JPS6332637B2 - - 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]

BACKGROUND ART Materials having relief patterns are widely used in various fields including exterior and interior applications of architecture.

[Conventional technology]

Traditionally, typical methods for forming relief patterns on the surface of a mortar layer include (1) a method using a trowel or a spatula, (2) a method using a roller, (3) a method using spraying, and (4) a method using embossing. , (5) Methods using blasting, etc. are known.

However, method (1) was developed as a finishing method for solid walls, and it was extremely difficult to form fine relief patterns and required skill.

In addition, method (2) forms unevenness by stamping with a pattern roller, so it is suitable for forming simple repeating patterns, but it is suitable for forming complex and fine patterns. It was not suitable.

Furthermore, method (3) is suitable for forming a random uneven pattern with a spray gun, but
This method has the disadvantage that it is not possible to form any specific pattern such as a design or a character.

Furthermore, although method (4) is suitable for mass production in factories, it is not suitable for applying different patterns to individual products.

Method (5) partially masks the mortar layer,
The unmasked areas are removed by blasting to form an uneven relief pattern. However, this method causes a deterioration of the working environment due to the generation of dust and noise during the blasting process, has a large negative impact on the surroundings of the workplace, takes a long time, and is dangerous. It had the following drawbacks.

Further, when applying mortar to a concrete panel, the following method is known as a means of making the concrete surface uneven in order to improve the adhesion between the mortar and concrete. That is, this is a method of manufacturing an uneven concrete panel in which a formwork is partially coated with a cement hardening retardant in advance, concrete is then poured into the formwork, cured, and then washed out.

However, this method requires a formwork and cannot be applied to any base material. Furthermore, the obtained unevenness was not a sharp (sharp outline) and deeply carved unevenness pattern.
Therefore, this method was inappropriate as a means for forming relief patterns for aesthetic purposes.

[Problem that the invention seeks to solve]

In view of the current state of the art in the field of embossed patterns as described above, the present inventors have developed a method for easily forming an uneven relief pattern of any clear, non-random pattern on any base material without requiring any skill. As a result of intensive studies, the present invention was arrived at.

[Means for solving problems]

That is, the present invention includes (i) applying mortar on a base material to form a mortar layer; (ii) forming a pattern from a liquid-permeable portion and a liquid-impermeable portion while the mortar layer is uncured; After placing the formed sheet on the mortar layer or placing the liquid-impermeable sheet in a pattern on the mortar layer, cement hardening with a viscosity of 10 to ¹⁰³ poise (at 20℃) is applied to the surface of the mortar layer. (iii) After removing the sheet, curing the mortar layer; (iv) After curing the mortar layer, cleaning the mortar layer at the location where the cement curing retarder solution has been applied. The present invention relates to a method for forming a relief pattern having deep unevenness, including the following steps:

In the method of the present invention, the mortar layer is impregnated with a cement hardening retardant solution according to the pattern of the sheet that is in close contact with the uncured mortar layer. Therefore, the hardening of the areas impregnated with the hardening retarder is delayed and can be easily removed by washing even after curing. Therefore, the method of the present invention has the advantage of being able to form on the surface of the mortar layer an embossed pattern having a sharp shape and deep unevenness in accordance with the pattern of the sheet.

In addition, in the present invention, by appropriately controlling the thickness of the mortar layer and the degree of impregnation and removal of the cement hardening retarder, it is possible to create the desired shape, not only with shallow irregularities but also with deep irregularities. It has the advantage of being able to freely form an embossed pattern with uneven depth. Furthermore, the method of the present invention has the advantage that since the relief pattern is made of a mortar layer, it is possible to form a relief pattern with deep unevenness at a very low cost.

Hereinafter, the method for forming a relief pattern having unevenness according to the present invention will be explained in more detail.

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

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

As the mortar used in the present invention, any mortar that has been commonly used can be used as is. That is, it consists of aggregates such as cement and sand, and water, and if necessary, coloring pigments, various additives, etc. are added. Also, so-called resin mortars containing acrylic resin emulsions, vinyl acetate resin emulsions, epoxy resin emulsions, sterene butadiene resin emulsions, etc. can also be used in the present invention.

In the present invention, in addition to using mortar of the same color, the mortar layer may be formed by applying mortar of different colors multiple times. By forming multiple mortar layers with different colors in this way, in the cleaning and removal process described later, the depth can be adjusted by adjusting the degree of removal at each location when cleaning and removing the mortar layer, that is, the depth of the recess. It becomes possible to form an uneven relief pattern with multicolored changes depending on the color.

While the mortar layer formed in this manner is still uncured, preferably when the free water on the surface of the mortar layer disappears and the surface does not deform when lightly pressed with a finger, the liquid-permeable portion and the liquid-permeable portion are separated. The sheet with the pattern formed thereon is brought into close contact with the surface of the mortar layer. Specifically, the sheet is preferably a silk screen commonly used in the paint industry. Alternatively, a sheet cut out in a pattern (to form a desired pattern) can be brought into close contact with the surface of the mortar layer.

In another embodiment of the present invention, a liquid-impermeable sheet can be closely attached to the mortar layer so that the sheet forms a pattern.

After the sheet is placed on the mortar layer in this manner, a cement hardening retarder solution is applied onto the surface of the mortar layer from above the sheet. Furthermore, the applied cement retardant solution is impregnated into the mortar layer other than the one in close contact with the liquid-impermeable portion of the sheet.
That is, in order to place the sheet on the mortar layer while the mortar layer is uncured, there is no space between the mortar layer and the sheet (liquid impermeable portion), and the sheet is placed on the mortar layer while the mortar layer is uncured. The covered mortar layer is not impregnated with the cement retarder solution.

Further, by adjusting the viscosity and application amount of the cement hardening retarder solution, the depth of the unevenness can be freely changed. That is, for example, by lowering the viscosity of the cement hardening retarder and/or increasing the amount applied, the cement hardening retarder can be impregnated more deeply, and the depth of the unevenness can be increased.

The viscosity of the cement hardening retardant solution used in the present invention is preferably 10 to 10 ³ poise (at 20° C.) in consideration of permeability into the mortar layer. By using a cement hardening retardant solution having a viscosity within this range, a sharper U-shaped recess can be formed.

In the present invention, as the cement hardening retarder solution, those commonly used in the past can be used as they are. Specifically, representative examples include sodium dihydrogen phosphate, disodium hydrogen phosphate, sodium phosphate, sodium tetraborate, sugars, acetic acid, calcium, oxycarboxylic acids, lignin sulfonates, alcohols, etc. It can be given as In addition, solid substances are used as aqueous solutions. If the viscosity is lower than the above range, the viscosity can be adjusted to the above range by adding a thickener such as polyvinyl alcohol, methylcellulose, sodium alginate, bentonite, or the like.

In addition, by applying a cement hardening retardant solution containing a coloring agent to the mortar layer, the areas impregnated with the cement hardening retarder solution that should be cleaned and removed can be identified by coloring. It can be useful in the process.

In the present invention, after applying the cement hardening retarder solution, the sheet is removed, and then the mortar layer is cured for a certain period of time. As the curing method, a natural curing method, a steam curing method, a pressure curing method, etc., which are generally known as mortar curing methods, can be adopted.

The curing time is such that in the cleaning and removal process described later, the mortar layer in areas where the cement hardening retardant solution has not been applied and impregnated has hardened to the extent that it cannot be removed, and the areas where the cement hardening retarder solution has been applied and impregnated have hardened to the extent that they are not removed. The time required for the mortar layer to be uncured or semi-cured to the extent that it can be removed relatively easily. Specifically, for example, in the case of a natural curing method, it is preferable to set it at room temperature (20°C) for 8 to 50 hours.

After cultivating the mortar layer, apply a cement hardening retardant solution by using a cleaning solution consisting of water or water and a solvent and rubbing with a rotating brush, or by spraying the cleaning solution under high pressure.
Wash and remove the mortar layer at the impregnated area.

In this way, a mortar layer is obtained in which a relief pattern with deep unevenness is formed. In the present invention, it is also possible to add color and adjust the glossiness, if necessary. Furthermore, in order to impart weather resistance, water resistance, chemical resistance, etc., a different colored coating may be applied to the entire surface or concave portions (or convex portions), or a coating film such as clear or color clear may be applied to the entire surface, or It can also be polished.

As described above, by the method of the present invention, it is possible to easily and inexpensively obtain a relief pattern having deep unevenness of any depth. Furthermore, by varying the pattern formed on the sheet, a desired uneven pattern can be easily obtained.

Furthermore, the mortar layer with the uneven pattern obtained by the method of the present invention can be used for building materials, decorative items, etc., and has the feature that it can be manufactured in a factory or on-site.

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

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

Example 1 Asbestos slate board with a wooden frame around it (900
×1800×10mm) Portland cement on the surface
A smooth mortar layer with a thickness of 3 mm was formed using a trowel using a mortar consisting of 100 parts of silica powder, 200 parts of silica powder, 1 part of water reducing agent, and 75 parts of water. After leaving it for 1 hour and confirming that the water on the surface has disappeared and that it is not deformed by pressing lightly with your finger, a silk screen with a pattern formed from a liquid-permeable part and a liquid-impermeable part is tightly attached to the surface of the mortar layer. Ta.

Next, a mixture containing 8 parts of disodium hydrogen phosphate, 1.5 parts of a methylcellulose thickener, 1 part of phthalocyanine blue, and 90 parts of water with a viscosity of 280 poise (20°C)
The cement retardant solution was applied (100 g/m ² ) onto the silk screen using a doctor blade.
Then after removing the silk screen, temperature 20
℃ and 75% relative humidity for one day.

Then, pour water (30/min) for 5 min/m ²
A nylon thread (diameter) rotating (250 rpm) at a rate of
0.6mm) with a circular brush (φ100mm),
The mortar layer impregnated with the cement retardant solution was removed.

On the resulting surface, sharp pattern-like unevenness with an average depth of about 1 mm was formed, corresponding to the pattern of the silk screen.

Next, an acrylic clear lacquer was applied to the entire surface.

On the surface of the mortar layer obtained in this way,
A relief pattern with an extremely embossed appearance was obtained.

Example 2 Same as Example 1 except that a cement hardening retarder solution with a viscosity of 80 poise (20°C) consisting of 15 parts of calcium acetate, 1 part of methylcellulose thickener, 1 part of phthalocyanine blue and 83 parts of water was used. to form irregularities on the surface of the mortar layer.

On the resulting surface, sharp pattern-like unevenness with an average depth of about 2.5 mm corresponding to the silk screen pattern was formed, and a relief pattern with an extremely embossed appearance was obtained.

Example 3 A resin mortar consisting of 30 parts of Portland cement, 25 parts of silica powder, 1 part of methyl cellulose thickener, 8 parts of vinyl acetate resin emulsion (NV50%), 0.3 parts of water reducing agent and 25 parts of water was applied to a thickness of 12 mm. death,
Having formed a mortar layer, trisodium phosphate
A mortar layer was prepared in the same manner as in Example 1, except that a cement hardening retarder solution with a viscosity of 20 poise (at 20°C) consisting of 20 parts of methyl cellulose thickener, 1 part of phthalocyanine blue, and 79 parts of water was used. Irregularities were formed on the surface.

On the obtained surface, sharp pattern-like unevenness with an average depth of about 3.5 mm corresponding to the silk screen pattern was formed, and a relief pattern with an extremely embossed feeling was obtained.

Example 4 30 parts of white Portland cement, 25 parts of silica powder, 1 part of methylcellulose thickener, and acrylic resin emulsion (NV50) were applied to the surface of the asbestos slate board.
%), 0.3 parts of Phthalocyanine Blue, 1 part of Hansa Yellow, 0.3 parts of water reducing agent, and 25 parts of water. Apply a mortar to a thickness of 3 mm, then add 1 part of Naphthol Red in place of the coloring agent in the mortar. The mortar was applied to a thickness of 2 mm.

After leaving it for 2 hours and confirming that the water on the surface has disappeared and that it is not deformed by pressing lightly with your finger, a silk screen with a pattern formed from a liquid permeable part and a liquid impermeable part is tightly attached to the surface of the mortar layer. Ta.

Next, the same cement hardening retardant solution as used in Example 3 was applied onto the silk screen, and in the same manner as in Example 1, irregularities were formed on the surface of the mortar layer.

On the resulting surface, sharp pattern-like unevenness with an average depth of approximately 3.5 mm corresponding to the silk screen pattern can be formed, the concave portions are edge colored and the convex portions are red.
A relief pattern with an extremely embossed appearance was obtained.

Claims (1)

[Claims] 1 (i) A step of applying mortar on a base material to form a mortar layer; (ii) A step of applying a sheet having a pattern formed of a liquid-permeable part and a liquid-impermeable part on the mortar layer. After placing it on
Alternatively, after placing a liquid-impermeable sheet on the mortar layer in a pattern, the viscosity is applied to the surface of the mortar layer.
Step of applying a cement hardening retardant solution of 10 to ^{10 3} poise (at 20°C); (iii) removing the sheet and curing the mortar layer; (iv) delaying cement hardening after curing of the mortar layer. A method for forming an embossed pattern with deep unevenness, comprising the following steps: washing and removing the mortar layer at the location where the agent solution has been applied. 2. The method for forming a relief pattern according to claim 1, wherein the sheet on which the pattern is formed is a silk screen. 3. The method for forming a relief pattern according to claim 1, wherein the mortar layer is composed of a plurality of mortar layers of different colors.