JPH0550412A - Manufacture of inorganic board - Google Patents

Abstract

PURPOSE:To simply and easily fabricate a cement inorganic board of improved decorative design having a delustered pattern surface wherein natural appearance such as in the quality, material is provided in a pattern. CONSTITUTION:Water absorbing polymer 2 is sprayed over a form 1 in a predetermined pattern and water 3 is applied to the polymer to swell it and then retardant or accelerator 4 is applied or sprayed and thereafter reemulsification type emulsion 5 is applied to form it into a film, following which cement slurry is poured thereinto, cured, removed from the form and then the patterned surface is brushed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an inorganic plate. More specifically, the present invention provides a simple and easy production of a cement-based inorganic board having an improved design, which has an optional pattern and has a matt pattern surface with a natural feeling such as texture and material feeling. The present invention relates to a method for producing a possible inorganic plate.

[0002]

2. Description of the Related Art Conventionally, cement-based inorganic plates have been used as building materials such as exterior materials for houses and ceiling materials. About this cement-based inorganic board, heat insulation,
Various types of products with excellent performance such as sound insulation have been developed so far, and the appearance has been upgraded, and those with various surface patterns and surface shapes with good designability have been developed. It is provided.

Such an inorganic plate is generally manufactured by a casting method using a pattern mold having the following procedure as shown in FIG. 2, for example. (A) First, a pattern mold (a) for forming a desired surface pattern is arranged on the bottom surface of the mold (a). This pattern type (a)
Generally, a metal type, a resin type such as urethane, a steel type and the like are used.

(B) Then, a cement slurry (c) in which an aggregate such as silica sand and additives are mixed with a cement component such as ordinary Portland cement is injected. (C) After curing and curing, the mold (a) and the pattern mold (a) are demolded to obtain an inorganic plate (d).

[0005]

However, in the case of the method for producing a cement-based inorganic plate by the casting method as shown in FIG. 2, for example, a pattern type (a type) such as a metal mold, a resin type, a steel type or the like is used. ) Is placed in the mold (a) and molded, a cement-rich skin layer is formed on the surface of the inorganic plate (d), and the pattern surface becomes a glossy smooth surface,
For example, there is a drawback in that the surface does not have a rough and natural textured pattern such as washed out.

[0006] In order to form a matt and natural textured surface, conventionally, in the case of an inorganic plate in which a surface material such as a tile or crushed stone is driven, a surface material such as a tile or crushed stone is placed on the surface. Later, the retarder is applied and washed with water after curing, but it is difficult to apply this to the casting method using the pattern type (a) as illustrated in FIG. 2 because of its constitution.

Further, in the case of the manufacturing method illustrated in FIG. 2, since the pattern mold (a) is used, the size of the pattern mold (a) and the size of the mold frame (a) must be the same.
There is also a problem that it is necessary to prepare a pattern type (a) each time, the work is troublesome, and it is not possible to flexibly deal with the production of inorganic plates of various sizes. The present invention has been made in view of the circumstances as described above, eliminates the drawbacks of the conventional method for producing an inorganic plate, and is matte with an arbitrary pattern and a natural feeling such as texture and texture. It is an object of the present invention to provide a method for producing an inorganic plate which has a patterned surface and which can easily and easily produce a cement-based inorganic plate having an improved design.

[0008]

In order to solve the above-mentioned problems, the present invention is to spray a water-absorbing polymer on a mold in a predetermined pattern, apply water to swell, and then apply a retarder or a curing agent. After applying or spraying an accelerator, then applying a re-emulsifying emulsion to form a film, injecting cement slurry, curing and demolding, and then brushing the patterned surface of an inorganic plate characterized by A manufacturing method is provided.

For example, as shown in the manufacturing process of FIG. 1, in the method for manufacturing an inorganic plate of the present invention, <a> First, a mold (1) is set, and a water-absorbing polymer (2 ) Is sprayed in a predetermined pattern. In this case, the kind of the water-absorbent polymer (2) is not particularly limited, and may be any of starch-based, cellulose-based, polyvinyl alcohol-based, acrylic-based and the like.
Further, the shape may be an arbitrary shape such as a granular shape or an irregular shape. For spraying the water-absorbent polymer (2), for example, a computer-controlled sprayer can be used, and a pattern corresponding to a desired surface pattern or surface shape is formed.

<B> Next, water (3) is sprinkled to swell the water-absorbent polymer (2). <C> A retarder or a curing accelerator (4) is applied or sprinkled on the swollen water-absorbent polymer (2). The hardening accelerator can maintain the pseudo-setting state in the cement slurry to be injected, and the same effect as the retarder can be obtained.
The types of the retarder and the curing accelerator are not particularly limited, and any conventionally known one can be used. Further, the state may be arbitrary such as liquid state and powder state. For example, the retarder may be citric acid.

In this process, in order to maintain the shape of the swollen water-absorbing polymer (2) before applying or spraying the retarder or curing accelerator (4), an emulsion resin such as acrylic resin is used. It is also possible to apply and form a film. <D> Thereafter, a re-emulsifying emulsion (5) such as an acrylic type or a vinyl acetate type is applied to form a film. This re-emulsifiable emulsion (5) allows the retarder or set accelerator (3) to be temporarily trapped on the water-absorbing polymer (2).

<E> Then, a cement slurry (6) in which an aggregate such as silica sand or an additive is mixed into a cement component such as ordinary Portland cement is injected and a predetermined curing is performed. When the surface layer is rich in aggregate such as crushed stone and sand, it is shaken after the cement slurry (6) is injected,
The coarse aggregate contained in the cement slurry (6) can be settled on the surface side of the water absorbent polymer (2). This vibration can be appropriately performed depending on the compounding components of the cement slurry (6) and the like. Of course, it is not necessary to apply vibration.

<F> After the cement slurry (6) is cured, the mold (1) is released from the mold to obtain a shaped body (7) having a desired surface pattern. <G> Next, the pattern surface of this shaped body (7) is brushed with a brush (9) or the like while spraying water (8) to wash away the uncured portion. <H> In this way, a cement-based inorganic board (10) having a matte pattern surface with a natural feel such as texture and material feeling is obtained.

The method of the present invention is not limited to patterning only on one side, but can be patterned on both sides.

[0015]

In the present invention, a water-absorbing polymer is used,
By appropriately controlling the spraying state, a surface pattern having an arbitrary pattern can be obtained. The pattern mold used in the conventional casting method is no longer necessary, and the mold size can be flexibly accommodated. Further, a water-absorbent polymer swollen with water and having a predetermined surface pattern is coated or sprayed with a retarder or a curing accelerator and a re-emulsifying emulsion to be molded, and the pattern surface after demolding is brushed. so,
It is possible to create a matte, uneven textured surface with a natural texture such as texture. The design of the cement-based inorganic board is improved.

[0016]

[Examples] The following will describe the method for producing an inorganic plate of the present invention in more detail with reference to Examples. Example 1 A water-absorbent polymer (Aronzap RS: manufactured by Toagosei Kagaku Kogyo Co., Ltd.) was sprayed into a concave-convex pattern in a mold using a computer-controlled sprayer, and then water was applied with a spray gun to swell the water-absorbent polymer. . Then, after spraying citric acid as a retarder, a re-emulsifying emulsion (acrylic SA-56: manufactured by Chuo Rika Kogyo) was applied to form a film. After that, cement slurry of cement / silica sand = 1/3 was injected, and heat curing was performed at 60 ° C. for 10 hours to remove the mold.

The pattern surface of the thus obtained shaped body was brushed while spraying water to wash away the uncured portion. A cement-based inorganic board having a rough surface with a rough surface of a rough stone carved along the pattern was obtained. Example 2 An inorganic plate was produced in the same manner as in Example 1 except that silica sand, crushed stone, or the like having a large particle size was mixed as the cement slurry and the mixture was shaken after the cement slurry was injected.

A cement-based inorganic board having a good appearance and having a natural stone-like appearance in which the surface layer is rich in aggregate was obtained. Of course, the present invention is not limited to the above examples. It goes without saying that various aspects can be applied to the details of the types of the water-absorbent polymer and the retarder, the components and the compounding ratio of the cement slurry, the curing conditions, and the surface pattern of the inorganic plate.

[0019]

Industrial Applicability As described in detail above, according to the present invention, a cement-based inorganic board having an excellent design having an arbitrary pattern and having a matt surface pattern with a natural feel such as texture and texture is cast. Manufactured by molding. Since the pattern mold is not needed and the size of the mold can be flexibly accommodated, its manufacture is simple and easy.

[Brief description of drawings]

FIG. 1 is a process sectional view illustrating a process of a method for manufacturing an inorganic plate according to the present invention.

FIG. 2 is a process sectional view showing a conventional method for manufacturing an inorganic plate.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Formwork 2 Water-absorbent polymer 3 Water 4 Retarder or hardening accelerator 5 Re-emulsion type emulsion 6 Cement slurry 7 Shaped body 8 Water 9 Brush 10 Cement-based inorganic board

Claims (3)

[Claims] 1. A water-absorbing polymer is sprayed on a mold in a predetermined pattern, and after swelling by applying water, a retarder or a curing accelerator is applied or sprayed, and then a re-emulsifying emulsion is applied. A method for producing an inorganic plate, which comprises forming a film, injecting cement slurry, curing and demolding, and then brushing the pattern surface. 2. The method according to claim 1, wherein the water-absorbent polymer is swollen with water and then the emulsion resin is applied. 3. The method according to claim 1, wherein the cement slurry is injected and then vibrated.