JPS582823B2 - Frame for forming joints for manufacturing architectural tile blocks - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION This invention is used to manufacture architectural tile blocks for forming tile-finished precast concrete plates (hereinafter referred to as tile PC plates) from foamable or non-foamable thermoplastic resin sheets. The present invention relates to a frame for forming joints.

Conventional architectural tile blocks are made by laminating the tile surfaces in alignment on a paper adhesive sheet as a release material, and the tile PC version is made by pouring a specified amount of concrete into the block from the back side of the tile, and then hardening it. It is made by peeling off a paper adhesive sheet.

However, in this type of block, the injected concrete flows to the tile surface and hardens, so after peeling off the paper adhesive sheet, it is necessary to scrape away the concrete at the joints between each tile to form joints of a predetermined depth. There is a problem with the work efficiency of tile PC plate manufacturing.

For this reason, various release materials have been proposed that are shaped to prevent concrete from flowing into the joint molding area.For example, release materials are made by molding a resin sheet coated with a pressure-sensitive adhesive into a predetermined shape, and paint is molded into a predetermined mold. There are release materials that are formed by pouring.

However, this type of release material has poor removal workability and does not necessarily achieve its purpose in terms of improving workability, such as the need to remove glue residue left on the tile surface. Molding is very tedious.

In light of the above circumstances, the inventors have already arranged a plurality of tiles on the surface of a foamable or non-foamable thermoplastic resin sheet at predetermined intervals by inserting a joint forming frame between each tile. When the sheets are brought into contact with each other and then heated under pressure or non-pressure, the sheets flow out into the gaps between the tiles due to the fluidity force of the softened state or the expansion force due to foaming, and the sheets are brought into contact with each other by the frame body to a predetermined depth, that is, the depth of the joint forming part. An architectural tile block is obtained which is thermally bonded to each tile, and when the thermoplastic resin sheet is peeled off after pouring a specified amount of concrete into this block, a tile PC plate having joints of a specified depth is formed. I discovered that.

According to this, there is no need to perform complicated molding on the thermoplastic resin sheet in advance to form joints, and the work efficiency in manufacturing architectural tile blocks and tile PC plates can be greatly improved. .

The present invention aims to provide a joint forming frame having a special structure for use in such an already proposed method, and will be explained below based on the drawings.

FIGS. 1 to 3 show an example of the joint forming frame of the present invention, in which the frame 1 includes a metal lattice-shaped base frame 3 having a plurality of parallel tile fitting holes 2; , and an elastic member 5 covering the side wall 4 of the base frame 3, that is, the circumferential wall 4' of the hole 20, and the elastic member 5 has flexibility and is suitable for use in the production of architectural tile blocks from thermoplastic resin sheets. It is not thermally deformed or thermally altered when softened by heating, and is preferably made of a silicone-based, fluorine-based, acrylic-based, phenol-based, urethane-based, epoxy-based, or polyester-based resin.

For example, such a joint forming frame 1 is first formed by punching out a plurality of tile fitting holes 2 in a metal plate, and then forming a lattice-shaped base frame 3.
Next, as shown in FIG. It can be easily manufactured by injecting the above-mentioned curable liquid resin between the base frame 3 and removing the tile 7 after the resin has hardened.

In FIG. 5, the frame body 1 is inserted between a plurality of tiles 7 arranged at predetermined intervals, and this arrangement and insertion are carried out by inserting the tiles 7 into each fitting hole 2 from the tile surface 8 side or from the tile surface 8 side. Fit from the back side 9 side and at least the tile front side 8 side into the hole 2
Just make it stick out.

Due to the flexibility of the elastic member 5 during fitting, even if the tile I has poor dimensional accuracy and is relatively larger than the specified size, it can be easily fitted, and the tightness with the frame 1 after fitting is also improved. Becomes good.

6A to 6F show the peripheral wall 4 of the tile fitting hole 2 of the lattice-shaped base frame 3.
Various modifications of the joint forming frame in which the tapered portion 10 is formed are shown in ``,'' and all of them can be manufactured by the same method as described above.

In the case shown in A to D, the tile 7 is fitted from the lower position in the drawing, and in the cases shown in E and F, the tile 7 is fitted from the upper position in the drawing, so that the tile surface 8 protrudes to the upper position in the drawing.

According to A and H, the diameter of the fitting opening is enlarged, so C and D
, E, and F, the thickness of the elastic member 5 near the insertion opening is large, so that its flexibility can be utilized more easily, so that the tile 1 can be fitted more easily.

7 to 8 show a structure in which a metal bottom plate 11 is integrally formed on a lattice-shaped base frame 3 to close one opening surface of the tile fitting hole 2, and the back surface 9 of the tile is brought into contact with the bottom plate 11. When the tiles 7 are fitted in this way, the tiles 7 are aligned in the same manner as described above, and the frame 1 is inserted between the tiles, and the flexibility of the elastic member 5 is also utilized.

In this example as well, tapered portions 10 as shown in FIGS. 6C-F can be formed on the lattice-shaped base frame 3 as desired.

In FIG. 5, a thermoplastic resin sheet 12 is in contact with the tile surface 8 protruding from the tile fitting hole 2, and this sheet 12 is placed above the tile 7 on the support plate 13 in the drawing. However, on the contrary, the tile I may be located above the thermoplastic resin sheet 12.

The thermoplastic resin sheet preferably contains nitroso-based, sulfonyl hydrazide-based,
It is best to use a foamable sheet containing various types of foaming agents such as aso-based foaming agents, and if necessary, a laminated sheet with two or more layers, or at least one layer of the laminated sheet containing the above-mentioned foaming agent. In addition, a reinforcing material such as veneer plywood, paperboard, or metal plate is bonded to the opposite surface 15 of the surface 14 that contacts the tile surface 8 of these sheets.

Further, at least the resin component of the sheet layer that is brought into contact with the tile surface 8 usually has a melt index of 0.0.
3 to 80, preferably a thermoplastic resin in the range of 1 to 10, such as polyethylene resins of which ethylene-vinyl acetate copolymer is a typical example, olefin resins such as polypropylene resins and polybutene resins, polystyrene resins, etc. Alternatively, a tackifying agent such as a terpene resin, a rosin resin, or a pinene resin may be added to these resins.

FIG. 9 shows such a thermoplastic resin sheet 12 being placed on a pressure plate (
(not shown), preferably under pressure, for example, in a heating oven to a temperature above its softening temperature, or, if the sheet 12 contains a foaming agent, at a temperature above its softening temperature and above the foaming agent. This shows the state when heated to a temperature higher than the decomposition temperature of.

The sheet softens and flows due to flow force, expansion force due to foaming, and external stress to form joints 17 in tile gaps 16.
Further outflow is stopped by the joint forming frame 1.

Moreover, the elastic member 5 expands due to the heating, and even if the dimensions of the fitting tile 70 are smaller than the specified dimensions, the tile side surface 18
Even if there is a gap to some extent between the frame body 1 and the frame body 1, the gap is filled and firmly adhered to the tile side surface 18.

As a result, sheet 1 is removed from the interface between the tile side surface 18 and the frame body 1.
2 rarely leaks out.

If the elastic member 5 has a larger wall thickness on the protruding side of the tile surface 8 (upper position in FIG. 6), that is, on the outflow side of the sheet 12 as shown in FIGS. 6E and F, the above-mentioned outflow prevention effect is more pronounced. become.

After heating and cooling, when the frame 1 is removed, the tile surface 8 side is buried in the thermoplastic resin sheet 12 to the depth h of the joint forming portion 17, as shown in FIG. 10, and the tile back surface 9 is buried.
An architectural tile block with exposed sides is obtained.

In addition, in the joint forming frame having the bottom plate 11 as shown in FIGS. 7 and 8, the bottom plate 11 has through holes (
If the frame body 1 is formed in advance (not shown), the frame body 1 can be easily removed.

When a predetermined amount of concrete is poured into the obtained tile block from the tile back surface 9 side and cured for a predetermined period of time, moisture in the concrete penetrates into the interface between the tile I and the sheet 12,
As a result, the sheet 12 is easily detached from the tile 1,
As shown in FIG. 11, the back surface 9 side of the tile 7 is buried in the concrete layer 19 to form a tile PC plate having joints of depth h.

This tile PC version has a very good finished appearance at the joints.

As detailed above, the present invention relates to a frame for forming joints used when manufacturing architectural tile blocks from foamable or non-foamable thermoplastic resin sheets. It consists of a base frame and an elastic member that adheres closely to the side of the tile covered on the side wall. If the frame is made entirely of an elastic member, as the number of times it is used increases, the frame will gradually warp and deform due to heating. There is a risk that the dimensional accuracy of the resulting tile block will deteriorate, but with the frame made of the metal base frame mentioned above, there is almost no such concern. Even if it is necessary to use the thermoplastic resin sheet, the gap that tends to occur between the frame and the side surface of the tile when inserted between the tiles can be filled with an elastic member that expands when the thermoplastic resin sheet is heated. Since the sheet firmly adheres to the side surface of the tile by expansion, it is possible to prevent the sheet from flowing out along the side surface of the tile, which might go beyond the joint forming part, and as a result, a tile PC plate with excellent finished appearance of the joint part can be formed.

Further, according to the present invention, where the base frame is particularly shaped into a grid, it is possible to simultaneously position the tiles and insert the frame between the tiles by simply fitting the tiles into the respective fitting holes. Moreover, since the flexibility of the elastic member can be used for mating, even when using tiles that are somewhat larger than the specified dimensions, it can be easily mated, and the adhesion between the tile and the frame after mating is good. Tile P has an excellent finished appearance at the joints even for such tiles.
It becomes possible to form a C plate.

Below, an example will be described in which an architectural tile block was actually produced using the joint forming frame of the present invention, and a tile PC board was further formed.

<Manufacture of joint forming frame> A metal lattice-shaped base frame (thickness 5
mm) and pretreated with Primer C manufactured by Shin-Etsu Chemical Co., Ltd., silicone sealant KE4 manufactured by Shin-Etsu Chemical Co., Ltd. was applied between the base frame and the tile according to the manufacturing method shown in Figure 4.
No. 22 was injected into the joint forming frame body with a silicone-based elastic member attached to the side wall of the base frame.

The basic dimensions and the thickness of the elastic member are as shown in FIG.

Manufacturing of architectural tile blocks> Place the above joint forming frame on a support plate treated with polytetrafluoroethylene, and fill each fitting hole with vertical and horizontal dimensions in the range of 45.8 to 46.8 mm. A plurality of tiles with a thickness of 7 mm inside are fitted.

Even tiles larger than the size of the fitting hole (46 mm both vertically and horizontally) were easily fitted because the flexibility of the elastic member could be utilized.

Next, a foamable thermoplastic resin sheet is brought into contact with the tile surface protruding from the fitting hole, and a support plate similar to that described above is further provided thereon.

The foamable thermoplastic resin sheet contains 100 parts of polyethylene (Sumikasen L-705, manufactured by Sumitomo Chemical Co., Ltd.), 5 parts of a blowing agent (Spancel DS#25, manufactured by Eiwa Kasei Co., Ltd.), and 1 part of a crosslinking agent (Percmill D, manufactured by NOF Corporation). After kneading it with a mixing roll, it is made into pellets with a pelletizer, and then it is made into pellets with a die temperature of 130°C using an extrusion molding machine (using a T-type die) to a thickness of 0.
It is molded to 5mm.

Next, after holding both the upper and lower support plates between two pressure plates, 0. The sheet is heated and foamed at 200° C. for 5 minutes while applying a pressure of 1 kg/cm 2 .

During this heating, the silicone elastic member expanded and firmly adhered to the side surface of the tile.

After cooling to room temperature, the pressure plate, support plate, and joint forming frame were removed to obtain an architectural tile block in which the foam sheet had a thickness of 2.8 mm and the joint forming portion had a depth of 2 mm.

<Formation of Tile PC Plate> When a specified amount of concrete was poured into the above architectural tile block, cured at room temperature for one week, and the foam sheet was peeled off, a tile PC plate with a joint depth of 2 mm was formed.

The finished appearance of the joint portion of this PC plate was very good.

[Brief explanation of drawings]

Fig. 1 is a partially cutaway perspective view showing an example of the joint forming frame of the present invention, Figs. 2 and 3 are enlarged views of the ■ and ■ parts in Fig. 1, respectively, and Fig. 4 is an enlarged view of the above-mentioned frame. FIG. 5 is a cross-sectional view showing the frame inserted between a plurality of tiles that are in contact with the surface of the thermoplastic resin sheet, and FIG. A sectional view showing the state after heating, FIGS. 6A-F are sectional views showing modified examples of the frame shown in FIG. 1, and FIG. 7 is a basic view of the frame shown in FIG. 1. A partially cutaway perspective view of an integrally formed metal bottom plate,
FIG. 8 is an enlarged view of the part shown in FIG. FIG. 12 is an enlarged sectional view of the main part showing the shape and size of the joint forming frame used in a specific manufacturing example of architectural tile blocks (described in detail in the text). 1... Frame for joint formation, 2... Tile fitting hole, 3... Metal base frame (lattice base frame), 4
, 4l...Side wall of base frame, 5...Elastic member, 7...Tile, 10...Tapered part, 11...Metal Bottom plate, 14... Thermoplastic resin sheet surface, 16... Tile gap, 17
...Glut forming part, 18...Tile side.

Claims (1)

[Scope of Claims] 1. The sheet is inserted between a plurality of tiles that are in contact with the surface of a foamable or non-foamable thermoplastic resin sheet and is heated to stop the sheet from flowing out into the gap between the tiles to the depth of the joint forming part. A frame for forming joints for manufacturing architectural tile blocks, in which a metal base side wall is covered with an elastic member that adheres to the side surface of the tile. 2. A frame for forming joints for manufacturing architectural tile blocks according to claim 1, wherein the metal base frame is a lattice-like base frame having a plurality of tile fitting holes. 3. A frame for forming joints for manufacturing architectural tile blocks according to claim 2, which comprises a lattice-shaped base and a metal bottom plate. 4. A frame for forming joints for manufacturing architectural tile blocks according to claims 1 to 3, wherein the side wall is provided with a tapered portion.