JPH07291706A - Production of artificial stone - Google Patents

Abstract

PURPOSE:To obtain a lightweight artificial architectural stone having high strength by compounding specified proportions of hydraulic cement, mixture aggregate of coarse aggregate and fine aggregate, and water to prepare a lightweight inner layer material. CONSTITUTION:A mixture compsn. for a lightweight inner layer is prepared by compounding 100 pts.wt. hydraulic cement such as Portland cement, 50-150 pts.wt. coarse aggregate having <1.2 specific gravity and >=0.35mm grain size, and 5-105 pts.wt. fine aggregate having <=1.2 specific gravity and <0.35mm particle size, in total 55-255 pts.wt. aggregate, and 10-180 pts.wt. water, and reinforcing material or the like, and then kneading these materials in a kneader or the like for 120-600sec. Then a mixture compsn. for a surface material is prepared by kneading specified proportions of cement, aggregate and water and is supplied to a form equipped with a vibrator. After the surface of the poured material is made flat by vibrating the form, the kneaded material for a lightweight inner layer is supplied therreon and the surface is made flat. The compsn. is press formed under specified pressure to obtain a planer laminated body, which is cured by natural curing or steam curing to make the laminated body into one body. Thus, the lightweight artificial architectural stone having enough strength is obtd.

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 artificial stone material. Specifically, it relates to a method for manufacturing an artificial stone material laminate, which is a lightweight stone building material widely used for buildings, furniture and the like.

[0002]

2. Description of the Related Art Stone materials have been used as important construction materials since ancient times, and have gained a position comparable to wood in Japan as well as Europe and America. This is largely due to its outstanding strength and durability compared to other materials, as typified by many medieval castle walls that remain today.

There are two types of stone materials, natural stone materials and artificial stone materials. Natural stone materials may be depleted of resources or may become difficult to obtain in the future. However, artificial stone materials hardly cause problems and are ecologically friendly to the earth. It is a material. In recent years, it has been used in large quantities as a building material and has improved designability in addition to strength and durability, making it easier for designers to express their intentions. Artificial stone materials meet this need. In other words, natural stones have different original patterns at the time of generation and there are problems in design, but artificial stones have the characteristic that the filler to be blended can be changed freely and the same design can be easily created. ing. As described above, the artificial stone material has an excellent advantage in design selectivity, but on the other hand, the physical properties thereof are as hard as the natural stone material and heavy. Therefore, construction and processing at the construction site are not always easy, and it has been required to reduce the weight of the artificial stone material.

An artificial stone material laminate in which a lightweight artificial stone material is used as an inner layer material and a cementitious artificial stone material is used as a surface layer material has been a means of reducing the weight. Therefore, as shown in, for example, JP-A-63-261040, by using lightweight calcium silicate as an inner layer material and attaching a thin artificial or natural stone material as a surface material to the surface thereof with an adhesive, Artificial stone materials by laminating and bonding which improve the lightness and crack resistance are known.

The inventors of the present invention first put the surface material constituents in the mold, and evenly level the surface to some extent, and then pour the light weight inner layer material constituents onto the surface of the surface and mold it with a press machine.
After that, Japanese Patent Application No. Hei 5
Proposed as -090452. However, in the case of bonding by bonding, the reliability of the adhesive strength is not sufficient, and
The number of work processes increased because it was necessary to procure thin stone plates in advance. In addition, according to the manufacturing method according to Japanese Patent Application No. 5-090452, it is possible to obtain an artificial stone material that is lightweight and has both compactness and bondability, but the material before molding process contains a large amount of water. In pressure molding by a press machine, excess water that is not absorbed by stone materials is extruded during the compression process. This extra water had to be drained, so problems such as wastewater treatment were unavoidable. Therefore, a dry molding method in which excess water is not discharged outside the system has been desired.

[0006]

Conventionally, it is widely known that an artificial stone material and a heavy mortar are laminated by a dry molding method. In the dry molding method, two layers of an artificial stone material mortar and a heavy-weight inner layer material mortar are brought into close contact with each other and brought into close contact by pressure molding. The water mixed in the artificial stone material layer is extruded at the time of pressure molding, and the extruded water is absorbed by the heavy mortar having an extremely low water content. Therefore, the dry molding method does not require draining excess water.

The artificial stone material has few air bubbles inside the molded body,
Moreover, it has a dense structure with a low water content. However, there was no improvement in weight compared to natural stone. In order to obtain the lightness of the artificial stone material laminated body by the dry molding method, lightweight mortar is used instead of heavy mortar. At this time, the lightweight mortar is extremely bulky, and the one whose water content is reduced to the limit is used. Since such mortar is a powder that is difficult to call mortar, it is inevitable that a large amount of air will be mixed in during molding, and the resulting laminate will swell, crack, and chip corners, which will affect the quality of the artificial stone material. It was a problem.

The present inventors have found that by blending a coarse and lightweight aggregate in the inner layer material, air is easily transmitted between the coarse aggregate particles to escape. An object of the present invention is to provide a method for efficiently manufacturing a lightweight artificial stone material having sufficient strength by integrally molding a surface material of a cementitious artificial stone material and an inner layer material for weight reduction by a dry molding method. That is.

[0009]

SUMMARY OF THE INVENTION An object of the present invention, however, is to provide a method for producing a multi-layered artificial stone material which is composed of a surface material containing a filler and a lightweight inner layer material, and is integrally molded by a dry molding method. The method for producing an artificial stone material is characterized in that a lightweight inner layer material is prepared from the following blends (a) to (c).

(A) 100 parts by weight of hydraulic cement (b) 55-255 parts by weight of mixed aggregate of (a) and (b) (a) Specific gravity of 1.2 or less and particle size of 0.35 mm or more Coarse-grained aggregate 50 to 150 parts by weight (b) Fine-grained aggregate having a specific gravity of 1.2 or less and a particle size of less than 0.35 mm 5 to 105 parts by weight (c) Water 10 to 180 parts by weight

Alternatively, (a) 100 parts by weight of hydraulic cement (b) Mixed aggregates 20 to 3 of (a), (b1) and (b2)
35 parts by weight (a) 10 to 150 parts by weight of coarse aggregate having a specific gravity of 1.2 or less and a particle size of 0.35 mm or more (b1) a specific gravity of 0.3 to 1.2 and a particle size of 0. 35 mm
5 to 105 parts by weight of fine aggregate (b2) Light weight fine aggregate having a specific gravity of less than 0.3 and a particle size of less than 0.35 mm 5 to 80 parts by weight (c) Water 10 to 180 parts by weight or less The present invention will be described in more detail below.

First, the invention of claim 1 will be described. The basic composition of the artificial stone material used as the surface material is composed of three kinds of seed stone, hydraulic cement, and water, and the seed stone is usually a crushed stone of natural stone,
Glass pieces, pottery pieces, metal pieces, etc. are used, and the amount of use is 100 to 1000 parts by weight, preferably 200 to 500 parts by weight, based on 100 parts by weight of cement, and the designability of the finished design is mainly achieved, and It can be determined in consideration of physical properties such as hardness and abrasion resistance.

The hydraulic cement includes calcium silicate type and aluminum oxide type, and specifically, Portland cement, blast furnace cement, silica cement and the like are used. Water is 20 for every 100 parts by weight of hydraulic cement.
To 150 parts by weight, preferably 30 to 90 parts by weight.

In addition to the above, as an auxiliary agent for the surface material, a surfactant or a thickening agent that promotes fluidization of the uncured artificial stone material,
Add defoaming agents that reduce air bubbles, modifiers that accelerate curing, and additives such as cement matrix reinforcing agents according to the purpose.
~ 5 kinds can be added. The raw materials for the surface material are mixed by using a concrete mixer which is usually used for kneading concrete materials, for about 120 to 480 seconds to obtain a surface material kneaded product.

The lightweight inner layer material is prepared from the above-mentioned compounds (a) to (c), and its characteristic is (b). That is, the aggregate of (b) is a mixed aggregate of (a) and (b) (claim 1), (a) a coarse aggregate having a specific gravity of 1.2 or less and a particle size of 0.35 mm or more. . (B) Fine aggregate having a specific gravity of 1.2 or less and a particle size of less than 0.35 mm.

Alternatively, a mixed aggregate of (a) and (b1) and (b2) (claim 2) is used. (A) Coarse-grained aggregate having a specific gravity of 1.2 or less and a grain size of 0.35 mm or more. (B1) Specific gravity is 0.3 to 1.2 and particle size is 0.35 mm
Fine aggregate of less than. (B2) Light-weight fine-grain aggregate having a specific gravity of less than 0.3 and a particle size of less than 0.35 mm.

The coarse-grained aggregate (a) is used to prevent air entrapment in the lightweight inner layer material. If the particle size is too small, air entrapment occurs. Is 1.2 or less, preferably 0.5 or less, and the particle size is 0.35 mm or more, preferably 0.5 to 3.
5 mm is selected. As such materials, industrial glass recycled aggregates, natural glass or silica or alumina balloon aggregates obtained by foaming natural glass, and inorganic aggregates or resin beads obtained by granulating ceramic aggregates are used. Coarse-grained aggregate can prevent air entrapment by mixing in a large amount, and reduce air bubbles inside the lightweight inner layer material, but if too much, cement or fine-grained aggregate will be added to the lightweight inner layer material after molding. Since it is not satisfied, the compactness is lost. Therefore, the blending amount of the coarse-grained aggregate (a) is 50 to 150 parts by weight, preferably 70 to 130 parts by weight.

The fine-grain aggregate (b) is used for increasing the compactness of the lightweight inner layer material, and its specific gravity is 1.2 or less, preferably 0.5 or less, and the particle diameter is less than 0.35 mm, preferably. Those having a thickness of 0.003 to 0.30 mm are selected. Those having a specific gravity of 0.3 or more generally have high compressive strength and are difficult to be crushed at the time of pressure molding, and the amount of coarse-grained aggregate can be reduced by mixing them to some extent or more. Therefore, the blending amount of the fine-grained aggregate (b) is 5 to 105 parts by weight, preferably 10
The amount is 90 parts by weight.

If the amount of water (c) is too large, water is extruded during pressure molding, and the extruded water makes continuous molding difficult. Mixing ratio is 1 to 100 parts by weight of hydraulic cement.
It is 0 to 180 parts by weight, preferably 20 to 150 parts by weight. Other compounds that improve mechanical properties include carbon fiber, glass fiber, pulp, polyvinyl acetal, polyvinyl alcohol, polyvinyl acetate,
Fibers such as polypropylene and acrylic may be used as the reinforcing material.

In addition to the above, as the auxiliary agent for the lightweight inner layer material, 1 to 5 kinds of the same agents as those used for the surface material can be added. Although it is possible to use a concrete mixer that is usually used for kneading concrete materials to mix the raw materials for the lightweight inner layer material, water is absorbed by the fine-grain aggregate and the light-weight fine-grain aggregate to form a powder. Therefore, it is preferable to knead for about 120 to 600 seconds using a blender (powder mixer) or a twin-screw kneader (two-screw extruder) to obtain a lightweight inner layer material kneaded product.

As described above, the surface material and the light weight inner layer material are mixed, and then the surface material and the light weight inner layer material are laminated by a conventional molding process. That is, the surface material raw material kneaded product is supplied into the mold in an uncured state, and the mold is vibrated to remove bubbles contained in the surface material raw material kneaded product and level the surface material. A raw material kneaded material for the light-weight inner layer material is supplied thereon, and the surface thereof is leveled by a method similar to the method used for flattening the grain of a grain that has been scratched with a scratch. After that, pressure molding is performed. The molding pressure is 30 to 200 kg / cm ² , preferably 40 to 90 kg / cm ² (2.94 × 10 ^{6 to} 19.6).
× 10 ⁶ Pa, preferably 3.92 × 10 ^{6 to} 8.82
× 10 ⁶ Pa). The pressure-molded product becomes a plate-shaped laminate.

The hydraulic cement in the raw material kneaded product is more preferably supplemented with water necessary for promoting hydration by watering or humidification by steam. In this way, the obtained laminated body is subjected to natural curing or steam curing together with the mold to cure the surface material and the lightweight inner layer material, respectively, and laminate and integrate them. Then, after the surface material is appropriately polished and cut, the product is inspected and shipped.

Next, the invention of claim 2 will be described.
In the invention of claim 2, the coarse-grained aggregate (a) is claimed in claim 1.
It is similar to that used in the invention, but is characterized in that two kinds of aggregates having different specific gravities are used as the fine grain aggregates. That is, the fine aggregate (b1) and the lightweight fine aggregate (b2)
Among them, those having a particularly low specific gravity are used for the purpose of filling a gap between coarse-grained aggregates. Fine aggregate (b
The specific gravity of 1) is 0.3 to 1.2, preferably 0.35.
At 0.5, the particle size is less than 0.35 mm, preferably 0.
003 to 0.30 mm is selected, lightweight fine grain aggregate (b2)
Has a specific gravity of less than 0.3, preferably less than 0.25. Particle size is less than 0.35 mm, preferably 0.003
~ 0.30 mm is selected. As such materials, natural glass minerals, shirasu balloon foamed from natural glass, pearlite, and industrial glass recycled aggregate are used. If the fine-grain aggregates (b1) and the light-weight fine-grain aggregates (b2) are too small, the gap between the coarse-grain aggregates cannot be filled and the compactness is lost. As a mixing ratio, hydraulic cement 10
The fine-grain aggregate (b1) is 5 to 105 parts by weight, preferably 10 to 90 parts by weight, and the lightweight fine-grain aggregate (b2) is 5 to 80 parts by weight, preferably 10 to 70 parts by weight. Parts by weight. According to the second aspect of the present invention, since the fine-grained aggregate is used in a relatively large amount, the amount of the coarse-grained aggregate (a) may be slightly small. Therefore, hydraulic cement 1
It is used in an amount of 10 to 150 parts by weight, preferably 20 to 130 parts by weight, based on 00 parts by weight.

[0024]

EXAMPLES The present invention will be described in more detail with reference to examples below, but the present invention is not limited to the following examples as long as the gist thereof is not exceeded. (Example 1) The raw material kneaded mixture of the surface material is as follows.

[0025]

[Table 1] As the seed stone, commercially available crushed stones of the following natural stones were used. Peony Average particle size 12mm 30 parts by weight Botan 〃 5mm 20 parts by weight Serpent pattern 〃 3mm 10 parts by weight Hakuryu 〃 0.7mm 10 parts by weight Granite powder 〃 0.02mm 10 parts by weight

As the cement, 20 parts by weight of Portland cement manufactured by Onoda Cement Co. was used, and a total of 94.5 kg of the seed stone and the cement was weighed. 11.7 of clean water
KUM-3 type (rotation number 34r
pm, 2PS (rotation speed 0.57S ^-1 , 1.47KW))
The concrete was mixed for 300 seconds.

The lightweight inner layer material was prepared by kneading a total of 52.5 kg in the mixing ratio shown in Table 1 in Example 1 using the same kind of concrete mixer as described above. Since the raw material for the lightweight inner layer material is bulky, the number of times of kneading was divided into 3 times, and kneading was performed for 600 seconds each. Next, the raw material kneaded material of the surface material was weighed and supplied to a mold with a vibrator of 400 mm square. Then, after vibrating the formwork and leveling it evenly, a kneaded material for the lightweight inner layer material is further supplied thereon, and the surface thereof is the method used for leveling the edges of the grain laid by the measure I made it even in the same way.

Thereafter, the pressure is 140 kg / cm ² (13.
Pressure molding was performed at 7 × 10 ⁶ Pa) for 15 seconds. The above molding operation was repeated to obtain 20 substantially uniform plate-shaped molded bodies.
After that, all the articles were naturally cured for 3 weeks and polished to obtain artificial stone materials. Product inspection of the finished product,
Defects such as cracking and swelling of the plate-shaped molded body were not found in the surface material and the lightweight inner layer material, and were good in 20 cases out of 20 cases.
The manufactured artificial stone material was extremely lighter than the natural stone material, and the overall specific gravity of the artificial stone material was 1.3. The quality of the artificial stone material was excellent in adhesiveness, mechanical strength, and design.

(Example 2) Table 2 shows the blending ratio of the lightweight inner layer material.
Twenty artificial stone materials that were polished in the same manner as in Example 1 were obtained except that Example 2 was used. The product inspection result was good in 20 cases. (Example 3) The compounding ratio of the lightweight inner layer material is shown in Table 1 as Example 3.
Except that the artificial stone material polished in the same manner as in Example 1 was used.
I got one. The result of the product inspection was as good as that of Example 1, but only one of the 20 cases had a slight lateral crack.

(Comparative Example 1) The mixing ratio of the lightweight inner layer material is shown in the table.
Twenty artificial stone materials that were polished in the same manner as in Example 1 except for Comparative Example 1 of Example 1 were obtained. As a result of product inspection, in 20 cases out of 20 cases, cracks and cracks due to air entrainment occurred in the lightweight inner layer material.

(Comparative Example 2) The mixing ratio of the lightweight inner layer material is shown in the table.
Twenty artificial stone materials that were polished in the same manner as in Example 1 were obtained except that Comparative Example 2 of Example 1 was used. As a result of product inspection, in 9 out of 20 cases, cracks and cracks due to air entrainment occurred in the lightweight inner layer material. The phyllite used in Example 3 has a high compressive strength,
It has the gap required for air propagation. However, it is considered that the sankylite YO2 used in Comparative Example 2 partially crushed during pressure molding, and the crushing clogged the gap required for air propagation.

[0032]

[Table 2]

[0033]

INDUSTRIAL APPLICABILITY The present invention industrially advantageously provides the lightness, which has been a drawback of conventional artificial stone materials, as an artificial stone material in which a stone surface material is laminated by an ecological molding method called dry molding. Therefore, it can be used for a wide range of purposes such as buildings and civil engineering.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical indication location C04B 14:24 14:02) Z (72) Inventor Atshiko Yamamoto 1000 Kamoshida-cho, Midori-ku, Yokohama-shi, Kanagawa Address Sanryo Kasei Co., Ltd. Research Institute (72) Inventor Yoshihisa Washio 2-5-2 Marunouchi, Chiyoda-ku, Tokyo Sanryo Kasei Co., Ltd.

Claims (2)

[Claims] 1. A method for producing an artificial stone material having a multi-layer structure, comprising a surface material containing a filler and a lightweight inner layer material, wherein the lightweight inner layer material is a mixture of the following (a) to (c): A method for producing an artificial stone material, which comprises: (A) 100 parts by weight of hydraulic cement (b) 55-255 parts by weight of mixed aggregate of (a) and (b) (a) Coarse-grained bone having a specific gravity of 1.2 or less and a grain size of 0.35 mm or more 50-150 parts by weight of material (b) 5 to 105 parts by weight of fine aggregate having a specific gravity of 1.2 or less and a particle size of less than 0.35 mm (c) 10 to 180 parts by weight of water 2. A method for producing an artificial stone material having a multi-layer structure, comprising a surface material containing a filler and a lightweight inner layer material, wherein the lightweight inner layer material is a mixture of the following (a) to (c): A method for producing an artificial stone material, which comprises: (A) 100 parts by weight of hydraulic cement (b) Mixed aggregates 20 to 3 of (a), (b1) and (b2)
35 parts by weight (a) 10 to 150 parts by weight of coarse aggregate having a specific gravity of 1.2 or less and a particle size of 0.35 mm or more (b1) a specific gravity of 0.3 to 1.2 and a particle size of 0. 35 mm
5 to 105 parts by weight of fine aggregate of less than (b2) 5 to 80 parts by weight of fine aggregate having a specific gravity of less than 0.3 and a particle size of less than 0.35 mm (c) 10 to 180 parts by weight of water