JPH05104507A - Natural stone-like building material - Google Patents

Abstract

PURPOSE:To manufacture an artificial building material close to a natural stone by means of small equipment by arranging a number of cut natural stones of given thickness with their cut faces exposed on the surface side of a substrate base composed of gypsum, mineral powder and the like kneaded all together and embedding the stones therein. CONSTITUTION:Natural stones such as marble, granite and the like are cut into the given thickness. Natural stone flat plates 2 are laid with their surfaces facing the bottom face of a frame 11 and a kneaded material composed of water, gypsum, mineral powder and the like are poured therein to manufacture an artificial stone 10 with the natural stone flat plates 12 embedded on the surface side. Thus a large number of natural stone flat plates 12 can be exposed on the surface of a product by said arrangement to manufacture a building material closer to a natural stone. A cutter to be used can be a small type. Also, artificial ceramic plates can be used instead of natural stone flat plates 12. The natural powder of 20mum-5cm grain diameter can be used. As the substrate base 13, a material containing mineral powder in the range of 0-95wt.%, gypsum of 0-70wt.% and an inorganic pigment of 0-3wt.% can be used. White cement or the like can be substituted for gypsum.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building material for natural stones used as a building material for interiors and exteriors, such as the top plate of a vanity and sink and a bathroom counter.

[0002]

2. Description of the Related Art Terrazzo, artificial marble and the like are already known as artificial stones of this type. FIG. 4 shows an example of a conventional method for manufacturing the terrazzo 1, and FIG. 5 is a perspective view of the manufactured terrazzo 1. As shown in the figure, in the conventional production of terrazzo 1, first, a crushed stone having a particle size of 5 cm or less such as marble or granite is used as a seed stone 2, and a white cement 3 containing the seed stone is used.
Is poured into the mold 4 to be cured and cured. Then, after removing the mold, the surface of the molded body is polished to obtain Terrazo 1 as a product.

Another conventional method for manufacturing artificial marble is shown in FIG. In this case, first, a large crushed stone having a particle size of about 1 to 10 cm is used as a seed stone 5, which is arranged in a large prismatic formwork and solidified with a synthetic resin or cement 6 to form a prism having a side of 30 cm or more. I've got 7. Then, as shown by the chain line in FIG. 6, this is cut with a large-sized saw-saw type or endless belt type cutter for each predetermined thickness, and FIG.
The artificial marble 8 as shown in is obtained. The cut surface 9 of the seed stone 5 is exposed on the surface of the artificial marble 8 after being cut.

[0004]

However, in the above-mentioned conventional method for manufacturing the terrazzo 1, crushed stone powder having a particle size of 5 is used.
Since small seed stones 2 having a size of cm or less are used, a large amount of white cement 3 appears on the surface of the product, which makes it difficult to obtain a natural stone appearance pattern.

Further, in the conventional method of manufacturing an artificial marble shown in FIG. 6, once a large prism 7 having a side of 30 cm or more is used.
Needs to be manufactured and then cut with a large cutter. The large cutter is extremely expensive and has a drawback that the entire equipment attached thereto is large. Artificial marble 8 cut with a large cutter
Since the surface of (1) was extremely rough, it was necessary to polish the surface to improve the surface accuracy.

[0006]

SUMMARY OF THE INVENTION The present invention has been made by improving and removing the above-mentioned conventional problems, and it is for natural stones that can use a small equipment and that the surface of the seed stone is exposed to the surface of the product much. The building materials will be provided.

The means adopted by the present invention to solve the above-mentioned problems are as follows. A kneaded material such as gypsum or mineral powder is used as a base substrate, and natural stone is cut to a predetermined thickness on the surface side of the base substrate. A natural stone-like building material, characterized in that a large number of natural stone flat plates are arranged and buried so that the cut surface of the natural stone flat plate is exposed.

[0008]

In the present invention, the surface of a natural stone plate obtained by cutting natural stone to a predetermined thickness is laid on the bottom surface of the form, and after that, a kneaded product such as water, gypsum, and mineral powder is poured, We are trying to obtain an artificial stone in which a natural stone plate is buried on the surface side. In this way, by laying out and arranging the natural stone flat plates obtained by cutting the natural stone to a predetermined thickness, a large amount of the natural stone flat plates can be exposed on the surface of the product. Therefore, it is possible to obtain a more natural stone-like building material. Also, the cutter may be small so as to cut natural stone.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of the present invention will be described below with reference to the embodiments shown in the drawings.

1 to 3 show a natural stone-like building material 10 of the present invention.
FIG. 1 is a partial cross-sectional perspective view of the natural stone-like building material 10, FIG. 2 is a perspective view of a formwork 11 showing the method of manufacturing the natural stone-like building material 10, and FIG. 3 is a natural stone after production. It is a longitudinal cross-sectional view of the building material 10. To manufacture the natural stone-like building material 10, first, a large-sized crushed stone having a particle size of about 5 to 10 cm is cut into a predetermined thickness with a small cutter to prepare a natural stone flat plate 12. Then, as shown in FIG. 2, the natural stone flat plates 12 are laid on the bottom surface of the mold 11 made of metal or the like at predetermined intervals. At this time, if the area occupied by the natural stone flat plate 12 is 90% or more of the area of the bottom surface of the mold 11, a product closer to natural stone can be obtained. After that,
A kneaded product of small-sized mineral powder such as marble or granite and water, gypsum, pigment, etc. is poured into the mold 11 and cured and cured to obtain a base substrate 13. After the whole is cured, the mold may be removed and the natural stone-like building material 10 as a product may be taken out. As described above, according to the present invention, since the natural stone flat plate 12 obtained by cutting large crushed stone to a predetermined thickness is used,
It is possible to use a small cutter, and dispose large crushed stones on a large formwork as a seed stone as in the past.
It is not necessary to form a prism having a size of cm or more and then cut it with a large cutter. Next, a manufacturing procedure of the natural stone-like building material 10 of the present invention will be described based on specific examples described below.

[0011]

Example 1 First, a natural stone flat plate 12 is prepared by cutting a marble lump having a particle size of about 10 cm to a thickness of 1 cm with a small cutter manufactured by Maruto Co., Ltd., for example. On the other hand, a mold release agent is applied to the inner side surface and the bottom surface of a metal mold 11 having a length of 30 cm, a width of 30 cm, and a thickness of 2 cm. Further, natural stone flat plates 12 cut to a predetermined thickness are laid on the bottom surface of the mold 11 coated with the release agent at intervals of about 0 to 3 mm. And each of these natural stone flat plates 12
Marble powder having a particle size of about 1 to 3 mm is spread evenly between them in an amount of 100 g. Next, as the base substrate 13, a kneaded product having the following mixing ratio is generated. That is, 400 parts by weight of water and 500 parts by weight of small marble powder having a particle size of 1 to 3 mm as mineral powder,
1000 parts by weight of calcined gypsum and 3 parts by weight of an inorganic pigment are prepared, and these are kneaded to produce a raw material for the base substrate 13. The kneaded raw material of the base substrate 13 is poured into the mold 11. After that, after the kneaded material of the base substrate 13 was naturally cured for about 2 hours, the metal mold 11 was released from the mold, and the natural stone-like building material 10 as a product was taken out. With the natural stone-like building material 10 thus obtained, the area occupied by the natural stone flat plate 12 exposed on the surface thereof exceeds 90%, and an appearance pattern that is no different from natural marble can be obtained. It is possible. In the conventional case,
Even if the occupied area ratio of the natural stone is increased, it is inevitable that the white cement portion or the resin portion forming the matrix is exposed like a honeycomb, and it is difficult to obtain a natural stone appearance pattern.

[0012]

[Embodiment 2] In this embodiment 2, the raw material of the base substrate 13 is poured into the metal mold 11 in the same manner as in the above-mentioned embodiment 1, and 2
The underlying substrate 13 has an open porosity of 10 after being naturally cured for a time
% Natural stone-like building material was obtained. Then, the open pores of the natural stone-like building material 10 were further impregnated with an epoxy resin, and the whole was heat-cured at 40 ° C. for 4 hours to obtain a product. By impregnating the open pores with an epoxy resin, it is possible to obtain a product in which dirt and the like do not penetrate. Others are the same as those in the first embodiment. In addition, also in the case of this Example 2, it is possible to obtain an appearance pattern that is not different from that of natural marble.

By the way, the present invention is not limited to the above-mentioned embodiments, but can be appropriately modified. For example, the natural stone flat plate 12 may be an artificial ceramic plate made of alumina, zirconia, mullite, silicon carbide, silicon nitride or the like, and the powder diameter of the mineral powder is 20 μm.
It is possible to use the thing of m-5 cm. 20μ
This is because when it is less than m, the effect of appearing as a natural stone pattern on the surface texture is small, and when it exceeds 5 cm, the thickness of the product is limited.

Furthermore, the mineral powder, gypsum, and inorganic pigment as the base substrate 13 are not necessarily required, and may be in the following ranges. That is, the range of mineral powder is 0 to 95 wt% and the range of gypsum is 0 to
70 wt% and the range of the inorganic pigment is 0 to 3 wt%. The upper limit of each value means that if the content of mineral powder exceeds 95 wt%, molding with gypsum becomes difficult, and if the content of gypsum exceeds 70 wt%, the product price becomes too high. If it exceeds 3 wt%, the pigment is likely to be exposed on the surface of the surface layer, and there is a problem that it is easily stained.

Furthermore, it is possible to replace the gypsum in the base substrate 13 made of the mineral powder, gypsum, and inorganic pigment with white cement or polymer cement. In that case, the ratio may be in the range of 20 to 80 wt%. If it is less than 20 wt%, there is a problem that the strength such as bending strength and compressive strength becomes weaker, and 80 wt%
This is because if it exceeds%, there is a problem that mineral powder (natural stone powder, etc.) is difficult to appear on the surface layer surface.

Further, in the base substrate 13 made of mineral powder, gypsum, and inorganic pigment, the entire gypsum is replaced with 5 to 20 wt% of a synthetic resin containing a predetermined hardening agent, or a part of the gypsum is a water-soluble synthetic resin. It is also possible to replace with ~ 20 wt%. This is because if the synthetic resin content is less than 5 wt%, the amount of resin as the binder becomes too small to allow molding, and the required strength cannot be obtained. This is because when the synthetic resin and the water-soluble synthetic resin exceed 20 wt%, the fire resistance of both deteriorates. The reason for using the water-soluble synthetic resin is to reinforce the bending strength and compressive strength of the plaster.

In addition, the opening porosity of the base substrate 13 may be set to 0 to 20 wt% and the opening porosity may be impregnated with the synthetic resin. The reason for limiting the open porosity is that if it exceeds 20 wt%, there is a problem that the fire resistance drops sharply.

[0018]

As described above, according to the present invention,
Natural stone flat plates obtained by cutting natural stone to a specified thickness are laid out side by side on the bottom of the mold and poured with a kneaded product such as gypsum or mineral powder.
A natural stone-like building material in which the natural stone flat plate is buried on the surface side is obtained. Since such a building material only cuts natural stone, it is possible to use an extremely small cutter such as a hand type cutter. This is one of the conventional manufacturing methods, in which a prism with a side of 30 cm is manufactured and this is manufactured with a large cutter, but it is possible to significantly simplify the entire equipment compared to this case. Is. Further, in the present invention, the cut surface of natural stone is largely exposed on the surface of the obtained product, and it is optional to increase the occupying ratio, so that a building material having a pattern closer to natural stone can be obtained. It is possible.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional perspective view of a natural stone-like building material according to the present invention.

FIG. 2 is a perspective view of a mold showing a method for manufacturing a natural stone-like building material according to the present invention.

FIG. 3 is a vertical sectional view of a natural stone-like building material according to the present invention.

FIG. 4 is a vertical cross-sectional view of a mold for manufacturing a conventional terrazzo.

FIG. 5 is a perspective view showing a conventional terrazzo.

FIG. 6 is a perspective view showing a prism in the case of manufacturing another conventional artificial marble.

FIG. 7 is a perspective view showing another conventional artificial marble.

[Explanation of symbols]

 10 ... Natural stone-like building material 11 ... Formwork 12 ... Natural stone flat plate 13 ... Base substrate

Claims (10)

[Claims] 1. A kneaded material such as gypsum or mineral powder is used as a base substrate, and a large number of natural stone flat plates obtained by cutting natural stone to a predetermined thickness are arrayed and embedded on the surface side of the base substrate. A natural stone-like building material characterized by being exposed. 2. The base substrate is 0 to 95 wt% mineral powder.
2. The natural stone-like building material according to claim 1, comprising 0 to 70 wt% of gypsum and 0 to 3 wt% of an inorganic pigment. 3. The natural stone-like building material according to claim 1, wherein the natural stone flat plate is an artificial ceramic flat plate. 4. The mineral powder is of the same type as the natural stone plate and has a particle size of 2.
The natural stone-like building material according to claim 1, which has a size of 0 μm to 5 cm. 5. The underlying substrate has an open porosity of 0 to 20%, and the pores are impregnated with a synthetic resin containing a predetermined curing agent,
The natural stone-like building material according to claim 1, further cured. 6. The natural stone-like building material according to claim 1, wherein the natural stone flat plate is marble or granite. 7. The natural stone-like building material according to claim 1, wherein 0 to 50 wt% of the mineral powder is replaced with an inorganic fiber. 8. The whole gypsum is white cement 20-80.
wt% or polymer cement concrete 20-80w
The natural stone-like building material according to claim 1, wherein the natural stone-like building material is replaced by t%. 9. The natural stone-like building material according to claim 1, wherein all of the gypsum is replaced by 5 to 20 wt% of a synthetic resin containing a predetermined hardening agent. 10. A part of gypsum is water-soluble synthetic resin powder 0-2.
4. The composition is replaced by 0 wt%.
Natural stone-like building material according to item.