JP6744637B2 - Method of manufacturing structure and structure - Google Patents

Description

The present invention relates to a method for manufacturing a makeup structure and a makeup structure.

Artificial stone finishing methods known as artificial stone finishing and on-site terrazzo finishing are known as methods for finishing artificial stone structures with beautiful patterns such as marble. These construction methods apply a mixture of cement paste and seed stones such as crushed marble to the substrate, and when the degree of hardening of the cement paste is measured, grind with a grindstone, a grinder, a grinder, etc. This is a method of grinding a seed stone to obtain a flat decorative surface. The decorative structure by such a construction method is used indoors and outdoors of a building, for example, floors, walls, waist walls, skirting boards, sinks, counter tops, table tops, and the like.

The difference between the artificial stone sharpening finish and the on-site terrazzo finish is mainly the size of the seed stone used. The artificial stone sharpening finish is often referred to as a construction method when a relatively small seed stone is used, and the on-site terrazzo finish is often referred to as a construction method when a relatively large seed stone is used. In the present specification, they may be described as a sharpened finishing method without distinguishing them.

As a prior art document related to the sharpening finishing method, there is Patent Document 1, for example. Patent Document 1 discloses a step of preparing an aggregate aggregate including aggregates adhered to each other with an adhesive, a step of embedding the aggregate aggregate in cement paste, a step of curing the cement paste, and a cured cement. An invention relating to a method for producing terrazzo, which includes a step of polishing the surface of the paste to polish the aggregate aggregate, is disclosed.

JP 2012-001403 A

In the conventional general sharpening finishing method, a mixture obtained by kneading cement paste and seed stone is applied to the substrate, the surface of the hardened material after the cement paste in the mixture is hardened to some extent is ground, and the seed stone is polished. A method is used in which the product is sharpened and wax is applied to the finish to give a flat and glossy decorative surface.

In the above-mentioned conventional general sharpened finishing method (hereinafter sometimes referred to as “conventional method”), when the mixture of the cement paste and the seed stone is applied, the seed stone is buried in the cement paste. There is. Therefore, the degree of clogging of the seed stone cannot be known until after the surface of the hardened material after the cement paste in the applied mixture hardens is scraped. Therefore, if there is a problem with the degree of clogging of the seed stone, it will be necessary to redo the work after grinding and polishing, so in order to avoid such a situation as much as possible, the work of applying the mixture Requires skilled skills.

Further, in the above-mentioned conventional method, the curing period after applying the mixture and before grinding or polishing is usually about 3 to 5 days, but the curing period was too long when grinding or polishing was performed. Therefore, if the cement paste is hardened too much, it becomes difficult to perform grinding or polishing. On the other hand, if the cement paste is not sufficiently hardened due to the curing period being too short and grinding or polishing is performed, the seed stones will come out of the cement paste like jumping. Therefore, in the above-mentioned conventional method, it is necessary to carry out the polishing work while observing the degree of hardening of the cement paste.

Further, the above conventional method requires a lot of work in the step of grinding and polishing the surface of the applied mixture. In this grinding and polishing operation, first, rough cutting is performed first, and then intermediate cutting, finishing cutting and the like are performed. Further, when the cement paste and the seed stone are kneaded, air is entrained in the mixture, and the air entrained during the kneading is an air hole ( It is visually recognized as a pinhole. Therefore, it is necessary to work to fill the pinholes in the polishing step.

As described above, the above-mentioned conventional construction method requires a skilled construction technique, and is a construction method that requires a lot of labor and a long construction period.

Therefore, the present invention provides a method capable of obtaining a makeup structure having a makeup surface having a design of a sharpening tone with a simpler work and a smaller number of steps as compared with the conventional sharpening finishing method, and a novel sharpening tone method. It is intended to provide a makeup structure having a makeup surface of the above design.

According to the present invention, a mixing step of kneading a resin binder and a plurality of beautiful aggregates to prepare a kneaded product thereof, and a coating step of applying the kneaded product to a substrate to form a coated product. Curing the resin binder in the coating, and curing the resin binder, and the plurality of beautiful aggregates bonded by the resin binder in the state of having voids between the plurality of beautiful aggregates. And a curing step of forming a beautiful aggregate layer, and polishing the surface of the beautiful aggregate layer, the surface of the plurality of beautiful aggregate exposed visibly on the surface side, the polished surface is ground flat. There is provided a method for manufacturing a decorative structure including a polishing step of forming a decorative aggregate layer having the decorative aggregate layer.

Further, according to the present invention, a decorative aggregate layer including a resin binder and a plurality of beautiful aggregates which are adhered with the resin binder and are visibly exposed on the surface side is provided. The layer has, on the surface side, a polishing surface in which the exposed surfaces of the plurality of exposed beautiful aggregates are flattened, and the plurality of the beautiful aggregates provided with the polishing surface is a convex portion, and, There is provided a decorative structure having a concave-convex structure in which a recess is formed between the plurality of beautiful aggregates which is a peripheral portion thereof.

Furthermore, according to the present invention, a resin binder, a plurality of beautiful aggregates that are bonded by the resin binder and are visibly exposed on the surface side, and between the plurality of beautiful aggregates that are the peripheral portions thereof. And a decorative aggregate layer containing, and the decorative aggregate layer has, on the surface side, a polished surface on which the surfaces of the exposed beautiful aggregates are flattened, Provided is a makeup structure in which the plurality of beautiful aggregates provided with the polishing surface and the filling material provided between the plurality of beautiful aggregates which are the peripheral portions are formed flush with each other. It

According to the present invention, as compared with the conventional sharpening finishing method, a method capable of obtaining a makeup structure having a decorative surface having a sharpening-like design with a simpler work and fewer steps, and a novel sharpening finishing method. It is possible to provide a makeup structure having a makeup surface of the above design.

It is a flow chart showing an example of a manufacturing method of a makeup structure of a 1st embodiment of the present invention. It is sectional drawing which shows typically an example of the beautiful aggregate layer obtained after the hardening process in the manufacturing method of the decorative structure of 1st Embodiment of this invention. It is sectional drawing which shows typically an example of the makeup|decoration structure of 1st Embodiment of this invention. It is a flow chart showing an example of a manufacturing method of a makeup structure of a 2nd embodiment of the present invention. It is sectional drawing which shows typically an example of the makeup|decoration structure of 2nd Embodiment of this invention. It is a flow chart showing an example of a manufacturing method of a makeup structure of a 3rd embodiment of the present invention. It is sectional drawing which shows typically an example of the makeup|decoration structure of 3rd Embodiment of this invention.

Hereinafter, embodiments of the present invention may be described with reference to the drawings, but the present invention is not limited to the following embodiments. In addition, the same components in each drawing are denoted by the same reference numerals, and the description thereof may be omitted.

As described above, the conventional general sharpened finishing method (conventional method) requires a skilled construction technique and requires a lot of labor and a long construction period. Therefore, compared to the conventional sharpening finish construction method, the present inventors have a simpler work without a skilled technique, and with a smaller number of steps, a makeup with a design that can be obtained by the conventional sharpening finish construction method. The method for obtaining the decorative structure having a face was earnestly studied.

In the above examination, first of all, the present inventors selected a resin binder as a binder for a beautiful aggregate as a seed stone, which has a shorter curing period than the cement paste (cement binder) and is easy to grind and polish. I decided to use it. Then, the kneaded material of the resin binder and the plurality of beautiful aggregates is applied to cure the resin binder, and the cured resin binder and the beautiful aggregate adhered by the resin binder in the state of having voids After forming a beautiful aggregate layer (an aggregate of beautiful aggregates) containing it, the surface of the beautiful aggregate layer was polished. Then, at that stage, the raised decorative aggregate layer in which a plurality of beautiful aggregates are bonded has a polished surface on which the surfaces of the plurality of beautiful aggregates that are visibly exposed on the surface side are flattened, It is possible to obtain a makeup structure (see the first embodiment described later) having a new sharpened design decorative surface in which a plurality of polished beautiful aggregates are three-dimensionally viewed in relation to the voids in the peripheral portion thereof. all right.

In addition, after polishing the surface of the above-mentioned beautiful aggregate layer, by providing a filling material in the above-mentioned voids, it is possible to obtain a plurality of polished beautiful particles even though it looks like a decorative surface obtained by the above-mentioned conventional method in plan view. A decorative structure (see the second embodiment described later) having a decorative surface with a novel sharpened design in which the aggregate looks three-dimensionally in relation to the surrounding filling material and has a more distinct contrast is obtained. I understood it.

Furthermore, by forming the filling material provided in the voids flush with a plurality of polished beautiful aggregates, the decorative surface looks like a flat decorative surface obtained by the above-mentioned conventional method. It was found that a makeup structure (see the third embodiment described later) having a makeup surface with a novel sharpened design in which the occurrence of pinholes was suppressed was obtained as compared with the above.

As described above, the method for manufacturing a decorative structure according to an embodiment of the present invention provides a surface of a beautiful aggregate layer including a resin binder and a plurality of beautiful aggregates bonded with the resin binder in a state of having voids. Is ground to form a decorative aggregate layer having a polished surface in which the surfaces of a plurality of beautiful aggregates are flattened. Further, the makeup structure of one embodiment of the present invention is a makeup structure having a novel sharpening-like design makeup surface, which was found as a result of the study by the present inventors based on such a construction method.

In the present specification, the “makeup structure” refers to a structure using a beautiful aggregate that can be seen by people indoors or outdoors. "Beautiful aggregate layer" means a layer containing a resin binder and a plurality of beautiful aggregates before being polished, which are adhered with a resin binder in a state having voids, and the "decorative aggregate layer" is , After the surface of the beautiful aggregate layer has been polished. Further, the “decorative surface” refers to a surface on the surface side visually recognized in the decorative structure. Further, the "sharpened design decorative surface" means the decorative surface of the decorative aggregate layer. Therefore, it can be said that the sharpened design decorative surface is a cosmetic surface in which the beautiful aggregate is more positively polished than the binder because the surface of the beautiful aggregate layer is polished. In this respect, the decorative surface of the sharpened design is the decorative surface obtained by the above-mentioned conventional method (that is, by polishing the cement hardened material in which the seed stone is buried, Exposed face)).

(The manufacturing method of 1st Embodiment)
FIG. 1 is a flowchart showing an example of a method for manufacturing a decorative structure according to the first embodiment of the present invention (sometimes simply referred to as the “manufacturing method of the first embodiment”). The manufacturing method of the first embodiment includes a mixing step S1 of kneading a resin binder and a plurality of beautiful aggregates to prepare a kneaded product, and a step of applying the kneaded product to a substrate to form a coated product. The attaching step S2 is included. In addition, this manufacturing method cures the resin binder in the coating, and a plurality of the beautiful aggregates bonded with the cured resin binder and the plurality of the beautiful aggregates in a state having voids between the plurality of the beautiful aggregates. And a curing step S3 for forming a beautiful aggregate layer including and. Further, this manufacturing method comprises polishing the surface of the beautiful aggregate layer, and forming a decorative aggregate layer having a polishing surface in which the surfaces of the plurality of beautiful aggregates visibly exposed on the surface side are ground flat. Step S4 is included.

In the mixing step S1, a resin binder and a plurality of beautiful aggregates are kneaded to prepare a kneaded product thereof. In the mixing step S1, a resin before curing is preferably used, and a curable resin that cures from a liquid state to a solid state at room temperature (5 to 35° C.) is more suitably used.

As the resin (active ingredient) contained in the resin binder, any of the resins used as the resin binder in the conventional decorative structure can be used. Examples of such a resin include urethane-based resins, epoxy-based resins, acrylic-based resins, and unsaturated polyester-based resins, and one or more of them can be used.

As the beautiful aggregate, any of the seed stones used in the above-mentioned conventional method can be used. Examples of the material of the beautiful aggregate include natural stone, artificial stone, artificial stone, and marble, and examples of the shape include cobblestone and crushed stone. The size of the beautiful aggregate is not particularly limited, and for example, a beautiful aggregate having a particle size of 3 to 24 mm can be preferably used. One of the beautiful aggregates may be used alone, or two or more thereof may be used in combination.

The mixing ratio of the resin binder and the plurality of beautiful aggregates is not particularly limited, but the resin may be mixed so as to form a beautiful aggregate layer having voids between the plurality of beautiful aggregates in the subsequent curing step S3. The mixing ratio is preferably such that the beautiful aggregate is not completely buried in the binder. From such a viewpoint and adhesiveness, the amount of the resin binder used is preferably 1 to 40 parts by mass, and 2 to 20 parts by mass as the solid content of the resin, relative to 100 parts by mass of the beautiful aggregate. Parts are more preferred, and 3 to 10 parts by mass are even more preferred. In addition, in the mixing step S1, it is preferable to thoroughly knead the plurality of beautiful aggregates with a hoe or the like until the resin binder is uniformly mixed.

In the applying step S2, the kneaded material prepared in the mixing step S1 is applied to the base material to form a coating material containing a resin binder and a plurality of beautiful aggregates on the base material. The substrate to which the kneaded product is applied is not particularly limited, and examples thereof include mortar, concrete, asphalt, slate, and wood board. Before applying the kneaded product to the substrate, a primer for increasing the adhesive strength between the substrate and the beautiful aggregate may be applied to the substrate.

When applying the kneaded material to the substrate, it is preferable to apply it smoothly using a metal trowel or the like, and it is preferable to apply it so that the beautiful aggregate becomes dense on the surface side. Also, at this time, in the subsequent curing step S3, kneading is performed so that the beautiful aggregate is not completely buried in the resin binder so that a beautiful aggregate layer having voids is formed between the plurality of beautiful aggregates. It is preferable to apply the article to the substrate. In this way, or in addition to this, by using a resin binder that is transparent enough to visually recognize the beautiful aggregate, it is possible to remove the beautiful aggregate before the subsequent polishing step S4. It is possible to check the clogging condition and the line condition, which is also advantageous in comparison with the above-mentioned conventional method.

That is, in the above-mentioned conventional method, at the stage of applying the mixture of cement paste and seed stone, since the seed stone is buried in the cement paste, the degree of clogging of the seed stone is after hardening of the applied mixture. Only after the surface of the cured product has been scraped will it be known. Therefore, if there is a problem in how the seed stones are clogged, it becomes necessary to perform the grinding and polishing work again. On the other hand, in the manufacturing method of the embodiment of the present invention, since the resin binder is used as the binder, it is easy to check the clogging degree of the beautiful aggregate in the step of the applying step S2 as described above. Also, it is easy to avoid re-applying after the polishing step S4, and as a result, there is an advantage that no work by an expert is required.

In the curing step S3, the resin binder in the coating material formed on the substrate in the coating step S2 is cured. As a result, as shown in FIG. 2, a cured resin binder (not shown) and a plurality of beautiful aggregates 12 bonded with the resin binder in the state of having voids 14 between the plurality of beautiful aggregates 12. A beautiful aggregate layer 11 containing is formed on the substrate 1. The resin binder in the beautiful aggregate layer 11 is present in a state of being coated on the surface of each beautiful aggregate 12, adheres the plurality of beautiful aggregates 12 to each other, and forms the plurality of beautiful aggregates 12 and the base 1 with each other. Glue. The “state having voids between a plurality of beautiful aggregates” in the beautiful aggregate layer 11 means a state in which the beautiful aggregate 12 is not completely buried in the resin binder in the beautiful aggregate layer 11. As a result, the beautiful aggregate layer 11 has a raised appearance in which the plurality of beautiful aggregates 12 are bonded to each other with the voids 14 between the plurality of beautiful aggregates 12. In other words, in the steps up to the curing step S3, the beautiful aggregate layer 11 having a concavo-convex structure in which the beautiful aggregate 12 is a convex portion and the void 14 is a concave portion is formed.

Since the resin binder is used as the binder, the curing time (curing period) of the resin binder in the curing step S3 is greater than the curing time (curing period) in the case of the above-mentioned conventional method using cement paste. It can be greatly shortened. Specifically, assuming that the construction is actually carried out at a construction site under the condition of about 20° C., in the case of the above-mentioned conventional construction method, curing is generally performed for about 5 days, whereas the production of one embodiment of the present invention. With the method, one day of curing is sufficient.

In the polishing step S4, the surface of the beautiful aggregate layer (11; see FIG. 2) obtained in the curing step S3 is polished. As a result, as shown in FIG. 3, the decorative aggregate layer 16 having the polishing surface 12a in which the surfaces of the plurality of beautiful aggregates 12 that are visibly exposed on the surface side are ground flat is formed. Therefore, like the beautiful aggregate layer 11, the decorative aggregate layer 16 at the stage of the polishing step S4 also has the voids 14 between the plurality of beautiful aggregates 12. By the polishing step S4, the decorative aggregate layer 16 has the polishing surface 12a, and the plurality of beautiful aggregates 12 provided with the polishing surface 12a are the convex portions 13, and the plurality of beautiful aggregates which are the peripheral portions thereof. It has a concavo-convex structure in which the space between 12 (that is, the void 14) is a recess 15. Further, since the decorative aggregate layer 16 is obtained by polishing the surface of the beautiful aggregate layer 11, at least the polishing surface 12a of the decorative aggregate layer 16 is not provided with the resin binder (removed). ) Can be configured. Due to the configuration and the concavo-convex structure described above, the decorative surface 10a that is hard to slip even when wet with rain or the like is likely to be formed. In addition, at the time of the polishing step S4, the polishing surface 12a may be provided on all or part of the plurality of visibly exposed beautiful aggregates 12 on the surface side of the decorative aggregate layer 16.

In the polishing step S4, a grindstone, various kinds of grinders and grinders can be used, and preferably a disc grinder can be used. The polishing step S4 preferably includes a rough cutting step and a finishing cutting step after the rough cutting step. In the rough cutting step, it is preferable to perform a step of flattening the surface of the beautiful aggregate by using an abrasive having a grain size coarser than that of the abrasive used in the finishing step (more preferably, an abrasive for a metal pad). In the finishing step, the surface of the beautiful aggregate that has been flattened in the roughing step is used by using an abrasive material with a finer grain size (more preferably, an abrasive material of a resin pad) than the abrasive material used in the roughing step. It is preferable to carry out a polishing step.

In the manufacturing method of one embodiment of the present invention, since the binder in the beautiful aggregate layer to be polished is made of resin, the seed stone in the above-mentioned conventional method is more polished than the one buried in the hardened cement paste. It is possible to reduce the labor and amount of shaving in the process. That is, in the above-mentioned conventional method, since it is necessary to polish a hard cement hardened product in which the seed stone is buried together with the seed stone, the pad used for polishing is comparatively fine from the very coarse grain size even at the rough cutting stage alone. It requires multiple man-hours such as polishing while changing to a grain size. On the other hand, in the polishing step S4 in the manufacturing method according to the embodiment of the present invention, since the beautiful aggregate adhered with the resin binder is polished, the roughing step of flattening the surface of the beautiful aggregate is relatively performed. It can also be performed in one step using a fine grained pad. Therefore, it is possible to reduce the labor (including tools used) and the amount of scraping (the amount of dust) in the polishing process.

Further, in the above-mentioned conventional method, after the mixture containing the seed stone and the cement paste is applied and cured, the air entrapped when the cement paste and the seed stone are kneaded in the step of scraping the surface of the cured product. Since it is visually recognized as a pinhole, it is necessary to fill the pinhole. On the other hand, in the manufacturing method according to the embodiment of the present invention, a beautiful aggregate layer in a state of having voids between a plurality of beautiful aggregates is a polishing target, and most of the visible aggregates are beautiful aggregates. Therefore, since the pinhole is hard to be visually recognized as an appearance, the work of filling the pinhole can be omitted. Further, as will be described later, the work of filling the pinholes can be omitted by performing the filling process of providing the filling material in the voids (see the second and third embodiments described later).

In the method for manufacturing a decorative structure according to one embodiment of the present invention, after the polishing step S4, a filling step of providing a filling material in the voids between the plurality of beautiful aggregates in the decorative aggregate layer may be performed. However, it is also possible to adopt a mode in which the filling step is not performed. This aspect is referred to as the manufacturing method of the first embodiment in this specification, and an example of the makeup structure obtained by the manufacturing method of the first embodiment is referred to as the makeup structure of the first embodiment. ..

(The makeup structure of the first embodiment)
FIG. 3 is a schematic cross-sectional view showing an example of the makeup structure of the first embodiment. The decorative structure 10 of the first embodiment is a decorative aggregate that includes a resin binder (not shown) and a plurality of beautiful aggregates 12 that are bonded with the resin binder and are visibly exposed on the surface side. The layer 16 is provided. The resin binder in the decorative aggregate layer 16 exists in a state of being coated on the surface of the beautiful aggregate 12 excluding the polishing surface 12a, and bonds the plurality of beautiful aggregates 12 to each other. 12 and the base 1 are bonded. The decorative aggregate layer 16 has, on the surface side, a polishing surface 12a in which the exposed surfaces of the plurality of beautiful aggregates 12 are flattened, and the plurality of beautiful aggregates 12 provided with the polishing surfaces 12a are provided with convex portions. 13 and has a concave-convex structure in which recesses 15 are formed between the plurality of beautiful aggregates 12 which are the peripheral portions thereof. The decorative aggregate layer 16 has voids 14 between the plurality of beautiful aggregates 12, which are the peripheral portions, forming concave portions 15 having an uneven structure.

The makeup structure 10 of the first embodiment includes a resin-like binder and a plurality of beautiful aggregates 12 adhered by the resin binder with a void 14 between the plurality of beautiful aggregates 12. The aggregate layer 16 has a polished surface 12a in which the surfaces of the plurality of beautiful aggregates 12 that are visibly exposed on the surface side are ground flat. With such a configuration, the plurality of polished beautiful aggregates 12 are visually recognized as the convex portions 13 having the concave-convex structure, and the voids 14 in the peripheral portion are visually recognized as the concave portions 15 having the concave-convex structure, so that a new three-dimensional appearance can be obtained. The makeup structure 10 has the makeup surface 10a having a sharpened design.

The decorative aggregate layer 16 in the decorative structure 10 according to the first embodiment has a plurality of beautiful aggregates 12 provided with the polishing surface 12a as convex portions 13 and a plurality of beautiful aggregates 12 which are the peripheral portions thereof. Since it has a concavo-convex structure in which the voids 14 are concave portions 15, it is less slippery than the flat and glossy decorative surface obtained by the above-mentioned conventional method. The decorative structure having a decorative surface obtained by the above-mentioned conventional method has a flat decorative surface and has a gloss and a mirror surface, which makes it slippery due to rainfall, etc. It is in. On the other hand, the decorative structure 10 according to the first embodiment is not slippery due to the configuration of the uneven structure or the like, and thus can be suitably used as an outdoor flooring material.

On the surface side of the non-slip decorative aggregate layer 16, the slip resistance value by a pendulum skid resistance tester in a wet state is preferably 40 BPN or more, more preferably 45 BPN or more, and more preferably 50 BPN or more. Is more preferable. The upper limit of measurement of the slip resistance value is about 150 BPN, and the decorative aggregate layer 16 in the decorative structure 10 of the first embodiment more preferably has the slip resistance value of 80 BPN or less in a wet state.

(The manufacturing method of 2nd Embodiment)
FIG. 4 is a flowchart showing an example of a method for manufacturing a decorative structure according to the second embodiment of the present invention (which may be simply referred to as “the manufacturing method according to the second embodiment”). The manufacturing method according to the second embodiment is different from the manufacturing method according to the first embodiment in that the manufacturing method according to the first embodiment further includes a filling step S5 after the polishing step S4 described above.

That is, the manufacturing method of the second embodiment includes the mixing step S1, the applying step S2, the curing step S3, and the polishing step S4 described above, and after the polishing step S4 described above, the decorative aggregate layer (16). The method further includes a filling step S5 for providing a filling material in the voids (14; see FIG. 3) between the plurality of beautiful aggregates (12).

Specifically, the filling step S5 in the present embodiment is a concavo-convex structure in which a plurality of beautiful aggregates provided with a polished surface are formed as convex portions, and a plurality of beautiful aggregates which are peripheral portions thereof are formed as concave portions. So as to form a filling material in a space between the plurality of beautiful aggregates. As a result of this step S51, as shown in FIG. 5, the plurality of beautiful aggregates 12 have the polishing surfaces 12a on which the surfaces are flattened, and the plurality of beautiful aggregates 12 provided with the polishing surfaces 12a form the convex portions 13. In addition, the decorative aggregate layer 26 having a concavo-convex structure in which the filling material 28 provided between the plurality of beautiful aggregates 12, which is the peripheral portion, is used as the concave portion 29 is formed.

More specifically, in the filling step S51 in the present embodiment, after the filling material is rubbed in or poured into the gap, the polishing surface is made higher than the surface of the filling material in the peripheral portion to the surface side. It is preferable to include a step of scraping out the filling material in the peripheral portion. Further, it is preferable that the filling step S51 includes a step of wiping off the filling material attached to the surface of the beautiful aggregate including the polished surface. After performing these steps, the filling material is cured to obtain the decorative aggregate layer having the above-mentioned concavo-convex structure. Rubbing or pouring of the filling material into the voids in the filling step S51 may be performed by allowing the filling material to enter the voids in the entire decorative aggregate layer so as to reach the substrate. Depending on the viscosity of the filling material used, the filling material may be rubbed into the void, may be poured, or may be poured while being rubbed. By adjusting the amount of the filling material rubbed into or poured into the void and the amount of the filling material raked out in the peripheral portion, the portion between the plurality of beautiful aggregates (joint portion) is deep (deep joint type). ) Or a shallow structure (shallow joint type) of a decorative aggregate layer can be formed.

When the filling material is provided in the void, a curable filling material before curing is preferably used, and at room temperature (5 to 35° C.), a curable filling material that hardens from a liquid state to a solid state is used. It is more preferably used. As such a filling material, an organic material such as the resin binder mentioned above and the resin materials mentioned in the description thereof may be used, or a cement binder may be used. As the cement binder, for example, cement paste, mortar, ready-mixed concrete or the like can be used.

In the above-mentioned filling step S51, it is preferable to use a rubber trowel for the work of rubbing or pouring the filling material into the gap and scraping the filling material in the peripheral portion. Further, in the above-mentioned filling step S51, the wiping operation of the filling material attached to the surface including the polished surface of the beautiful aggregate is performed after the filling material is rubbed or poured, and after the filling material is cured to some extent, Etc. are preferably used. For example, when cement paste is used as the filling material before curing, after rubbing or pouring of the cement paste, preferably 15 to 90 minutes later, more preferably 30 to 60 minutes later, still more preferably 45 to 60 minutes later. It is good to wipe it.

Since the manufacturing method of the second embodiment also includes the mixing step S1, the applying step S2, the curing step S3, and the polishing step S4 described above, the same effects as the effects described in the manufacturing method of the first embodiment described above. Can play. An example of the makeup structure obtained by the manufacturing method of the second embodiment will be described below as the makeup structure of the second embodiment.

(Decorative structure of the second embodiment)
FIG. 5 shows a schematic cross-sectional view showing an example of the makeup structure of the second embodiment. The decorative structure 20 according to the second embodiment includes a decorative aggregate layer 26 including a resin binder and a plurality of beautiful aggregates 12 that are adhered with the resin binder and exposed on the surface side in a visually recognizable manner. The decorative aggregate layer 26 has, on the surface side, a plurality of exposed beautiful aggregates 12 having a polished surface 12a obtained by flatly scraping the surfaces, and the plurality of beautiful aggregates 12 provided with the polished surfaces 12a are convex. It has a concavo-convex structure which is a part 13 and has a recess 29 between the plurality of beautiful aggregates 12 which is the peripheral part thereof. The decorative aggregate layer 26 further includes a filling material 28 that forms a concave portion 29 having an uneven structure between the plurality of beautiful aggregates 12 that are the peripheral portions. As described above, in the makeup structure 20 of the second embodiment, as compared with the makeup structure 10 of the above-described first embodiment, in the first embodiment, the portions forming the concave portions 15 and 29 in the uneven structure are different from those of the makeup structure 10 in the first embodiment. In contrast to the voids 14, the second embodiment is different in that it is a filling material (hardened filling material) 28.

As described in the manufacturing method of the second embodiment, a relatively small amount of the filling material 28 is provided between the plurality of beautiful aggregates 12 (joint portions), so that the joint portions (recesses 29) are deeply formed (deep joints). Structure) or by providing a relatively large amount of the filling material 28 between the plurality of beautiful aggregates 12 (joint portions), the makeup aggregate layer having a shallow joint portion (recess 29) (shallow joint configuration). 26 can be formed. In the deep joint structure, the depth of the joint portion (recess 29) from the polishing surface 12a can be set to, for example, about 0.6 to 2 mm. In the shallow joint structure, the joint portion (recess 29) from the polishing surface 12a may have a depth of, for example, about 0.1 to 0.5 mm.

The makeup structure 20 of the second embodiment includes the filling material 28 provided between the plurality of beautiful aggregates 12, so that the makeup surface 20a has a makeup surface obtained by the above-described conventional method in plan view. It seems. However, in the decorative structure 20 according to the second embodiment, the polishing surface 12a is the convex portion 13 and the filling material 28 provided between the plurality of beautiful aggregates 12 is the concave portion 29. 12a has a decorative surface 20a having a novel sharpened design with a sharper contrast, which looks three-dimensional in relation to the filling material 28.

The decorative aggregate layer 26 in the decorative structure 20 according to the second embodiment includes the filling material 28 that forms the recesses 29 between the plurality of beautiful aggregates 12, but has a concavo-convex structure. It is less slippery than the flat and glossy decorative surface obtained in. Therefore, the decorative structure 20 can also be suitably used as an outdoor flooring material. The decorative aggregate layer 26 in the decorative structure 20 preferably has a slip resistance value in the wet state of 30 BPN or more, more preferably 40 BPN or more, and further preferably 45 BPN or more.

(The manufacturing method of 3rd Embodiment)
FIG. 6 is a flowchart showing an example of a method for manufacturing a decorative structure according to the third embodiment of the present invention (sometimes simply referred to as the “manufacturing method of the third embodiment”). The manufacturing method of the third embodiment differs from the manufacturing method of the first embodiment in that it further includes a filling step S5 after the polishing step S4 described above, as compared with the manufacturing method of the first embodiment described above. Further, the manufacturing method of the third embodiment is different from the manufacturing method of the second embodiment in the way of providing the filling material in the filling step S5, as compared with the manufacturing method of the second embodiment. ..

That is, the manufacturing method of the third embodiment includes the above-described mixing step S1, application step S2, curing step S3, and polishing step S4, and after the polishing step S4, the decorative aggregate layer (16). The method further includes a filling step S5 of providing a filling material in the voids (14; see FIG. 3) between the plurality of beautiful aggregates 12 in FIG.

Specifically, the filling step S5 in the present embodiment is performed between the plurality of beautiful aggregates so that the plurality of beautiful aggregates provided with the polishing surface and the plurality of beautiful aggregates are formed flush with each other. The step S52 of providing a filling material in the void is included. As a result of this step S52, as shown in FIG. 7, the plurality of beautiful aggregates 12 have polishing surfaces 12a, the surfaces of which are ground flat, and the plurality of beautiful aggregates 12 provided with the polishing surfaces 12a and the surroundings thereof. It is possible to obtain the decorative aggregate layer 36 in which the filling material 38 provided between the plurality of beautiful aggregates 12, which is a portion, is flush with each other.

More specifically, in the filling step S52 in the present embodiment, after the filling material is rubbed or poured into the voids, the surface including the polishing surface of the plurality of beautiful aggregates is also covered with the filling material, It is preferable to include a step of curing the filling material. Further, it is preferable to include a step of polishing the hardened filling material covering the beautiful aggregate after the step. By these steps, the hardened filling material covering the beautiful aggregate is removed by polishing, and the plurality of beautiful aggregates having the polishing surface provided by the above-mentioned polishing step and the hardened material provided by the filling step are removed. It is easy to obtain a decorative aggregate layer that is flush with the above-mentioned filling material. The rubbing or pouring of the filling material into the voids in the filling step S52 is performed by inserting the filling material into the voids of the entire decorative aggregate layer so as to reach the base and fill the voids. Good.

In the step of polishing the hardened filling material covering the beautiful aggregate, a grindstone, various kinds of grinders and grinders can be used, and a disc grinder can be preferably used. In this process, the filler that can use the cement binder is ground, but since the beautiful aggregate has already been polished in the polishing process and the thickness of the filler covering the beautiful aggregate can be reduced, Compared with the conventional method, the curing period before polishing is short, and the labor (including tools used) and the amount of scraping required for polishing can be reduced. In addition, since the filler is not usually blended with a beautiful aggregate, it is difficult for air to be entrapped, so that it is possible to obtain a decorative aggregate layer in which pinholes unlike the conventional method are unlikely to occur. Therefore, also in the manufacturing method of the third embodiment, the work of filling the pinhole can be eliminated.

(The makeup structure of the third embodiment)
An example of the makeup structure obtained by the manufacturing method of the above-described third embodiment will be described as the makeup structure of the third embodiment with reference to FIG. 7. FIG. 7 is a schematic cross-sectional view showing an example of the makeup structure of the third embodiment. The decorative structure 30 according to the third embodiment includes a resin binder, a plurality of beautiful aggregates 12 that are adhered with the resin binder and are visibly exposed on the surface side, and a plurality of beautiful bones that are the surrounding portions. A decorative aggregate layer 36 including a filling material 38 filling the space between the materials 12 is provided. The decorative aggregate layer 36 has, on the surface side, a plurality of exposed beautiful aggregates 12 having a polished surface 12a on which the surfaces are flattened, and a plurality of the beautiful aggregates 12 provided with the polished surfaces 12a. And the filling material 38 provided between the plurality of beautiful aggregates 12, which is the peripheral portion, are formed flush with each other.

Since the makeup structure 30 of the third embodiment has the above-mentioned configuration, it looks like a flat makeup surface obtained by the above-mentioned conventional method, but the generation of pinholes is suppressed as compared with the makeup surface. It has a decorative surface 30a with a new sharpened design. Further, since the decorative structure 30 of the third embodiment is obtained by the manufacturing method of the above-described third embodiment, it is possible to reduce the need for skilled techniques compared to the conventional method, and the labor and time required for construction. It does not take much, and can have a low-cost decorative surface 30a having a flat, sharpened design.

According to the manufacturing method of the first to third embodiments described above in detail, the manufacturing method of the decorative structure according to the embodiment of the present invention is simpler and requires less work than the conventional method described above. In the process, like the makeup structures of the first to third embodiments, it is possible to obtain a makeup structure having a new sharpened design makeup surface. INDUSTRIAL APPLICABILITY The decorative structure according to one embodiment of the present invention can be widely used indoors and outdoors of buildings, for example, floors, walls, waist walls, skirting boards, sinks, counter tops, and table tops.

As described above, in the applying step in the manufacturing method according to the embodiment of the present invention, it is preferable to apply the beautiful aggregate to the substrate so as to be dense, and in the makeup aggregate layer in the makeup structure, The ratio of the beautiful aggregate to the surface is preferably 40 to 90%, more preferably 50 to 80%, further preferably 55 to 70%.

In addition, the decorative surface of the decorative structure according to the embodiment of the present invention can be provided with luster, if necessary. In that case, wax can be provided on the surface of the obtained decorative aggregate layer in the method for producing a decorative structure according to one embodiment of the present invention. When wax is not provided on the surface of the decorative aggregate layer, it is possible to obtain a calm finished non-slip decorative surface.

As described above, the manufacturing method of the decorative structure according to the embodiment of the present invention can adopt the following configurations [1] to [6].
[1] A mixing step of kneading a resin binder and a plurality of beautiful aggregates to prepare a kneaded product thereof; a coating step of coating the kneaded product on a substrate to form a coated product; The resin binder in the work is cured, and the cured resin binder and the plurality of beautiful aggregates bonded with the resin binder in the state of having voids between the plurality of beautiful aggregates are included. A hardening step of forming a beautiful aggregate layer, and polishing the surface of the beautiful aggregate layer, and a decorative bone having a polished surface in which the surfaces of the plurality of the beautiful aggregate exposed visibly on the surface side are ground flat A method of manufacturing a decorative structure, comprising: a polishing step of forming a material layer.
[2] The method for manufacturing a decorative structure according to [1], further including a filling step of providing a filling material in the voids between the plurality of beautiful aggregates in the decorative aggregate layer after the polishing step. ..
[3] In the filling step, a concavo-convex structure is formed in which the plurality of beautiful aggregates provided with the polishing surface are convex portions and the plurality of beautiful aggregates which are peripheral portions thereof are concave portions. As described above, the method for producing a decorative structure according to the above [2], including a step of providing the filling material in the voids between the plurality of beautiful aggregates.
[4] In the filling step, the plurality of beautiful aggregates provided with the polishing surface and the plurality of beautiful aggregates are formed so as to be flush with each other. The method for producing a decorative structure according to the above [2], including a step of providing the filling material in the void.
[5] In the filling step, after the filling material is rubbed or poured into the gap, the polishing surface is higher than the surface of the filling material in the peripheral portion toward the surface side, The method for manufacturing a decorative structure according to the above [3], including a step of scraping out the filling material in the peripheral portion, and a step of wiping off the filling material adhering to the surface of the beautiful aggregate including the polishing surface. ..
[6] In the filling step, while covering or pouring the filling material into the voids, the surface including the polishing surface of the plurality of beautiful aggregates is also covered with the filling material, and then the filling is performed. The method for manufacturing a decorative structure according to the above [4], comprising a step of curing a material, and a step of polishing the cured filling material covering the beautiful aggregate after the step.

Moreover, the makeup|decoration structure of one Embodiment of this invention can take the following structures [7]-[11].
[7] A decorative aggregate layer including a resin binder and a plurality of beautiful aggregates that are adhered by the resin binder and are visibly exposed on the surface side, and the decorative aggregate layer is the surface. On the side, the exposed surfaces of the plurality of beautiful aggregates have a polished surface that is flattened, and the plurality of the beautiful aggregates provided with the polishing surface are convex portions and are the peripheral portions thereof. A decorative structure having a concavo-convex structure having recesses between the plurality of beautiful aggregates.
[8] The decorative structure according to the above [7], wherein the decorative aggregate layer has a void that forms the concave portion of the concave-convex structure between the plurality of beautiful aggregates that are the peripheral portions.
[9] The decorative structure according to the above [7], wherein the decorative aggregate layer further includes a filling material forming the concave portion of the concave-convex structure between the plurality of beautiful aggregates which are the peripheral portions. body.
[10] The decorative structure according to any one of [7] to [9], wherein the decorative aggregate layer has a slip resistance value of 40 BPN or more in a wet state on a pendulum type skid resistance tester on the surface side. body.
[11] A resin binder, a plurality of beautiful aggregates that are bonded with the resin binder and are visibly exposed on the surface side, and a filling material that fills the space between the plurality of beautiful aggregates that is the peripheral portion. And a decorative aggregate layer including, and the decorative aggregate layer has, on the surface side, a polishing surface in which the exposed surfaces of the plurality of beautiful aggregates are flattened, and the polishing surface is provided. A decorative structure in which the plurality of beautiful aggregates and the filling material provided between the plurality of beautiful aggregates, which are the peripheral portions, are flush with each other.

Hereinafter, the method for producing a makeup structure of one embodiment of the present invention and the makeup structure obtained thereby will be described more specifically with reference to Test Examples, but the present invention is limited by the following Test Examples. Not a thing. In addition, "%" and "part" in the following text are based on mass (respectively "mass%" and "part by mass") unless otherwise specified.

(Test Example A1)
Quasi-double-sided plywood (290 mm x 220 mm x thickness 5.5 mm) was used as the substrate. A frame (27 cm×20 cm=540 cm ² ) was made on this base by using a backup material having a width of 10 mm and a height of 10 mm. On the other hand, 100 parts of natural stone (mixed with 40% of quartile stone (particle size: about 7-9 mm) and 60% of 1-quarter stone (particle size of about 3-5 mm) as beautiful aggregate) And 4.5 parts of resin binder (urethane resin; manufactured by Yabu Hara Sangyo Co., Ltd., trade name "colored-out binder") (solid content conversion) were kneaded to prepare a kneaded product. The prepared kneaded product was smoothly applied with a metal iron to the inside of the frame of the produced substrate to form a coated product. After the application of this coating was completed, it was cured at 20° C. for 3 days to cure the resin binder. This formed a beautiful aggregate layer containing the cured resin binder and a plurality of the above-mentioned natural stones adhered by the resin binder in the state where voids were formed between the natural stones.

The surface of the obtained beautiful aggregate layer was attached to an electronic disk grinder (manufactured by Hitachi Koki Co., Ltd., trade name "G10VH") with an art cup (metal cup) #60/80 (sold by CRT World) as an abrasive. The surface of the beautiful aggregate layer was ground by about 1 mm, and the flatness of the natural stone was adjusted. Then, the particle size of the abrasive was changed to a slightly finer Art cup (metal cup) #120/140 to finely adjust the flatness of the surface of the natural stone. Hereinafter, the work of polishing as described above using the metal cups #60/80 and #120/140 is referred to as "polishing work 1". Depending on the hardness of the beautiful aggregate used, the polishing with the metal cup #60/80 may be omitted and the polishing with the metal cup #120/140 may be started. When the flatness of the natural stone is decided, the art cup (metal cup) is replaced with resin pad #100 (sold by CRT World) and polished, and further, the resin pad #200, #400, # with a finer abrasive grain size. It was polished and finished while changing the order to 800. Hereinafter, after the above-mentioned "polishing operation 1", the operation of polishing as described above using the resin pads #100, #200, #400 and #800 is referred to as "polishing operation 2". As described above, the surface of the plurality of natural stones that are visibly exposed on the surface side has a polished surface that is ground flat, and the natural stone provided with the polished surface is a convex portion, and its peripheral portion. A decorative structure of Test Example A1 including a decorative aggregate layer having a concave-convex structure with the voids as concave portions was obtained.

(Test examples A2 to A8)
Compared with Test Example A1, the same operations as in Test Example A1 were carried out except that the natural stone used as the beautiful aggregate was changed to obtain decorative structures of Test Examples A2 to A8. In Test Example A2, as the natural stone, 40% of quartile stone (grain size: about 7 to 9 mm) with gravel name “Fushimi” and 60% of 1-quarter stone (grain size of about 3 to 5 mm) were used. In addition, as the natural stones, in Test Example A3, the olivine olivine (grain size: about 7 to 9 mm), in Test Example A4, the "orange salt" dichotomite (grain size: about 5 to 7 mm), and Test Example A5. In this case, a quarry stone of "orange salt" (particle size of about 3 to 5 mm) was used. Further, as a natural stone, in Test Example A6, "Fushimi" quartile (particle size: about 7 to 9 mm), in Test Example A7, "Fushimi" quartile (particle size: about 5 to 7 mm), and in Test Example A8, "Fushimi's 1-minute stone (particle size of about 3 to 5 mm) was used.

(Test Examples A9 to A14)
Compared with Test Example A1, the tests were carried out except that the natural stone used as the beautiful aggregate was changed to that shown in Table 1 below and that the polishing of the surface of the beautiful aggregate layer was completed in “polishing operation 1”. By the same operation as in Example A1, the decorative structures of Test Examples A9 to A14 were obtained.

(Test examples A15 to A20)
Compared with Test Example A1, the same as in Test Example A1 except that the natural stone used as the beautiful aggregate was changed to that shown in Table 1 below and the polishing operation for the surface of the beautiful aggregate layer was changed. By operation, the makeup structures of Test Examples A15 to A20 were obtained. As for the polishing work, in Test Examples A15 and A18, after performing the above-mentioned “polishing work 1” on the surface of the beautiful aggregate layer, wax was applied without performing “polishing work 2” and buffing was performed. The decorative aggregate layer was finished by polishing. Hereinafter, this polishing work (“polishing work 1”+wax+buffing) is referred to as “polishing work 3”. Moreover, in Test Examples A16, A17, A19, and A20, after the above-mentioned “polishing operation 2” (including “polishing operation 1”) was performed on the surface of the beautiful aggregate layer, the particle size of the abrasive was further increased. Fine resin pads #1500 and #3000 were ground in this order to finish the decorative aggregate layer. Hereinafter, this polishing work is referred to as "polishing work 4".

(Test Example B1)
Quasi-double-sided plywood (290 mm x 220 mm x thickness 5.5 mm) was used as the substrate. A frame (27 cm×20 cm=540 cm ² ) was made on this base by using a backup material having a width of 10 mm and a height of 10 mm. On the other hand, 100 parts of natural stone (mixed with 40% of quartile stone (particle size: about 7-9 mm) and 60% of 1-quarter stone (particle size of about 3-5 mm) as beautiful aggregate) And 4.5 parts of resin binder (urethane resin; manufactured by Yabu Hara Sangyo Co., Ltd., trade name "colored-out binder") (solid content conversion) were kneaded to prepare a kneaded product. The prepared kneaded product was smoothly applied with a metal iron to the inside of the frame of the produced substrate to form a coated product. After the application of this coating was completed, it was cured at 20° C. for 3 days to cure the resin binder. This formed a beautiful aggregate layer containing the cured resin binder and a plurality of the above-mentioned natural stones adhered by the resin binder in the state where voids were formed between the natural stones.

The surface of the obtained beautiful aggregate layer was polished by the above-mentioned "polishing operation 2" to obtain a decorative aggregate layer. Next, in the voids between the natural stones in the decorative aggregate layer, as a room temperature-curable filling material, a cement binder (manufactured by Yabu Hara Sangyo Co., Ltd., "cladding material" (powder product) in "color wash") 100 parts And 26-28 parts of water and cement paste) were poured while rubbing with a rubber trowel. After that, the polishing surface is formed more than the surface of the filling material in the surrounding portion so that the uneven structure in which the natural stone provided with the polishing surface is the convex portion and the space between the natural stones which is the peripheral portion is the concave portion is formed. The cement binder in the peripheral portion was scraped off with a rubber iron so that the cement binder in the surrounding area was high. In addition, 45 to 60 minutes after the cement binder was rubbed in (poured), it was confirmed that the cement binder was slightly hardened, and the cement binder adhered to the surface of the natural stone including the polished surface was wiped off with a waste cloth. It was Then, it was cured at 20° C. for 3 days. In this way, the surface of the plurality of natural stones exposed visibly on the surface side has a polished surface that is ground flat, and the natural stone provided with the polished surface is a convex portion, and the surrounding portion A decorative structure of Test Example B1 including a decorative aggregate layer having a concave-convex structure with a deep joint structure in which the provided filling material was used as a recess was obtained. The depth of the recess from the polished surface was about 1 mm.

(Test Example B2)
Compared to Test Example B1, the same procedure as in Test Example B1 was performed except that the operation of scraping out the cement binder in the peripheral portion of the natural stone provided with the polishing surface was performed with a smaller scraping amount than that in Test Example B1. Finished the decorative aggregate layer. In this way, a decorative bone having a polishing surface and a concavo-convex structure of a shallow joint structure in which the natural stone provided with the polishing surface is a convex portion and the filling material provided in the peripheral portion is a concave portion A decorative structure of Test Example B2 including a material layer was obtained. The depth of the recess from the polished surface was about 0.5 mm.

(Test Example B3)
Compared with Test Example B1, natural stone used as a beautiful aggregate was gravel named “Fushimi” with 40% quartile (particle size about 7-9 mm) and 1-minute stone (particle size about 3-5 mm). A decorative structure of Test Example B3 was obtained by the same operation as in Test Example B1 except that the composition was changed to 60%.

(Test Example B4)
Compared with Test Example B1, the natural stone used as the beautiful aggregate was changed to the same as that used in Test Example B3, and the work of scraping out the cement binder around the natural stone provided with the polishing surface Was carried out in the same manner as in Test Example B1 except that the conditions were the same as in Test Example B2 to obtain a decorative structure of Test Example B4.

(Test Example B5)
Compared with Test Example B1, the natural stone used as a beautiful aggregate was gravel named “Guilin” with 50% quartile (particle size about 7-9 mm) and 1-minute stone (particle size about 3-5 mm). It was changed to a mixture of 50%, a cement paste prepared by mixing 100 parts of white Portland cement (manufactured by Taiheiyo Cement Co., Ltd.) and 30 to 32 parts of water was used as a room temperature curable filling binder, and A decorative structure of Test Example B5 was obtained by the same operation as in Test Example B1 except that the curing period of the filling binder was set to 5 days.

(Test Example B6)
Compared with Test Example B1, the natural stone used as a beautiful aggregate was 40% of a quarry stone (grain size about 5 to 7 mm) and 1 minute stone (grain size of about 3 to 5 mm) under the gravel name “wood grain stone”. A decorative structure of Test Example B6 was obtained in the same manner as in Test Example B1 except that 60% was mixed.

(Test examples B7 to B12)
Compared with Test Example B1, the decorative work of Test Examples B7 to B12 was obtained by the same operation as in Test Example B1 except that the natural stone used as the beautiful aggregate was changed. As the natural stones, in Test Example B7, the "orange salt" quartite (particle size: about 7 to 9 mm), in Test Example B8, the "orange salt" quartite (particle size: about 5 to 7 mm), and in Test Example B9. "Orange salt" 1-minute stone (particle size of about 3 to 5 mm) was used. Further, in Test Example B10, "Fushimi" quarts (particle size of about 7 to 9 mm), in Test Example B11 "Fushimi" quarts (particle size of about 5 to 7 mm), and in Test Example B12, "Fushimi". A quarry stone (particle size of about 3 to 5 mm) was used.

(Test examples B13 to B18)
Compared with Test Example B1, the tests were carried out except that the natural stone used as the beautiful aggregate was changed to that shown in Table 2 below and that the polishing of the surface of the beautiful aggregate layer was completed in “polishing operation 1”. By the same operation as in Example B1, the decorative structures of Test Examples B13 to B18 were obtained.

(Test Examples B19 to B24)
Compared with Test Example B1, the natural stone used as the beautiful aggregate was changed to that shown in Table 2 below, and the polishing of the surface of the beautiful aggregate layer was performed in "polishing operation 4". By the same operation as in Test Example B1, the decorative structures of Test Examples B19 to B24 were obtained.

(Test Example C1)
Quasi-double-sided plywood (290 mm x 220 mm x thickness 5.5 mm) was used as the substrate. A frame (27 cm×20 cm=540 cm ² ) was made on this base by using a backup material having a width of 10 mm and a height of 10 mm. On the other hand, 100 parts of natural stone (a mixture of 50% of quarry stone (grain size: about 7-9 mm) and 50% of 1-quarter stone (grain size of about 3-5 mm) with beautiful gravel) And a resin binder (urethane-based resin; manufactured by Yabu Hara Sangyo Co., Ltd., trade name "Aya washout binder") (4.5 parts) (solid content conversion) were kneaded to prepare a kneaded product. The prepared kneaded product was smoothly applied with a metal iron to the inside of the frame of the produced substrate to form a coated product. After the application of this coating was completed, it was cured at 20° C. for 3 days to cure the resin binder. This formed a beautiful aggregate layer containing the cured resin binder and a plurality of the above-mentioned natural stones adhered by the resin binder in the state where voids were formed between the natural stones.

The surface of the obtained beautiful aggregate layer was polished by the above "polishing operation 1" to obtain a decorative aggregate layer. Next, as a room temperature-curing filling material, a cement binder (manufactured by Yabu Hara Sangyo Co., Ltd., a mixture of 100 parts of "filling material" (powder product) in "color washout") and 26 to 28 parts of water. The paste) was poured into the voids between the natural stones in the decorative aggregate layer while rubbing it with a rubber trowel to cover the surface including the polished surface of the natural stone, and then cured at 20° C. for 3 days to cure. After that, the entire surface of the hardened filling material (hardened material of the cement binder) covering the natural stone (provided on the entire surface of the decorative aggregate layer) is covered with an art cup (metal cup) #120/140 ( Polished with an electronic disk grinder (sold by CRT World Co., Ltd., manufactured by Hitachi Koki Co., Ltd., product name "G10VH") and ground so that the polished surface of the natural stone and the filling material between the natural stones are flush with each other. did. Next, the abrasive material attached to the electronic disk grinder is replaced with resin pad #100 (sold by CRT World Co., Ltd.) for polishing, and further, resin pads #200, #400, and #800 having finer particle sizes are sequentially attached. Polished and finished. Hereinafter, the entire polishing operation performed in Test Example C1 is referred to as "polishing operation 5". In this way, the surface of the plurality of natural stones that are visibly exposed on the surface side has a polished surface that is ground flat, and the natural stone provided with the polished surface and the fillings provided in the peripheral portion thereof. A decorative structure of Test Example C1 including a decorative aggregate layer that was formed flush with the material was obtained.

(Reference example 1)
Quasi-double-sided plywood (290 mm x 220 mm x thickness 5.5 mm) was used as the substrate. A frame (27 cm×20 cm=540 cm ² ) was made on this base by using a backup material having a width of 10 mm and a height of 10 mm. On the other hand, as a beautiful aggregate, 200 parts of natural stone (50% of gravel quarry stone (grain size about 7-9 mm) and 50% of 1-quarter stone (grain size of about 3-5 mm)) Cement paste (a kneaded product of 100 parts of Terrazo Powder manufactured by Yabu Hara Sangyo Co., Ltd. and 32 to 35 parts of water) was mixed to prepare a kneaded product. The prepared kneaded product was smoothly applied to the frame of the produced substrate with a gold iron to form a coating product in which natural stone was buried in cement paste. After the application of this coating was completed, it was cured at 20° C. for 5 days to cure the cement paste. As a result, a hardened cement product in which natural stones were buried was obtained.

An art cup (metal cup) #30/40 (sold by CRT World Co., Ltd.) was attached as an abrasive to the surface of the hardened cement material in which the natural stone was buried, as an abrasive on an electronic disk grinder (Hitachi Koki Co., Ltd., product name "G10VH"). Polished with a thing and sharpened natural stone. Next, the grain size of the abrasive was changed to a slightly finer Art cup (metal cup) #60/80 for polishing, and then changed to a finer Art cup (metal cup) #120/140 for polishing. When the flatness is decided, the art cup (metal cup) is replaced with a resin pad #100 (sold by CRT World) for polishing, and further, resin pads #200, #400, #800 with a finer grain size are used. Polishing was performed while changing the order, wax was applied, and buffing was performed to finish. Hereinafter, the entire polishing operation performed in Reference Example 1 is referred to as “polishing operation 6”. As described above, a decorative structure having a flat decorative surface aggregate layer obtained by polishing natural stone was obtained by the sharpening finishing method.

(Reference example 2)
Compared with Reference Example 1, the same operation as in Reference Example 1 was performed except that the used natural stone was changed to a gravel named “Granite (72)” 1-minute stone (particle size of about 3 to 5 mm). A makeup structure of Reference Example 2 was obtained.

(Measurement of slip resistance)
Using the pendulum skid resistance tester with the surface side of each makeup structure obtained in each test example and reference example as a measurement object (test body), the slip resistance value (BPN) in a dry state and a wet state Was measured. The higher the slip resistance value, the harder it is to slip, and the lower the slip resistance value, the easier it is to slip. As the "wet state", water was sprayed onto the test body using a spray spray, and the entire test body was sufficiently wet with water and sprayed until the water was collected. As a method of measuring the slip resistance value, the pendulum was finely adjusted up and down so that the contact distance of the sliding piece was 125 ± 1.6 mm, the pendulum was swung down on the test body, and the pendulum passed through the test body and swung up. The numerical value (BPN) at each position was read. The measurement was carried out until the variation in the measured values of 5 consecutive times was less than 3 BPN, and the median value of these 5 times was taken as the slip resistance value of the test body.

Tables 1 to 3 show the results of the slip resistance value (BPN) in each of the above-mentioned test examples and reference examples together with the beautiful aggregate used, the number of the above-mentioned polishing work, and the filling state.

In Test Examples A1 to A20, the surface of a plurality of beautiful aggregates that is visibly exposed on the surface side in a raised decorative aggregate layer that includes a plurality of beautiful aggregates bonded with a resin binder in a state of having voids A decorative structure was obtained which had a polished surface that was ground flat. With such a structure, in the decorative structures obtained in Test Examples A1 to A20, the plurality of polished beautiful aggregates are visually recognized as the convex portions of the concave-convex structure, and the voids in the surrounding portions are visually recognized as the concave portions of the concave-convex structure. As a result, it was confirmed that the cosmetic surface had a novel sharpened design that looks three-dimensional. Further, it was confirmed that the decorative aggregate layer having such a concavo-convex structure is less slippery on the surface side than the aggregate layer in the decorative structure obtained by the sharpening finishing method of Reference Examples 1 and 2. It was

In Test Examples B1 to B24, a decorative structure including a decorative aggregate layer having a concave-convex structure in which a beautiful aggregate provided with a polished surface was a convex portion and a filling material provided between the beautiful aggregates was a concave portion was used. Was obtained. With such a structure, in the decorative structures obtained in Test Examples B1 to B24, the polishing surface forming the convex portion looks three-dimensionally in relation to the filling material forming the concave portion, and the contrast becomes clearer. It was confirmed to have a new sharpened design makeup surface. Further, it was confirmed that the decorative aggregate layer having such a concavo-convex structure is less slippery on the surface side than the aggregate layer in the decorative structure obtained by the sharpening finishing method of Reference Examples 1 and 2. It was For Test Examples B1 to B4, B6, and B19 to B24, the ratio of natural stone to the decorative surface of the decorative aggregate layer was determined. As a result, 61.7% in Test Example B1, 62.4% in Test Example B2, 57.9% in Test Example B3, 60.5% in Test Example B4, 58.6% in Test Example B6, and Test Example. B19 is 63.1%, Test Example B20 is 62.6%, Test Example B21 is 66.5%, Test Example B22 is 61.9%, Test Example B23 is 61.3%, and Test Example B24 is 65.5%. %Met. The ratio of natural stone to the decorative surface was simply measured as follows. First, a plan view image of the makeup surface was taken. Then, at an arbitrary position in the image, a straight line parallel to the width direction of the decorative surface is provided over the width of the decorative surface (width of the decorative surface of 20 cm), and all the lengths of the overlapping portions of the natural stones on the straight line are measured, The sum of them (total value of the lengths of natural stone parts) was obtained. The total length of the obtained natural stone parts is divided by the length of the straight line provided on the width of the decorative surface (divided) and multiplied by 100, and the obtained value is the ratio of natural stone to the decorative surface (%) And Three straight lines were arbitrarily drawn and the average value of the three measured values was taken.

In Test Example C1, a decorative structure including a decorative aggregate layer in which the beautiful aggregate provided with the polished surface and the filling material provided between the beautiful aggregates were formed flush with each other was obtained. With this configuration, the decorative structure obtained in Test Example C1 looks flat like the decorative surface of the decorative structures obtained by the sharpening finishing method of Reference Examples 1 and 2, but pinholes are generated. It was confirmed to have a makeup surface of a new sharpened design in which the above-mentioned was suppressed.

10: Decorative structure 10a: Decorative surface 1: Base material 11: Beautiful aggregate layer 12: Beautiful aggregate 12a: Polished surface 13: Convex part 14: Void 15: Recessed part 16: Decorative aggregate layer 20: Decorative structure body 20a: Decorative surface 26: Decorative aggregate layer 28: Filling material 29: Recessed portion 30: Decorative structure 30a: Decorative surface 36: Decorative aggregate layer 38: Filling material

Claims (9)

A mixing step of kneading a resin binder and a plurality of aggregates to prepare a kneaded product thereof,
And dabs forming the kneaded mixture coated on the substrate, the coating of a state having voids extending from Oite surface to said substrate between said plurality of aggregate,
Wherein curing the resin binder of the coating material in a cured the resin binder, together and a plurality of aggregate bonded by the resin binder in a state having the gap, concave the gap and portions, and a curing step of forming a Rukotsu material layer having a structure of irregularities said plurality of aggregate and a convex portion,
Polishing the surface of the pre-Symbol aggregate layers, the plurality whereby said plurality of aggregate flattened cutting surface of said plurality of aggregate by being polished actively, visibly exposed to the surface side A polishing step of forming a decorative aggregate layer having a polishing surface in which the surface of the aggregate is flatly ground;
After the polishing step, the plurality of aggregates provided with the polishing surface are formed into a convex portion, and a concave-convex structure in which a gap is formed between the plurality of aggregates which is a peripheral portion thereof is formed in the void. A filling step of inserting a filling material to reach the base,
Manufacturing method of including structure body. In the wiping process, the resin binder the kneaded mixture so that the plurality of the aggregate is not completely buried in daub on the substrate, a manufacturing method of the structure body according to claim 1. In the polishing step, polishing the surface of the pre-Symbol aggregate layer with a disc grinder, a manufacturing method of the structure body according to claim 1 or 2. In the filling step, after rubbing or pouring the filling material into the void, the polishing surface of the peripheral portion is higher than the surface of the filling material of the peripheral portion to the surface side. A step of scraping out the filling material,
Method for manufacturing a structure body according to claim 1 comprising a step of wiping the eyes packed material attached to the surface including the polished surface before Symbol aggregate. The method for manufacturing a structure according to claim 1, wherein the aggregate is at least one selected from the group consisting of natural stone, artificial stone, artificial stone, and marble. The structure according to any one of claims 1 to 5, wherein the amount of the resin binder used is 2 to 20 parts by mass with respect to 100 parts by mass of the plurality of aggregates as a solid content of the resin. Manufacturing method. Provided on the substrate, and a plurality of aggregate was visibly exposed to the resin binder and the front side provided with including decorative aggregate layer,
The decorative aggregate layer is adhered by the resin binder in a state in which the plurality of aggregates have a void reaching from the surface to the base between the plurality of aggregates, and at the peripheral portion of the plurality of aggregates. the weather stripping material buried in a state of reaching the substrate to the gap existing between some of the plurality of the aggregate is more Dressings containing,
The decorative aggregate layer, in the surface side, and has a polished surface in which the surface of a plurality of aggregates and the exposed is shaved flat, the plurality of the aggregate in which the abrasive surface is provided with a convex portion, and structure Zotai that having a the uneven structure and the recess of the eye packed material provided between said plurality of aggregate wherein a peripheral portion. The decorative aggregate layer, in the surface side, structure Zotai of claim 7 slip resistance by pendulum skid resistance tester is 40BPN least in the wet state. The structure according to claim 7 or 8, wherein a ratio of the aggregate to the surface on the surface side of the decorative aggregate layer is 55 to 70%.

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