JPH0576406B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming an uneven relief pattern on the surface of a mortar layer.

[Industrial application field]

BACKGROUND ART Materials having relief patterns are widely used in various fields including exterior and interior applications of architecture.

[Prior art] Conventionally, typical methods for forming relief patterns on the surface of a mortar layer include (1) a method using a trowel or a spatula, (2) a method using a roller, (3) a method using a spraying method, and ( 4) Embossing method, (5) Blasting method, etc. are known.

However, method (1) was developed as a finishing method for solid walls, and it was extremely difficult to form fine relief patterns and required skill.

In addition, method (2) forms unevenness by stamping with a pattern roller, so it is suitable for forming simple repeating patterns, but it is suitable for forming complex and fine patterns. It was not suitable.

Furthermore, although method (3) is suitable for forming a random uneven pattern with a spray gun,
This method has the disadvantage that it is not possible to form any specific pattern such as a design or a character.

Furthermore, although method (4) is suitable for mass production in factories, it is not suitable for applying different patterns to individual products.

Method (5) partially masks the mortar layer,
The unmasked areas are shaved off by blasting to form an uneven relief pattern. However, with this method, during the blasting process,
The production of dust, noise, etc. leads to a deterioration of the working environment, has a large negative impact on the surroundings of the workplace, and has disadvantages such as long working hours and danger.

Further, when applying mortar to a concrete panel, the following method is known as a means of making the concrete surface uneven in order to improve the adhesion between the mortar and concrete. That is, this is a method of manufacturing an uneven concrete panel in which a formwork is partially coated with a cement hardening retardant in advance, concrete is then poured into the formwork, cured, and then washed out.

However, this method requires a mold and cannot be applied to any base material. Furthermore, the obtained unevenness was not a sharp (sharp outline) and deeply carved unevenness pattern.
Therefore, this method was inappropriate as a means for forming relief patterns for aesthetic purposes.

[Problem that the invention seeks to solve]

In view of the current state of the art in the field of embossed patterns as described above, the present inventors have developed a method for easily forming an uneven relief pattern of any clear, non-random pattern on any base material without requiring any skill. I considered it carefully. As a result, the following findings were obtained. That is,
When the surface of the mortar layer is covered with a sheet that has a liquid-permeable part (a part that also permeates water vapor) and a liquid-impermeable part (a part that does not permeate water vapor or is difficult to permeate), the liquid under this liquid-permeable part One layer of mortar dries quickly, while the layer of mortar below the liquid-impermeable part becomes more moist. Therefore, the moisture in the mortar layer moves from the liquid-impermeable part to the liquid-permeable part. Therefore, the cement hardening retardant that has migrated from the liquid-permeable portion into the mortar layer remains under the liquid-permeable portion because of the movement of moisture, and moves deep into the mortar layer. As a result, the cement hardening retardant moves deep according to the shape of the liquid-permeable portion, making it possible to form an uneven pattern with sharp outlines and deep carvings. Based on this knowledge, the inventors arrived at the present invention.

[Means for solving problems]

That is, the first aspect of the present invention includes (i) forming a mortar layer on a base material; (ii) a sheet having a pattern formed of a liquid-permeable portion and a liquid-impermeable portion; A step of impregnating the mortar layer with the cement hardening retarder coated or impregnated in the liquid-permeable part of the sheet by placing a cement hardening retarder coated or impregnated on the liquid permeable part of the sheet on the mortar layer, ( iii) curing the mortar layer; (iv) removing the sheet after curing the mortar layer;
The present invention relates to a method for forming an embossed pattern with deep unevenness, which comprises the following steps: washing and removing the mortar layer impregnated with a cement hardening retarder.

Furthermore, a second aspect of the present invention includes (i) forming a mortar layer on a base material; (ii) a sheet having a pattern formed with a liquid-permeable portion and a liquid-impermeable portion; A step of impregnating the mortar layer with the cement hardening retarder coated or impregnated in the liquid-permeable part of the sheet by placing a cement hardening retarder coated or impregnated on the liquid permeable part of the sheet on the mortar layer, ( iii) removing the sheet and curing the mortar layer; and (iv) cleaning and removing the mortar layer impregnated with the cement hardening retarder after curing the mortar layer. The present invention relates to a method for forming a relief pattern.

In the method of the present invention, the mortar layer is impregnated with a cement hardening retardant solution according to the pattern of the sheet that is in close contact with the uncured mortar layer. Therefore, the hardening of the areas impregnated with the hardening retarder is delayed and can be easily removed by washing even after curing. Therefore, the method of the present invention has the advantage that a relief pattern having a sharp shape and deep unevenness can be formed on the surface of the mortar layer in accordance with the pattern of the sheet.

In addition, in the present invention, by appropriately controlling the thickness of the mortar layer and the degree of impregnation of the cement hardening retarder and removal of the mortar layer,
It has the advantage of being able to freely form embossed patterns with unevenness of a desired depth, not only those with shallow unevenness but also those with deep unevenness. Furthermore, the method of the present invention has the advantage that since the relief pattern is made of a mortar layer, it is possible to form a relief pattern with deep unevenness at a very low cost.

Hereinafter, the method for forming a relief pattern having unevenness according to the first aspect of the present invention will be explained in more detail.

First, as the base material used in the present invention, any base material to which known mortar can be adhered can be used. Examples include metals such as iron, aluminum, and stainless steel, glass, tiles, ceramics, concrete, bricks, stones, wood, plastics, and laminates thereof. The surface does not necessarily have to be flat, and may be curved, for example. If necessary, these base materials can be subjected to surface treatments such as roughening, coloring, and applying a primer.

In the present invention, as a first step, mortar is applied onto the above-mentioned base material by a commonly used means such as a trowel, a spatula, or a spray to form a mortar layer. The thickness of the mortar layer is not particularly limited. However, depending on the depth of the carving of the unevenness, it is practically preferable to set the depth to about 1 to 20 mm.

As the mortar used in the present invention, any mortar that has been commonly used can be used as is. In other words, it consists of aggregates such as cement and sand, and water, and if necessary, it may also contain coloring pigments, extender pigments, fibrous substances, hardening accelerators, hardening retarders, thickeners, water reducers, antifoaming agents, etc. It is formulated with various additives, etc. In addition, so-called resin mortars containing acrylic resin emulsions, vinyl acetate resin emulsions, epoxy resin emulsions, styrene-butadiene resin emulsions, etc. can also be used in the present invention.

In the present invention, for the mortar layer, in addition to using mortar of the same color, mortar of different colors can be applied multiple times. By forming multiple mortar layers with different colors in this way, in the cleaning and removal process described later, the depth can be adjusted by adjusting the degree of removal at each location when cleaning and removing the mortar layer, that is, the depth of the recess. It becomes possible to form an uneven relief pattern with multicolored changes depending on the color.

While the mortar layer thus formed is uncured, preferably there is some free water on the surface of the mortar layer, or water oozes out when the surface of the mortar layer is lightly pressed with a finger. To,
A sheet having a pattern formed of a liquid-permeable part and a liquid-impermeable part, the liquid-permeable part being coated or impregnated with a cement hardening retarder, is brought into close contact with the surface of the mortar layer.

The above-mentioned sheet used in the present invention is, for example, (i) a sheet consisting of a liquid-permeable portion and a liquid-impermeable portion made of a material that forms a liquid-impermeable film such as paint or resin solution on the liquid-permeable sheet; (ii) Cement hardening Obtained by applying a material that forms a liquid-impermeable film, such as a paint or a resin solution, in a pattern on one side of a liquid-permeable sheet that has been coated or impregnated with a retardant using a method such as a silk screen method. Examples include, but are not limited to, things such as .

In other words, when the sheet is placed on the mortar layer and brought into close contact with the side with the liquid-impermeable film facing the mortar layer, the cement hardening retarder is impregnated into the mortar layer only from the liquid-permeable portion of the sheet. Any sheet structure can be used in the present invention, regardless of the manufacturing method of the sheet.

The material of the liquid-permeable sheet is not particularly limited, and examples thereof include Japanese paper, Western paper, woven fabric,
Examples include nonwoven fabric, porous plastic film, porous ceramic sheet, plastic mesh, wire mesh, and the like.

Further, the cement hardening retarder coated or impregnated into the sheet may be in an undried state or a dry state inside the sheet. That is,
Even if the cement hardening retarder is dry inside the sheet, when the sheet is placed on the mortar layer, free water on the surface of the mortar layer enters the sheet through the liquid-permeable part of the sheet and dissolves the cement hardening retarder ( This is because the free water impregnates the mortar layer from the liquid-permeable portion of the sheet together with the cement hardening retarder.

In the present invention, since the sheet itself is coated or impregnated with a cement hardening retarder in advance, work efficiency is improved compared to a method in which the cement hardening retarder is applied after the sheet is placed on a mortar layer at the work site. do.

In the present invention, as the cement hardening retarder solution, those commonly used in the past can be used as they are. Specifically, examples include sodium dihydrogen phosphate, disodium hydrogen phosphate, sodium phosphate, sodium tetraborate, sugars, calcium acetate, oxycarboxylate, lignin sulfonate, alcohol, and the commercially available product Rittal ( Representative examples include Nisso Matter Builders Co., Ltd. (trade name), Vinsol 80R (Yamaso Kagaku Co., Ltd. trade name), Aircoal (Manol Co., Ltd. trade name), KW-100 (Kao Soap Co., Ltd. trade name), etc. can give. In addition, solid substances are used as aqueous solutions.

In addition, by using a cement hardening retardant solution containing a coloring agent, the parts of the mortar layer impregnated with the cement hardening retarder solution that should be washed and removed can be identified by coloring. It can be useful in the process. It goes without saying that various additives such as thickeners and surfactants may be added to the cement hardening retardant solution as necessary.

In the present invention, after placing the sheet on the surface of the mortar layer and bringing it into close contact with each other, the sheet is left for several minutes to several hours, and the cement hardening retarder in the sheet is impregnated into the mortar layer from the liquid-permeable part of the sheet. . Further, in some cases, water or the like may be sprayed on the surface of the mortar layer or sheet to actively impregnate the mortar layer with the cement hardening retarder. Note that there is no gap between the liquid-impermeable portion of the sheet and the mortar layer, so that the cement hardening retarder does not impregnate the mortar layer covered with the liquid-impermeable portion.

In the present invention, after a cement hardening retarder is impregnated into a mortar layer, the mortar layer is cured for a certain period of time. As the curing method, a natural curing method, a steam curing method, a pressure curing method, etc., which are generally known as mortar curing methods, can be adopted.

The curing time is such that the mortar layer in areas not impregnated with the cement setting retarder solution is hardened to such an extent that it is not removed in the cleaning and removal process described later, and the mortar layer in areas impregnated with the cement setting retardant solution is hardened to the extent that it is not removed. This is the time required for the material to remain uncured or semi-cured to the extent that it can be removed relatively easily. Specifically, for example, in the case of a natural curing method, it is preferable to set it at room temperature (20°C) for 8 to 50 hours.

After curing the mortar layer, the sheet is removed. In particular, curing with the sheet on it suppresses the evaporation of water in the mortar layer, prevents mortar dryout, promotes uniform hardening, and prevents the use of cement hardening retarders in areas other than liquid-permeable areas. It is desirable because it can prevent penetration and provide a sharper uneven pattern that matches the pattern of the sheet.

After curing the mortar layer, the mortar in the area impregnated with the cement hardening retarder is removed by rubbing with a rotating brush using a cleaning solution consisting of water or water and an emulsifier, or by spraying the cleaning solution at high pressure. Wash off the layer.

The second aspect of the present invention is the same as the first aspect of the present invention, except that the sheet having a pattern formed of a liquid-permeable portion and a liquid-impermeable portion is removed before curing the mortar layer. It can be implemented similarly.

In addition, the removal of the sheet in which a pattern is formed by a liquid-permeable part and a liquid-impermeable part should be carried out not only before or after the curing of the mortar layer, but also during the curing of the mortar layer in parallel with the curing. Of course, it is also possible.

In this way, a mortar layer is obtained in which a relief pattern with deep unevenness is formed. In the present invention, if necessary, in order to add color, adjust gloss, and further impart weather resistance, water resistance, chemical resistance, etc., the entire surface or concave portions (or convex portions) may be It is also possible to apply another colored coating, to coat the entire surface with a coating such as clear or colored clear, or to polish.

〔Effect of the invention〕

As described above, by the method of the present invention, it is possible to easily and inexpensively obtain a relief pattern having deep unevenness of any depth. Furthermore, by varying the pattern formed on the sheet, a desired uneven pattern can be easily obtained.

Furthermore, the mortar layer with the uneven pattern obtained by the method of the present invention can be used for building materials, decorative items, etc., and has the feature that it can be manufactured in a factory or on-site.

Hereinafter, the present invention will be explained in more detail with reference to Examples.

In the examples, "parts" and "%" are based on weight.

Example 1 Asbestos slate board with a wooden frame around it (900
A smooth mortar layer with a thickness of 3 mm was formed on the surface of the sample (1800 x 10 mm) using a trowel, using a mortar consisting of 100 parts of white cement, 50 parts of silica powder, and 50 parts of water.

Next, we silk screen printed the paint ["Bildeitsuku" (trade name, manufactured by Dainippon Toyo Co., Ltd.)] on about 0.1 mm thick Japanese paper, and applied a lignin-based hardening retarder [on the back side of the patterned Japanese paper (opposite the paint film)]. “Vinsol
80R” (trade name manufactured by Yamasou Kagakusha)] 10 parts, polysaccharide resin retardant [“Pullulan” (trade name manufactured by Hayashibara Co., Ltd.)] 5 parts,
Air spray a cement retardant solution consisting of 1 part phthalocyanine blue and 85 parts water.
A sheet of Japanese paper coated at a rate of 100 g/m ² and dried was placed on the surface of the mortar layer with the silk screen printed side facing the mortar layer, and pressed with a rubber roller to make it adhere tightly.

1 in an atmosphere with a temperature of 20°C and a relative humidity of 75%.
I let it cure for a day.

Then, after removing the sheet, pour water (30/
rotation (250rpm) at a rate of 5min/ ^m2
The mortar layer impregnated with the cement hardening retardant solution was removed by rubbing with a circular brush (φ100 mm) made of bundled nylon threads (0.6 mm in diameter).

On the resulting surface, sharp pattern-like unevenness with an average depth of about 1.7 mm was formed, corresponding to the pattern printed on the sheet.

On the surface of the mortar layer obtained in this way,
A relief pattern with an extremely embossed appearance was obtained.

Example 2 100 parts of Portland cement as mortar,
A mortar consisting of 200 parts of silica powder, 1 part of water reducing agent, and 75 parts of water was used, and 200 mesh nylon mesh was used instead of Japanese paper, and 10 parts of trisodium phosphate was added as a cement retarder solution. ,
A pattern-like unevenness corresponding to the pattern printed on a sheet with an average depth of about 2 mm was carried out in the same manner as in Example 1, except that a solution consisting of 5 parts of methylcellulose-based thickener, 1 part of phthalocyanine blue, and 85 parts of water was used. was formed into a mortar layer. On the surface of the mortar layer thus obtained, an embossed pattern similar to that of Example 1 was obtained.

Example 3 A smooth mortar layer with a thickness of 3 mm was formed on the surface of an asbestos slate board using a blue mortar consisting of 100 parts of white cement, 200 parts of silica powder, 2 parts of phthalocyanine blue, 1 part of water reducing agent, and 75 parts of water, and was kept for 1 hour. After standing, add 100 parts of white cement, 50 parts of barite, 0.2 parts of methyl cellulose thickener, 0.5 parts of calcium chloride,
A red mortar consisting of 2 parts naphthol red and 50 parts water was coated to a thickness of 2 mm to form a smooth multi-layer mortar layer.

Next, the paint was silk screen printed on a white cotton cloth with a thickness of about 0.2 mm in the same manner as in Example 1, and on the back side, 20 parts of a tin-based hardening retarder ["KW-100" (trade name manufactured by Kao Soap Co., Ltd.]) and 10 parts of Pullulan were applied. A cement hardening retardant solution consisting of 1 part of phthalocyanine blue and 70 parts of water was applied at a rate of 150 g/m ² and a sheet of dried white cotton cloth was placed on the surface of the mortar layer with the silk screen printed side facing the mortar layer. The presser foot was placed in close contact with the rubber roller. Thereafter, curing, sheet removal, and washing and removal of the mortar layer were carried out in the same manner as in Example 1.
Sharp pattern-like unevenness with an average depth of 2.8 mm was formed on the obtained surface, corresponding to the pattern printed on the sheet.

The surface of the mortar thus obtained had an extremely embossed pattern with blue recesses and red protrusions.

Claims (1)

[Claims] 1. (i) A step of forming a mortar layer on a base material; (ii) A sheet having a pattern formed of a liquid-permeable portion and a liquid-impermeable portion, the liquid-permeable portion; (iii) placing a sheet coated or impregnated with a cement hardening retarder on the mortar layer, and impregnating the mortar layer with the cement hardening retarder coated or impregnated on the liquid permeable portion of the sheet; (iii) mortar; curing the layer; (iv) removing the sheet after curing the mortar layer;
A method for forming an embossed pattern with deep unevenness, comprising the following steps: washing and removing the mortar layer impregnated with a cement hardening retarder. 2. The method for forming a relief pattern according to claim 1, wherein the mortar layer is composed of a plurality of mortar layers of different colors. 3. (i) Forming a mortar layer on a base material; (ii) A sheet having a pattern formed of a liquid-permeable part and a liquid-impermeable part, and applying a cement hardening retarder to the liquid-permeable part. a step of placing the coated or impregnated material on the mortar layer and impregnating the mortar layer with a cement hardening retarder that has been coated or impregnated on the liquid-permeable portion of the sheet; (iii) removing the sheet and removing the mortar; (iv) After curing the mortar layer, cleaning and removing the mortar layer at locations impregnated with a cement hardening retarder. 4. The method for forming a relief pattern according to claim 3, wherein the mortar layer is composed of a plurality of mortar layers of different colors.