JPS6258632B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a sand wall material and a method for manufacturing the same. An object of the present invention is to provide a sand wall material containing colored processed aggregate that has good workability and excellent grain feel and aesthetic appearance. Another object of the present invention is to provide a method for producing a sand wall material, which allows the colored aggregate to be obtained in a short time and without forming into plates or blocks.

Conventionally known sand wall materials include silica stone, crushed stone, kansui stone,
It includes colored processed aggregates in which a colored layer is formed on the surface of granular aggregates such as inorganic granules, crushed synthetic resins, and granulated synthetic resins. This colored aggregate is produced by stirring the granular aggregate, pigment, extender pigment, and organic adhesive at the same time and drying the mixture. However, when the granular aggregate of this sand wall material has acute angular protrusions, the acute angular protrusions engage the trowel surface, significantly inhibiting trowel elongation during troweling, and sometimes scratching the finished surface. Therefore, it was difficult to form an aesthetically pleasing wall surface. Improvements in this respect have already been proposed in Japanese Patent Publication No. 30829/1983. That is, in the present invention, the above-mentioned drawbacks are solved by wearing away the acute-angled protrusions of the granular aggregate. However, in the colored processed aggregate obtained by this invention, the fine powder generated during abrasion gets mixed into the colored layer, resulting in a dirty finish, and depending on the type, the particle size of the granular aggregate becomes fine due to abrasion. It has become clear that there is another problem in that it is difficult to express the granular feel characteristic of sand walls due to excessive graininess. In addition, it has been found that the colored aggregate contained in the conventional sand wall materials described above has the following problems in terms of manufacturing method.

(1) Coloring process: Because the pigment, extender pigment, and organic adhesive are colored by stirring them at the same time as the granular aggregate without mixing them in advance, a homogeneous colored layer is formed on the surface of the granular aggregate. This requires a long period of stirring. For this reason, not only a large amount of energy is required, but also the stability of the organic adhesive is impaired, causing the already attached pigments, extender pigments, and organic adhesive to fall off during stirring. In addition, pigments, extender pigments, and organic adhesives do not effectively adhere to the surface of the granular aggregate, but instead adhere to the stirrer or form aggregates. Therefore, not only are pigments, extender pigments, and organic adhesives used in vain, but the agitator is also contaminated, requiring a great deal of effort when changing the color tone of the colored layer.

(2) Drying process: In the conventional methods for manufacturing sand wall materials described above, methods of drying while moving the material to be dried, such as flash drying and fluidized drying, cannot be adopted. The reason for this is that when these drying methods are used, pigments, extender pigments, and organic adhesives attached to the surface of the granular aggregate fall off due to movement of the granular aggregate, which is not only wasted, but also requires coloring. This is because it impairs the aesthetic appearance of the aggregate, furthermore it stains the dryer and requires a great deal of effort when changing the color tone of the colored layer. Therefore, it is necessary to use a dryer that can dry the material to be dried without moving it, such as a box-type or continuous band-type ventilation dryer, which has poor drying efficiency.

In this case, due to the presence of the organic adhesive, adjacent granular aggregates adhere to each other and form plates or blocks, and it becomes necessary to crush the aggregates because granules cannot be obtained. Therefore, the aforementioned Tokuko Sho 57-
As in the invention described in Publication No. 30829, even if the sharp protrusions of the granular aggregate are worn away during agitation, new acute protrusions are generated, which significantly reduces the workability during troweling, and the granular aggregate This exposes the surface of the product and reduces its cosmetic properties.

As a result of intensive research in view of the above circumstances, the present inventors have completed a new sand wall material that solves the above problems and a method for manufacturing the same.

That is, in the sand wall material according to the present invention, a colored layer containing a pigment, an extender pigment, and an organic adhesive is formed on the surface of granular aggregate of 10 to 80 meshes, and an anti-blocking material layer is formed on the colored layer. It is characterized by containing colored processed aggregate.

Furthermore, the method for producing a sand wall material according to the present invention includes 10
A colored paste containing pigments, extender pigments, and organic adhesives is added to ~80 mesh of granular aggregate and stirred to adhere the colored paste to the granular aggregate. The paste is characterized in that it contains a colored aggregate obtained by adding and mixing an anti-blocking material while the paste is in a wet state and then drying the paste.

Typical granular aggregates suitable for carrying out the present invention are silica sand, crushed stone, akansui stone, crushed synthetic resin, synthetic resin granules, and inorganic granules, and their shapes have acute angular protrusions. It is desirable to use one that is as close to a spherical shape as possible. The reason for specifying the particle size of granular aggregate to be 10 to 80 mesh is as follows. If it is too large than 10 mesh, the coating thickness of the decorative surface becomes large, which not only increases the weight of aggregate used per unit area of the wall surface, but also significantly reduces the workability of troweling.
If it is too small than the mesh size, it will not be possible to express the granular feel peculiar to sand walls.

The pigment, extender pigment, and organic adhesive used in the present invention may be those conventionally used in producing sand wall materials. The pigment may be either organic or inorganic. Any organic adhesive may be used as long as it has water resistance and adhesiveness. Extender pigments include calcium carbonate, clay, talc, mica powder, and the like.

In the present invention, the pigment, extender pigment, and organic adhesive are mixed in advance to form a colored paste before being stirred with the granular aggregate. The viscosity of this colored paste is preferably 10,111 to 40,000 cps (at 25°C). If it is lower than 10,000 cps, the colored paste will "sag" and it will not be possible to make a thick film with one coloring. On the other hand, if it is higher than 40,000 cps, it will not only be difficult to handle, but especially if the granular aggregate used This is because the colored paste cannot be sufficiently dispersed and mixed when it has acute-angled protrusions. Moreover, it is desirable that this colored paste be 3% by volume or more with respect to the granular aggregate. This is because if the amount is less than 3% by volume, when the granular aggregate used has acute angular protrusions, it will not be possible to sufficiently fill the recesses on the surface of the granular aggregate. By satisfying the above conditions regarding the viscosity and usage ratio of the colored paste, a thick colored layer with strong hiding power is formed on the granular aggregate, resulting in a beautiful cosmetic that does not partially expose the surface of the granular aggregate. It becomes a natural sand wall material. At the same time, the colored aggregate obtained becomes almost spherical, so when applying with a trowel, the colored aggregate does not touch the surface of the trowel or the base, making it easier to move with the trowel, thereby preventing trowel elongation and trowel slippage. It becomes significantly better.

As the antiblocking material used in the present invention, ultrafine silicic acid particles can be used in addition to those used as the extender pigments. The amount used cannot be specified because it varies depending on the type of granular aggregate and colored paste. If the amount used is extremely large, it will not be spread on the surface of the colored layer and will be released and will be filled between the colored aggregates when forming the wall surface, resulting in a poor sand wall-like finish. On the other hand, if the amount used is extremely small, the anti-blocking effect will not be obtained and it will not contribute to improving workability.

Next, the manufacturing process of the present invention will be explained. The colored paste prepared in advance is stirred together with the granular aggregate. This stirring causes a colored paste layer to adhere to the surface of the granular aggregate. Immediately after that, when the colored paste layer on the surface of the granular aggregate is in a wet state, when the anti-blocking material is added and stirred, the anti-blocking material layer is adhered to the surface of the colored paste layer adhered to the surface of the granular aggregate. It turns out. At this time, since the colored paste layer has not yet been stabilized, a portion of the colored paste layer is mixed into the anti-blocking material layer, and the interface between the colored paste layer and the anti-blocking material layer becomes unclear. That is, the closer to the inner periphery of the antiblocking material layer, the more pigments, extender pigments, and organic adhesives contained in the colored paste layer are contained. On the other hand, since the colored paste is not mixed into the outer periphery of the anti-blocking material layer, the colored paste layers on the surfaces of adjacent granular aggregates do not adhere to each other. By applying the thus obtained product to a suitable dryer to remove moisture, a colored processed aggregate in which a colored layer and an anti-blocking material layer are formed on the surface of the granular aggregate is obtained.

Incidentally, the spreading of the anti-blocking material needs to be completed in a short time. This is because if stirring is continued after dewatering has started, the attached colored paste layer and anti-blocking material layer tend to fall off from the granular aggregate.

The colored aggregate obtained in this way is mixed with CMC, which provides workability for troweling, and a synthetic resin emulsion, which provides adhesive strength, and is kneaded with an appropriate amount of water to form a sand wall material. Can be done.

Since the sand wall material according to the present invention has an anti-blocking material layer formed on the outer surface of the spherical colored aggregate, the following effects can be obtained. That is, since the anti-blocking material layer swells during kneading with water, the material is soft to the touch and stretches smoothly with the trowel, significantly improving workability. In addition, because the colored aggregate has good water retention, it also prevents sagging during painting, allowing the installer to easily work on the elevation.

Furthermore, the sand wall material according to the present invention has excellent graininess and aesthetic appearance because it contains colored processed aggregate in which a desired colored layer is formed on the surface of the aggregate that maintains a desired particle size.

In the method for producing sand wall materials according to the present invention, pigments, extender pigments, organic adhesives, etc. are mixed in advance to form a colored paste, so colored processed bones are formed with a homogeneous colored layer on the surface of the granular aggregate. materials can be obtained with short mixing times. Furthermore, in the method for producing sand wall materials according to the present invention, an anti-blocking agent is added and mixed while the colored paste adhering to the surface of the granular aggregate is in a wet state, so that it does not become plate-shaped or blocked when drying. There is no risk of it happening.

Next, the present invention will be explained based on examples.

Example 1 Water-dispersible pigment (product name: Yellow PM-6R manufactured by Sumika Color Co., Ltd., solid content 24%) 300g, titanium oxide (solid content 60%) 2500g, clay 2500g, acrylic synthetic resin emulsion (product name: polysol
4,500 g of AP604 (manufactured by Showa Kobunshi Co., Ltd.) was mixed uniformly with a hand mixer to obtain a colored paste (27,000 cps, BH type No. 5 rotor 10 rpm).

Next, 500 kg of silica sand (product name: Silica Sand, produced in Australia) having a particle size of 10 to 80 mesh was uniformly stirred for 60 seconds, and then 5000 g of talc was added as an anti-blocking material and mixed again for 30 seconds. This was dried in a flash dryer to obtain colored aggregate.

Next, 5000g of this product was mixed with 50g of CMC and acrylic synthetic resin emulsion (product name: Polysol).
AP50 (manufactured by Showa Kobunshi Co., Ltd.) 300g and water 2200g
When the mixture was kneaded with a trowel and applied to a wall surface, workability such as elongation with a trowel was good, and a wall surface with a beautiful appearance and a sense of mass could be formed without causing any drooping phenomenon on the wall surface during painting.

Example 2 500g of inorganic powder pigment (red iron), titanium oxide
2500g, talc 5000g, ultrafine silicic acid (product name:
Aerosil 200, Nippon Aerosil Co., Ltd.) 700
g. Acrylic synthetic resin emulsion (product name:
Polysol AP604 manufactured by Showa Kobunshi Co., Ltd.) and water
A colored paste was obtained by uniformly mixing 2000 g with a hand mixer.

This colored paste (30,000 cps, BH type No. 5 rotor 10 rpm) and 250 kg of inorganic granules with a particle size of 10 to 80 mesh were stirred for 60 seconds, and talc and inorganic powder pigment were added in a ratio of 4:1 as an anti-blocking material. 10,000 g of the mixture was added and stirred and mixed again for 30 seconds. When this was dried in a continuous band type aerated dryer, a colored aggregate with no blocking was obtained.

When a wall material was formed using this in the same manner as in Example 1, it gave the feeling of calmness and rust similar to that of a clay wall, and was also able to express the granular feel of a sand wall.

Claims (1)

[Scope of Claims] 1. Granular aggregate of 10 to 80 mesh, with pigment/
1. A sand wall material comprising colored processed aggregate on which a colored layer containing an extender pigment and an organic adhesive is formed, and an anti-blocking material layer is formed on the colored layer. 2 Add a colored paste containing pigment, extender pigment, and organic adhesive to 10 to 80 meshes of granular aggregate and stir to make the colored paste adhere to the surface of the granular aggregate. 1. A method for producing a sand wall material, comprising: adding and mixing an anti-blocking material to the colored paste while it is in a wet state; and then drying the colored aggregate. 3. Claim 2, wherein the granular aggregate has acute angular protrusions, the colored paste has a viscosity of 10,000 to 40,000 cps, and the proportion of the colored paste added to the granular aggregate is 3% by volume or more. The method for manufacturing the sand wall material described in .