a large number of decorative granules are exposed on the surface of the panel.
In addition to providing a new aesthetic appearance in the field of LC panels, the decorative granules are highly resistant to collisions with foreign objects from the outside.
It also acts to protect the LC base material. Furthermore, since the decorative granules are present only on the surface of the panel, the decorative granules do not disperse inside and become wasted, unlike in the past.

According to the method for manufacturing an ALC decorative panel according to claim 2, since the specific gravity of the large number of decorative granules is greater than the specific gravity of the ALC raw material slurry at the time of foaming, they sink and come into contact with the inner bottom surface of the formwork due to gravity. and line up almost evenly. AL in this state
Since the C raw material slurry solidifies to form an uncured panel, if the uncured panel is cured, a cured panel in which a large number of decorative granules are present only on the surface of the ALC base material can be obtained. By removing the surface of the ALC base material on the bottom side of this cured panel, an ALC decorative panel with a large number of decorative granules exposed on the surface can be obtained. At this time,
Since the ALC matrix is often softer than the decorative granules, mainly only the ALC matrix is removed, often resulting in relatively protruding decorative granules.

[Example] Hereinafter, an example embodying the present invention will be described with reference to FIGS. 1 to 4.

First, the ALC decorative panel of this embodiment will be explained with reference to FIG.
and decorative granules 3.

Reinforcing bars 4 are embedded in the ALC base material 2. The reinforcing bars 4 are of a known type, and are made by welding two frames 4a made by vertically and horizontally welding main and sub-reinforcements, arranged at a predetermined distance, spacers 4b spanned between both frames 4a. By doing so, it is shaped like a basket.

The decorative granules 3 are buried in approximately one or two rows only on the surface of the ALC base material 2, and a portion of the decorative granules 3 are buried in the surface of the ALC base material 2.
It is exposed on the surface of the base material 2.

This decorative granular material 3 may be any material as long as it has a higher specific gravity than the ALC raw material slurry at the time of foaming and a particle size larger than the raw material in the slurry.
For example, natural stones such as granite, serpentine, and large buried stones, artificial stones, ceramics, glass, metals, and other various materials can be used.

Therefore, the ALC decorative panel 1 has its ALC base material 2
The large number of decorative granules 3 exposed to the surface gives a new aesthetic appearance to the field of ALC panels, and
C A large number of decorative granules 3 which are often harder than the base material 2
is exposed on the surface of the panel 1, thereby protecting the ALC base material 2 from collisions with foreign objects from the outside and increasing the strength of the surface portion. In addition, since the decorative granules 3 are present only on the surface of the ALC panel l, only a small amount is required, and the decorative granules 3 are not dispersed inside and wasted as in the past, resulting in lower material costs. It is possible to reduce the

Next, the method for manufacturing the decorative panel will be explained step by step.

■ First, as shown in FIG. 2, the reinforcing bars 4 are placed inside the formwork 5
A step of floating and arranging the mold 5 from the bottom of the formwork 5 by support means (not shown).

Here, the formwork 5 is shaped like a rectangular box extending in a direction perpendicular to the plane of the paper and having an open top surface in the figure, and its side walls can be opened outward.

(2) Next, a step of mixing a large number of the decorative granules 3 into a known ALC raw material slurry made of silica sand, concrete quicklime, a foaming agent, etc. and stirring the mixture.

(2) Next, as shown in FIG. 2, the ALC raw material slurry mixed with the decorative granules 3 is poured into the mold 5 and foamed and solidified, so that the decorative granules 3 sink to the bottom. A step of obtaining a cured uncured panel 6.

The injected ALC slurry expands while generating numerous bubbles, raising the liquid level and filling the mold 5.

At this time, since the specific gravity of the large number of decorative granules 3 is greater than the specific gravity of the slurry at the time of foaming, they sink and contact the inner bottom surface of the mold 5 due to gravity and are arranged in approximately one or two rows. Their positions are approximately uniform on the bottom. In this state, the ALC raw material slurry solidifies and becomes an uncured panel 6 in a semi-cured state. Thereafter, the side wall of the formwork 5 is opened and the uncured panel 6 is taken out.

Further, if necessary, the ends of the semi-hardened uncured panels 6 are cut with a wire or the like to smooth the end surfaces or adjust the dimensions.

(2) Next, the uncured panel 6 is transferred to a well-known autoclave, and cured under high temperature and high pressure steam (for example, 180 degrees Celsius, 10 atm) to completely cure the panel. Decorative granules 3 are placed on the surface (second
The top and bottom of the image have been reversed. 〉Process of obtaining a cured panel 7 that is uniformly aligned.

(2) Finally, a step of removing at least the surface portion of the ALC base material 2 of the cured panel 7 to expose a large number of decorative granules 3 on the surface.

Here, removal processing refers to any processing method that can remove the surface portion of the ALC base material 2 regardless of the specific method, and includes cutting processing,
This includes grinding, free abrasive processing, and other special processing.

For example, as shown in FIG. 4, the surface portion of the cured panel 7 on which the large number of decorative granules 3 are substantially uniformly present is ground with a removal processing means 8 such as a grindstone or a wire brush. At this time, in most cases, ALC is softer and easier to remove than decorative granules 3, so only the ALC base material 2 is mainly removed.
This often results in the decorative granules 3 being easily exposed and protruding relative to the ALC base material 2.

As described above, according to the manufacturing method of this embodiment, an ALC decorative panel l in which the decorative granules 3 are uniformly exposed on the surface can be manufactured by simple steps and operations. Unlike the conventional method, there is no need for a complicated work process to uniformly expose the decorative granules 3.

It should be noted that the present invention is not limited to the tank of the above-mentioned embodiments, and can be modified and embodied as appropriate without departing from the spirit of the present invention. [Effects of the Invention] The present invention is constructed as described above. As a result, the following excellent effects can be achieved.

According to the ALC decorative panel of claim 1, the decorative granules are exposed on the surface, giving a new aesthetic appearance, and the strength of the surface area is improved, and the decorative granules are not used unnecessarily, making it inexpensive. It also becomes.

According to the method for manufacturing a decorative panel made of ALC according to claim 2, the decorative granules are uniformly exposed on the surface of the ALC panel.
decorative panels can be easily produced.

[Brief explanation of drawings]

Fig. 1 is a partial perspective view showing a cross section of the ALC decorative panel of this embodiment, Fig. 2 is a cross-sectional view showing a certain forming process using a formwork in the manufacturing method of this embodiment, and Fig. 3 is also a cross-sectional view of the ALC decorative panel after curing. FIG. 4 is a cross-sectional view showing a cured panel, and FIG. 4 is a cross-sectional view showing the same removal process. ■...ALC decorative panel, 2...ALC base material, 3
... Decorative granular material, 5... Formwork, 6... Uncured panel, 7... Cured panel.

Claims (1)

[Claims] 1. A lightweight cellular concrete base material (2), and a large number of decorative granules (3) existing only on the surface of the lightweight cellular concrete base material (2) and exposed on the surface. A decorative panel made of lightweight aerated concrete consisting of a combination of 2. A step of mixing a large number of decorative granules (3), which have a specific gravity larger than that of the foamed slurry and a particle size larger than the raw material in the slurry, into the lightweight aerated concrete raw material slurry, and forming a mold (5). ) is injected with a lightweight aerated concrete raw material slurry mixed with the decorative granules (3), and is foamed and solidified to obtain an uncured panel (6) in which the decorative granules (3) have sunk to the bottom. a step of curing the uncured panel (6) to obtain a cured panel (7); and a step of removing the surface of the lightweight cellular concrete base material on the bottom side of the cured panel (7). A method for producing a decorative panel made of lightweight aerated concrete, comprising the step of exposing a large number of decorative granules (3) on the surface of the decorative panel.