JPH09136308A - Manufacture of concrete product with ceramic tile and ceramic tile integrated sheet used therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ceramic tile integrated sheet in which the projected faces of respective uneven surfaces can be put together, and post treatment is simple even for large-sized tiles having an uneven surface. SOLUTION: A ceramic tile integrated sheet A in a state in which ceramic tiles 1 with an uneven pattern formed on the surface are arranged at prescribed intervals, the whole surface is coated a plastic sheet 10 to be integrated, and the plastic sheet 10 is inserted into the gap between the ceramic tiles 1. By placing a filler 2a between the surface of the ceramic tile 1 and the plastic sheet 10, the back of each ceramic tile 1 is positioned on almost the same plane.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a concrete product with a ceramic tile and a ceramic tile integrated sheet used for the method.

[0002]

2. Description of the Related Art Conventionally, the following method has been used to drive a tile or a stone material having a flat surface onto a concrete surface. That is, first, as shown in FIG. 17, tiles 31 and the like are laid on the bottom of the mold 32 in an appropriate pattern and laid out, and then the gaps between the tiles 31 and the like are filled with a filler 33 such as a sponge. At the same time, the sealing material 34 is filled on the filling material 33 up to a certain height (the thickness of the tile 31 or the like or less). Next, a concrete material 35 is cast from the upper end opening of the mold 32, and after the curing and curing of the concrete material 35, the filler 33 and the sealant 34 are removed,
The removal mark is formed on the joints, and a concrete product having tiles imprinted on the surface is manufactured.

[0003]

However, in the above method, the filler 33 and the sealant 34 filled between the tiles 31 and the like must be removed after the curing and curing, and this removing work is time-consuming and costly. It will be up. Further, in the above method, the tile 31 and the like are large (for example,
If the size is 600 cm x 600 cm or more) and the surface has an uneven pattern 31a such as split skin, even if you try to drive it into a precast concrete board (PC board) for buildings etc. As shown in FIG. 18, since the tiles 31 and the like are inclined and the projecting surfaces do not match, it was very difficult in the manufacturing method. Therefore, the uneven pattern 31 on the surface
In reality, large tiles 31 and the like on which a is formed are not used for PC boards.

The present invention has been made in view of the above circumstances, and even in the case of a large tile having an uneven surface, the projected surface of each uneven surface can be aligned, and further, after curing and curing. It is an object of the present invention to provide a method for producing a concrete product with a ceramic tile which is easy to process, and a ceramic tile integrated sheet used for the method.

[0005]

In order to achieve the above object, the present invention provides a ceramic tile having a plurality of concave and convex surfaces arranged at a predetermined gap, and the entire surface of the ceramic tile is covered and integrated with a plastic sheet. Prepare a ceramic tile integrated sheet with a plastic sheet inserted in the gap between them, put this ceramic tile integrated sheet in a molding form for concrete material injection, and place the back surface of the ceramic tile integrated sheet. It is a manufacturing method of a concrete product with a ceramic tile, which is a contact surface for the concrete material, and then the concrete material is poured into the molding frame to be hardened, and then the plastic sheet is peeled off to dispose the ceramic tile on the generated concrete surface. The above ceramic tile surface and plastic sheet The first method is to manufacture a concrete product with a ceramic tile in which the back surface of each ceramic tile is located on substantially the same plane by interposing a filler between the ceramic tiles. A ceramic tile integrated sheet in which a plurality of the ceramic tiles are arranged in a predetermined gap, the entire surface is covered with a plastic sheet, and the plastic sheet is inserted into the gap between the ceramic tiles. A second aspect of the present invention is a ceramic tile-integrated sheet in which a filler is interposed between and, and the back surfaces of the respective ceramic tiles are located on substantially the same plane.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION That is, according to the method for producing a concrete product with a ceramic tile of the present invention, a plurality of ceramic tiles having a plurality of uneven surfaces are arranged at a predetermined gap, and the entire surface is covered with a plastic sheet to form an integrated ceramic tile. Using a ceramic tile integrated sheet with a plastic sheet inserted in the gap between them is a method for producing a concrete product with a ceramic tile in which a ceramic tile is arranged on the concrete surface, and the surface of the ceramic tile and the plastic sheet A filler is interposed between the ceramic tiles so that the back surfaces of the respective ceramic tiles are located on substantially the same plane. In this way, when the back surfaces of the ceramic tiles forming the ceramic tile integrated sheet are located on substantially the same plane, the ceramic tiles may tilt even if they are placed in the molding frame. The projection surface of the uneven surface of each ceramic tile matches. Therefore, even a large ceramic tile having an uneven surface can be used as a PC board for buildings and the like. Moreover, the post-treatment after demolding from the molding frame is only the work of peeling the plastic sheet from the concrete surface, and this work does not take much time, and as a result, the cost of the product etc. can be reduced. In addition, the entire surface of multiple ceramic tiles is covered with a plastic sheet, and the plastic sheet is inserted into the gaps between the ceramic tiles. Does not adhere to the tile surface. Further, according to the ceramic tile integrated sheet of the present invention,
By using this in the production method of the present invention, the above excellent concrete product can be produced. The present invention can be applied to a molding frame placed horizontally on the ground or the like and also to a molding frame placed vertically.

Next, the present invention will be described in detail.

Examples of the material of the ceramic tile used in the present invention include natural raw materials such as clay, porcelain stone, silica stone and feldspar, and synthetic raw materials such as alumina, zirconia, silicon carbide and silicon nitride, and preferably clay Is used. A color close to that of natural stone may be forcibly expressed by partially mixing different pigments into such a ceramic style. It is also conceivable to add a foam material.

The material of the plastic sheet used in the present invention includes polyethylene (PE) and polypropylene (P
P), polyvinyl chloride (PVC), acrylonitrile-
Examples thereof include thermoplastic resins such as butadiene-styrene copolymer resin (ABS) and polystyrene (PS). The thickness of the plastic sheet is set in the range of 1.0 to 5.0 mm, and the strength thereof is 250 to 750 kg / cm.
It is set in the range of ² (tensile strength). By setting the strength in such a range, the plastic sheet can be used as a contact surface for the concrete surface.

Any material having an appropriate hardness may be used as the material of the filler used in the present invention, and preferably clay, mud, unvulcanized rubber, or thermoplastic unvulcanized resin. Etc. are used. However, when unvulcanized rubber, thermoplastic unvulcanized resin, or the like is used, heat treatment or the like is performed in order to impart shape retention.

Further, in the present invention, since the entire surface of a plurality of ceramic tiles is covered and integrated with a plastic sheet, a vacuum is drawn from the back surface side of the ceramic tiles.
Alternatively, the surface of the ceramic tile is pressurized with a compressed gas, or the vacuum evacuation and the compressed gas are simultaneously performed. A known vacuum forming apparatus or the like is used as such a vacuuming means, and a known pneumatic forming apparatus is used as a pressurizing means with a compressed gas.

Next, an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 shows a ceramic tile 1 used in an embodiment of the present invention, and an uneven pattern such as a split surface is formed on a surface 1a thereof. First, a desired number of such ceramic tiles 1 are prepared. Then, the clay blocks 2 (filler) are placed at a plurality of locations on the surface of each ceramic tile 1 (only two locations are shown in the drawing). The height of the clay mass 2 is set higher than the uneven pattern on the surface 1a of the ceramic tile 1. Next, as shown in FIG. 2, the ceramic tile 1 on which the clay lump 2 is placed is housed in a case 3 having an upper opening, and a flat press plate 4 covers the upper opening of the case 3. The upper surfaces of the plurality of clay blocks 2 are pressed by the lower surface of the plate 4 to be flattened, thereby producing the convex portions 2a made of clay having a flat upper surface, and at the same time, the upper surfaces of the convex portions 2a are flush with each other. It also becomes a state. Such an operation is performed on all the prepared ceramic tiles 1. As a result, the distance between the back surface of each ceramic tile 1 and the upper surface of the convex portion 2a provided thereon is the same for all the prepared ceramic tiles 1.

FIG. 3 shows a vacuum forming apparatus used in one embodiment of the present invention. This vacuum forming apparatus includes a mold 6 having an open top surface, a communication pipe 7 extending from a suction port formed in a bottom wall 6a of the mold 6, and a vacuum pump (not shown) communicating with the communication pipe 7. ) And a perforated plate 8 with perforations 8 a placed on the stepped portion of the inner peripheral surface of the mold frame 6. First, as shown in FIG. 4, a plurality of the ceramic tiles 1 (having the convex portions 2a formed on the surface 1a) produced above are placed on the perforated plate 8 with a gap therebetween while facing upward. Next, as shown in FIG. 5, each ceramic tile 1
A large number of beads 9 are filled in the spaces between them and adjusted to a predetermined height. Next, as shown in FIG. 6, the plastic sheet 10 is attached to the upper end of the mold 6 by using the attachment frame 6b, and the heater 11 is arranged above the plastic sheet 10. After that, the plastic sheet 10 is softened by the heater 11, and the inside of the mold 6 is evacuated through the communication pipe 7, as shown in FIG. As a result, as shown in FIG. 8, the plastic sheet 10 is integrated with the surface of the ceramic tile 1 and the surface of the convex portion 2a, and the ceramic tile is integrated with the plastic sheet 10 in the gap between the ceramic tiles 1. The chemical conversion sheet A is obtained. The ceramic tile-integrated sheet A thus obtained is set in the molding frame 12 with its back surface facing upward (see FIG. 9). At this time, as shown in FIG. 10, the sealing material 13 is filled in the connecting portion between the adjacent plastic sheets 10. As a result, the concrete material 14 does not enter from this connecting portion. Further, there is an effect that a joint portion is formed at this connecting portion. After that, FIG.
As shown in FIG. 12, the concrete material 14 is filled from the upper end opening of the molding frame 12, and after curing and curing, the plastic sheet 10 is peeled off from the concrete surface as shown in FIG. As a result, a concrete product as shown in FIG. 13 is obtained. A plurality of ceramic tiles 1 are decorated on the surface of the concrete product thus obtained.

As described above, in the above embodiment, the surface 1
A plurality of convex portions 2a are provided on the surface 1a of the ceramic tile 1 having a concave and convex pattern formed on a, and the upper surfaces of the convex portions 2a are flush with each other. Therefore, when the ceramic tile-integrated sheet A is set on the molding frame 12 so that the back surface thereof faces upward, each of the convex portions 2a has a plastic sheet 1
The ceramic tile 1 is prevented from inclining horizontally by contacting the bottom surface of the molding frame 12 through 0. Moreover, unlike the conventional example, the filler 33 and the sealant 34 are not used, and the post-treatment after curing and curing can be performed by simply peeling off the plastic sheet 10, which simplifies the post-treatment. Furthermore, the joints between the ceramic tiles 1 can be formed by overlapping the outer peripheral portions of the plastic sheets 10 and filling the sealing material 13 on the outer peripheral portions, and the concrete material 14 can be prevented from entering. . In addition, since the plastic sheet 10 is integrated on the surface of the ceramic tile 1 and the surface of the convex portion 2a, and the plastic sheet 10 is inserted in the gap between the ceramic tiles 1, the concrete material 14 is not mixed with the ceramic material during the placing. It does not adhere to the surface 1a of the tile 1.

FIG. 14 shows another embodiment of the present invention. In this embodiment, the plastic sheet 10 is integrated with the surface of the ceramic tile 1 by pressing the surface side of the plastic sheet 10 with a compressed gas. Therefore, the mold 15 in which the suction port is not formed in the bottom wall 15a as in the above embodiment is used, and the plurality of ceramic tiles 1 are directly mounted on the bottom wall 15a of the mold 15. Then, as in the above-described embodiment, a large number of beads 9 are filled between the ceramic tiles 1, and then the plastic sheet 10 is attached to the upper end of the mold 15 using the attachment frame 15b and the heater 11 is used. Soften. After that, the pressing plate 17 is mounted on the mounting frame 15b to seal the internal space, and in this state, the pressing plate 17 is
Compressed air is sent to the internal space from each branch pipe 16a of the manifold 16 attached to the. The other parts are the same as those in the above embodiment, and the same parts are denoted by the same reference numerals.

FIG. 15 shows still another embodiment of the present invention (connecting portion of adjacent ceramic tile integrated sheets A).
Is shown. In this embodiment, the entire surface 1a of the large-sized ceramic tile 1 is covered with a layered filler 18 made of clay, mud, or the like, and a plastic sheet 10 is attached to each ceramic tile 1 and the plastic sheet 10 is attached. The integrated sheet A is formed by superimposing the joint-corresponding portion of the peripheral edge portion on the joint-corresponding portion of the plastic sheet 10 of the adjacent ceramic tile 1. In this case, if the filler 18 has some adhesiveness, or if it is not adhesive, if an adhesive is applied to the interface between the plastic sheet 10 and the filler 18, the adhesiveness between each ceramic tile 1 and the plastic sheet 10 will be improved. Is improved. In FIG. 15 as well, the case 3 and the press plate 4 shown in FIG. 2 are used, and the ceramic tiles 1 used are all set to have the same thickness.

FIG. 16 shows still another embodiment of the present invention. In this embodiment, the ceramic tile 1
A double-sided adhesive tape 19 using a sponge having a thickness of 0.5 to 2 mm as a base material is attached to the surface 1a of the. In this case, the bonding strength between the ceramic tile 1 and the plastic sheet 10 is strong, the ceramic tile 1 falls off from the plastic sheet 10 during transportation, or the concrete material 14 wraps around the surface of the ceramic tile 1 during concrete pouring. No dripping at all. In addition, the ceramic tile 1 absorbs the impact force received during transportation and handling.
There is also an advantage that the surface pattern of can be protected.
Other parts are the same as those of the above-described embodiment, and the same parts are denoted by the same reference numerals.

The beads 9 used in each of the above-mentioned embodiments are glass beads formed into a spherical shape, a tubular shape, or the like.
Examples include sand and metal powder. The joint depth of such beads 9 can be adjusted by the number of the beads 9 to be filled, and air permeability can be provided by the gaps formed between the beads 9.

In addition, in each of the above-described embodiments, the convex portion 2a provided on the surface 1a of the ceramic tile 1 is made of clay, but the present invention is not limited to this, and unvulcanized rubber or thermoplastic unvulcanized rubber is used. Sulfur resin or the like is used. In this case, after placing unvulcanized rubber or thermoplastic unvulcanized resin on the surface 1a of the ceramic tile 1, the case 3 and the press plate 4 shown in FIG. After that, it is heated and cured. As a result, the unvulcanized rubber, the thermoplastic unvulcanized resin, or the like has shape-retaining properties and can act as the convex portions 2a.

[0021]

As described above, according to the method for producing a concrete product with a ceramic tile of the present invention, even a large-sized ceramic tile having an uneven surface can be used as a PC board for a building or the like. it can. The post-treatment after removing the mold from the molding frame is only the work of peeling off the plastic sheet from the concrete surface, and this work does not take much time and the cost can be reduced. In addition, the entire surface of multiple ceramic tiles is covered with a plastic sheet, and the plastic sheet is inserted into the gaps between the ceramic tiles. Does not adhere to the tile surface. On the other hand, according to the ceramic tile integrated sheet of the present invention, this can be used in the production method of the present invention to produce the excellent concrete product.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram showing an embodiment of a ceramic tile used in the present invention.

FIG. 2 is an explanatory diagram showing a state in which a convex portion is formed on the surface of the ceramic tile.

FIG. 3 is an explanatory diagram of a vacuuming device used in the present invention.

FIG. 4 is an explanatory diagram showing a state in which a ceramic tile is placed on a porous plate.

FIG. 5 is an explanatory diagram showing a state where beads are filled in the gaps between the ceramic tiles.

FIG. 6 is an explanatory view showing a state in which a plastic sheet is attached to the mold.

FIG. 7 is an explanatory diagram showing a state in which a vacuum is drawn.

FIG. 8 is an explanatory diagram of a ceramic tile integrated sheet of the present invention.

FIG. 9 is an explanatory diagram showing a state in which a ceramic tile integrated sheet is set in a molding frame.

FIG. 10 is an enlarged explanatory view showing a main part in the molding frame.

FIG. 11 is an explanatory view showing a state where concrete material is cast into the molding form.

FIG. 12 is an explanatory view showing a state where the plastic sheet is peeled off.

FIG. 13 is an explanatory diagram of a concrete product.

FIG. 14 is an explanatory diagram showing another embodiment of the present invention.

FIG. 15 is an explanatory diagram showing still another embodiment of the present invention.

FIG. 16 is an explanatory diagram of a ceramic tile showing still another embodiment of the present invention.

FIG. 17 is an explanatory diagram of a conventional example.

FIG. 18 is an explanatory diagram of another conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Ceramic tile 1a Surface 2 Filler 10 Plastic sheet 12 Forming mold 14 Concrete material A Ceramic tile integrated sheet

Claims (4)

[Claims] 1. A ceramic tile in which a plurality of ceramic tiles having a plurality of uneven surfaces are arranged at a predetermined gap, the entire surface is integrally covered with a plastic sheet, and the plastic sheet is inserted into the gap between the ceramic tiles. Prepared sheet, put the ceramic tile integrated sheet in a molding form for concrete material injection, and make the back surface of the ceramic tile integrated sheet a contact surface for the concrete material, and then put the concrete material in the molding form. A method for producing a concrete product with a ceramic tile, in which the plastic sheet is peeled off and the ceramic tile is disposed on the surface of the generated concrete after the resin is injected and cured, and a filler is provided between the surface of the ceramic tile and the plastic sheet. By interposing the A method for producing a concrete product with a ceramic tile, characterized in that the back surface of the tile is located on substantially the same plane. 2. Integrating with a plastic sheet, the plastic sheet is placed on the entire surface of a plurality of ceramic tiles arranged at a predetermined gap, and vacuum suction is performed from the back side of the ceramic tile using the gap, or The ceramic according to claim 1, wherein a plastic sheet is placed on the entire surface of a plurality of ceramic tiles arranged at intervals, and the surface of the ceramic tile is pressurized with compressed gas, or the suction and the pressure are applied simultaneously. How to make concrete products with tiles. 3. The method for producing a concrete product with a ceramic tile according to claim 1, wherein the filler is partially interposed between the surface of the ceramic tile and the plastic sheet. 4. A ceramic tile having a plurality of ceramic tiles having a plurality of concavo-convex surfaces arranged at a predetermined gap, the entire surface of which is covered and integrated with a plastic sheet, and the plastic sheet is inserted into the gap between the ceramic tiles. A ceramic sheet, characterized in that a filler is interposed between the surface of the ceramic tile and the plastic sheet, and the back surface of each ceramic tile is located on substantially the same plane. Integrated sheet.