JPH11107497A - Unit flooring and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain excellent workability by installing a flooring main body and a support member, in which a part is buried on the underside side of the flooring main body and fixed onto the flooring main body and a leg, which is grounded on a laying surface and in which a space is formed between the flooring main body and the laying surface, is projected. SOLUTION: A flooring main body 2a, in which a molding material containing an inorganic composition using at least SiO2 -Al2 O3 powder, an alkaline metal silicate and water as main components is cured and formed in a tabular shape, is molded. The unit flooring A is formed of the flooring main body 2a and a support member 1a with a base section 11 molded of a synthetic resin, a plurality of engaging sections 12, 13, a plurality of legs 14 and buried projecting sections 15. The base section 11 is formed in a tabular shape having lattices crossed at equal pitches, and the legs 14 are projected from the rear of the base section 11 at the each intersection of the lattices of the base section 11, and the engaging sections 12 are formed in the same height as the legs 14. Accordingly, the flooring main body and the support member are unified and the state of fine laying can be brought.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a unit flooring and a method for producing the same.

[0002]

2. Description of the Related Art Unit flooring materials as disclosed in Japanese Patent Application Laid-Open No. 7-42349 have been conventionally put on the market.
Such a unit flooring material includes a support member (laying frame) made of a synthetic resin including a base portion formed in a lattice shape, a plurality of legs protruding from a lower surface of the base portion, and a plurality of fired tiles. The respective fired tiles are integrated with the base portion via an adhesive.

[0003] By engaging the engaging means provided on the supporting member with the engaging means provided on the supporting member of the adjacent unit floor material, it can be connected to the adjacent unit floor material and laid. Sometimes, the leg forms a predetermined space between the lower surface of the support member body and the laying surface, which serves as a flow path for rainwater or the like that has fallen on the surface of the fired tile.

[0004] However, the conventional unit flooring has the following problems since the support member and the fired tile are integrated via an adhesive as described above.

[0005] That is, after the fired tile and the support member are separately manufactured, the fired tile and the support member must be bonded to each other. However, there is a problem that it is expensive and the curing time of the adhesive is long.

[0006]

SUMMARY OF THE INVENTION In view of such circumstances, an object of the present invention is to provide a unit flooring material which is excellent in manufacturing workability and can be manufactured at low cost, and a method of manufacturing the same. And

[0007]

SUMMARY OF THE INVENTION The unit flooring material according to the present invention has a SiO ₂ —
A floor material body formed into a plate by curing a molding material containing at least an inorganic composition mainly composed of Al ₂ O ₃ powder, an alkali metal silicate and water, and a lower surface side of the floor material body. A support member having a portion buried and fixed to the floor material main body, and a plurality of legs projecting downward to ground on the laying surface and form a predetermined space between the floor material main body and the laying surface. And a configuration having:

In the unit flooring material according to the present invention, the supporting member has a buried protrusion on the surface opposite to the leg, and the buried protrusion is buried in the floor material body. According to a fourth aspect of the present invention, the supporting member includes a lattice-shaped base portion formed such that the legs protrude from the lower surface, and a part of the lattice of the base portion is buried at least in the flooring body. Is preferable.

Further, in the configuration of claim 2, claim 3
It is preferable that the embedded protrusion is formed of a metal material as described above. The shape of the embedded protrusion is not particularly limited as long as it can be engaged with a part of the floor material main body in a state of being buried in the floor material main body and can prevent the support member from being detached from the floor material main body. Those having a hook shape are preferred.

[0010] In the configuration of claim 4, as in claim 5, at least both side surfaces of the buried lattice are formed so as to gradually approach the center axis of the lattice toward the lower end direction of the base portion. It is more preferable that each lattice is buried in the floor material main body at least up to the edge of the lower surface.

Further, in the constructions of the first to sixth aspects, the support member engages with the engaging portion provided on the support member of the adjacent unit floor material, thereby forming the adjacent unit floor material. It is preferable to provide a configuration having an engagement structure for connecting the components. Further, in the configuration of claims 1 to 7,
As in claim 8, the molding material is obtained by dispersing and mixing an aggregate having a coarse particle diameter into an inorganic composition mainly composed of SiO ₂ —Al ₂ O ₃ powder, an alkali metal silicate and water, The floor material main body may be configured to have water permeability.

On the other hand, production of unit flooring material according to the present invention
The method uses at least SiO_Two-Al _TwoO_ThreeSystem powder, Al
An inorganic composition mainly composed of potassium metal silicate and water
Filling the mold with the slurry-like molding material containing, supporting
Mold the member with its leg side up until it is buried in the floor material body.
Submerging molding material in the mold, curing and curing the molding material in the mold
And a step of performing

[0013] In the manufacturing method of the present invention, claim 1 is provided.
As shown in FIG. 0, the mold is closed by the lid with the legs of the support member being supported by the lid facing the back side of the lid for closing the mold, and the support member is molded to the buried position by the weight of the lid. It is preferable to forcibly submerge the material.

In the present invention, SiO 2_Two-Al_TwoO_Threesystem
As the powder, SiO_Two: Al_TwoO _Three= 1: 9-9: 1
(Weight ratio) as well as the whole powder
Is SiO_TwoAnd Al_TwoO_Three50% by weight or more
What is rare is desirable. That is, less than 50% by weight
Content, low reactivity with alkali metal silicate aqueous solution
And the strength of the resulting floor material may be reduced.

Examples of such SiO ₂ —Al ₂ O ₃ based powders include the following, which can be used alone or in combination. Fly ash containing at least 80% by weight of particles having a particle size of 10 μm or less

Decolorized fly ash containing 80% by weight or more of particles having a particle size of 10 μm or less Inorganic powder obtained by melting fly ash or clay and spraying it into a gas

Inorganic powder obtained by further heating inorganic powder obtained by applying mechanical energy of 0.1 to 30 kwh / kg to clay at 100 to 750 ° C.

[0018] 0.1 to 30 kwh /
Inorganic powder obtained by applying kg of mechanical energy Ash of electric precipitator during production of corundum or mullite

Crushed calcined bauxite metakaolin

Incidentally, ordinary fly ash is defined in JIS.
A The fine ash particles collected by a dust collector from a pulverized coal combustion boiler specified in A6201 have a SiO ₂ content of 40% or more, a moisture content of 1% or less, a specific gravity of 1.95 or more, and a specific surface area of 270.
It passes through a standard sieve of 0 cm ² / g or more and 44 μm or more by 75% or more.

Then, the fly ash is obtained by using this ordinary fly ash, for example, by wet sedimentation classification, wind classification,
Classification using a classifier that is usually performed, such as separation by specific gravity, a method using a pulverizer such as a jet mill, a roll mill, and a ball mill, a method using a continuous system of a classifier and a pulverizer, etc. It can be obtained by processing by a conventionally known method.

The reason why the particles having a particle size of 10 μm or less must be contained in an amount of 80% by weight or more, such as fly ash, is that if the amount of the fly ash having a particle size of 10 μm or less is less than 80% by weight, alkali metal silicate This is because the reactivity with the salt aqueous solution is reduced, and there is a possibility that the strength is reduced or curing failure is caused.

The above decolorized fly ash is obtained by baking fly ash at 400 to 1000 ° C. or baking ordinary fly ash at 400 to 1000 ° C.
Can be obtained in the same manner as fly ash.
That is, fly ash is generally black, and if this black fly ash is fired at a temperature of 400 ° C. or higher as described above, it can be decolorized. However, when firing at a temperature exceeding 1000 ° C., the reactivity with the aqueous solution of the alkali metal silicate decreases, so firing at the above temperature range is desirable.

The inorganic powder is obtained by melting fly ash or clay and spraying it in a gas.
As a method of melting and spraying in a gas, a spraying technique applied to a ceramic coating, preferably a spraying technique in which the fly ash and clay are melted at a temperature of 2000 to 16000 ° C and sprayed at a speed of 30 to 80 m / s. ,
Specifically, a plasma spraying method, a high energy gas spraying method, an arc spraying method, and the like can be given.

In general, the specific surface area of the inorganic powder obtained by the above spraying technique is controlled to 0.1 to 60 m ² / g.

The above-mentioned inorganic powder and the clay used as a raw material of the inorganic powder include SiO ₂ as a chemical composition;
5 to 85 wt%, Al ₂ O _3; 90~10 clay containing wt%, for example, kaolinite, dickite, nacrite, kaolin minerals such as halloysite, muscovite, illite, phengite, glauconite, Seradonaito, Mica clay minerals such as paragonite and branmarite, montmorillonite, beidellite, nontronite, sabonite,
Examples include smectites such as saconite, chlorite, pyrophyllite, talc, and sand shale.

The mechanical energy used in the production of the inorganic powder refers to a compressive force, a shearing force, and an impact force, which may be used alone or in combination of two or more. . Examples of the equipment for making these act specifically include a ball mill, a vibration mill, a planetary mill, a medium stirring type mill, a roller mill, a mortar, and a jet powder crusher.

The particle diameters of the clay and metakaolin used in the production of the above inorganic powders are not particularly limited.
The average particle diameter is preferably from 0.01 to 500 μm, more preferably from 0.1 to 500 μm, in order to effectively exert mechanical energy.
It is preferably from 1 to 500 μm, particularly preferably from 0.1 to 1 μm.
00 μm.

When the mechanical energy applied during the production of the inorganic powder is less than 0.1 kwh / kg, the reactivity of the obtained inorganic powder with the aqueous alkali metal silicate solution is reduced, and the If it exceeds, the load on the above-mentioned crushing device increases, and the wear and damage of the device increase,
Since problems such as impurities to the above-mentioned clay occur, 0.1 to
Limited to 30 kwh / kg, preferably 1.0 to 26
Act at kwh / kg.

The reason why the mechanical energy applied to the above-mentioned metakaolin is limited to 0.1 to 30 kwh / kg is the same as in the above cases. When applying mechanical energy, a grinding aid may be added as necessary.

The grinding aid is for preventing the powder of clay or metakaolin from adhering or remarkably aggregating inside the apparatus when applying mechanical energy. For example, alcohols such as methyl alcohol and ethyl alcohol, Examples thereof include alcohol amines such as triethanolamine, metal soaps such as sodium stearate and calcium stearate, and acetone vapor. These may be used alone or in combination of two or more.

The inorganic powder is obtained by applying steam mechanical energy to the clay, and then heating the clay to 100 to 750 ° C., because the mechanical strength is improved by heating. If the heating temperature is lower than 100 ° C., no improvement in strength is observed. If the heating temperature is higher than 750 ° C., crystallization of the inorganic powder occurs, and the reactivity with respect to the alkali metal silicate aqueous solution decreases. Limited, preferably limited to 200-600 ° C. In addition, when the heating time is short, the mechanical strength of the obtained floor material main body is little improved, and when the heating time is long, the energy cost increases.

And the inorganic powders described in JP-B-3-9
060 and Japanese Patent Publication No. 4-45471. The commercially available metakaolin can be used.

The alkali metal silicate used in the present invention is a silicate represented by M ₂ O · nSiO ₂ (at least one metal selected from M = K, Na and Li), When the value is small, a floor material body having a good appearance cannot be obtained, and when the value is large, gelation easily occurs.
1 to 8, more preferably 0.5 to 2.5.

The alkali metal silicate is preferably added in the form of an aqueous solution. Further, when the aqueous solution is used, when the concentration is low, the reactivity with the SiO ₂ —Al ₂ O ₃ powder is reduced, and when the concentration is high, the alkali metal salt is easily formed. %, More preferably 10 to 60% by weight. That is,
When the concentration is less than 10% by weight, the strength of the obtained flooring material decreases, and when the concentration is higher than 70% by weight, the viscosity of the alkali metal silicate aqueous solution increases, and the workability at the time of mixing and molding decreases. Might be.

The aqueous alkali metal silicate solution may be prepared by dissolving the alkali metal silicate in water as it is under pressure and heating.
The iO ₂ component may be dissolved under pressure and heat so that n becomes a predetermined amount, or a commercially available aqueous solution of an alkali metal silicate is used after being adjusted to a predetermined composition with a metal hydroxide and water. You may.

The added amount of the alkali metal silicate is SiO ₂ −
The amount is preferably 1 to 300 parts by weight (10 to 1300 parts by weight as an aqueous solution) based on 100 parts by weight of the Al ₂ O ₃ powder.
0 to 250 parts by weight (10 to 1000 parts by weight as an aqueous solution) is more preferable. That is, if the amount of addition is too large, cracks and the like may occur in the floor material main body.

The water used in the present invention may be added in its entire amount as an aqueous solution of an alkali metal silicate, or may be added in the form of both an aqueous solution of an alkali metal silicate and independent water. . If the amount of water is too small, it will not cure sufficiently, and if it is too large, the strength of the floor material itself will decrease.
10 to 10 parts by weight of SiO ₂ —Al ₂ O ₃ powder
1000 parts by weight, preferably 10 to 750 parts by weight, more preferably 50 to 500 parts by weight.

In the unit flooring material according to the eighth aspect, the aggregate having a coarse particle size may be an inorganic material or an organic material as long as it can impart water permeability to the flooring body obtained by mixing the main component with the main component. However, for example, stone or gravel having a diameter of about 2 to 10 mm (preferably about 3 to 5 mm), or coke crushed to have a long diameter of about 5 to 50 mm is preferable. The amount of the aggregate varies depending on the type of the aggregate. For example, when a stone or gravel having a diameter of about 2 to 10 mm is used, a mixture of the stone and the gravel of 4 to 6 with respect to 1 of the inorganic composition is used. The ratio is preferably set, and a compounding ratio of about 5 is more preferable.

In the molding material of the present invention, if necessary, an inorganic filler, a reinforcing fiber, a lightweight aggregate, a pigment, a foaming agent, a foaming aid, a foaming agent and the like can be added.

As the inorganic filler, rock powder, volcanic ash (silaz, anti-firestone, etc.), wollastonite, calcium carbonate, silica stone powder, mica, mica, silica fume and the like can be used. The amount _is preferably 900 parts by weight or less with respect to SiO 2 -Al ₂ O ₃ -based powder 100 parts by weight. If the amount exceeds 900 parts by weight, the mechanical strength may be reduced.

As the reinforcing fibers, reinforcing fibers used in ordinary cement products can be used, and polypropylene, vinylon, rayon, alkali-resistant glass, carbon, acrylic,
Fibers such as aramid and acrylonitrile can be used alone or in combination. Fiber diameter is 1 ~ 500μ
m and a fiber length of 1 to 15 mm are desirable. That is, if the fiber diameter is less than 1 μm, a fiber ball is formed during mixing,
When the strength exceeds 500 μm or the fiber length is less than 1 mm, a reinforcing effect such as improvement in tensile strength cannot be expected. On the other hand, if the fiber length exceeds 15 mm, the dispersibility decreases, and a floor material body having uniform strength cannot be obtained.

The amount of the reinforcing fiber added is SiO ₂ -A
It is desirable that the content be 10 parts by weight or less based on 100 parts by weight of the l ₂ O ₃ -based powder. If it exceeds 10 parts by weight, the dispersibility of the fiber may be reduced.

As the lightweight aggregate, inorganic foams such as pearlite, glass balloon, silica balloon, fly ash balloon, and shirasu foam, and organic foams such as phenol resin, urethane resin, polyethylene, and polystyrene can be used. The amount of the lightweight aggregate added is SiO ₂ −
It is desirable that the amount be 150 parts by weight or less based on 100 parts by weight of the Al ₂ O ₃ -based powder. If the amount exceeds 150 parts by weight, there is a possibility that the strength, surface smoothness or molding workability may be reduced.

As the pigment, metal oxide pigments such as iron oxide, titanium oxide and cobalt oxide, and carbon black are desirable. The addition amount of the pigment with _respect to SiO 2 -Al ₂ O ₃ -based powder 100 parts by weight or less is preferable 50 parts by weight.
Even if it exceeds 50 parts by weight, the hiding power is not improved and it is uneconomical.

As the foaming agent, Mg, Ca, Cr, M
n, Fe, Co, Ni, Cu, Zn, Al, Ga, S
n, Si, metal powders such as ferrosilicon, hydrogen peroxide water or sodium peroxide, potassium peroxide, peroxide powders such as sodium perborate, and the like, cost, safety,
Considering availability and ease of mixing, Al and hydrogen peroxide are preferred.

The powder of the foaming agent preferably has a particle diameter of 1 to 200 μm. That is, if the particle diameter is smaller than 1 μm, the dispersibility is reduced, and rapid foaming is caused. If the particle diameter is larger than 200 μm, the reactivity may be reduced. The addition amount of the foaming agent (solution 100% basis), compared SiO ₂ -Al ₂ O ₃ -based powder 100 parts by weight or less is preferable 5 parts by weight. That is, if the amount exceeds 5 parts by weight, the strength is significantly reduced, and handling of the floor material main body or the like becomes impossible.

As foaming agents, higher alcohol sulfates, alkyl ether sulfates, aromatic derivative sulfonates, imidazoline derivatives, fatty acid amides,
Animal protein systems can be used. The addition amount of the foaming agent is S
It is desirable that the content be 10 parts by weight or less based on 100 parts by weight of the iO ₂ -Al ₂ O ₃ powder. If the amount is more than 10 parts by weight, poor curing tends to occur.

Examples of the foaming aid include porous powders such as silica gel, zeolite, activated carbon and alumina gel, and metal soaps such as metal stearate and metal palmitate. The addition amount of the foaming aid is SiO ₂ —Al ₂ O
10 parts by weight or less is desirable for 100 parts by weight of the ₃ series powder. If the amount is more than 10 parts by weight, there is a possibility that bubbles may be broken.

In order to obtain the slurry-like molding material by mixing, an ordinary mixer such as a paddle rotary mixer, an oscillating mixer or a screw mixer can be used. As a mixing method, a method in which a powder or solid raw material is dry-mixed, and an alkali metal silicate aqueous solution is further added to the obtained mixture and mixed, a method in which all raw materials are simultaneously supplied and mixed, and a method in which alkali metal is mixed Any method may be used in which the silicate aqueous solution and a part of the powder raw material are mixed, and the remaining raw materials are sequentially added and mixed.

When a foaming agent is used, mixing at the end of the mixing step is advantageous in terms of workability and bubble stability. When a foaming agent is used, a method in which the foaming agent is added last, or a slurry is made from a raw material other than the foaming agent, and mixed with an aqueous solution in which bubbles are generated by the foaming agent and water is preferable. Foaming agent concentration of 0.1 to 5 when used as an aqueous solution
% Is desirable. If it is less than 0.1%, the stability of the foam is inferior and the foam breaks, and if it is more than 5%, poor curing occurs.

The filling of the slurry-like molding material into the mold may be carried out by a free-fall method or may be carried out forcibly by a pump or the like. Vibration may be applied during or after filling the slurry for leveling or defoaming the slurry. When the viscosity of the slurry is high, press molding may be performed. The mold is not particularly limited, and examples thereof include metals, resins, and rubbers. If an irregular pattern is formed on the mold surface, the floor material has a surface shape excellent in decorativeness according to the irregularities of the mold surface. You can get the body.

The curing and curing conditions of the slurry-like molding material are as follows.
It is preferable to hold for 2 hours. The heating method is not particularly limited, and examples thereof include an oven. It goes without saying that the higher the heating temperature, the shorter the curing time. When the heat curing is completed, the mold is released.

The support member is not particularly limited.
In consideration of weight reduction and corrosion resistance, a synthetic resin is preferable. The synthetic resin constituting the support member is not particularly limited, and examples thereof include polyvinyl chloride, ABS, polypropylene, and polyethylene.

[0055]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below.
This will be described in detail with reference to the drawings. FIG. 1 and FIG.
The embodiment of the second aspect of the unit floor material according to the present invention is shown.

As shown in FIGS. 1 and 2, the unit floor material A includes a support member 1a and a floor material main body 2a. As shown in FIGS. 3 and 4, the support member 1a is formed of a synthetic resin, and has a base 11 and a plurality of engaging portions 12 and.
.... 12,13 ... 13 and a plurality of legs 14 ... 14
And embedded projections 15... 15.

The base portion 11 is a grid 1 intersecting at a constant pitch.
1a. The legs 14... 14 protrude from the back surface of the base 11 at the respective intersections of the lattice 11 a of the base 11, and the center thereof has a cover for the support member 1 a when a manufacturing method described later is performed. A screw hole 14a used for fixing to the base is formed. Engaging part 12 ... 12
14 have the same height as the legs 14... 14, and are provided in a projecting manner on two sides sandwiching one corner of the base 11.

On the other hand, the engaging portions 13... 13 are located slightly symmetrically with respect to the other two sides of the other base portion 11 and slightly outside the side edges of the base portion 11. 12 are provided at the same height as the engaging portions 12... 12, and an engaging hole 13 a with which the engaging portion 12 is engaged is provided at the center of the protruding portion. .

As shown in FIG. 5, each of the embedding projections 15 has a cylindrical shape projecting from the surface of the base 11, and
A protrusion 15a is provided on the inner peripheral surface of the upper end of the tube, and has a hook-like cross section.

The floor material main body 2a is made of at least SiO ₂ -A
A molding material containing an inorganic composition mainly composed of l ₂ O ₃ -based powder, alkali metal silicate and water is formed into a plate shape by curing, and as shown in FIG. The lower surface is received from below and the base 1
The embedding projection 15 provided on the surface of No. 1 is buried inside.

Next, a method of manufacturing the unit floor material A will be described in detail. First, as shown in FIG. 6, a mold 4 and a lid 5 for closing an opening of the mold 4 are prepared. The support member 1a is arranged so that the legs 14... 14 are in close contact with the back surface of the lid 5, and the screw holes 1 provided in the legs 14.
Screws 51... 51 are screwed into the lid 4a through the lid 5, and the support member 1a is fixed to the lid 5.

Then, as shown in FIG. 6B, after the slurry-like molding material 6 is poured into the mold 4,
As shown in (c), the opening of the mold 4 is closed by the lid 5. That is, as described above, the slurry-like molding material 6 has entered the mold 4 until the molding material 6 comes into contact with the surface of the base 11 of the support member 1a fixed to the back surface of the lid 5. When the opening of the mold 4 is closed by 5, the embedding projections 15... 15 sink completely into the molding material 6 up to the root.

Lastly, while the lid 5 is closed, the slurry-like molding material 6 is cured and hardened.
By removing 1... 51 and removing from the lid 5, the unit floor material A can be obtained.

As described above, the unit floor material A can form and harden the slurry-like molding material 6 to obtain the floor material main body 2a, and can also integrate the support member 1a and the floor material main body 2a. Therefore, the manufacturing process can be simplified. Also,
Since there is no need to bond with an expensive adhesive, product cost can be reduced. Also, since the embedding protrusions 15... 15 having hook-shaped sections are buried in the floor material main body 2a,
The bonding strength between the support member 1a and the floor material main body 2a is excellent.

Further, if the engaging portion 12 provided on the peripheral portion of the support member 1a is engaged with the engaging hole 13a of the engaging portion 13 provided on the peripheral portion of the adjacent unit floor material A, Therefore, the unit floor material A can be firmly connected to the adjacent unit floor material A of the same shape, and the unit floor material A can be prevented from shifting and moving at the time of laying. Also, the engaging portions 12... 1
13 are at the same height as the legs 14.
And the legs 14..., Form a space between the back surface of the base 11 and the laying surface for the height of the engaging portions 12. can do.

Therefore, even if rainwater or the like that has fallen on the surface of the floor material main body 2a flows into the laying surface side from between the unit floor materials A, the space can be smoothly discharged as a flow path. .

According to the above-described manufacturing method, the supporting member 1
a is fixed to the lid 5 and the embedded protrusions 15.
Since the five portions are submerged in the slurry-like molding material 6 in the mold 4, the weight of the lid 5 is added to the support member 1 a, and even if the slurry-like molding material 6 is hard, it sinks smoothly. The working time can be shortened, and the positioning of the support member 1a is easy.

FIGS. 7 and 8 show a unit flooring according to a fifth embodiment of the present invention. FIG.
As shown in FIG. 8 and FIG. 8, the unit flooring B does not have the embedded protrusion 15 on the surface side of the base 16 of the support member 1b, and each lattice 16a has a substantially inverted trapezoidal cross section. . That is, both sides 16b of the grid 16a are formed so as to face the lower surface of the base 16 and gradually approach the central axis of the grid 16a.

Then, as shown in FIG.
The unit floor member A is the same as the unit floor member A, including the manufacturing method, except that b is buried in the floor member main body 2b. As described above, since the lattice 16a has a substantially inverted trapezoidal cross section, the unit floor material B is excellent in connection strength between the floor material main body 2b and the support member 1b.

FIGS. 9 and 10 show a unit flooring according to a sixth embodiment of the present invention. As shown in FIG. 9, the unit floor material C is a support member 1c.
The embedded projection 15 is not provided on the surface side of the base portion 19 of the base member 19, and the grid 19a of the base portion 19 is completely
It is the same as the above unit floor material A except that it is buried in.

In this unit flooring material C, in addition to the effect of the unit flooring material A, since the lattice 19a of the base 19 is completely buried in the flooring body 2c, as shown in FIG.
No matter where it is cut on site, the support member 1c and the floor material body 2c
And the state of being firmly integrated is maintained. That is, the same finishing can be performed up to the corner of the laying surface, and a beautiful laying state can be obtained.

FIG. 11 shows the third and eighth embodiments of the unit flooring according to the present invention.

As shown in FIG. 11, this unit floor material D
Means that the embedded protrusion 15 ′ of the support member 1 d is made of a metal part
One end of the material 9 is formed integrally with the base 17 made of synthetic resin during molding.
It is formed by burying and
Body 2d is SiO_Two-Al_TwoO _ThreePowder, alkali metal silicon
With respect to 100 parts by weight of an inorganic composition comprising an acid salt and water
Stones 61 having a particle size of 3 to 5 mm
Formed by a molding material dispersed and mixed in a proportion of 0 parts by weight.
Same as unit flooring A except that it has water permeability
It has become.

As described above, since the embedding projections 15 'are made of metal, the unit flooring D can be smoothly embedded in the embedding projections 15' even if a hard molding material in which stones are dispersed and mixed is used. Can be submerged in a slurry-like molding material. Further, since the obtained floor material main body 2d has water permeability, rainwater or the like falling on the floor material main body 2d immediately permeates to the lower surface side of the floor material main body 2d, and the floor material main body 2d is used even in heavy rain. Water does not accumulate on the main body 2d.

The unit flooring and the method of manufacturing the same according to the present invention are not limited to the above embodiment. For example, in the above-described embodiment, the surface of the floor material main body is flat, but it may be provided with an inclination, or a pattern is provided on the mold surface of the mold, and when the floor material main body is formed. This pattern may be transferred to make up the surface. For example, if a protrusion is provided in a lattice shape on the mold surface, a floor material body provided with joints can be obtained.

In the above embodiment, the engaging portion 12 and the engaging portion 13 are used also as legs.
The engaging portion may be provided with a separate engaging structure on the side surface of the base portion. Further, a reinforcing material such as a wire net or a synthetic resin net may be embedded in the floor material main body as necessary. Further, if necessary, a fitting structure for positioning may be provided on the mold and the lid.

[0077]

Embodiments of the present invention will be described below in detail.

Example 1 Metakaolin (Engelher)
Product name: SATENTONE SP33, average particle size 3.3μ
m, BET specific surface area: 5.8cm^Two/ g) 100 parts by weight and
Triethanolamine 25% by weight and ethanol 75% by weight
0.5 part by weight of the mixed solution of Ultra Fine Mill
(Mitsubishi Heavy Industries, use zirconia ball 10mm, ball
(Filling rate: 85% by volume) and 10kwh / kg of mechanical energy
With the action of luggie, SiO_Two-Al_TwoO _ThreeSystem powder
Was. The applied mechanical energy is
The power supplied to the Rafine mill is divided by the unit weight of the treated powder.
It appeared.

The thus obtained SiO ₂ —Al ₂ O ₃
100 parts by weight of base powder, 20 parts by weight of mica as inorganic powder (M-100 manufactured by Repco), 30 parts by weight of talc (Takul S manufactured by Nippon Talc), wollastonite (Chemolit A-60 manufactured by Tsuchiya Kaolin) ) 57.5 parts by weight and vinylon fiber as a reinforcing fiber (RM182 manufactured by Kuraray Co., Ltd.)
-3) 0.5 parts by weight was supplied to an Erich mixer and dry-mixed for 5 minutes to obtain a mixed composition A.

100 parts by weight of the mixed composition A and an aqueous alkali metal silicate solution (manufactured by Nippon Chemical Industrial Co., Ltd. [SiO ₂ : 25
%, Na ₂ O: 17%, water: 58%] of those) fed in 75 parts by weight and the Omni Mixer (manufactured by Chiyoda Giken Kogyo Co., Ltd.), and mixed for 2 minutes to obtain a slurry of mineral composition. This slurry-like inorganic composition is poured as a molding material into a mold 4 as shown in FIG. 6 under natural flow, and then the cover 5 with the support member 1c fixed to the back surface as shown in FIG. 9 is closed to close the support member 1c. Was sunk into the molding material until the grid 19c was completely sunk.

Next, with the lid 5 closed, the mold 4 was heated to 85 ° C.
Was placed in an oven for 3 hours to cure the molding material to obtain a unit floor material C. In the obtained unit floor material C, the base 19 was completely buried in the floor material main body 2c, and the floor material main body 2c and the support member 1c were firmly integrated.

When the obtained unit floor material C was cut, no matter where it was cut, the floor material main body 2c and the supporting member 1 were cut.
and c were firmly integrated and did not peel off.

(Example 2) To 100 parts by weight of the inorganic composition used in Example 1, 500 parts by weight of fine aggregate for concrete (passing at least 85% of a 5 mm mesh sieve) as an aggregate having a coarse particle diameter was used as an omni mixer. Then, the obtained slurry-like mixture is filled as a molding material in a 400 × 400 × 40 mm iron mold and pressed at 100 kg / cm ² to form the molding material. The opening of the mold is closed with the lid having the support member 1d provided with the mating projection 15 'attached to the back surface, and the engaging projection 15' is immersed in a molded body in the mold for 3 hours in an oven at 85 ° C. The molding material was put into the container and cured to obtain a unit floor material D.

In the obtained unit flooring material D, the flooring material body had good water permeability, the bending strength was 42 kg / cm ² , and the porosity was 25%.

[0085]

The unit flooring material according to the present invention is constructed as described above, so that it is excellent in manufacturing workability, and
It can be manufactured at low cost. Claims 2 to 6
With such a configuration, the floor material body and the support member are more firmly integrated.

In particular, according to the third aspect, even when the slurry-like molding material has a hard composition at the time of manufacturing, it can be buried smoothly. According to claim 6,
Regardless of where it is cut on site, the support member and the flooring body are maintained in a tightly integrated state. Therefore, it can be cut freely to a desired size, the same finishing can be performed up to the corner of the laying surface, and a beautiful laying state can be obtained.

Further, according to the structure of the seventh aspect, it is possible to firmly connect the adjacent unit floor material of the same shape, and it is possible to prevent the unit floor material from shifting and moving at the time of laying. Further, according to the configuration of claim 8,
Since the floor material main body has water permeability, drainage is good even in heavy rain and the like, and water does not accumulate on the floor material surface.

According to the method for manufacturing a unit flooring according to the present invention, the unit flooring of the present invention can be manufactured with simple equipment. According to the manufacturing method of the tenth aspect, even if the supporting member is lightweight, the supporting member can be quickly and accurately sunk to a predetermined position of the molding material in the mold by the weight of the lid.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of a unit flooring according to claim 2 of the present invention.

FIG. 2 is a sectional view of the unit floor material of FIG. 1;

FIG. 3 is a perspective view of a support member of the unit flooring of FIG. 1 as viewed from the back side.

FIG. 4 is a perspective view of a support member of the unit flooring of FIG. 1 as viewed from the front side.

FIG. 5 is an enlarged sectional perspective view of a protruding portion of the support member of FIG. 4;

FIG. 6 is an explanatory view showing a method of manufacturing the unit flooring material of FIG. 1 in the order of steps.

FIG. 7 is an enlarged sectional perspective view of a main part of a supporting member of a unit flooring according to an embodiment of the present invention.

FIG. 8 is a sectional view showing an embodiment of a unit flooring material according to claim 5 of the present invention.

FIG. 9 is a cross-sectional perspective view of a main part of an embodiment of the unit flooring according to claim 6 of the present invention, viewed from the back side thereof.

FIG. 10 is a perspective view showing a cut state of the unit floor material of FIG. 9;

FIG. 11 is a sectional view of an essential part of an embodiment of a unit flooring material according to claims 3 and 8 of the present invention.

[Explanation of symbols]

 A, B, C, D Unit floor materials 1a, 1b, 1c, 1d Support members 11, 16, 19 Bases 11a, 17, 19a Grids 12, 13, 14 Legs 15 Projections 16a Side surfaces 2a, 2b, 2c , 2d Floor material body 4 Mold 5 Lid 6 Slurry molding material

Claims (10)

[Claims] A floor material body formed by curing a molding material containing at least an inorganic composition mainly composed of SiO ₂ —Al ₂ O ₃ powder, an alkali metal silicate and water, and a plate-shaped floor material body. A plurality of legs, which are partially buried on the lower surface side of the floor material main body and are fixed to the floor material main body, are grounded on the laying surface to form a predetermined space between the floor material main body and the laying surface, and And a supporting member projecting from the unit flooring. 2. The unit flooring according to claim 1, wherein the support member has an embedding projection on a surface opposite to the leg, and the embedding projection is buried in the flooring body. 3. The unit flooring according to claim 2, wherein the embedded projection is formed of a metal material. 4. The support member has a lattice-like base portion formed such that legs protrude from the lower surface, and at least a part of the lattice of the base portion is buried in at least the floor material body. 2. The unit flooring according to 1. 5. The unit flooring according to claim 4, wherein at least both side surfaces of the buried lattice are formed so as to gradually approach the central axis of the lattice toward the lower end direction of the base. 6. The unit flooring according to claim 4, wherein each of the lattices is buried in the flooring main body up to at least an edge portion of the lower surface thereof. 7. The supporting member according to claim 1, further comprising an engaging structure for engaging with an engaging portion provided on the supporting member of the adjacent unit floor material and connecting the adjacent unit floor materials. Item 7. The unit flooring material according to any one of Items 6. 8. A molding material comprising a SiO ₂ —Al ₂ O ₃ powder,
8. The floor material according to claim 1, wherein an aggregate having a coarse particle diameter is dispersed and mixed in an inorganic composition mainly composed of an alkali metal silicate and water, and the floor material body has water permeability. Unit flooring as described. 9. A step of filling a mold with a slurry-like molding material containing at least an inorganic composition containing SiO ₂ —Al ₂ O ₃ powder, an alkali metal silicate and water as main components,
4. The method according to claim 1, further comprising: submerging the support member in a slurry-like molding material in the mold with the leg side up to a position where the support member is buried in the floor material body; and curing and curing the molding material in the mold. Item 10. The method for producing a unit flooring material according to any one of Items 8. 10. The mold is closed by the lid in a state where the legs of the support member are supported by the lid toward the back side of the lid for closing the mold, and the slurry in the mold is moved to the buried position by the weight of the lid. The method for producing a unit flooring according to claim 9, wherein the unit flooring is forcibly submerged in a shaped molding material.