JPH04189955A - Thermal spraying decoration for mortar tile - Google Patents

Abstract

PURPOSE:To manufacture a mortar tile which provides a high class feeling and the superior durability by forming a tile member through the mold pressing shaping of mortar, forming a rough surface on the surface for applying decoration, and thermal-spraying the decoration material on the rough surface. CONSTITUTION:The part between the upper and lower metal molds of a press machine is charged with mortar, and the upper metal mold is pressed to the lower metal mold, and a tile member 2 is formed through dehydration. Then, the tile member 2 is dried, and solidified. In this case, fine uneven patterns are formed on the upper metal mold, and the surface 2a of the tile member 2 is formed to a rough surface 3 having the uneven pattern. The copper in mist form is applied to the surface 2a by using a thermal-spraying device. Accordingly, the sprayed decoration material is firmly coagulated through cooling contraction, the durability is improved drastically, and a tile 1 having a high class feeling can be manufactured at a low cost.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a method of applying decoration to the surface of mortar tiles.

[Conventional technology]

Generally, mortar tiles are decorated by molding mortar to form a tile material, drying it, and then applying a desired coating film to the surface of the tile material to be decorated.

[Problem to be solved by the invention]

When a roof is covered with tiles decorated using the above-mentioned conventional method, there is a problem in that the paint tends to deteriorate quickly due to exposure to strong sunlight, wind and rain. Furthermore, if the paint deteriorates and pinholes or the like are formed in the paint film, rainwater enters through the pinholes, causing the paint film to peel off, thereby reducing the durability of the mortar tile. On the other hand, as the prices of land and real estate have skyrocketed in recent years, houses have become more luxurious, and people are now looking for high-class roofs with tiles made of copper plates or ceramics. In order to meet these demands, tiles are coated with glaze and then fired, or the surface to be decorated is coated with adhesive, copper powder is applied to the adhesive, and the top surface is coated with adhesive. There are some that apply clear paint to the
The method of applying glaze to tiles and firing them has the problem of not being able to be used on mortar tiles, which are susceptible to high heat, and the method of attaching copper or ceramic powder to the tile material with adhesive is difficult to apply. It requires a lot of processing steps and a lot of effort, such as applying a chemical agent, applying copper powder, applying clear paint, etc., and it is expensive and unnecessary (as mentioned above, the clear paint deteriorates quickly and the adhesive deteriorates quickly). The copper powder peels off quickly (there was a problem with durability).The present invention was proposed in view of the above problems, and it is possible to provide a mortar tile with excellent durability and a luxurious feel even though it is a mortar tile. The purpose is to

[Means for Solving the Problems] In order to achieve the above object, the first method of thermal spraying decoration of a mortar tile according to the present invention is to form a tile material by stamping mortar, and to form a thermal spray decoration of the tile material. The second method is characterized in that the surface to be coated is formed into a rough surface, and a decorative material is thermally sprayed onto the rough surface to fix the thermal spray particles to the rough surface. Water is removed from the sprayed decorative surface during press molding,
This method is characterized in that the solid lumps in the mortar are exposed to the sprayed decorative surface to form a rough surface. [Function] First, mortar is placed in a press mold and pressed, dehydrated to form a tile material, and then the tile material is dried and solidified. At this time, the sprayed decorative surface of the dried tile material is formed into a rough surface with a finely wavy cross-sectional shape. Next, when melted copper metal, for example, is sprayed onto the thermally sprayed decorative surface of the tile material, the surrounding area of the molten copper particles is cooled and gradually hardens as they fly, but the inside is still in a soft molten state. It is. When this is sprayed onto the finely corrugated rough surface of the sprayed decorative surface, the molten copper particles bite into the uneven portions of the rough surface and are cooled. Then, due to cooling shrinkage, the molten particles are firmly embedded in the uneven parts of the rough surface and fixed, and the decorative surface of the tile material is decorated in a copper color, as if it were made of copper plate. In this way, the molten copper particles that are cooled while biting into the uneven parts of the finely corrugated rough surface of the thermal sprayed decorative surface are kept firmly fixed to the uneven parts of the rough surface due to cooling contraction. be. Here, the temperature of the molten particles immediately after being thermally sprayed is quite high, but when they are sprayed onto the thermally sprayed decorative surface, the heat capacity of the tile material is greater, so they are immediately cooled down, and the surface temperature of the tile material is not so high. It does not rise, and the tile material will not be damaged by the heat.

【Example】

The present invention will be explained below based on the drawings. FIG. 1 shows a perspective view of a mortar tile manufactured by the thermal spray decoration method for mortar tiles of the present invention, and the reference numeral 1 in the figure indicates the mortar tile as a whole. This mortar tile 1 is first made by mixing cement, sand, and water in a predetermined ratio, then placing mortar between an upper mold and a lower mold (both not shown) in a press machine. The tile material 2 is formed by pressing the mold against the lower mold and dewatering and molding. Next, the shaped tile material 2 is dried and solidified. At this time, if a fine uneven pattern is applied to the upper mold for shaping the surface 2a of the tile material 2, the surface 2a of the dried tile material 2 will have fine unevenness as shown in FIG. A rough surface 3 with a continuous pattern is formed. In this way, a fine uneven pattern is formed on the surface, and a mist of copper is sprayed onto the surface (sprayed decorative surface) 2a of the dried tile material 2 using a thermal spraying device. This thermal spraying equipment melts copper wire onto metal wire using an arc.
Electric wire thermal spray equipment that uses compressed air to form a mist and spray it, or gas melt wire thermal spray equipment that melts copper wire using a high-temperature gas flame and sprays it into a mist using compressed air, or melts metal powder with a high-temperature flame and blows it away. Powder spray equipment is used. The molten copper particles 4, which are blown onto the surface 2a of the tile material 2 while being melted in this way, are cooled and gradually hardened as they fly as shown in Figure 3, but the inside is still molten. When this is blown onto the rough surface 3 of the surface 2a of the tile material 2, the molten copper particles 4 pierce the tips of the uneven parts of the rough surface 3, or are blown densely into the valleys. surface 2a of tile material 2
A thin layer of copper metal is formed on the surface. When the molten copper particles 4 are cooled while being stuck to the tips of the uneven portions of the rough surface 3, the molten copper particles 4
is cooled and shrunk to a state where it firmly clings to the tips of the uneven portions of the rough surface 3, and is firmly fixed. In addition, molten copper particles 4 are sprayed in a thin layer in the valley.
The heat they possess causes them to fuse together, forming a relatively smooth layer. Here, the temperature of the molten particles 4 immediately after being thermally sprayed is quite high, but when it hits the surface 2a of the tile material 2, the results of experiments conducted by the present applicant show that the temperature of the molten particles 4 immediately increases due to the large heat capacity of the tile material 2. Since it is cooled, the temperature of the surface 2a of the tile material 2 rises only to about 150 degrees, and the temperature at which the mortar tile material 2 is damaged by heat is about 300 degrees.
It was found that there was no damage due to temperature rise. Also, the surface 2a of the tile material 2 on which the molten copper particles 4 are sprayed
If the apex angle θ of the uneven portion is made acute, even if another object comes into contact with the molten copper particles 4 attached to both slopes, the force F acting on the molten copper particles 4 will be The surface 2 of the tile material 2 is different from the direction of the force f trying to pull it out.
This prevents the copper particles fixed to a from peeling off. In this way, when the molten copper particles 4 are cooled while biting into the tips of the uneven portions of the rough surface, the entire surface 2a of the tile material 2 is decorated in a copper color as if it were made of a copper plate. It is. The copper particles fixed on the surface 2a of the tile material 2 are oxidized with a chemical solution to generate a patina, or a clear paint is applied to the upper surface of the copper particles or the patina. In some cases, it is processed and shipped. In the above embodiment, the rough surface 3 of the surface 2a of the tile material 2 is formed by applying a fine uneven pattern to the upper mold of a press machine, but mortar is formed by pressing the mortar with a press machine. Sometimes, if a fine wire mesh such as a filter cloth or mesh is provided in the upper mold part that shapes the surface 2a of the tile material 2 and the water is dehydrated from this to form the rough surface 3, the shape of the mesh of the filter cloth or wire mesh is In addition to forming irregularities, the dehydration exposes the solids in the mortar to the sprayed decorative surface, further improving the effect of fixing the sprayed particles. Further, in the above embodiment, copper is thermally sprayed onto the surface 2a of the tile material 2, but it goes without saying that other metals, ceramics, glass, etc. can be thermally sprayed in substantially the same manner. That's a good thing.

【Effect of the invention】

As explained above, according to the thermal spray decoration method for mortar roof tiles of the present invention, the surface of the tile material molded with mortar to be thermal sprayed is made into a rough surface, and the decorative material is thermally sprayed onto this rough surface. Since the sprayed particles are fixed on the rough surface, the tiles manufactured in this way suffer from shrinkage of the sprayed decorative material due to cooling shrinkage.
It remains firmly fixed due to the uneven parts of the rough surface. This has the advantage that there is less deterioration and the durability can be greatly improved compared to the conventional method of fixing the powder of the decorative material with paint or adhesive. Furthermore, the manufacturing process is as simple as making the thermal sprayed decorative surface rough and spraying the decorative material onto this rough surface, making it possible to inexpensively manufacture high-quality temperature-sensitive tiles with the thermal sprayed decorative surface decorated with decorative material. There is also an advantage. In addition, even if a clear paint is applied after the decorative material is thermally sprayed, even if the clear paint deteriorates early, the thermal spray particles that are fixed to the thermally sprayed decorative surface have a strong fixing force, so the thermal spray particles will remain intact. It does not peel off easily, and has the advantage of preventing roof tiles from becoming unsightly due to early deterioration of the clear paint.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention; FIG. 1 is a perspective view of a mortar tile, FIG. 2 is a partially cutaway longitudinal sectional front view thereof, and FIG. 3 is an enlarged longitudinal sectional view of the main part.

Claims (2)

[Claims] (1) Form a tile material by stamping mortar, form the surface of the tile material to be coated by thermal spraying into a rough surface, and spray the decorative material onto the rough surface to fix the sprayed particles to the rough surface. A method for spraying decorative mortar tiles. (2) A thermal spray decorative method for a mortar tile, characterized in that water is dehydrated from the thermal spray decorative surface during embossing of the mortar, and solid lumps in the mortar are exposed to the thermal spray decorative surface to form a rough surface. .