JPH11216708A - Decorative molded sheet with surface of cement-setting material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to mold an uneven pattern on the surface of a cement/setting material and decorate the surface by coloring or the like in addition to advantages such as significantly easy conveyance work and manufacturing. SOLUTION: A decorative molded sheet 3 with the uneven pattern of a simulated stone face or the like is press-or vacuum- or injection-molded using a thin sheet such as a foamed resin sheet. Alternatively, a decorative layer 5 is formed on the this sheet with an uneven surface by spraying or applying a cured or coagulated inorganic material or a coloring material obtained by mixing resin, a fibrous material or the like. In addition, finely granulated aggregates obtained by grinding a natural stone or the like are made to stick to the decorative layer 5 with an adhesive and an inorganic setting material is sprayed or applied to form the decorative layer 5. At a construction site or a plant, this decorative molded sheet 3 is arranged in a frame 6 and a cement setting material such as concrete is formed to obtain the uneven pattern on the surface of the sheet 3 or the decorative layer 5 is stuck to the surface of the decorative molded sheet 3 so that the its surface is colored.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative molded sheet on a cement-based hardened material surface capable of forming irregularities or coloring the surface of a cement-based hardened material such as mortar or concrete by imitating the surface with a stone or the like. It is.

[0002]

2. Description of the Related Art When building materials or constructing civil engineering structures using cement-based hardening materials such as mortar and concrete, in recent years, natural stones and the like have been imitated in order to adapt to the surrounding environment and create a sense of quality. The surface is formed to be uneven. For such unevenness molding, a decorative formwork made of a foam material such as styrene foam is used. Irregularities are formed on the decorative formwork, and the cement-based hardening material that has entered the irregularities is cured to form irregularities on the surface.

[0003]

The biggest problem with such a decorative mold using a foamed resin is its thickness.
In other words, the mold made of foamed resin usually has a thickness of 80 to 100 mm or more, is extremely large and bulky when transported, and the cost for transport is extremely large. In addition, the foamed resin decorative form is discarded once it is used, but the disposal cost of the waste has been rapid. From the viewpoint of environmental protection in recent years, disposal of a large amount of foamed resin is not preferable.

For this reason, in a factory or the like, a general-purpose decorative mold made of rubber is used, and concrete is poured into such a mold to form the mold. It is adopted that decoration such as coloring and surface pattern such as granite is performed together. In the case of a rubber decorative formwork, a coloring material or granite-like fine-grained aggregate is sprayed on the surface of the rubber formwork at the factory to harden it, and if concrete is poured on it, the color and bone will be applied to the surface. It can be decorated with materials attached. However, if the formwork is colored one by one in a factory or a site, it is impossible to rapidly build up a large amount of structures and products.

[0005] The present invention has been made to solve the above problems, it is very easy to transport without bulk.
This is a decorative molded sheet whose amount can be extremely reduced as waste, and enables the surface of a cement-based hardening material to be shaped by imitating it with a stone, etc. It is an object of the present invention to provide a decorative molded sheet having a cement-based hardened material surface which can be easily colored and decorated.

[0006]

The decorative molded sheet on the surface of the cement-based hardening material used in the present invention is a thin sheet much thinner than the conventional decorative formwork, and the surface of the hardening material is formed by the unevenness formed on this sheet. By forming
This is to solve the above problem. In addition, a decorative layer using a coloring material or a fine-grained aggregate is previously attached to the uneven surface of the decorative molded sheet, and the decorative layer is attached by bringing the material to the site or factory and placing a hardening material thereon. This problem is solved by forming a roughened surface.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION A decorative molded sheet according to the present invention is a rigid thin-walled sheet formed of a resin such as polyethylene, polypropylene, polystyrene, polycarbonate, polyvinyl chloride, polyamide or the like. May be used. Alternatively, a sheet such as paper may be used as long as the sheet has some rigidity. Sheet thickness is 0.5
The thickness is preferably from about mm to several mm, and a certain degree of rigidity is sufficient as long as it has a surface strength that does not cause the unevenness of the surface to collapse even when some pressure is applied. In order to form irregularities on the surface of the sheet, irregularities may be formed on the surface of the manufactured synthetic resin sheet or synthetic resin foam sheet, or by press working or vacuum forming on the surface of the paper, or resin may be injected into the mold. It may be formed by injection molding in which a sheet having irregularities is formed. In the case of paper or the like, press molding is performed. The height of the unevenness does not need to be very high, and the unevenness having a height of about 2 to 3 mm may be formed by imitating a stone surface or the like. It is preferable that the sheet does not absorb moisture, and if it is paper, it is preferable that the surface is coated with wax or the like. In addition, in order to improve the separation from the decorative layer, an aqueous release agent may be applied before attaching the decorative layer.

[0008] These decorative molded sheets are stacked and carried to the site or factory. The decorative molded sheet is significantly thinner than a conventional decorative mold, and can be transported in large quantities by stacking them.
These are placed alongside the formwork plate at the site or factory, and a cement-based hardening material such as mortar or concrete is cast,
The uneven pattern of the decorative molded sheet is formed on the surface of the cured material.

As described above, it is also possible to form the surface with a decorative molded sheet, peel off the decorative molded sheet, and then spray or apply a paint on the surface of the cured material to color the cured material. If a plurality of colors are sprayed or colored, a granite-like decoration is also possible.

A decorative sheet may be formed by attaching a decorative layer in advance to the surface of a thin sheet formed asperities. The decorative layer can be formed by spraying or applying a colored material obtained by mixing a fibrous substance, a synthetic resin, and a pigment or dye with an inorganic material that solidifies or hardens due to a hydration action and dissolves the material on the surface of the decorative molding sheet. is there. As an inorganic material which solidifies or hardens due to hydration, calcium oxide, calcium carbonate, calcium silicate, silica, alumina, fly ash, gypsum, etc. can be used, and any one of them or a mixture of two or more thereof can be used. It is also possible to use an inorganic material containing the above material as a main component.
For example, Portland cement containing calcium oxide, silica or alumina as a main component can be used as the inorganic hardening material. As the fibrous substance, synthetic fibers can be widely used in addition to wood fibers. Examples of the synthetic fibers include glass fibers, polypropylene fibers, polyethylene fibers, polyvinyl chloride fibers, and vinylon fibers. The length of the fiber can be arbitrarily selected from 1 mm to several cm. Acrylic resin, vinyl acetate resin, fluorine resin,
Can be widely used such as copolymer resins. The thickness to be sprayed or applied is about a few mm to about 2 mm. Even if the inorganic material that has been thinly solidified or cured has a crack, the inorganic material is not easily peeled off from the sheet due to the fibrous substance. In this state, carry it to the site or factory,
If the cement-based hardening material is placed and placed on the plate of the mold frame, the decorative layer adheres to the surface of the hardened cementitious material, and the uneven surface is formed and the colored surface appears.

The decorative layer may be formed by using fine-grained aggregate obtained by crushing natural stone or the like. A known adhesive such as acrylic, epoxy, or urethane is applied to the surface of the decorative molded sheet. Fine aggregates obtained by grinding natural stone, ceramic, synthetic resin, or the like are scattered on the adhesive. By scattering fine-grained aggregates of multiple colors, complex shades such as shades can be created. An inorganic hardening material such as mortar, resin mortar, cement paste or the like is further applied or sprayed thereon to form a decorative layer. If such a decorative molding sheet is transported to the site or factory and attached to the formwork plate, and a cement-based hardening material is cast, a decorative layer adheres to the surface of the hardening material, forming irregularities and fine-grained bone. The surface colored by the material appears.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on an embodiment shown in the drawings. In the figure, reference numeral 1 denotes a thin sheet made of a foamed resin. In the embodiment, a thin sheet of polystyrene having a thickness of about 2 mm is used. The thin sheet 1 is pressed from above and below by a press machine 2 to form a surface as shown in FIG. In the embodiment, the height of the unevenness is set to about 3 mm at the maximum. If the height of the irregularities is increased, a more attractive surface can be formed, but a height of about 3 mm is sufficient to simulate the sandstone surface, and a lower height is better, as described later. Even if concrete is poured, the unevenness does not collapse due to the weight of the concrete.

FIG. 3 shows an embodiment in which the decorative layer 5 is formed by attaching a coloring material 4 to the surface of the decorative molded sheet 3. The coloring material 4 is obtained by mixing vinyl acetate as a synthetic resin, an inorganic hardened material mainly composed of calcium oxide, calcium carbonate, calcium silicate and silica, and vinylon fiber as a fibrous substance, and mixing a pigment. It is a combination. The pigments are dispersed in water and are also mixed with thickeners to increase viscosity. In the embodiment, the coloring material 4 is used in order to form the decorative layer 5 which brings out a granite tone.
Use three colors of white, black and gray. First, an oily release material is sprayed or painted on the surface of the decorative sheet 3 as necessary. A black coloring material 4 is sprayed thereon so as to fly particles, then a white coloring material 4 is sprayed so as to cover the entirety, and a gray coloring material 4 serving as a base is further sprayed thereon to decorate as shown in FIG. Layer 5 to sheet 3
Form on the surface. After the decorative layer 5 has hardened, as shown in FIG. The decorative layer 5 has a thickness of about 1 mm, and the cured decorative layer 5 is cracked, but is not easily peeled off during transportation or work due to a fibrous substance. Even if the decorative molding sheet 3 to which the decorative layer 5 is attached is stacked, it does not become bulky,
Large quantities can be transported at one time.

FIG. 7 shows a case where a concrete molded product is manufactured using the decorative molded sheet 3 in a factory. The decorative molding sheet 3 is laid on the mold 6 so that the decorative layer 5 side is facing upward, and the back surface is attached to the plate of the mold 6. When the concrete 7 is poured into the mold 6 and hardened in this state, the concrete 7 and the inorganic material of the decorative layer 5 are integrated and hardened, and the concrete 7 remains in the color of granite.
The decorative layer 5 adheres to the surface. (FIG. 8) When the concrete 7 is poured, the coloring material 4 does not flow because the decorative layer 5 is hardened. If the decorative molded sheet 3 is peeled off after releasing from the mold frame 6, a concrete product having a granite surface appears. These products may be carried to the site and used as building exterior walls or concrete formwork. It is also possible to carry the decorative molding sheet 3 to the site, attach it to the plate of the formwork, and cast concrete into the formwork to directly construct a structure. The amount of the peeled sheet 3 is extremely small as compared with the conventional foam decorative formwork, and the problem of industrial waste treatment is significantly reduced.

FIG. 6 shows a fine aggregate 8 obtained by crushing natural stone.
Is used to form the decorative layer 5, an epoxy-based adhesive is applied to the surface of the decorative molding sheet 3, and a plurality of types of fine-grain aggregates 8 having different colors and diameters are spread thereon, Fix it. An inorganic hardening material 10 in which Portland cement is melted is sprayed thereon, and an aggregate 9 is further scattered thereon to form the decorative layer 5. As described above, if a concrete product is manufactured by laying the decorative molding sheet 3 on the formwork 6 as described above, the decorative layer 5 adheres to the surface, and the surface is uneven, and fine stone aggregates are used as natural stone or the like. It becomes the surface imitating.

[0016]

The present invention has the above-described configuration, and can obtain the following effects. Since the decorative molded sheet is extremely thin compared to the conventional decorative formwork, it does not become bulky even if a large number of sheets are stacked,
The transportation cost is reduced and the work is significantly easier. Also, the amount of industrial waste after use becomes extremely small. By forming the decorative layer on the decorative molding sheet in advance, the decorative layer adheres to the surface of the hardened material simply by placing it in the formwork and hitting the hardened material at the site or factory, which is troublesome at the factory and site. The surface can be shaped unevenly without coloring, and at the same time, decoration such as coloring can be performed. If the decorative layer is formed using a coloring material including a material that solidifies or hardens due to hydration, the decorative layer hardened on the sheet surface does not flow out even if concrete is poured, and is not a single color but as desired. It is possible to attach patterns of a plurality of colors and shapes. If a coloring material mixed with a fibrous substance is used as the decorative layer, the fibrous substance becomes a link, and even in a thin decorative layer, the strength increases, and the cured inorganic material is peeled off together with the coloring agent. Will not fall. Therefore, the decorative layer does not easily come off during stocking, transportation, or use. If the resin is mixed with the decorative layer, the strength of the decorative layer is increased and the pigment and the like do not flow down into rainwater.

[Brief description of the drawings]

FIG. 1 is a sectional view of press-forming a decorative molded sheet.

FIG. 2 is a cross-sectional view of a decorative molded sheet having irregularities.

FIG. 3 is an explanatory view of forming a decorative layer on the surface of a decorative molded sheet using a coloring material.

FIG. 4 is an enlarged cross-sectional view of a decorative molded sheet having a decorative layer formed of a coloring material.

FIG. 5 is a side view in which a plurality of decorative molded sheets are stacked.

FIG. 6 is an enlarged cross-sectional view of a decorative molded sheet having a decorative layer formed of fine-grain aggregate.

FIG. 7 is a perspective view of placing a decorative molded sheet in a mold.

FIG. 8 is a perspective view of placing concrete in a mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Thin sheet 2 Press machine 3 Decorative molding sheet 4 Coloring material 5 Decorative layer 6 Formwork 7 Concrete 8 Fine aggregate 9 Aggregate

Claims (3)

[Claims] 1. A decorative molded sheet on the surface of a hardened cementitious material, which is a thin sheet having rigidity and on the surface of which a textured pattern such as a stone surface is formed. 2. A thin sheet having rigidity, the surface of which is formed with a concavo-convex pattern imitating a stone surface.
A decorative layer is formed by spraying or applying a coloring material in which a fibrous substance, a synthetic resin, a pigment or a dye, or a mixed coloring material of a pigment and a dye are dispersed and dispersed in an inorganic material which solidifies or hardens by hydration. A decorative molded sheet on the surface of a cement-based hardening material. 3. A thin sheet having rigidity, on the surface of which an uneven pattern such as a stone surface is formed on the surface,
A decorative molded sheet on the surface of a cement-based hardened material obtained by spraying or applying an adhesive, adhering fine aggregate to the adhesive, and spraying or applying an inorganic hardening material thereon to form a decorative layer.