JPH11324213A - Building material block and manufacturing thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a building material block having design efficiency giving a feeling of natural stone grain, and high rigidity. SOLUTION: A building material block 1 is formed in an angular shape having a stone grain layer on the front side and a cement layer 3 on the rear side. The stone grain layer 2 is so formed that screenings or stone pieces or both of them are mixed with binder and are solidified. The surface 2a of the stone grain layer 2 is formed in an uneven shape in imitation of the surface of a natural stone. The cement layer 3 is formed in a state to solidify mortar constituted of cement, aggregate like sand and water mixed with each other and, at the same time, the cement and binder of the stone grain layer in the mortar react against each other to fix the cement layer 3 to the rear side of the stone grain layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a building material block such as a concrete block and a method for manufacturing the same.

[0002]

2. Description of the Related Art Some building material blocks are formed entirely by mixing a binder with stone powder or stone grains, or formed entirely by cement.

[0003]

The conventional whole formed by mixing a binder with a stone powder or a stone grain has a design that makes a natural stone skin feel, but is more rigid than the whole formed by cement. Chip. Although the whole made of cement has high rigidity, it cannot be denied that the artificial tasteless dry feeling is intuitive and lacks in design.

[0004] Accordingly, an object of the present invention is to provide a building material block having both a design property that allows a natural stone surface to be felt and high rigidity, and a method of manufacturing the same.

[0005]

According to a first aspect of the present invention, there is provided a building material block, comprising: a stone surface layer made of one or both of stone powder and stone particles and a binder; and a back surface of the stone surface layer. And a cement layer made of mortar adhered to the mortar. The building material block according to the second aspect of the present invention is characterized in that the cement layer according to the first aspect is fixed by reacting with the cement in the mortar and the binder of the stone layer. In the method of manufacturing a building material block according to claim 3 of the present invention, a material obtained by mixing one or both of a stone powder and a stone and a binder into a mold is poured and pressed from above. Before the material has not completely set, pour the mortar, which is a mixture of cement, sand-like aggregate, and water, into the interior of the formwork, the binder in the material that was first put inside the formwork, and the material that was put in afterwards. It is characterized in that when the cement layer is entirely solidified in a form in which the cement layer adheres to the back surface of the stone surface layer while chemically reacting with the cement therein, the molded product is released from the mold. According to a fourth aspect of the present invention, there is provided a method for manufacturing a building material block, wherein a mold having an uneven bottom surface is used as the mold according to the third aspect.

[0006]

FIG. 1 shows the appearance of a building material block 1 according to an embodiment of the present invention. In FIG. 1, a building material block 1 has a square shape having a stone layer 2 on the front side and a cement layer 3 on the rear side. The stone skin layer 2 is formed in a solidified state in which one or both of the stone powder and the stone grains and the binder are well mixed. Surface 2a of stone skin layer 2
Is formed in an irregular shape simulating the surface of natural stone. The cement layer 3 is formed by solidifying a mortar in which an aggregate such as cement and sand and water are mixed well, and the cement in the mortar and the binder of the stone layer 2 react to form the stone surface. It is fixed to the back surface of layer 2.

According to the building material block 1 of this embodiment,
Since the stone layer 2 is on the front side and the cement layer 3 is on the rear side, the stone layer 2 is used when building a building such as a wall or when the building material block 1 is used like a paving stone.
By using the surface of the stone layer 2 as a surface, it is possible to combine the design property of the stone layer 2 with the natural stone surface and the high rigidity of the cement layer 3 supporting the stone layer 2 from behind.

Further, according to the building material block 1 of this embodiment, the binder of the stone layer 2 and the cement in the mortar chemically react, and the cement layer 3 is fixed to the back surface of the stone layer 2. The adhesion between the stone layer 2 and the cement layer 3 is strong in the anchored state.

In order to manufacture the building material block 1 of this embodiment, for example, stone powder or stone particles are placed in an unillustrated formwork having an uneven bottom surface in which the unevenness of the surface 2a of the stone surface layer 2 is inverted. After pouring a material obtained by mixing one or both of them and a binder and applying pressure from above using a tool such as a weight (not shown) or a press machine, before the material is completely hardened, Immediately, pour mortar, which is a mixture of cement, aggregate such as sand, and water, into the interior of the mold. Then, in a process in which each material is solidified inside the mold, the binder in the material put in the mold first and the cement in the material put in later form a chemical reaction, and the cement layer 3
Is solidified as a whole in a form fixed to the back surface of the stone layer 2.
Then, the solidified molded product is released from the mold to form a building material block 1 in which the stone surface layer 2 on the front side and the cement layer 3 on the rear side are integrally and inseparably fixed.

[0010] According to the manufacturing method of this embodiment, after the material of the stone layer 2 put in the inside of the mold is pressed,
Since the mortar which is the material of the cement layer 3 is put into the mold, the reversibility of the stone layer 2 with respect to the mold is good, and the stone layer 2 and the cement layer 3 are divided into two layers. And the design of the stone layer 2 is high.

In the above-described embodiment, the cement layer 3 is formed only by solidifying the mortar. However, if a reinforcing member such as a reinforcing bar is arranged inside the cement layer 3, the rigidity is further increased.
Also, an aggregate such as gravel may be added to the mortar.

[0012]

As described above, according to the first aspect of the present invention, a stone surface layer composed of one or both of stone powder and stone particles and a binder, and a cement adhered to the back surface of the stone surface layer When building a building such as a wall, or when using a building material block as a paving stone, etc. This makes it possible to combine the design property of feeling the natural stone surface by the stone layer and the high rigidity of the cement layer that supports the stone layer from behind. According to the invention of claim 2,
Since the cement layer reacts with the cement in the mortar and the binder of the stone layer, and adheres, the adhesion between the cement layer and the stone layer can be strengthened. According to the invention of claim 3, inside the mold, a material obtained by stirring one or both of the stone powder and the stone and the binder is poured and pressed from above, and before the material is completely hardened, Mortar mixed with cement and aggregates such as sand and water is poured into the formwork, and the binder in the material put earlier in the formwork and the cement in the material put in later form a chemical reaction. When the cement layer is solidified as a whole with the cement layer adhered to the back surface of the stone layer, the molded product is released from the mold, so that the stone layer and the cement layer are divided into two layers. It is possible to easily obtain a building material block having both the design property of allowing the natural stone surface to be felt by the layer and the high rigidity of the cement layer that supports the stone layer from behind. According to the invention of claim 4, since the mold having the uneven bottom surface is used as the mold, it is possible to easily obtain the building material block having the unevenness in which the uneven shape of the mold bottom is inverted on the surface of the stone layer. Can be.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the present invention.

[Explanation of symbols]

 1 building material block 2 stone layer 3 cement layer

Claims (4)

[Claims] 1. A stone surface layer comprising one or both of stone powder and stone particles and a binder, and a cement layer comprising cement, aggregate and water fixed to the back surface of the stone surface layer. A building material block characterized by that: 2. The building material block according to claim 1, wherein the cement layer is fixed by reacting with the cement in the mortar and the binder of the stone surface layer. 3. A material obtained by mixing one or both of a stone powder and a stone with a binder is poured into a mold and pressed from above, and cement and sand are mixed before the material is completely hardened. The mortar mixed with aggregate and water is poured into the formwork, and the cement layer in the formwork is chemically reacted with the binder in the material put in earlier and the cement in the material put in later. A method for manufacturing a building material block, comprising releasing a molded product from a mold frame when the whole is solidified in a form of being fixed to a back surface of a stone surface layer. 4. The method for manufacturing a building material block according to claim 3, wherein a mold having an uneven bottom surface is used as the mold.