JPS6317783B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a natural stone-like architectural component having a decorative effect.

Natural stones, such as cut plates and blocks, are in high demand because of their decorative effects. In particular, slate, marble plates, tiles or planks are used for flooring, veneers and wall coverings. Granite is used as irregularly cut paving stones or building blocks. This block is used for wall materials, decorative materials, wall covering materials, fences, paving stones, etc.

However, the use of natural stone in the construction industry is constrained by the fact that it is expensive as resources are becoming scarce. In particular, marble and black granite, which are in high demand, are produced in limited quantities and are expensive.

When cutting and processing natural stone, small pieces and granules with little value are generated. Conventionally, a method has been proposed in which such fragments are further crushed and a binder is added thereto to use them as building stones or plates. A method is also known in which fragments of this natural stone are coated on the surface of an inexpensive core material.
However, none of the products obtained by conventional methods have the original appearance of natural stone. That is, because of the pulverization or the binder, the surface was uniform, lacking in structural features, and could not be said to be aesthetically pleasing. Natural stone plates are generally very brittle and are susceptible to cracking or breakage during manufacture, transportation, or use.

This invention was made in view of the above circumstances, and its purpose is to create a natural stone that has an appearance similar to natural stone, is extremely similar to, for example, marble, slate, or granite, and is also extremely inexpensive compared to natural stones. We provide various building materials. Another object of the present invention is to provide a natural stone-like building material that has greater mechanical strength, ie, tensile strength and bending strength, than natural stone.

That is, the present invention is a building material consisting of a core and a coat layer containing particles of natural stone or artificial mineral having a decorative effect on the surface thereof, the particles are bound with an organic binder, and the coat layer has two layers. ~60
The object of the present invention is to provide a natural stone-like building material characterized by comprising 98 to 40 parts by weight of coarse grains of natural stone or artificial stone, and 10 to 100 parts by weight of an organic binder. A preferred composition of this coating layer is one consisting of 10 to 40 parts by weight of graphite, 90 to 60 parts by weight of coarse grains of natural stone or artificial mineral, and 20 to 60 parts by weight of an organic binder. be.

By using such a relatively small amount of organic binder and using relatively coarse-grained minerals, it is possible to obtain a surface that is very similar to the corresponding natural stone. Graphite's presence is indispensable because its special crystal structure enhances the structural effect of coarse mineral grains. The combination of graphite and mineral coarse particles also creates a contrast effect, giving it a decorative aesthetic.

The natural stone coarse particles used as the coating layer in this invention are preferably selected from slate, marble, and granite. When these mineral coarse particles are combined with graphite, they become almost indistinguishable from cut or cut natural slate, marble or granite.

Another embodiment of the present invention uses particles of stained glass frit to provide a special decorative aesthetic. In this case too, graphite strengthens the contrast and brings structural beauty. Glass beads, glass fragments, etc. can be used as the glass frit.

In the present invention, "relatively coarse particles" refers to particles of such a size that a clear surface structure can be seen with the naked eye. The practical lower limit size is 20 μm, and if the size is smaller than this, it is difficult to distinguish individual particles with the naked eye. However, it may contain a small amount of particles of 20 μm or less, as long as it does not cause any particular adverse effects. The upper limit of particles in the coating layer is 5000μ
m (5 mm). Therefore, the particles are preferably selected in the range of 50 to 1000 μm, more preferably 50 to 250 μm. Coarse grains in this range have the most remarkable decorative effect.

Appropriate selection of the ratio of mineral grains to organic binder provides a surface roughening effect (or relief effect). Too much binder will result in a completely smooth surface. This unevenness effect can be significantly accentuated by coating, especially by diffusion method. Even when the amount of binder is relatively small relative to the mineral grains, the mineral grains can be strongly fixed in the coating layer. The mineral grains stick together, protecting the organic binder from the outside air and improving its durability over time.

The size of graphite particles is 20 to 1000μ
m, particularly preferably in the range of 50 to 250 μm. Graphite of this size allows the crystal planes to be clearly seen, contributing to improving the beauty of the surface structure of the product.

Another advantage of the addition of graphite is that a coating layer with good binding properties is obtained even at high solids contents. This is due to the lubricity of graphite. This is extremely important regardless of whether the coating layer is formed by a spray method or a diffusion method.

When using glass frit that has been crushed to an appropriate size, glass frit that is commonly used in the pottery industry can be used. That is,
Glass particles suitably colored red, green, yellow, blue, etc. can be used. White opal glass and black glass could also be used in the same way.

In this invention, the mineral grains are not limited to those of the above-mentioned specific examples, but any mineral can be used as long as it has the desired decorative effect. Moreover, these mineral grains may be used in combination with different types of natural stones and artificial stones. This makes it possible to obtain something that cannot be found in conventional natural stone, but even in this case it has the characteristics of natural stone.

The artificial ore used in this invention is glass that has been partially or completely crystallized by heat treatment, and is crushed into a predetermined size. For example, one commercially available as "Synopal" (trademark) can be used.

A sufficiently inexpensive material can be used as the building material core material used in this invention. For example, it is a fired clay product such as a brick, which is effective in applying a coating to one or two sides, and is inexpensive.
Other core materials include wood, asbestos cement, gypsum, concrete, and foamed inorganic or organic materials.

Small pieces of wood, scraps, chips, etc. can be used as lightweight core materials with high mechanical strength, resulting in products with high mechanical strength. Asbestos cement, gypsum, and concrete can be reinforced with wire, glass fiber, natural or artificial fiber netting, etc., as necessary, to create inexpensive products with high mechanical strength. In addition, as the artificial fiber, polyamide or polyester can be used. Particularly lightweight products can be provided using foam materials. For example polyurethane or polystyrene foam. Other natural foamed or porous materials, such as expanded vermiculite, may also be used.

Example 1 Approximately 200 mesh marble powder (Grise Italia)
100 g was mixed with 20 g of 200 mesh graphite powder and then mixed into 50 g of liquid epoxy resin. Then, an amine curing agent was added and then diffused onto a rough wooden board, and the coated layer was cured at room temperature for 24 hours. This mixture was easily diffused and formed a gray coating layer. As a result of polishing this, a product with an appearance similar to natural marble was obtained.

Example 2 100g of slate (blue-black) with a grain size of 200 mesh
Mixed with 50g of graphite with a particle size of 200 mesh,
Mix this into 90g of polyurethane, mix thoroughly, and then spread it on a wooden plate.
It was left at 20 to 30°C for 8 to 10 hours. After the surface had hardened, it was polished using an abrasive with a grain size of 280, brushed with a steel brush, and then polished with wax. The result was a product indistinguishable from natural slate plates.

Example 3 Acetone was added to the mixture obtained in Example 2 to give it a sprayable viscosity, and a floating agent (bentonite) was added as appropriate to prepare a spray mixture.
Spray this mixture onto a wooden plate and use for 20~
After being left at 30° C. for 8 to 10 hours, polishing and brushing were performed in the same manner as in Example 2, and similar results were obtained.

Example 4 100 g granite of 200 mesh particle size and 50 g graphite were mixed with 85 g styrene containing polyester liquid containing 2% benzoyl petroxide and a small amount of reaction accelerator. This mixture was carefully kneaded and spread on a wooden plate. After drying this in an oven or heating tunnel at a temperature of 90°C for 15 minutes, the surface was brushed with a steel brush to obtain a product indistinguishable from natural granite.

Example 5 70 grams of 200 mesh marble, granite, slate powder was mixed with polyurethane to obtain a "dry" filler with sufficient binding properties. Add acetone to this, spread, apply, dab,
It has binding properties suitable for spray coating, etc.
This was applied onto a wooden plate, dried, and then the surface was polished or brushed. The resulting product was indistinguishable from natural marble, granite, or slate.

Example 6 100 g of black granite with a particle size of 50 to 250 μm and a particle size of 50 to 250 μm
A mixture of 50 g of 100 μm graphite was mixed into 90 g of polyurethane, and the mixture was further diluted with acetone to obtain a viscosity for spraying. This was sprayed under stirring onto a plaster plate, an asbestos cement plate and a concrete plate, respectively, and then post-treated in the same manner as in Example 5. The resulting products were no different from natural granite.

Example 7 The same operation as in the above example was carried out except that a polyurethane foam plate having a specific gravity of 200 Kg/m ³ was used as the core material. The resulting product had an appearance similar to natural cut granite, was extremely light in weight, and had high strength.

Example 8 100 g of white opal glass with a particle size of 20 to 250 μm,
A mixture with 3 g of graphite having a particle size of 50 to 100 μm was mixed into 30 g of polyurethane, and acetone was further added to provide binding properties suitable for diffusion. This coating material was applied by roll to a regular brick surface. This was cured at 20 to 30°C for 8 to 10 hours to obtain a product with a white or gray-white decorative surface and a beautiful rough surface structure rich in contrast.

Claims (1)

[Scope of Claims] 1 A natural stone-like building material consisting of a core and a coat layer coated thereon, the coat layer consisting of particles of natural stone or artificial minerals having a decorative effect bound together with an organic binder. Natural stone-like, wherein the coating layer is composed of 2 to 60 parts by weight of graphite, 98 to 40 parts by weight of coarse grains of natural stone or artificial mineral, and 5 to 100 parts by weight of an organic binder. Building materials. 2 Coating layer is 10 to 40 parts by weight of graphite, 90
The natural stone-like building material according to claim 1, comprising ~60 parts by weight of natural stone or artificial mineral coarse particles and 20-60 parts by weight of an organic binder. 3. The building material according to claim 1 or 2, wherein the natural stone coarse particles are slate, marble, or granite. 4. The building material according to claim 1 or 2, wherein the artificial mineral is stained glass. 5. The building material according to any one of claims 1 to 4, wherein the core is made of sintered clay. 6. The building material according to any one of claims 1 to 4, wherein the core portion is made of a plate of wood, asbestos cement, gypsum, concrete, foamed inorganic or organic material. 7 The particle size of coarse grains of natural stone or artificial mineral is 20~
Claims 1 to 6 which are 5000 μm
Building materials listed in any of the paragraphs. 8. The building material according to claim 7, wherein the coarse particles have a particle size of 50 to 250 μm. 9. The building material according to any one of claims 1 to 8, wherein the graphite has a particle size of 20 to 1000 μm. 10. The building material according to any one of claims 1 to 9, wherein the organic binder is a curable tree selected from polyester, epoxy resin, or polyurethane.