JPH06101322A - Decorative board for forming decorative surface on concrete product and its manufacturing method - Google Patents

Abstract

PURPOSE:To improve compressive strength and flexibility by arranging numbers of decorative material, having irregular uneven patterns on their surface, on the same plane, fitting a specified polyolefine group resin foam particle formed body layer on the surface side of the decorative material and providing a protrusion protruding beyond the formed body layer more than the specified quantity of decorative material thickness on the back side of the decorative material. CONSTITUTION:Numbers of decorative material 'a' having irregular uneven patterns on their surface are arranged on the same plane. A polyolefine group resin foam particle formed body layer 5 of density of 0.036 to 0.060g/cm<3>, compressive strength of 2.7 to 6.5kg/cm<2> and thickness of 25 to 170mm is fitted to the surface side of the decorative board 'a'. On the back side of the decorative board 'a', a plural number of protrusions 7 protruding beyond the formed body layer 5 by 1/4 or more of the decorative board thickness is provided. Thus the decorative board may not be damaged nor the formed body layer be deformed or broken even if external force is applied during transportation and workability of removing a mold from concrete after placing concrete can be improved.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used for producing concrete products such as precast concrete boards and concrete blocks whose outer surface is used as a courtesy wall of a building and whose outer surface is finished to have an uneven decorative surface. The present invention relates to a decorative plate for forming a decorative surface and a method for producing the same.

[0002]

2. Description of the Related Art When a concrete form is filled with concrete to manufacture a concrete plate or a concrete block, a decorative plate is attached to a required inner surface of the form frame in advance, or a part of the form frame is formed with a decorative plate. Then, fill the inside of the mold on the back side of the decorative plate with concrete, and after demolding,
It is well known to manufacture concrete products with a veneer surface on the outer surface. Further, as shown in FIG. 4, instead of using the existing plate-shaped body as the decorative plate, a decorative material a ′ such as an irregularly shaped crushed stone or tile piece is used inside the frame 1 ′ for the decorative plate. It is also practiced that a large number of tiles are laid out and concrete b'is thinly laid on the top surface and assembled into one plate body, and this plate body is used as a decorative plate 6'to make a concrete product having the decorative surface.

However, the decorative plate 6'obtained by simply laying out the large and small irregularly shaped decorative materials a'in the dedicated mold 1'and thinly filling the upper surface thereof with concrete b ', contacts the lower surface. It is necessary to prevent the concrete from seeping out to the front side as much as possible, while the concrete layer on the back side, which corresponds to the top surface, may be concrete in some places if stone pieces of uneven height are dense. Since the layer is extremely thin, when it is laid inside the concrete product formwork with the front side facing down, it shakes without adjusting to the formwork bottom, and the weight of the concrete to be filled at the same time and the addition at the time of filling The impact of vibration often causes the concrete layer to be damaged.

On the other hand, as a method of manufacturing a precast concrete board which has been developed in recent years, as shown in FIG. 5, an irregularly shaped decorative material a "is lined up in a formwork 1" for a decorative board, and the upper surface thereof is covered. Cover with a release film 4 "of polyethylene or the like, and spread a foaming liquid such as urethane foam on it to form a slightly thick foam layer 5", thus forming a decorative plate 6 "whose top and bottom surfaces are almost flat. (FIG. 5 (A)) This decorative plate was laid on a concrete product formwork 8 ″ with the foam layer 5 ″ as the lower surface, and concrete 9 ″ was cast from above to form the required concrete product 10 ″. , (FIG. 5 (B)), the concrete product is taken out from the mold and the foam layer 5 ″ is peeled off together with the release film 4 ″ (JP-A-4-11154).

[0005]

In the decorative plate 6 "shown in FIG. 5, the irregular shape and the slightly thick foam layer 5" located above a large number of decorative materials a "are used for focusing. It is stable because it is held, and the thickness of the decorative plate is almost uniform, which is convenient for filling concrete.
Since the foam layer 5 ″ is urethane foam, the release film may be covered and the foaming agent solution may flow into the space between the decorative materials a ″ and adhere. Further, the above method takes time and labor for using the release film, the workability is poor, and the cosmetic material holding power of the mold frame for holding the cosmetic material is also unavoidably reduced.
There is a problem that the decorative material comes off the form during the transportation process before placing concrete. Further, the foamed polyurethane has a problem that it cannot be recycled.

Also, since the foam is a urethane resin,
In the case of a soft material, the holding power of the decorative material and the compressive strength against the pressure during concrete pouring are insufficient, and the material is deformed by the concrete load, and a good precast concrete board cannot be obtained. On the other hand, when it is hard, it is inferior in flexibility, and if the mold is flexed by external force during transportation of the mold holding the decorative material, little recovery can be expected, so the cosmetic material is retained. You will not be able to do it. Further, the flexibility greatly affects the releasing work after the concrete is placed, and the hard urethane foam having poor flexibility naturally has a problem in the releasing work.

An object of the present invention is to provide a decorative board for forming a decorative surface in a concrete product and an industrially advantageous method for producing the same, which overcomes the drawbacks of the prior art.

[0008]

Means for Solving the Problems As a result of intensive studies for solving the above problems, the present inventors have found that a foamed resin foam particle molded article having a specific density, compressive strength and thickness is adopted as a foam layer. , It has been found that the above object can be achieved. The present invention has been made based on such findings. That is, according to the present invention, a large number of decorative materials having an irregular asperity pattern on the surface are arranged on the same plane and the density is 0.036 to 0.060 g / c on the surface side.
m ³ , compressive strength 2.7 to 6.5 kg / cm ² thickness 25 to 1
A concrete product, characterized in that a layer of 70 mm polyolefin resin foamed particle molded body is fitted, and a plurality of surfaces with which the back surface of the decorative material contacts the decorative material thickness 1/4 or more protrudes from the molded body layer. A decorative board for forming a decorative surface is provided. In addition, a box-shaped lower mold having a plurality of recesses on the upper surface of the bottom plate and having the same shape as the bottom surface of the bottom surface of the decorative material, and an upper mold capable of closing the upper surface of the lower mold are provided inside the molding mold. , A large number of decorative materials having an irregular asperity pattern on the surface are recessed into the recesses of the lower mold and laid out, and then the mold is fastened and steam is added after filling the polyolefin resin foam particles thereabove. According to the above, there is provided a method for producing a decorative plate for forming a decorative surface in a concrete product, which is characterized in that it is heat fused and molded.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, the sequence of manufacturing a decorative board in the invention will be described with reference to the drawings. FIG. 1 shows a form 1 dedicated to a decorative plate according to the present invention. This is composed of a box-shaped lower mold 2 having an opening on the upper surface and a lid-shaped upper mold 3 which is covered with the upper surface thereof. The bottom surface of the lower mold 2 has a plurality of recesses 4 into which the back surface of the decorative material a to be housed is recessed.
... is provided. As for the concave portion 4, if the shape of the back surface of the decorative material is predetermined, a method of forming the concave portion directly on the mold can be adopted. Further, even in other cases, a method of additionally providing a jig forming the concave portion in the mold can be adopted.

The order in which the required decorative plate is formed using this mold 1 will be described below. (1) The decorative materials a ... Are arranged in the lower mold 2 by dropping some of them into the recesses 4 (FIG. 1 (A)). (2) The upper mold 3 is closed and polyolefin is provided inside. The foamed resin particles b are filled. (FIG. 1 (B)) (3) Next, steam is blown into the mold 1 to heat and fuse the foamed particles b to obtain the decorative plate 6 to which the foamed particle molded body layer 5 is attached. (Fig. 1 (C))

Examples of the decorative board a used in the present invention include conventionally known tiles, stones, etc., which have an irregular pattern on the surface, and the size and shape are not particularly limited. Further, it is preferable that a projection for concrete adhesion is provided on the back surface thereof. The back surface of the decorative material projects from the polyolefin resin foamed particle molded body layer by 1/4 or more of the thickness of the decorative plate, preferably by about 1/3 to 2/3, as a decorative material holding effect, releasability, and concrete. It is desirable from the viewpoint of adhesiveness. The thickness of the decorative plate in the present invention means the maximum thickness of the decorative plate.

As the polyolefin resin foamed particles b, low density polyethylene, linear low density polyethylene,
Examples include polyolefin resins such as high-density polyethylene, polypropylene, ethylene-propylene random copolymer, ethylene-propylene block copolymer, propylene-butene random copolymer, propylene-butene block copolymer, and among others, polypropylene-based resin. The resin is preferable in terms of strength, and the thickness of the formed body layer can be reduced.

The pressure at the time of molding the expanded polyolefin resin particles may be in the range usually used, or may be in a slightly lower range. For example, when the decorative material a is not very durable against steam, it is necessary to perform it under a small pressure so as not to damage the decorative material. Vapor pressure varies depending on the type of decorative plate and the type of polyolefin resin expanded particles, but normally 0.5 to 5 kg / cm
² G, preferably ² to 4.5 kg / cm ² G. The steam may be introduced into the mold from the lower mold 2 side, the upper mold 3 side, or both sides. When considering the influence on the decorative material, introduction from the upper mold side is preferable.

The expanded particle molded body layer 5 according to the present invention has a density of 0.036 to 0.060 g / cm ^3, preferably 0.04.
~ 0.05 g / cm ³ , and the compressive strength is 2.7 ~.
6.5 kg / cm ² preferably 3.5~5.5kg / c
m ² , and the thickness is 25 to 170 mm. Density is 0.03
If it is less than 6 g / cm ² , the strength is insufficient and the decorative material may be damaged during transportation of the decorative board. Also 0.0
If it exceeds 60 g / cm ² , it is difficult for the decorative plate to come off the form. If the compressive strength is less than 2.7 kg / cm ² , defects such as deformation of the decorative board when concrete is poured and mortar leaching on the surface of the decorative material and disorder of the arrangement of the decorative material in the final product occur. To do. In addition, it is considered that the higher the compressive strength is, the better because it is possible to perform press molding to obtain high-strength precast concrete.
If it exceeds 0.060 kg / cm ² , the decorative material is retained, but the molded body layer is not molded according to the shape of the irregularities on the surface of the decorative material, and a space is formed between the molded body layer and the surface of the decorative material. If this is the case, an unbalanced load is applied to the decorative material when concrete is poured, and this load cannot be alleviated, causing damage to the decorative material. In the present invention, since the molded body layer is formed of a foamed particle molded body, it is considered difficult to transfer the irregularities on the surface of the decorative material without breaking, and it is considered that some space is formed.

The compressive strength of the foamed molded article layer can be adjusted by considering the composition of the base resin, the addition of the filler to the base resin, the method for molding the expanded particles, and the like. In the present invention, the thickness of the molded body layer fitted with the decorative material is also an important factor. If the thickness is less than 25 mm based on the above-mentioned density and compressive strength, the strength against bending, twisting, etc. will be insufficient and it will be difficult to hold the decorative material, resulting in damage to the decorative material during transportation of the decorative sheet. . On the other hand, the thickness is 17
If it exceeds 0 mm, the bending strength is too strong, so that the mold release workability after concrete placement is poor and the overall handling is not good. The decorative plate for forming a decorative surface of the present invention thus obtained generally has a shape as shown in FIGS. 2 and 3, and the surface side having an irregular pattern of the decorative material has a density of 0.03.
6 to 0.060 g / cm ³ , and the compressive strength is 2.7 to 6.5.
because it is fitted to the olefinic resin foamed bead molded article layer 5 of kg / cm ² Thickness 25～170Mm, it has sufficient compressive strength and flexibility, even decorative material as likened receives an external force during transportation There is no breakage, and the molded body layer is not distorted or broken. Also, since it has sufficient compressive strength even when concrete is placed, it is possible to obtain a high-precision, high-strength precast concrete board, and it is also excellent in mold release workability after concrete placement. is there.

If the back surface of the decorative material a is provided with protrusions 7 ... That increase the adhesiveness to concrete, it is integrally joined to the concrete portion when producing a concrete product, and there is no risk of detachment. . Further, when the decorative plate 6 is transported to a concrete product manufacturing factory, if the decorative plate is carried as it is, the decorative material does not rattle and there is no risk of damage.

Next, in order to produce a required precast concrete board which is a concrete product by using the decorative board 6, the same method as the known method shown in FIG. 3 may be used, and a typical mode thereof will be shown below. (1) The decorative plate 6 is accommodated and placed inside the precast concrete plate manufacturing form with the back surface of the decorative material facing upward, and the upper surface is filled with concrete. (2) The finished precast concrete board is taken out and placed on an appropriate pillow material with the foam body 5 side as the upper surface, and the foam body 5 is peeled off to reveal the surface of the decorative material a and the work is completed.

[0018]

Since the decorative plate for forming a decorative surface of the present invention has the above-mentioned constitution, it has the following operational effects. (1) Density 0.03 on the surface side having an irregular pattern
6 to 0.060 g / cm ³ , compressive strength 2.7 to 6.5 k
g / cm ² Since it is fitted to the olefin resin foamed particle molded body layer having a thickness of 25 to 170 mm, it has sufficient compressive strength and flexibility, and the cosmetic material is damaged even if an external force is applied during transportation. And the molded body layer is not distorted or broken. (2) Even if concrete is poured, it has a sufficient compressive strength, so that it is possible to obtain a precast concrete plate with high accuracy and high strength. (3) It is also excellent in mold release workability after placing concrete. (4) When the decorative board is transported to the concrete product manufacturing plant, if the decorative board is carried as it is, the decorative material does not rattle and there is no risk of damage. Further, since the method for manufacturing a decorative plate for forming a decorative surface of the present invention has the above-mentioned constitution, the decorative material can be placed in the mold by a simple operation, and after the placement, a general foamed particle molded article can be obtained. By applying the molding method of 1) as it is, a desired decorative plate can be obtained, which is an industrially extremely advantageous method.

[Brief description of drawings]

1A to 1C are explanatory cross-sectional views showing the order of making a decorative board of the present invention.

FIG. 2 is a perspective view of a decorative plate for forming a decorative surface according to the present invention.

3 is a sectional view taken along the line AA ′ in FIG.

FIG. 4 is an explanatory cross-sectional view showing an example of a conventional method for producing a concrete product.

FIG. 5 is an explanatory cross-sectional view showing an example of a conventional method for producing a concrete product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mold 2 Lower mold 3 Upper mold 4 Recessed portion 5 Foamed particle molded body layer 6 Decorative plate 7 Protrusion a Decorative material b Foamed particle

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Toru Yamaguchi 2-14-28 Yonan, Utsunomiya City, Tochigi Prefecture (72) Inventor Yoshimi Sudo 10-9, Heiwacho, Chigasaki City, Kanagawa Prefecture (72) Inventor Yasunori Yoshida Chiyoda, Tokyo Prefecture 1-6-1, Otemachi, Tokyo Nihon Cement Co., Ltd. (72) Inventor Tosho Koizumi 1-248 Ibara, Koshigaya, Saitama Prefecture

Claims (2)

[Claims] 1. A large number of decorative materials having irregular asperity patterns on the surface are arranged on the same plane, and a density of 0.03 is provided on the surface side.
6 to 0.060 g / cm ³ , compressive strength 2.7 to 6.5 k
g / cm ² polyolefin resin PP bead molding layer having a thickness 25~170mm is fitted, the plane striking the decorative material back surface is made with a plurality protrudes from 1/4 or more molded body layer of decorative material thickness A decorative board for forming a decorative surface in a concrete product, which is characterized in that 2. A molding die comprising a box-shaped lower die having an opening on the upper surface and having a plurality of recesses on the upper surface of the bottom plate, the depressions conforming to the shape of the back surface of each decorative material, and an upper die capable of closing the upper surface. Inside, a large number of decorative materials with irregular surface irregularities are recessed into the recesses of the lower mold and laid out, and then the mold is fastened and the polyolefin resin foam particles are filled into the mold. A method for producing a decorative plate for forming a decorative surface in a concrete product, characterized by comprising heat-melting and forming by steaming after heating.