JPH0627429B2 - Relief pattern forming method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming an uneven relief pattern on the surface of a mortar layer.

[Industrial application field]

The material having an embossed pattern is widely used in various fields including exterior and interior for construction.

[Conventional technology]

Conventionally, as a typical method of forming an embossed pattern on the surface of the mortar layer, there are (1) a trowel, a spatula method, (2) a roller method, (3) a spray method, and (4) an embossing method. Methods, (5) Plast method and the like are known.

However, the method (1) has been developed as a finishing method for plaster walls, and it is very difficult to form a fine relief pattern and it requires skill.

Further, the method (2) is a method suitable for forming a simple repetitive pattern because it forms an unevenness by imprinting the pattern roller, but for forming a complicated and fine pattern. It was not suitable.

Further, the method (3) is a method suitable for forming a random uneven pattern by a spray gun, but has a drawback that it cannot form an arbitrary specific pattern such as a design or a character. It was a thing.

Further, the method (4) is a method suitable for mass production in a factory, but it is not suitable for giving different patterns to individual products.

The method of (5) partially masks the mortar layer, and shavings by blasting the unmasked part,
An uneven relief pattern is formed. However, this method causes deterioration of the work environment due to dust and noise generated during the blast treatment, and also has a large adverse effect on the surroundings of the work place, and also requires a long working time and is dangerous. And the like.

Furthermore, when applying mortar to concrete panels,
For the purpose of improving the adhesion between mortar and concrete,
The following methods are known as means for making the concrete surface uneven. That is, this is a method for producing a concavo-convex concrete panel in which the cement hardening retarder is partially applied to the formwork in advance, concrete is then poured into the formwork, cured, and then washed out.

However, this method requires a mold and is not applicable to any substrate. Furthermore, the obtained unevenness was not a sharp (clearly defined) and deeply carved uneven pattern. Therefore, this method is unsuitable as a means for forming a relief pattern for the purpose of aesthetics.

[Problems to be solved by the invention]

In view of the current situation in the field of embossed patterns as described above, the present invention relates to a method for easily forming an embossed embossed pattern that is clear and is not a random pattern on any substrate without requiring skill. As a result of earnest study, the present invention has been achieved.

[Means for solving problems]

That is, the first aspect of the present invention is: (i) a step of forming a mortar layer on a base material; (ii) a sheet having a pattern formed of a liquid-permeable portion and a liquid-impermeable portion is placed on the mortar layer. Or a step of placing a liquid impermeable sheet on the mortar layer in a pattern, further laminating a water-soluble resin sheet having a cement hardening retarding effect, and impregnating the cement hardening retarder into the mortar layer, (iii) mortar A step of curing the layer, (iv) removing the sheet on the mortar layer after curing the mortar layer, and washing and removing the mortar layer at the portion impregnated with the cement hardening retarder. The present invention relates to a method for forming a relief pattern having irregularities.

In the method of the present invention, the cement hardening retarder is impregnated into the mortar layer according to the pattern of the sheet adhered onto the uncured mortar layer. Therefore, the portion impregnated with the curing retardant is delayed in curing and can be easily removed by washing even after curing. Therefore, the method of the present invention is characterized in that an embossed pattern having a sharp shape and deep irregularities can be formed on the surface of the mortar layer according to the pattern of the sheet.

Further, in the present invention, by appropriately controlling the thickness of the mortar layer and the degree of impregnation of the cement hardening retarder and removal of the mortar layer, not only those having shallow irregularities but also those having deep irregularities The feature is that an embossed pattern having irregularities of a desired depth can be freely formed. Further, the method of the present invention has a feature that the embossed pattern having deep ruggedness can be formed very inexpensively because the embossed pattern is composed of the mortar layer.

Hereinafter, the method for forming a relief pattern having irregularities according to the first aspect of the present invention will be described more specifically.

First, as the base material used in the present invention, any known base material to which mortar can be adhered can be applied. For example,
Examples thereof include metals such as iron, aluminum and stainless steel, glass, tiles, ceramics, concrete, bricks, stone materials, woods, plastics and laminates thereof. The surface does not necessarily have to be a flat surface, and may be a curved surface, for example. These base materials may be subjected to a surface treatment such as roughening, coloring or applying a primer, if necessary.

In the present invention, as the first step, mortar is applied to the above-mentioned base material by a commonly used means such as a trowel, spatula, or spray to form a mortar layer. The thickness of the mortar layer is not particularly limited. However, it is preferably about 1 to 20 mm for practical use depending on the depth of the unevenness.

As the mortar used in the present invention, those generally used conventionally can be applied as they are. Ie cement,
It consists of aggregates such as sand and water, and if necessary, various additives such as coloring pigments, extender pigments, fibrous substances or hardening accelerators, hardening retarders, thickeners, water reducing agents, defoaming agents and the like. Etc. are mixed. A so-called resin mortar containing an acrylic resin-based emulsion, a vinyl acetate resin-based emulsion, an epoxy resin-based emulsion, a styrene butadiene resin-based emulsion, or the like can also be used in the present invention.

In the present invention, the mortar layer may be formed by applying mortars having different colors in addition to the mortar having the same color. By forming a plurality of mortar layers having different colors in this way, the degree of removal at each place when the mortar layer is washed and removed in the washing and removing step described later,
That is, by adjusting the depth of the concave portion, it becomes possible to form an uneven relief pattern having a multicolored change depending on the depth.

While the mortar layer thus formed is uncured, preferably, there is some free water on the surface of the mortar layer, or while the mortar layer surface is in a state of bleeding when lightly pressed with a finger. , A sheet having a pattern formed of a liquid-permeable portion and a liquid-impermeable portion (hereinafter referred to as a pattern sheet) is placed on the mortar layer and adhered thereto, or the liquid-impermeable sheet is placed on the mortar layer in a pattern. Then, a sheet having a cement hardening retarding effect (hereinafter referred to as a hardening retarding sheet) is further laminated thereon.

As the "pattern sheet (sheet having a pattern formed of a liquid permeable portion and a liquid impermeable portion)" used in the present invention, for example, a liquid impermeable film such as paint or resin solution is formed on the liquid permeable sheet. Examples of the material include a material obtained by applying or impregnating the material in a pattern by means such as silk screen, or a silk screen usually used in the paint industry.
The material of the liquid permeable sheet is not particularly limited, and examples thereof include Japanese paper, foreign paper, woven cloth, non-woven cloth, porous plastic film, porous ceramic sheet, plastic net, and wire net. In particular, it is preferable to use a Japanese paper or a woven cloth that adheres well to the moist mortar layer.

Further, in the present invention, examples of the "liquid impermeable sheet" used for placing a pattern on the mortar layer include a plastic film and the like.

In the present invention, instead of the step (ii), a pattern sheet and a curing retardation sheet are preliminarily laminated with, for example, a water-soluble adhesive, and the pattern sheet side is the mortar layer side. Also included is a method that includes the step of placing on the mortar layer and impregnating the mortar layer with a cement retarder.

The hardening retardation sheet used in the present invention is one in which the cement hardening retarder is dissolved from the sheet by water, and any such material can be used without particular limitation. Specifically, for example, a liquid permeable sheet coated with or impregnated with a cement hardening retardant solution, or a water-soluble resin sheet such as a starch or polymaltotriose polysaccharide having a cement hardening delaying effect, or sodium alginate. , Polyvinyl alcohol, a cellulose derivative, poly (meth) acrylic acid or a salt thereof, gelatin, polyethyleneimine, polyvinylpyrrolidone and the like, and a sheet formed by mixing a cement hardening retarder with a water-soluble resin.

In the present invention, as the cement hardening retarder, those generally used conventionally can be used as they are.
Specifically, for example, sodium dihydrogen phosphate, disodium hydrogen phosphate, sodium phosphate, sodium tetraborate, saccharides, calcium acetate, oxycarboxylates, lignin sulfonates, alcohols or commercial products such as Rital (JP Soda Matter Builders' product name), Vinsol 80R (Yamaso Chemical Co., Ltd. product name), Air Coal (Manor Co., Ltd. product name), KW-100 (Kao Soap Co., Ltd. product name), etc. To be

Further, by using a cement hardening retarder mixed with a colorant, it is possible to identify the location of the mortar layer impregnated with the cement hardening retarder solution to be washed and removed by coloring, which is convenient in the washing and removing step described later. Sometimes.

In the present invention, since a sheet having a cement hardening retarding effect is used, the work efficiency is improved as compared with the method of applying the cement hardening retarder solution at the work site.

In the present invention, an aqueous solution resin sheet having a curing retarding effect laminated next to a patterned sheet or a liquid impermeable sheet on the mortar layer is dissolved by free water on the surface of the mortar layer to release the cement retarder, and after lamination. When left for several minutes to several hours, the mortar layer of the pattern sheet is impregnated with the liquid permeable portion or the portion where the liquid impermeable sheet is not placed. At that time, if necessary, water or the like may be sprayed on the surface of the mortar layer or the surface of the sheet to positively impregnate the mortar layer with the cement hardening retarder.

In the present invention, there is no space between the liquid-impermeable part of the pattern sheet or the liquid-impermeable sheet and the mortar layer, and the cement is hardened through the liquid-impermeable part or the liquid-impermeable sheet. Since the retarder is not impregnated, the liquid-impermeable portion or the mortar layer covered with the liquid-impermeable sheet is not impregnated with the cement hardening retarder.

In the present invention, after the cement hardening retarder is impregnated into the mortar layer, the mortar layer is cured for a certain period of time. As a curing method, a natural curing method, a steam curing method, a pressure curing method or the like which is generally known as a mortar curing method can be adopted.

The time for curing is in the cleaning and removing step described below.
The mortar layer where the cement hardening retarder is not impregnated is hard enough to be removed, and the mortar layer where the cement hardening retarder is impregnated is uncured or semi-cured to the extent that it can be removed relatively easily. The time required to do this. Specifically, for example, in the case of the natural curing method, it is preferable to set the temperature at room temperature (20 ° C.) for 8 to 50 hours.

After curing the mortar layer, the sheet on the mortar layer is removed.

After curing the mortar layer, mortar at the location where the cement hardening retarder is impregnated by a method of using water or a cleaning liquid consisting of water and an emulsifier, and rubbing with a rotating brush, or a method of injecting the cleaning liquid at a high pressure. The layers are washed off.

The second aspect of the present invention can be carried out in the same manner as the first aspect of the present invention, except that the sheet on the mortar layer such as a pattern sheet is removed before the mortar layer is cured. .

In addition, the removal of the sheet on the mortar layer such as the pattern sheet,
It is of course possible not only before or after curing the mortar layer, but also during curing of the mortar layer in parallel with the curing.

Thus, a mortar layer having a relief pattern having deep irregularities is obtained. In the present invention, in order to further impart color, adjust glossiness, and further impart weather resistance, water resistance, chemical resistance, etc., on the entire surface or in the concave portions (or convex portions) in the present invention. It is also possible to apply another colored coating film, apply a clear or color clear coating film to the entire surface, or polish.

〔The invention's effect〕

As described above, according to the method of the present invention, it is possible to easily and inexpensively obtain an embossed pattern having deep unevenness of any depth. Further, there is a feature that a desired concavo-convex pattern can be easily obtained by variously changing the pattern formed on the sheet.

Further, the product having the mortar layer having the uneven pattern obtained by the method of the present invention has a feature that it can be used for aliveness, decorations and the like, and can be manufactured in a factory or on-site.

Hereinafter, the present invention will be described in more detail with reference to Examples.

In the examples, "part" and "%" are based on weight.

Example 1 Asbestos slate board (900 × 18) with a wooden frame around it
(00 × 10 mm), a mortar composed of 100 parts of white cement, 50 parts of silica powder and 50 parts of water was used to form a smooth mortar layer having a thickness of 3 mm using a trowel.

Next, a paint [“Bildick” (trade name, manufactured by Dainippon Paint Co., Ltd.)] is silk-screen printed on Japanese paper about 0.1 mm thick, and the patterned Japanese paper sheet is mortar layer with the silk-screen printing side facing the mortar layer. It was placed on the surface and pressed down with a rubber roller for close contact.

Then, on about 0.1 mm thick Japanese paper, trisodium phosphate 10
Sheets, 5 parts of polyvinyl alcohol, 1 part of phthalocyanine blue, and 84 parts of water were impregnated with the cement hardening retarder solution.

Then, it was cured for 1 day in an atmosphere of a temperature of 20 ° C. and a relative humidity of 75%.

Then, after removing both the patterned Japanese paper and the Japanese paper impregnated with the cement retarder solution, it was spun with water (30 / min) and rotated at a rate of 5 minutes / m ² (25
A nylon brush (diameter: 0.6 mm) for 0 rpm) was rubbed with a circular brush (100 mm) to remove a mortar layer impregnated with the cement retarder solution.

On the obtained surface, sharp pattern-like irregularities having an average depth of about 1.5 mm corresponding to the pattern printed by silk screen were formed.

On the surface of the mortar layer thus obtained, a relief pattern having an extremely relief feeling was obtained.

Example 2 100 parts of Portland cement on the surface of asbestos slate board,
A mortar composed of 200 parts of silica powder, 1 part of a water reducing agent, and 75 parts of water was used to form a smooth mortar layer having a thickness of 3 mm using a trowel.

Then, a sheet obtained by silk-screen printing on a white cotton cloth having a thickness of about 0.2 mm in the same manner as in Example 1 was placed on the surface of the mortar layer, and pressed with a rubber roller to be in close contact.

Next, coat a tin-based retarder ["K
W-100 "(trade name, manufactured by Kao Soap Co., Ltd.)] 20 sheets, a methylcellulose-based thickener, 1 part, phthalocyanine blue 1 part, and a sheet impregnated with a cement hardening retarder solution consisting of 78 parts of water are laminated, and then the following: Curing, removal of the sheet and washing and removal of the mortar layer were carried out in the same manner as in Example 1 to form patterned unevenness having an average depth of about 2.5 mm and corresponding to the silk screen printed pattern. On the surface of the mortar layer thus obtained, a relief pattern having a relief feeling was obtained as in Example 1.

Example 3 100 parts of white cement, 50 parts of barite as mortar,
Vinyl acetate resin emulsion (solid content 50%) 3 parts,
A mortar consisting of 1 part of calcium chloride, 0.2 part of methylcellulose thickener and 47 parts of water is used. Instead of the sheet impregnated with the cement hardening retarder solution, a polymaltotriose film having a thickness of about 50μ is used. Other than using
In the same manner as in Example 1, pattern-shaped irregularities corresponding to the silk-screen printed pattern having an average depth of about 2 mm were formed.

On the surface of the mortar layer thus obtained, Example 1
A relief pattern with a relief feeling was obtained in the same manner as in.

Example 4 100 parts of white cement and silica powder 2 on the surface of asbestos slate board
A blue mortar consisting of 00 parts, 2 parts of phthalocyanine blue, 1 part of a water reducing agent and 75 parts of water was used to form a smooth mortar layer with a thickness of 3 mm, which was left for 1 hour and then white cement 10 was added.
0 parts, barite 50 parts, methylcellulose-based thickener 0.2
Part, 0.5 part of calcium chloride, 2 parts of naphthol red and 50 parts of water were red-coated in a thickness of 2 mm to form a smooth multi-layer mortar layer.

Then, the silk-screen-printed Japanese paper sheet used in Example 1 was placed on the mortar layer and adhered thereto.

Then, a sheet impregnated with a cement hardening retarder solution consisting of 20 parts of a tin-based hardening retarder, 10 parts of polymaltotriose, 1 part of phthalocyanine blue and 69 parts of water was laminated on a Japanese paper having a thickness of about 0.1 mm, and the following was carried out In the same manner as in Example 1, curing, sheet removal, and cleaning removal of the mortar layer were performed. On the obtained surface, sharp pattern-like irregularities having an average depth of about 2.5 mm corresponding to the pattern printed on the sheet were formed.

On the surface of the mortar thus obtained, an embossed pattern was obtained in which the concave portions were blue and the convex portions were red, which had an extremely embossed feeling.

Claims (2)

[Claims] 1. (i) a step of forming a mortar layer on a substrate, (ii) after a sheet having a pattern formed of a liquid permeable portion and a liquid impermeable portion is placed on the mortar layer, or liquid permeable Of the water-soluble resin sheet having a cement hardening retardation effect after placing the volatile sheet on the mortar layer in a pattern, and impregnating the cement hardening retarder into the mortar layer, (iii) curing the mortar layer, (Iv) A method for forming an embossed pattern having deep irregularities, which comprises the steps of removing the sheet on the mortar layer after curing the mortar layer and washing and removing the mortar layer at the portion impregnated with the cement hardening retarder. . 2. The method according to claim 1, wherein the mortar layer on the substrate comprises a plurality of mortar layers having different colors.