JPH0960267A - Finishing material with joint and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor material with a joint hardly fouled and damaged, capable of permanently securing a beautiful appearance and amenity, and excellent in productivity and execution property. SOLUTION: A slurry reactive inorganic compound is put in a resin frame 31 having multiple tread hold sections 61, 61,... partitioned by joint walls 51,..., then it is hardened, and multiple treads 21, 21,... are integrally molded via the joint walls 51, 51,.... Resin nets 41 are stretched in the tread hold sections 61 so that they are supported on the joint walls 51, 51,... partitioning the tread hold sections 61, 61,... in advance and buried in the corresponding treads 21.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a jointed finishing material as an interior / exterior material for a building and a method for manufacturing the same, and more particularly, to a jointed finishing material for finishing a floor surface or a wall surface by a dry method. Floor material, jointed wall material) and a method for manufacturing the same.

[0002]

2. Description of the Related Art When a surface finishing material such as a tile or a decorative material is attached to a floor surface such as a balcony or a terrace, the wet method using mortar or cement paste requires a specialist craftsman and who But it is not something that can be constructed. Even if a specialized craftsman does the work, the time required for drying, etc. is unrelated to the degree of skill and it is difficult to shorten it, and it depends on the weather.
As disclosed in No. 68254, No. 3-74734, No. 6-14344, No. 61-26847, the mortar, cement paste, etc. are not used and only placed. The dry type composite flooring material that can be installed by anyone is becoming widespread.

This type of composite floor material 1 is, for example, an actual Kaihei 3-
Explaining with the example described in Japanese Patent No. 68254, as shown in FIGS. 11 to 13, it is composed of a resin mat 2 and a plurality of tiles 3, 3, ... Lay on the upper surface of the resin mat 2. Thus, the resin mat 2 has a square substrate portion 4 formed in a grid pattern, and the substrate mat 4 has three squares on the upper surface thereof.
A total of nine tile laying portions 5, 5, ... Are sectioned and formed as recesses, and a square tile 3 is placed on the upper surface of each tile laying portion 5. Tile holding pieces 7, 7, ... Having elasticity are provided at four corners of the partition wall 6 that defines each tile laying section 5, and these tile holding pieces 7, 7 ,.
By pressing the four corners of the tile 3 housed in the tile laying section 5 from the side, the tile 3 is fixed to the resin mat 2. Further, hook portions 8a are provided on two adjacent sides of the resin mat 2, and engaging portions 8b that engage with the hook portions 8a are provided on the remaining two sides. These hook portions 8a
The engaging portion 8b has a function of connecting the resin mats 2 of the adjacent composite floor materials 1 when a plurality of composite floor materials 1 are laid.

[0004]

However, in the above-mentioned conventional dry type composite flooring material, dust is clogged in the joint gap between the tile 3 and the adjacent tile 3, and the aesthetics of the bending angle is deteriorated with time. There was a problem of going away. Further, the tile 3 made of an inorganic material has excellent bending strength, but has a defect that cracks easily occur because it is weak against impact. On the other hand, since the resin mat 2 supports the dynamic load of a person through the tiles 3, 3, ..., There is a problem that it is easily damaged. Further, the work of fixing the tile 3 to the tile laying portion 5 with the tile holding piece 7 is liable to be clever because the dimensional accuracy of the tile or the like varies, and if the tile 3 is fixed due to the dimensional defect of the tile or the like. In the case of imperfections, when the user steps on a shoe or the like, the tile 3 is squeaky and uncomfortable, and it is likely to lose the balance, making it difficult to walk.

On the other hand, similar to the above-mentioned conventional composite flooring material, a plurality of surface finishing materials / decorative materials such as tiles are held on a resin mat to form a composite wall material, and the outer wall, gate fence, etc. are finished by a dry method. It is also possible to construct it. However,
Some of the problems mentioned above regarding the conventional composite flooring material are also applicable to the composite walling material of the same structure as this. In addition, if the tile has dimensional defects,
The tile may come off the resin mat and fall from the wall surface. This is a drawback that cannot be adopted as a wall material at all.

The present invention has been made in view of the above-mentioned circumstances, and is a finish material with joints (floor material with joints) that is resistant to stains and damages, can maintain aesthetics and comfort forever, and is excellent in productivity and workability. , A jointed wall material) and a method for manufacturing the same.

[0007]

In order to solve the above-mentioned problems, the invention according to claim 1 relates to a finishing material with joints, and has a resin frame having a plurality of plate-shaped body holding portions defined by joint walls. After the slurry-like reactive inorganic compound is added to the above, a plurality of plate-like bodies are integrally molded through the joint wall by curing treatment.

The invention according to claim 2 relates to a finishing material with joints, wherein a slurry-like reactive inorganic compound is contained in a resin frame having a plurality of plate-shaped body holding portions defined by hollow joint walls. It is characterized in that a plurality of plate-like bodies are integrally molded through the hollow joint wall by performing a curing treatment after charging the material.

The invention according to claim 3 relates to the jointed finishing material according to claim 1 or 2, wherein each plate-shaped body holding portion is provided with a reinforcing linear member or mesh member. It is characterized in that it is stretched in a state of being supported in advance by the joint wall that defines the shape holding portion and being embedded in the corresponding plate-shaped body.

Further, the invention according to claim 4 relates to a method for manufacturing a finishing material with joints, wherein in a mold having a partition wall arranged corresponding to the joint wall constituting the resin frame on the bottom, Install the resin frame so that the upper or lower surface of the joint wall is placed on the upper surface of the partition wall, and then put the slurry-like reactive inorganic compound into the mold, and then perform hermetic heat-curing treatment. Then, the finishing material with joint according to claim 1, 2 or 3 is obtained.

Further, the invention according to claim 5 relates to a method for manufacturing the finish material with joints according to claim 4, wherein
After the resin frame was installed, and then a slurry-like reactive inorganic compound containing amorphous silica-alumina-based powder and an aqueous solution of alkali silicate as a main component was charged into the mold,
It is characterized in that the jointed finish material is obtained by carrying out a closed heat curing treatment at a temperature of -100 ° C for 2-15 hours.

[0012]

In the structure according to claim 1, the plurality of plate-shaped bodies are
Since it is integrally molded through the joint wall, it has very good productivity and workability. In addition, there is no problem such as dust clogging in the joint gap. Therefore, the beauty can be maintained forever. Further, since the reinforcing linear member and the net member are embedded in the inorganic plate-shaped member, impact resistance is improved and damage such as cracks can be reduced. Also, the joint wall is
Since it is made of a resin having excellent flexibility, it is well adapted to the unevenness of the ground, and therefore, even if the ground is uneven, it is possible to walk comfortably. Further, in the structure according to claim 2, since the joint wall is a hollow resin, the joint wall is more well adapted to the unevenness of the base,
Therefore, even if the ground is uneven, it is possible to walk more comfortably.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. The description will be specifically made using the embodiments. 1st Embodiment FIG. 1 is a perspective view showing the construction of a flooring material with joints according to a first embodiment of the present invention, and FIG. 2 is a vertical sectional view seen from the direction of arrow AA in FIG. 3 is a vertical cross-sectional view as seen from the direction of arrows B-B in FIG. 1, FIG. 4 is a perspective view showing the configuration of a resin frame incorporated in the floor material with joints, and FIG. FIG. 6 is a partial perspective view showing the appearance of many laid floors.
And FIG. 7 is a process drawing showing a manufacturing procedure of the flooring material with joints. The jointed flooring material 11 of this example relates to a floor-laying material with joints for laying down the floor surface such as terraces and balconies, approaches, etc. by a dry method, and as shown in FIG. A total of four square block treads (hereinafter simply referred to as treads) 21, 21, ...
1, the resin net 41 is embedded in each tread 21, as shown in FIGS. 2 and 3.

As shown in FIG. 4, the resin frame 31 is divided into a plurality of squares by joint walls 51, 51, ... With a height of 3 to 5 mm and a width of about 4 mm. 4), and the resin net 41 has a joint wall 51 of four circumferences.
It is stretched while being supported by 51, .... The resin frame 31 is obtained by, for example, injection-molding a polyolefin resin composition such as polyethylene or polypropylene. In addition, as a material of the resin frame 31, a resin having sufficient mechanical strength and excellent flexibility is preferable. As the resin having such requirements, in addition to olefins, for example, polycarbonate, polyamide, polyacetal, polyethylene terephthalate, chlorinated polyethylene, polystyrene, polyesteramide, polyphenylene sulfide, polyether ester, polyvinyl chloride, poly Methacrylic acid ester, polyacrylic acid ester, polymethylmethacrylate, fluororesin, sulfone resin, ethylene-vinyl acetate copolymer, vinyl chloride-vinylidene chloride copolymer, polyvinyl butyral, polyvinylidene fluoride, styrene-acrylic copolymer Thermoplastics such as coalesce, urea resin, melia resin, melamine
Examples include thermosetting plastics such as phenolic resins, metal-containing plastics, and reinforced plastics compounded with glass fibers.

The tread 21 is made by kneading amorphous silica-alumina powder (inorganic reactive powder) such as fly ash or metakaolin and alkaline silicate aqueous solution (hardening agent) at a predetermined mixing ratio. By heat curing in a mold, a square inorganic polymer molded body having a thickness of 10 to 20 mm is obtained. A filler may be added to this type of inorganic polymer molding material, if necessary. The filler is preferably one that does not dissolve in water and does not inhibit the curing reaction of the reactive inorganic compound, for example, silica sand, aggregate for cement mortar such as river sand, silica flour, silica fume, bentonbite, blast furnace slag, etc. Cement admixture,
Natural minerals such as sepiolite, wollastonite and mica, calcium carbonate, diatomaceous earth and the like are preferable. further,
For the purpose of reducing the weight, pearlite, silica balloons, silas balloons, glass balloons, inorganic natural foams such as foaming clay may be added. These may be added alone or in combination of two or more.

Next, referring to the process diagrams of FIGS. 6 and 7,
A method of manufacturing the floor material with joint 11 having the above structure will be described. Before manufacturing the floor material 11 with joints, a mold 71 and a resin frame 31 for molding the floor material 11 with joints (FIG. 4) are prepared in advance.
Be prepared. Here, the prepared mold 71 is made of urethane rubber or silicone rubber having excellent releasability, and is provided on the substrate 81 and the upper surface of the substrate 81 as shown in FIG. 6A. It has a mold 82. That is, the mold 82 is formed as a recess of the same size and shape as the resin frame 31 on the upper surface of the substrate portion 81, and the bottom surface of the mold 82 has horizontal and vertical sides forming the resin frame 31. Corresponding to the joint walls 51, 51, ..., the partition wall 83a of the hill,
83b, ... Are provided. Partition walls 83a, 83b,
Is a cross-sectional shape tapering upward, and the joint wall 5 is on the upper surface.
The width is approximately the same as 1, 51, .... Further, the upper surfaces of the partition walls 83a, 83b, ... Are set lower than the upper surface of the outer peripheral wall 84 of the mold 82 by the height of the joint wall 51.

When the mold 71 and the resin frame 31 are ready,
Next, 100 parts by weight of fly ash powder containing 60% by weight or more of a powder having a particle size of 10 μm or less and 55 to 650 parts by weight of a water glass solution (alkali silicate aqueous solution (hardening agent)) were put into a hand mixer to obtain about 10 parts. The mixture is kneaded for a minute to prepare a mud-like reactive inorganic compound (hereinafter referred to as slurry) 21a. The above-mentioned filler may be added if necessary. Here, the fly ash is a combustion furnace temperature of 160.
Fine particles of ash collected by a dust collector from a pulverized coal combustion boiler such as a high temperature coal-fired power plant at 0 to 1700 ° C., containing 45 to 55% by weight of amorphous silica and 25 to 35% by weight of alumina. It is a regular ash (amorphous silica-alumina-based powder (inorganic reactive powder)).

(1) Resin frame installation When the mold 71, the resin frame 31, and the slurry 21a are prepared, first, the resin frame 31 is turned upside down and installed in the mold 82. In this installation, the joint walls 51, 51, ... Are placed on the upper surfaces of the corresponding partition walls 83a, 83b ,. As a result, in the mold 82, four tread molds 82a, 82a corresponding to the four tread holders 61, 61, ...
82a, ... have been sectioned.

(2) Slurry Input (Casting) Next, as shown in FIG. 2C, the slurry 21a in the hand mixer is sequentially charged (casting) into the tread molds 82a, 82a, ....

(3) Lid (closed) When all the tread molds 82a, 82a, ... Are completely filled with the slurry 21a, as shown in FIG. The tread molds 82a, 8 on the upper surface of the
The slurry 21a in 2a, ... Is closed.

(4) Heat curing Next, the cast slurries 21a, 21a, ... Together with the mold 71 covered with the lid 91 are heated in a heating furnace at 80 to 100 ° C. for 2 to 15 hours. And cured to contain a large amount of water (hydrated molded body) 21b, 21b, ...
Get. It should be noted that, as shown in FIG. 7E, the lid 91 is placed on the mold 71 at the time of heating in order to prevent the water in the slurry 21a from evaporating. This is because the curing reaction stops when the water disappears from the slurry 21a. Therefore, if necessary, the lid 9
A weight may be further placed on 1. In the water-containing molded bodies 21b, 21b, ... Obtained in this way, the slurries 21a, 21a ... Are solidified in the state where the resin net 41 is buried, so that the resin frame 31 can be obtained without the aid of an adhesive agent. .. are firmly fixed and held in the step board holding portions 61, 61 ,.

(5) Demolding and heating and drying After this, the hydrous molded body 21 with the resin frame 31 in the mold 71
, b, 21b, ... are demolded and placed in a drying oven at 85 ° C. for 5 hours to evaporate the water content, and as shown in FIG. One tread 21,
21 .... completes the floor-laying material 11 with a joint, which is integrally formed through the vertical and horizontal joint walls 51, 51 ,.

According to the above structure, a plurality of treads 21, 2
Since 1, ... and the joint (material) are integrally molded, the production and construction are very good. In addition, there is no problem such as dust clogging in the joint gap. Therefore, the beauty can be maintained forever. Also, the tread 21, which is made of an inorganic polymer,
Since resin nets 41, 41, ... Are embedded in 21, ..., Impact resistance is improved and damage such as cracks can be reduced. Further, since the joint walls 51, 51, ... Are made of a resin having excellent flexibility, the joint walls 51, 51, ... Are well adapted to the unevenness of the ground, and therefore, even if the ground is uneven, the user can walk comfortably.

Second Embodiment FIGS. 8 and 9 are vertical sectional views showing the structure of a flooring material with joints according to a second embodiment of the present invention, and FIG. 10 is incorporated into the flooring material with joints. It is a perspective view which shows the structure of a resin frame. The difference between the jointed flooring material 11A of the second embodiment and that of the first embodiment (FIGS. 2 and 3) is that the solid joint wall 51 is eliminated and the hollow joint wall 51a prevents the resin frame 31a. Is the point that is configured. Here, the hollow joint wall 51a is obtained by extrusion molding, and the joint walls 51a, 51a, ... And the resin net 4 are assembled with an adhesive or the like to form the resin frame 31a of this example. 8 to 10, the same components as those in FIGS. 2 to 4 are designated by the same reference numerals and the description thereof will be omitted.

According to the structure of the second embodiment, the same effect as described above in the first embodiment can be obtained.
In addition, since the joint walls 51a, 51a, ... Are hollow resin, the joint walls 51a, 51a, ... Are more familiar to the unevenness of the ground, and therefore, even if the ground is uneven, the user can walk more comfortably.

Although the embodiment of the present invention has been described in detail above with reference to the drawings, the specific structure is not limited to this embodiment, and there are design changes and the like within the scope not departing from the gist of the present invention. Also included in the present invention. For example, the number of treads can be increased or decreased as appropriate. A metal net may be used instead of the resin net. Further, instead of the net (mesh-like member), linear members may be arranged vertically and horizontally. Further, in the above-described first embodiment, the upper surface of the joint wall is directed downward when the resin frame is installed, but the upper surface of the joint wall may be directed upward. Even if the net (net-like member) or the linear member is omitted, a plurality of treads can be integrally formed and held by forming a recess or a protrusion on the joint wall or performing a matting process or the like.

Although the flooring material with joints is described in the above-mentioned embodiment, in the finishing material with joints of the present invention, the plate-like body is firmly fixed and integrated to the resin frame, and there is a risk that it will come off from the resin frame. Since it does not have a joint, it can be applied to a wall material with joints.

[0028]

As described above, according to the structure of claim 1, the plurality of plate-like members are integrally molded through the joint wall, so that the productivity and the workability are very good. . In addition, there is no problem such as dust clogging in the joint gap. Therefore, the beauty can be maintained forever. Further, since the reinforcing linear member and the net member are embedded in the inorganic plate-shaped member, impact resistance is improved and damage such as cracks can be reduced. Further, since the joint wall is made of a resin having excellent flexibility, the joint wall is well adapted to the unevenness of the ground, and therefore, even if the ground is uneven, the user can walk comfortably.

According to the second aspect of the invention, since the joint wall is made of hollow resin, the joint wall is more compatible with the unevenness of the ground, and therefore, even if the ground is uneven, the user can walk more comfortably.

[Brief description of drawings]

FIG. 1 is a perspective view showing the structure of a flooring material with joints according to a first embodiment of the present invention.

FIG. 2 is a vertical sectional view as seen from the direction of arrow AA in FIG.

FIG. 3 is a vertical sectional view as seen from the direction of arrow BB in FIG.

FIG. 4 is a perspective view showing a configuration of a resin frame incorporated in the flooring with joints.

FIG. 5 is a partial perspective view showing a state of a floor surface on which a large number of jointed floor materials are laid.

FIG. 6 is a process drawing showing the manufacturing procedure of the flooring material with joints.

FIG. 7 is a process drawing showing the manufacturing procedure of the flooring material with joints.

FIG. 8 is a vertical sectional view showing the construction of a flooring material with joints according to a second embodiment of the present invention.

FIG. 9 is a vertical sectional view showing the structure of a flooring material with joints according to a second embodiment of the present invention.

FIG. 10 is a perspective view showing a configuration of a resin frame incorporated in the floor material with joints.

FIG. 11 is a plan view showing a configuration of a conventional dry type composite floor material.

FIG. 12 is a plan view showing a resin mat that constitutes the composite floor material.

FIG. 13 is an exploded perspective view showing an exploded configuration of the composite floor covering.

[Explanation of symbols]

 11, 11A Joint flooring material (finishing material with joints) 21 Tread (plate-like body) 21a Slurry (slurry-like reactive inorganic compound) 31, 31a Resin frame 41 Resin net (reticulated member) 51 Joint wall 51a Hollow Joint wall (hollow joint wall) 61 Tread plate holding part (plate-shaped body holding part) 71 Form 82 type 83a, 83b Partition wall

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location E04F 13/08 102 8913-2E E04F 13/08 102D

Claims (5)

[Claims] 1. A plurality of plate-like materials are prepared by introducing a slurry-like reactive inorganic compound into a resin frame having a plurality of plate-like body holding parts defined by joint walls and then curing the resin. A finishing material with joints, characterized in that the body is integrally molded through the joint wall. 2. A plurality of plates are prepared by introducing a slurry-like reactive inorganic compound into a resin frame having a plurality of plate-shaped body holding portions defined by hollow joint walls and then hardening the resin. A finishing material with joints, wherein the shaped body is integrally molded through the hollow joint wall. 3. A reinforcing linear member or a mesh member is supported on each of the plate-shaped body holding portions in advance in a state of being supported by the joint wall that defines the plate-shaped body holding portion. The finishing material with joints according to claim 1 or 2, which is stretched in a state of being buried in the plate-like body. 4. The resin frame is placed in a mold having a partition wall arranged corresponding to a joint wall forming the resin frame on the bottom surface, with the upper surface or the lower surface of the joint wall on the upper surface of the partition wall. The jointed finishing material according to claim 1, 2 or 3 is obtained by placing the slurry-like reactive inorganic compound into the mold, and then subjecting the slurry to a heat-sealing treatment. A method of manufacturing a finishing material with joints, which is characterized by the above. 5. The resin frame is installed in the mold,
Then, a slurry-like reactive inorganic compound containing amorphous silica-alumina-based powder and an aqueous solution of alkali silicate as main components was charged into the mold, and then at a temperature of 80 to 100 ° C., 2
The method for producing a finish with joints according to claim 4, wherein the finish with joints is obtained by performing a closed heat curing treatment for about 15 hours.