JPH11235899A - Imitation rock and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain an artificial rock having a touch of a natural stone, i.e., an imitation rock of a low cost. SOLUTION: A base material 1 is molded in a shape similar to a rock desired to be obtained for a synthetic resin foam material. Its surface is covered with a net 2 made of a glass fiber, and fixed by using a clamper 10. And, an undercoating layer 3 of a light-weight mortar containing a foam resin pulverized material as a main aggregate is formed from above the net, dried and cured, then finish coating, a patterning and surface coating are executed as desired. Any of the foam material to be the base material which has a hardness not easily deformed by pressing or the like may be arbitrary. And, foam polystyrene of foaming in a bead mold, foamed polystyrene by extrusion foaming, foam polyurethane or the like may be used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial rock having a texture of natural stone, that is, a pseudo rock and a method for producing the same.

[0002]

2. Description of the Related Art In parks, recreational facilities, residential yards, and the like, in addition to the arrangement of trees and ponds, landscapes of stones and rocks, so-called stone structures, are often provided. Although it is ideal to perform framing using collected natural stones, natural stones of the desired shape are not available, expensive if available, and it is difficult to handle natural stones because they are heavy. For the reasons described above, stone formation is being carried out using artificial rocks or pseudo-rocks made to have the texture of natural stone.

[0003] Conventionally, as a pseudo-rock, a base material is formed into a desired shape using a FRP (fiber reinforced plastic) into a desired stone (rock) or a desired shape using a reinforcing steel bar and a lath net. There is known a material in which the surface of a stone (rock) is applied by applying a cement mortar to the surface, and the stone is actually used as a base material of the stonework.

[0004]

However, although the rock expressed by FRP is light in weight and easy to handle, it has a drawback that it lacks the apparent weight and is not satisfactory. In the case where the cement mortar is applied to a base using a reinforcing bar and a lath net, a large-scale and long-term preparation is required for the construction of the base.

The present invention has been made in view of the above circumstances, and has as its object to be sufficiently lightweight, easy to handle, capable of being manufactured in a short period of time, and having a desired pattern. An object of the present invention is to provide a pseudo-rock capable of sufficiently expressing the texture of a desired natural stone, and a method for producing the same, since the finishing and the painting can be easily performed.

[0006]

A pseudo rock according to the present invention for solving the above-mentioned problems comprises a synthetic resin foam material as a base material formed into a shape similar to the shape of the rock to be obtained,
Preferably, a sheet covering the base material, an undercoat layer made of lightweight mortar mainly composed of a crushed foamed resin applied to the surface thereof, a finish coating layer and a surface coating layer applied on the undercoat layer At least.

Further, the method for producing a pseudo rock according to the present invention comprises forming a synthetic resin foam as a base material into a shape similar to the shape of the rock from which a synthetic resin foam is to be obtained, and if necessary, making the surface preferably alkali-resistant. After covering with a net made of glass fiber, an appropriate locking device is fixed by inserting it into the synthetic resin foam material through the net, and furthermore, the surface thereof is primed with a lightweight mortar using a foamed resin crushed product as a main aggregate. And then, after the undercoat layer is dried and cured, finish coating, desired patterning and surface coating are performed.

In the present invention, the foamed synthetic resin as the base material is not particularly limited as long as it has a hardness that does not easily deform by pressing or the like. , Foamed polyurethane, etc. are used, and foamed polystyrene is most preferable because it can be easily processed with a nichrome wire cutter. In the case of expanded polystyrene, the expansion ratio is about 20 to 80 times, so that molding is easy,
Moreover, it is preferable in that practical hardness can be obtained.

Any means and method may be used for forming a block-shaped or plate-shaped synthetic resin foam into a shape similar to the shape of a rock to be obtained. Performing the cutting process
This is an effective method because the work efficiency is high and a fine surface shape can be easily formed.

When the synthetic resin foam molded into an approximate shape is large in size (for example, the volume exceeds 1 cubic meter), the undercoat layer (and the finish coat layer)
In order to prevent cracking and peeling, the surface of the formed base material is preferably covered with a net made of alkali-resistant glass fiber, and the net is fixed so as to conform to the shape of the base material using an appropriate locking member. Is preferred. The size of the mesh of the net is preferably about 10 to 15 mm. In the case of a smaller mesh, a sufficient peeling prevention effect cannot be obtained,
If it is larger than this, a sufficient crack preventing effect cannot be obtained. Since the alkali-resistant glass fiber is not corroded by the light-weight mortar as the undercoat layer, the undercoat layer is prevented from cracking and peeling for a long time. Alternatively, a net made of a material such as acrylic or PVA can be used. If the dimensions of the synthetic resin foam as the base material are relatively small, a stable undercoat layer can be formed without using such a net.

The undercoat layer is formed of a lightweight mortar whose main aggregate is a pulverized foam resin. The material resin of the foamed resin pulverized product is preferably the same resin as the synthetic resin foam material as the base material because the cut loss during molding can be reused, for example, as the synthetic resin foam material as the base material When using expanded polystyrene, it is preferable to use a pulverized product of expanded polystyrene. The size of the pulverized foamed resin has an average particle diameter of about 1 to 6 mm, preferably 2
About 4 mm. The lightweight mortar mixed with the crushed foam resin as the main aggregate improves the fluidity of the cement particles and effectively functions as an adhesion mediator between the base material side and the finishing material layer. This facilitates free plastering along the shape of the base material, and also facilitates finish coating, desired patterning, and surface coating. This makes it possible to easily manufacture even a pseudo rock having a complicated external shape. Further, there is an advantage that the weight can be reduced as compared with the mortar.

In addition to the above-mentioned pulverized polystyrene foam, pulverized products such as EVA (ethylene vinyl acetate) foam and calcium carbonate / vinyl chloride foam can be used as the main aggregate. In the lightweight mortar that forms the undercoat layer,
It is preferable to add an appropriate amount of SBR, acryl, vinyl acetate emulsion or the like as an admixture for improving the adhesiveness. Further, it is preferable to add a cellulose derivative such as methylcellulose, polyvinyl alcohol or the like as the water-soluble resin. Thereby, effects such as improvement in workability and physical properties of the lightweight mortar can be obtained.

After the lightweight mortar as the undercoat layer is dried and hardened, if necessary, intermediate coating with the undercoat agent is performed in accordance with the shape of the pseudo rock to be obtained, and then finish coating and desired patterning and surface treatment are performed. Perform painting. The finish coating may be a normal mortar coating, or may be a mortar mixed with a color powder such as Mine (trade name). Further, the treatment may be performed using a known finishing material such as a commercially available diatomaceous earth finishing material or a decorative finishing material that has been previously blended. In any case, in order to prevent cracking, it is preferable to mix a naphthalene / melamine-based water reducing agent.

The patterning is performed as needed to further adjust the appearance of the pseudo rock, and the method is optional. For example, release powder is applied while the finish coating layer is soft, and Pressing a mold made of silicon or urethane from above to apply a pattern, or, when the surface of the finish coating layer is roughly tightened, scraping off the application surface with a putty knife, wire brush, etc. A method of giving a pattern is effective.

After performing the required patterning, the surface is coated as required. This is done when the finish is applied, for example, with sand cement mortar, silica sand mortar, commercial lightweight mortar, etc., in order to color the finished surface to the desired rock color, with a cement color.
For the coating, a water-based paint is preferably used, and diluted with water to change from a dark color to a light color a plurality of times (preferably two to three times).
Perform by applying multiple coats.

As described above, according to the present invention, since the base material is a synthetic resin foam material, the base material is lightweight and can be easily formed into a desired shape in a short time and easily. Is made of lightweight mortar with foamed resin crushed material as the main aggregate, improving the adhesive strength between the base material and the finish coating layer, enabling free plastering, and furthermore, if necessary Patterning and surface coating can be easily performed. Therefore, a pseudo rock having a desired appearance shape and a texture of natural stone can be easily manufactured at low cost.

[0017]

[Example 1] A block of expanded polystyrene (expansion ratio 50 times) by foaming in a bead mold (dimensions 100 x 200 x 80 cm)
Was cut into a shape close to the appearance of the pseudo rock to be obtained by using an electrically heated nichrome wire to obtain a base material 1 (FIG. 1). The entire substrate 1 is covered with a 10 mm mesh sheet 2 made of alkali-resistant glass fiber, and as shown in FIG. 2, a top plate 11 and an insertion leg 12 are provided. A plastic fastener (locking tool) 10 having the base material 1 through the sheet 2
To fix the sheet 2 to the surface of the substrate 1 (FIG. 3). A light-weight mortar having the following compositions (1) to (3) was prepared, and the entire surface of the substrate 1 was undercoated from above the sheet 2 to form an undercoat layer 3. Coating was performed by a technique such as levering or mechanical spraying, and the average thickness was about 10 mm (FIG. 3).

Composition (1) Portland cement 25 kg Expanded polystyrene crushed product: Average particle size 5 mm or less 31 L Sand 5 L Methyl cellulose 19 g Polyvinyl alcohol 63 g Acrylic fiber 10 mm cut 13 g Admixture (SRB polymer dispersion) 1 kg Kneading water 16-18 liter

Composition (2) Portland cement 25 kg Pulverized ethylene vinyl acetate foam: average particle size 5 mm or less 40 liters Methyl cellulose 19 g Polyvinyl alcohol 75 g Admixture (acrylic SRB polymer dispersion) 2 kg Kneading water 17-19 liters

Composition (3) Portland cement 25 kg Calcium carbonate / PVC foam pulverized product: average particle size 5 mm or less 25 liters Methyl cellulose 19 g polyvinyl alcohol 88 g Admixture (ethylene-vinyl acetate polymer dispersion) 2 kg Kneading water 17-19 liters

After drying and curing of the undercoat layer, finish coating (average coating thickness: 8 mm) is performed on the entire surface of the prepared mortar (Molden, table name: manufactured by Showa Denko KK) using a finishing material mixed with the dye Minkoge tea. After finishing the surface, the surface was patterned with a wire brush and then the finished layer was dried and hardened.

Example 2 A commercially available lightweight mortar (trade name: Rasmol: manufactured by Fujikawa Building Materials Co., Ltd.) was used as a finishing material. After the finishing material was dried and hardened, the dark gray aqueous paint was diluted with water to give a dark color. Pseudo-rock was produced in the same manner as in Example 1 except that the paint was applied three times to a light color from the above.

[Example 3] As a finishing material, a dye mine and rust were mixed in a mortar (table name: Caesoutica (white): manufactured by Osaka Gas Chemical Co., Ltd.), and another dye mine was mixed. Two types were prepared, and the surface of the undercoat layer was divided and painted in two colors. The release powder was applied while the overcoat mortar was soft, and a silicon mold was pressed against the release powder to form a recess. Except for the above, pseudo rock was produced in the same manner as in Example 1.

The pseudo rocks obtained in Examples 1 to 3 were finish-coated in a shape conforming to the shape of the base material, regardless of the undercoating agent of any composition. No delamination or cracking of the layer was observed. The weight of the pseudo rock was about 120 kg, and was about 1/20 of the average weight of natural stone of the same volume. In addition, all pseudo rocks showed a texture very similar to natural stone.

[0025]

According to the method for producing pseudo rock according to the present invention,
Since the synthetic resin foam material is used as the base material, it is lightweight and can be easily formed into a desired shape in a short time and easily. Because it is formed, it is possible to improve the adhesion between the base material and the finishing layer to perform free plastering, and furthermore, it is possible to easily perform patterning and surface painting as necessary Becomes Therefore, a pseudo rock having a desired appearance shape and a texture of natural stone can be easily manufactured at low cost.

[Brief description of the drawings]

FIG. 1 is a view showing a base material cut out so as to conform to the shape of a pseudo-rock intended to obtain a block-shaped synthetic resin foam material.

FIG. 2 is a diagram illustrating a locking tool used for fixing a sheet.

FIG. 3 is a view showing a state in which a sheet is fixed on the surface of a base material and a partial undercoat is applied.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Substrate made of synthetic resin foam molded into a shape similar to the shape of the rock to be obtained, 2 ... Sheet, 3 ... Undercoat layer, 10 ... Locking device, 11 ... Top plate, 12 ... Insertion leg , 1
3 ... fin

Claims (5)

[Claims] An undercoat with a lightweight mortar made of a synthetic resin foam as a base material molded into a shape similar to the shape of a rock to be obtained and a pulverized foam resin applied to the surface as a main aggregate. A pseudo rock comprising at least a layer and a finish coat layer applied on the undercoat layer. 2. The artificial rock according to claim 1, wherein the surface of the synthetic resin foam as a base material is covered with a net, and an undercoat layer is formed thereon. 3. Forming a synthetic resin foam as a base material into a shape similar to the shape of a rock from which a synthetic resin foam is to be obtained, and applying a primer to the surface of the mortar using a crushed foam resin product as a main aggregate. A method for producing a pseudo-rock, characterized in that after the undercoat layer has been dried and hardened, a finish coating and, if desired, patterning and surface coating are performed. 4. Forming a synthetic resin foam material as a base material into a shape similar to the shape of a rock for which a synthetic resin foam material is to be obtained, covering the surface with a net, and then forming the synthetic resin foam using a locking member. Fixed to the material, undercoated with a lightweight mortar with a foamed resin crushed product as a main aggregate from the net, and after drying and curing, a final coating and, if desired, a patterning and surface coating are performed. Production method. 5. The method according to claim 3, further comprising a step of scraping off a desired portion of the surface-coated surface using a wire brush or the like.