JPS6411441B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing patterned terrazzo tiles.

The surface layer of the tile is formed with mortar made by mixing chips made of stone such as marble, white cement, and water, and on top of that, the bottom layer of the tile is formed with ordinary mortar made by mixing river sand, ordinary cement, and water. Terrazzo tiles, which are manufactured by forming the tile surface layer and the tile bottom layer under pressure using a press, are often used as flooring materials or wall materials of various buildings. However, patterned terrazzo tiles, in which a single tile uses multiple types of natural marble chips with different colors to express beautiful patterns on the tile surface, have not been realized due to problems that must be overcome in manufacturing. The problems will be explained in detail below.

A method for manufacturing patterned terrazzo tiles using natural marble chips is to insert an inner frame mold 2 as shown in Figure 1b into a square tile outer frame mold 1 as shown in Figure 1a, and As shown in Figure c, the inner surface of the outer frame mold 1 is divided into a plurality of blocks A, B, and C, and a surface layer mortar made of marble chips and white cement is applied to the divided blocks A, B, and C. One possible method is to use a suitable combination of chips depending on their color. However, if you remove the inner frame mold 2 before the mortar hardens and insert ordinary mortar made of river sand, pea gravel, ordinary cement, etc. as the bottom layer material, the blocks will form due to the impact when the mortar is introduced and the pressure applied by the press. Another drawback is that the boundary line pattern, which is caused by the mixing of surface layer mortar near the boundary, does not appear beautifully. Therefore, as a countermeasure, for example, first insert mortar only into blocks A and C shown in Fig. 1c, remove the inner frame mold 2 after the mortar in blocks A and C hardens, and then insert mortar into block B. The method used was to insert mortar into the However, with this method, although the lines between blocks A and B and the boundaries between blocks B and C are sharp and the pattern is beautiful, it is necessary to wait until the mortar of blocks A and C has hardened. It took a long time to manufacture, and block A
Since the mortar of block B is inserted after the mortar of block C has solidified, the boundary between blocks A and B and the block B must be
The disadvantage is that distortion occurs at the boundary between the block C and the block C, resulting in weak strength.

This invention was made in view of the above-mentioned points, and it is necessary to wait for the surface layer mortar consisting of stone chips such as marble and white cement, which are first put into the blocks divided by the inner frame mold 2, to solidify. A method for manufacturing patterned terrazzo tiles in which the surface layer mortar is simultaneously introduced into each block and the block boundaries appear as sharp and beautiful lines even when the inner frame mold 2 is removed before the surface layer mortar hardens. The purpose is to provide The present invention will be explained in detail below based on the drawings.

FIGS. 2a to 2f are diagrams showing a manufacturing process for explaining a method for manufacturing a patterned terrazzo tile, which is an embodiment of the present invention. This figure is a cross-sectional view taken along the line X--X of the inner frame mold 2 inserted into the outer frame mold 1 shown in FIG. It is the base plate. In this way, the outer frame is placed on the vibration table plate 3, and the inner frame mold 2 is inserted and placed in the outer frame mold 1, and each block A,
Surface layer mortar consisting of marble chips, calcium carbonate, and white cement, which will become the surface layer of patterned terrazzo tiles, is applied to blocks A, B, and C.
After inserting marble chips of different colors for each case as shown in Figure a, the vibration driving unit installed at the bottom of the vibrating base plate 3 is activated to vibrate the vibrating base plate 3 back and forth and from side to side, and the surface Surface layers 4a to 4c are formed by dispersing the layer mortar to every corner of the mold and removing air bubbles.
make it flat. Next, as shown in Figure c, the inner frame mold 2 is pulled out from the outer frame mold 1, and dry powder mixed with calcium carbonate chips and ordinary cement powder is gently sprinkled on the surface layers 4a to 4c of the terrazzo tiles. Then, the tile intermediate layer 5 is formed. Subsequently, as shown in FIG. 4D, ordinary mortar mixed with river sand, pea gravel, and ordinary cement is poured onto the surface of the tile intermediate layer 5 to form the tile bottom layer 6. After applying high pressure to the top of this tile bottom layer 6 using a press 7 as shown in Figure e, the outer frame mold 1 is removed to create a terrazzo tile having a cross section as shown in Figure f. After curing for a day, the surface layer 4 is polished to complete the patterned terrazzo tile. The above is an overview of the method for manufacturing a patterned terrazzo tile according to an embodiment of the present invention, and each step will be explained in detail below.

First, the mold structure will be explained in detail. Figure 3 shows an outer frame mold 1 and an inner frame mold 2 as shown in Figure 1c.
FIG. 3 is a partially enlarged cross-sectional view taken along the line X--X in a state in which the device is inserted. Figure a shows a conventional mold, and figure b shows a mold according to an embodiment of the present invention. As shown in FIG. It had the shape of When pulled out from the inner frame mold 2 or unsolidified surface mortar layer 4 having such a shape, at that time,
Because the speed at which the surface layer mortar flows into the gap where the inner frame mold 2 was inserted is not constant, the cross section of the surface layer is disturbed as shown in L in Figure 4a, and a beautiful border line pattern appears on the tile surface. There is a drawback that there is no Therefore, as shown in Fig. 3b, if the cross section of the strip-shaped metal material constituting the inner frame mold 2 is formed into a wedge shape that is thicker at the top and thinner at the bottom, the inner frame mold 2 can be pulled out from the unhardened surface mortar layer. However, since the adjacent surface mortar layers adjoin each other in a straight line as shown by M in FIG. 4b, the line pattern appears beautifully and accurately on the tile surface.

Next, the production of marble chips that will become the surface layer will be explained. Patterned terrazzo tiles differ from conventional terrazzo tiles in that they use natural marble chips to create a mosaic-like feel, so their grain size and shape must be consistent.
In this example, the grain size of the marble chips was 1.8.
mm to 2.5 mm. After producing marble chips with this particle size and shape, the marble chips are washed with water to remove stone powder attached to the surface of the chips.
This is a step to prevent the white cement from discoloring when preparing the mortar that will become the surface layer 4, as will be described later. A plurality of types of marble chips thus cleaned are manufactured according to the color of natural marble.

The natural marble chips washed as above are mixed with calcium carbonate powder and white cement, mixed with water and kneaded to form the surface layer mortar which will become the surface layer 4 of the tile as shown in Figure 5 a to c. A′, B′, and C′ are manufactured separately. The reason why calcium carbonate powder is added here is to make the mortar harden quickly due to the high water absorption rate of calcium carbonate. The mortar that will become the surface layer of the tiles made in this way is placed on blocks A, B, and C, in which the inner surface of the outer frame mold 1 is divided by the inner frame mold 2, as described above. mortar A′,
As described above, B'C' is introduced, and then the vibrating table plate 3 is vibrated back and forth and left and right to disperse the mortar and remove air bubbles.

On the surface layers 4a to 4c of the marble chips, which have been dispersed and removed air bubbles by vibrating the vibrating table plate 3 as described above,
A dry powder mixture of calcium carbonate chips (particle size 0.6 mm to 1.2 mm) and ordinary cement powder is sprinkled, and the tile intermediate layer 5 is laminated. Normally, terrazzo tiles are made by pressure-forming by adding ordinary mortar, which is made of river sand, pea gravel, and ordinary cement, to form the bottom layer on top of the surface layer formed by so-called surface mortar. It is manufactured by dehydrating the surface layer of mortar using mortar. This principle is basically used for patterned terrazzo tiles, but from the outer frame mold 1 to the inner frame mold 2.
Remove the surface layer 4a~ which has not hardened yet.
When ordinary mortar is poured into mortar made of 4c marble chips, the impact or the impact of press pressure causes the surface layer mortar to mix in at the boundaries of the surface layers 4a and bc or the boundaries of the surface layers 4b and 4c, making it difficult to accurately It was impossible to show the boundary line, and this became the bottleneck for producing patterned terrazzo tiles. In order to solve this problem, in this embodiment, as described above, a mixed powder of calcium carbonate chips and ordinary cement is sprinkled on the surface layers 4a to 4c to form the intermediate layer of the tile. 4
It was designed to absorb moisture from a to 4c and rapidly dehydrate it. In particular, calcium carbonate chips have a high absorption rate and are therefore effective in reducing dehydration.

After the moisture in the surface layers 4a to 4c is rapidly absorbed by the mixed powder layer of dried calcium carbonate chips and ordinary cement as described above, ordinary mortar is made by adding water to river sand, pea gravel, and ordinary cement. is placed in an automatic feeder, etc., and press 7 is placed on top of it.
Even if pressure is applied by
At the boundary between a and 4b or between the tile surface layers 4b and 4c, the surface layer mortar made of marble chips does not mix, and the boundary appears as a beautiful line pattern. In addition, the thickness of each layer is approximately
12~15mm, middle layer about 2~3mm, bottom layer 15~20
mm, and a high-pressure hydraulic press with a pressure of approximately 200 kg/cm ² is used.

The semi-finished tiles that have been pressure-formed using a high-pressure press as described above are easily stored and steam-cured for at least 48 hours to harden. The surface layer 4 of the cured semi-finished tile is polished with a whetstone, which can be classified into three types depending on the purpose of use. In other words, the first stage is the surface polishing stage, the second stage is the polishing stage,
The third step is to add luster. The main raw materials for the grinding wheels used in the first polishing stage and the second polishing stage are alumina cement, pumice, and carborundum, and the only difference is the roughness of the grain.
For polishing to achieve a glossy shine, a fine grindstone made of alumina cement, carborundum, sulfuric acid, and lead is used. Polishing is carried out using a whetstone with the above configuration, but the whetstone at the third gloss stage contains oxidative acid as mentioned above, and although this oxalic acid is solid in the whetstone state, it does not affect the polishing process. Sometimes, it dissolves in the water used to form a film on the surface of the tile and at the same time penetrates into the tile. As a result, when tiles are placed on the floor, for example, patterned terrazzo tiles are created that retain their luster even after long periods of wear and tear.

In the above embodiment, natural marble chips were used for the surface layer mortar that forms the surface of the tiles, but it goes without saying that ordinary natural marble may be used as long as it produces beautiful colors. Furthermore, if the inner frame mold 2 is formed appropriately, it becomes possible to manufacture terrazzo tiles with various patterns as shown in FIGS. 6a, b, and c.

As explained in detail above, the method for manufacturing patterned terrazzo tiles according to the present invention involves inserting an inner frame mold into an outer frame mold into which the inner surface of the outer frame mold is divided into several blocks; After adding surface layer mortar to form the surface layer, the inner frame mold is removed and dry powder mixed with calcium carbonate chips and ordinary cement is sprinkled and laminated on the top of the surface layer to form an intermediate layer, and then ordinary mortar is added. The bottom layer was formed by stacking the layers, and then the bottom layer was formed using a press, so the middle layer, which was made by sprinkling and stacking a mixed powder of dry calcium carbonate and ordinary cement, absorbed the moisture in the surface layer and formed the surface layer. After that, regular mortar is added to form the bottom layer, and even if it is press-formed using a press, the pattern on the surface layer will not be disturbed by these impacts, resulting in patterned terrazzo tiles with beautiful border lines. Can be manufactured.

In addition, after rough polishing the semi-finished patterned terrazzo tiles manufactured as described above, the final polishing was performed using a grindstone made of lead, acid, and carborundum based on alumina cement.
It has extremely excellent effects, such as being able to produce patterned terrazzo tiles with a beautiful acid-induced luster that lasts forever.

[Brief explanation of drawings]

Figure 1 shows the mold; Figure a is a perspective view of the outer frame mold, Figure b is a perspective view of the inner frame mold, and Figure c is a state in which the inner frame mold is inserted into the outer frame mold. Surface view showing 2nd
Figures a to f are diagrams showing the manufacturing process of patterned terrazzo tiles, and Figure 3 is a cross-sectional view of the band-shaped metal material that constitutes the mold. Figure 4 shows the inner frame mold removed from the surface layer, Figure 5 shows the surface layer mortar, and Figures 6 a to C show various patterned terrazzo tiles. It is. In the figure, 1 is an outer frame mold, 2 is an inner frame mold, 3 is a vibration table plate, 4 is a surface layer, 5 is an intermediate layer, 6 is a bottom layer, 7
is a press.

Claims (1)

[Scope of Claims] 1. An inner frame mold for dividing the inner surface of the outer frame mold into a plurality of blocks is inserted into a tile outer frame mold placed on a vibrating table plate, and then natural marble, etc. Surface layer mortar, which is a mixture of stone chips, calcium carbonate, and white cement, is put into each block divided by the inner frame mold, and the drive section of the vibrating table plate is activated to vibrate the surface layer mortar to create a surface layer. After the layer mortar is dispersed to every corner of the mold and air bubbles are removed to form a surface layer, the inner frame mold is removed from the outer frame mold, and the calcium carbonate and ordinary cement on the surface layer mortar are mixed. Dry powder is sprinkled and laminated to form an intermediate layer, and ordinary mortar is added and laminated to form a bottom layer. A press is used to apply high pressure from the top of the bottom layer to form it under pressure, and finally the outer frame is formed. A method for producing a patterned terrazzo tile, which comprises removing the terrazzo tile. 2 Inside the tile outer frame mold placed on the vibration table plate,
The inner surface of this outer frame mold is divided into a plurality of blocks, and an inner frame mold is inserted and placed in which the cross section of the band-shaped metal material constituting the mold is formed into a wedge shape with a thicker upper part and a thinner lower part.
Next, surface layer mortar, which is a mixture of stone chips such as natural marble, calcium carbonate, and white cement, is poured into each block divided by the inner frame mold, and the drive unit of the vibrating table plate is activated to form the surface layer mortar. After applying vibration to the mortar to disperse the surface layer mortar to every corner of the mold and removing air bubbles to form a surface layer, the inner frame mold is removed from the outer frame mold, and carbonic acid is applied onto the surface layer mortar. A dry powder mixture of calcium and ordinary cement is spread and laminated to form an intermediate layer, and ordinary mortar is added and laminated to form a bottom layer, and a press applies high pressure from the top of the bottom layer to form it under pressure. and, finally, removing the outer frame. 3. An inner frame mold that divides the inner surface of the outer frame mold into multiple blocks is inserted into a tile outer frame mold placed on a vibrating table plate, and then stone chips such as natural marble and calcium carbonate are placed. A surface layer mortar mixed with white cement is poured into each block divided by the inner frame mold, and the drive unit of the vibrating table plate is started to vibrate the surface layer mortar, and the surface layer mortar is moved into the mold. After forming a surface layer by dispersing the powder into every corner of the mortar and removing air bubbles, the inner frame mold is removed from the outer frame mold, and a dry powder of a mixture of calcium carbonate and ordinary cement is sprinkled on the surface layer mortar. Laminate them to form an intermediate layer, add ordinary mortar and layer them to form a bottom layer, apply high pressure from the top of the bottom layer with a press to press and form, then remove the outer frame and cure, A method for manufacturing a patterned terrazzo tile, which is characterized in that the surface of the surface layer is roughly polished with a whetstone, and finally polished to a gloss with a whetstone made of lead, acid, and carborundum based on alumina cement.