JP2000185310A - Manufacture of concrete product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize the repeated use of a form for manufacturing an imitation rock. SOLUTION: In this manufacturing method, a concrete is placed in a form 9, at least the molding surface 9a of which is elastically deformable, which has the elongation at break of 800% or more, the breaking strength of 10 kgf/cm2 or more and Asker C hardness of 60 or less. Under the stage that the placed concrete cures and turns into a demoldable molded product, a nozzle 8 is inserted between the outer surface 11a of the molding and the molding surface 9a of the form 9 by utilizing the elasticity of the molding surface 9a so as to introduce a compressed gas through the nozzle 8 between them. The introduced compressed gas is dispersed over a wide range in a boundary between the molding surface 9 and the outer surface 11a of the molded product by utilizing the elasticity of the molding surface 9a. As a result, the molded product is released from the form 9.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a concrete product suitable for manufacturing a concrete product such as artificial rock having a complicated surface, which is provided on a slope or a riverbed of a river.

[0002]

2. Description of the Related Art Conventionally, in the fields of architecture, civil engineering, landscaping, and the like, demand for natural stone has been increasing.
In many cases, the shortage of natural stones becomes remarkable, making it difficult to obtain them. Therefore, instead of natural stone, various artificial rocks made of concrete have been produced.

[0003] This type of pseudo rock is prepared, for example, by preparing a steel plate form provided with a urethane resin layer obtained by transferring the form of a rock surface on its inner surface, casting concrete in the form, and placing the concrete in the form. At the stage when is hardened, the desired form rock is obtained by disassembling the mold into a plurality and releasing the mold.

[0004]

However, such a formwork in which the steel iron and the urethane resin are integrated has a very poor releasability between the urethane resin layer and the hardened concrete, and is difficult to remove when the mold is removed. Is to release the mold by hitting the urethane resin layer and the steel plate portion of the mold with a hammer to give an impact. In this case, if the artificial rock has a high height, the formwork becomes deeper, so that it may be difficult to release the mold even if it is hit with a hammer.
Similarly, when the number of pseudo rocks is large, it is difficult to remove the mold.

As described above, when the mold cannot be easily removed by hitting with a hammer, a stronger impact is applied, and not only a great deal of labor is required, but also the steel plate portion and the urethane resin portion of the mold are damaged. There was a problem of deformation. An object of the present invention is to solve such a problem.

[0006]

In order to achieve the above object, the present invention takes the following measures. In other words, the method for producing a concrete product according to the present invention is to prepare a mold having at least a molding surface capable of being elastically deformed, and molding the concrete molded product and the mold when the concrete poured into the mold hardens. A compressed gas is introduced by inserting a nozzle at the boundary with the product, and the compressed gas is dispersed to release the molded product from the mold.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION In the method for producing a concrete product according to the present invention, at least the molding surface is elastically deformable, the elongation at break is 800% or more, the breaking strength is 10 kgf / cm ² or more, and Asker C is used. Hardness is 60
Concrete is poured into the following formwork, and at the stage where the concrete has hardened to form a molded product that can be removed from the mold, the molding surface is formed between the outer surface of the molded product and the molding surface of the mold. A nozzle is inserted by utilizing elasticity, a compressed gas is introduced from the nozzle, and the introduced compressed gas is spread over a wide range at the boundary between the molding surface and the outer surface of the molded product by utilizing the elasticity of the molding surface. And dispersing the molded product to release the molded product from the mold.

With such a configuration, the molded article can be easily released from the mold by the compressed gas layer formed between the molded article and the mold. Therefore,
Conventionally, even high molded products, which were difficult to release,
Since the pressurized gas layer uniformly releases the mold over the entire area of the outer surface of the molded product that becomes the pseudo rock, it is possible to always perform a uniform release operation regardless of the size of the pseudo rock.

Further, since no external force that changes the shape of the mold is applied or broken when the mold is released, the shape of the mold is maintained even after the mold has been used. Moreover, since the mold can be elastically deformed, even if the inserted nozzle is pulled out from the mold, the hole formed by inserting the nozzle is closed, so long as the mold does not lose elasticity.
It can be used repeatedly.

It is preferable that the mold is provided with a nozzle penetrating portion in which the entire internal structure from the molding surface to the outer surface is made of a rubber-like substance that can be elastically deformed. Hollow needle-shaped ones that can be pierced. The nozzle includes one provided with one or a plurality of ejection holes for ejecting a compressed gas.

The mold is formed by bringing a thermoplastic material which is cured at room temperature into an elastically deformable body into contact with the outer surface of the matrix in a state of being heated and melted, and curing the thermoplastic material at room temperature. It is preferable that the frame main body is manufactured, and a required portion on the outer surface side of the frame main body is formed by holding the shape by means of shape retaining means. In this case, as the matrix, a naturally occurring rock or the like is preferable in order to make the molded product look like a rock. Examples of the shape retaining means include concrete, mortar, or cement paste, or concrete, mortar, or cement paste, and a rigid mold that restrains the outside of these. According to such a configuration, the usage amount of the thermoplastic material can be reduced. In addition, since the form main body is preserved by the form preserving means, it is possible to repeatedly produce a molded product that is very similar to the appearance of a rock even if the form body is thin.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. First, as shown in FIG. 1, a matrix 3 in which a rock 1 is placed on a base 2 and integrated is prepared. As the rock 1, for example, natural stone having a height of about 30 to 50 cm is preferably used, but is not necessarily limited to natural stone. This rock 1 has an outer shape that has no overhangs and grows larger toward the bottom.
Only the required number is arranged in a desired manner so as to form a desired artificial rock. Such a matrix 3 is placed in a rigid form 5 for pouring concrete 4 as shape retaining means. In addition,
A suspension ring 3 a for suspending the matrix 3 is provided on the bottom surface of the matrix 3.
Is fixed.

Then, the thermoplastic material 6 is brought into contact with the entire matrix 3 in a state of being heated and melted. Specifically, for example, “EM / M” (trade name; Sumitomo Osaka Cement Co., Ltd.) or the like is used as the thermoplastic material 6. This “EM / M” is a thermoplastic elastomer in which oil is sealed in a three-dimensional network structure of a special polymer, and becomes a rubber elastic body that can be elastically deformed at room temperature.
At higher temperatures than the temperature, it becomes oily.

As described above, the thermoplastic material 6 is
When the thermoplastic material 6 hangs down over the entire surface of the matrix 3, the thermoplastic material 6 flows along the outer surface of the matrix 3 sequentially due to its viscosity,
It will descend while being cooled. Then, as shown in FIG. 2, at the stage where the thermoplastic material 6 is cured to form the mold body 7 covering the matrix 3, an adhesive binder is applied on the mold body 7. Thereafter, concrete 4 as a shape-retaining means is cast into the rigid form 5 from above the form body 7 (FIG. 3). By applying the binder to the form body 7 in this way, the adhesion between the form body 7 and the concrete 4 is strengthened, and the form body 9 is peeled off from the concrete 4 after the form 9 is manufactured. Don't do it.
The average thickness of the mold body 7 formed by curing the thermoplastic material 6 is preferably about 0.5 cm to 2.0 cm, but is not necessarily limited to this value.

As shown in FIG. 4, the concrete 4 is cast until a part of the form body 7 is exposed to the surface, so that the entire form body 7 is not covered. That is, it is sufficient that the uppermost portion of the form body 7 is exposed during concrete casting. The exposed portion is a nozzle penetrating portion 7a through which the nozzle 8 described later pierces, and may have any area that allows the nozzle 8 to pierce. Since the nozzle penetrating portion 7a is made of the thermoplastic material 6, the entire internal structure is a rubber elastic body capable of elasticity. In this way, the formwork 9 composed of the formwork body 7, the concrete 4 and the rigid formwork 5 is formed.

Next, as shown in FIG. 5, after the concrete 4 poured into the rigid form 5 is hardened, the form 9 is turned upside down as shown in FIG. Remove from Then, as shown in FIG. 7, in a state in which the form 9 is facing upward, that is, in a state in which the forming surface 9a is facing upward, concrete for forming the artificial rock 11 as a molded product in the form 9 is formed. 10 is cast. In this embodiment, a mold body 7 substantially serving as a mold having a molding surface 9a is provided.
However, since it is formed of the heat-flexible material 6 as described above, it has characteristics that the elongation at break is 800% or more, the breaking strength is 10 kgf / cm ² or more, and the Asker C hardness is 60 or less. I have. While the concrete 10 is being poured, the suspension ring 12 may be buried so as not to come off from the concrete 10. This suspension ring 12 is a pseudo rock 11
When the mold is released from the formwork 9, the pseudo rock 11 is suspended. When the concrete 10 hardens, the pseudo rock 11 of the concrete 10 is formed.

In the state where the concrete 10 is hardened in the mold 9 in this manner, as shown in FIG.
The nozzle 8 is inserted between the molding surface 9a of the mold 9 and the outer surface 11a of the dummy rock 11 by utilizing the elasticity of the mold 9 by pressing the tip of the nozzle 8 against the mold. Although FIG. 8 illustrates a case where one nozzle 8 is used, several nozzles 8 may be inserted from the nozzle penetrating portion 7a. As shown in FIG. 11A, the nozzle 8 is formed of a hollow needle member having a sharp tip, and has an inclined opening 8b formed at the tip portion 8a so as to have a sharp tip. As shown in FIG. 11B, such a nozzle may be a nozzle 81 having a plurality of openings 81b, for example, two openings 81b at the distal end portion 81a and formed of a hollow needle member. The nozzle 8 is connected to a compressor that outputs compressed air, which is a compressed gas, so that compressed air can be supplied between the molding surface 9 a and the outer surface 11 a of the pseudo rock 11.

After the nozzle 8 is inserted, compressed air is sent from the compressor, and compressed air is introduced between the molding surface 9a and the outer surface 11a of the dummy rock 11. This compressed air is adjusted to an air pressure of 9.5 kgf / cm ² or less as an air pressure necessary for mold release. When the compressed air is introduced, as shown in FIG.
Is elastically deformed. At this time, the compressed air is widely dispersed according to the unevenness of the outer surface 11a of the pseudo rock 11. As a result, the molding surface 9a and the pseudo rock 11 outer surface 11
At the boundary with a, air layers of compressed air are formed at several places or widely, and the molding surface 9a is separated from the outer surface 11a.
In this way, when the air layer of the compressed air is formed, as shown in FIG. 10, the pseudo rock 11 is lifted through the suspension ring 12 through a wire (not shown) and released from the form 9,
The pseudo rock 11 is obtained. Since the shape of the rock 1 of the master block 3 is transferred to the pseudo rock 11 via the form body 7, the pseudo rock 1
The appearance of 1 is the same as or very similar to the rock 1. The nozzle 8 is pulled out from the mold body 7 after introducing the compressed air. However, since the mold body 7 can be elastically deformed,
When the nozzle 8 is pulled out, the hole through which the nozzle 8 has passed is closed.

As described above, according to the present manufacturing method, the concrete 10 is poured into the formwork 9, and at the stage when the concrete 10 is hardened to form a molded product that becomes the pseudo rock 11, the molded product, that is, the pseudo rock 11 and the mold are formed. Since the compressed air is widely dispersed on the boundary where the frame 9 is in contact by utilizing the elastic deformation of the form 9, the pseudo rock 11 is formed by the air layer formed between the form rock 11 and the form 9. The mold can be easily released from the mold 9. Therefore, even in the case of a high molded product which has conventionally been difficult to release, the mold is uniformly released in the entire area of the outer surface 11a of the molded product that becomes the pseudo rock 11 due to the air layer. Therefore, regardless of the size of the pseudo rock 11, A uniform release operation can always be performed. In addition, when the injection position of the compressed air by the nozzle 8 is set to several places, the compressed air enters almost the entire range of the form body 7, and the pseudo rock 11 can be extremely easily made from the form 9.

Further, since no external force that changes the shape of the mold body 7 is applied when the mold is released, the shape of the mold body 7 is maintained even after being used once. Since the mold body 7 can be elastically deformed, even if the nozzle 8 inserted into the nozzle penetrating portion 7a is pulled out from the mold body 7, the hole formed by the insertion of the nozzle 8 in the nozzle penetrating portion 7a is closed. As long as 7 does not lose elasticity, it can be used repeatedly.

Furthermore, the mold body 7 is manufactured by bringing the thermoplastic material 6 into contact with the outer surface of the matrix 3 including the rock 1 in a state where the thermoplastic material 6 is heated and melted, and is cured at room temperature. The amount can be reduced. In addition, since the form body 7 is preserved by the concrete 4, it is possible to repeatedly produce the pseudo-rock 11 having a very similar appearance to the matrix 3 even if the form body 7 is thin.

The present invention is not limited to the embodiment described above. In the above-described embodiment, the thermoplastic material 6 is brought into contact with the matrix 3 in a heated and molten state, and is cured to form the mold body 7 which forms the center of the mold 9.
Forms a frame for the thermoplastic material 6 around the rock 1 and pours the molten thermoplastic material 6 into the frame to create a form 109 that can stand alone without shape-retaining means. It may be something.

Specifically, in FIG. 12, first, a bottom plate 20 provided with an opening 20a in accordance with the rock 1 of the matrix 3 is placed above the base 2 with a gap G corresponding to the thickness of the mold 109. It is arranged with a gap. Next, the bendable side sheet metal 21 is fixed to the bottom sheet metal 20 with a gap corresponding to the thickness of the formwork 109 being left between the rock 1 and the rock 1. As shown in FIG. 13, the side sheet metal 21 is covered with the rock 1 according to the size of the rock 1 so that the thickness of the mold 109 is not too large and the elastic deformation of the thermoplastic material 6 is not reduced. It is bent so as to cover and forms an opening 22 into which the thermoplastic material 6 is poured above the rock 1.

In this state, the molten thermoplastic material 6 is poured from the opening 22 into the frame 22 formed by the bottom plate 20 and the side plate 21 (FIG. 14). Thermoplastic material 6
Is determined by the size of the gap, that is, the thickness of the side surface of the mold 109 and the thickness of the bottom surface of the mold 109. In this case, form 1
The thickness of the mold 109 is preferably about 5 to 7 cm at a thick place and about 2 cm at a thin place in order for the 09 to be self-supporting and elastically deformed, but is not necessarily limited to this value. After the thermoplastic material 6 is cured at room temperature, the side sheet metal 21 and the bottom sheet metal 20 are removed, and then the cured thermoplastic material 6 and the mother die 3 are separated to obtain a mold 109 (FIG. 15).

In the same manner as in the above embodiment, the mold 109 thus obtained can be cast with concrete inside to produce the pseudo rock 11. In this case, the formwork 109
Is made of a thermoplastic material 6 and can be elastically deformed similarly to the mold body 7 of the above-described embodiment.
By introducing compressed air between the outer surface of the molded article and the molding surface 109a of the mold 109 via the
09 can be released from the mold. That is,
As shown in FIG. 16, when the concrete 10 is cast and the concrete 10 is hardened, the nozzle 8 is connected to the mold 109.
And pressurized air is introduced through the nozzle 8 between the outer surface of the molded product and the molding surface 109a of the mold, and the compressed air is
09 is elastically deformed to form an air layer between the outer surface of the molded product and the molding surface 109a of the mold 109.
9 is released from the mold. With such a formwork 109, concrete as a shape-retaining means is not required, so that the formwork 109 is light in weight and easy to handle.

The above-described mold body 7 and mold 109
Has the physical property values shown in Table 1 as compared with a mold formed of a urethane resin because it is molded with the thermoplastic material 6.

[0027]

[Table 1]

Further, in order to show such physical property values, the thickness of the nozzle 8 that can be pierced into the mold body 7 and the mold frame 109 can be made thicker than a mold frame made of urethane resin. Moreover, as shown in Table 2, even if the thickness increases,
The ease of piercing is no substitute. Table 2 shows the mold thickness and ease of piercing when comparing the two.
Shown in

[0029]

[Table 2]

In addition, in each of the above embodiments,
If the concrete 10 is cast only at the portion corresponding to the rock 1, individual pseudo rocks that are not connected to each other, that is, not integrated at the pedestal portion, can be manufactured. In addition, the configuration of each unit is not limited to the illustrated example, and various modifications can be made without departing from the spirit of the present invention.

[0031]

As described above, according to the present invention, the molded article can be easily released from the mold by the compressed gas layer formed by the compressed gas between the molded article and the mold. .
Therefore, even a high-molded product, which had been difficult to release in the past, was evenly released over the entire area of the outer surface of the molded product that became pseudo-rock by the compressed gas layer, so it was always homogeneous regardless of the size of the pseudo-rock. A good release operation.

Further, since no external force that changes the shape of the mold is applied or broken when the mold is released, the shape when the mold is created is maintained even after the mold has been used. Moreover, since the mold can be elastically deformed, even if the inserted nozzle is pulled out from the mold, the hole formed by inserting the nozzle is closed, so long as the mold does not lose elasticity.
Can be used repeatedly.

The mold is provided with a nozzle penetrating portion in which the entire internal structure from the molding surface to the outer surface is formed of a rubber-like substance that can be elastically deformed, and the nozzle can pierce the nozzle penetrating portion. With a hollow needle-like shape, a nozzle can be inserted between the molding surface of the mold and the outer surface of the molded product. The outer surface of the mother mold is brought into contact with a thermoplastic material that is hardened at room temperature and becomes an elastically deformable object while being heated and melted, and the thermoplastic material is hardened at room temperature to produce a mold body. The required amount of the thermoplastic material can be reduced as long as the form is formed by holding a required portion on the outer surface side of the frame main body by the shape keeping means. In addition, since the form main body is preserved by the form preserving means, it is possible to repeatedly produce a molded product, such as natural stone, which is very similar to the appearance of the matrix, even if the form main body is thin.

[Brief description of the drawings]

FIG. 1 is a process explanatory view showing one embodiment of the present invention.

FIG. 2 is a process explanatory view showing the embodiment.

FIG. 3 is a process explanatory view showing the same embodiment.

FIG. 4 is a process explanatory view showing the embodiment.

FIG. 5 is a process explanatory view showing the embodiment.

FIG. 6 is a process explanatory view showing the embodiment.

FIG. 7 is a process explanatory view showing the embodiment.

FIG. 8 is a process explanatory view showing the embodiment.

FIG. 9 is a process explanatory view showing one process of the same example in an enlarged manner.

FIG. 10 is a process explanatory view showing the embodiment.

FIG. 11 is an enlarged cross-sectional view showing a nozzle and a modification of the nozzle in the embodiment.

FIG. 12 is a process explanatory view showing another embodiment of the present invention.

FIG. 13 is a process explanatory view showing another embodiment.

FIG. 14 is a process explanatory view showing another embodiment.

FIG. 15 is a process explanatory view showing another embodiment.

FIG. 16 is a process explanatory view showing another embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 3 ... Master mold 4 ... Concrete 6 ... Thermoplastic material 7 ... Form body 7a ... Nozzle penetration part 8 ... Nozzle 9 ... Mold form 9a ... Molding surface 10 ... Concrete

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Tatsuharu Tanahashi 7-55 Minamionkajima, Taisho-ku, Osaka City Sumitomo Osaka Cement Co., Ltd. Cement Concrete Research Laboratory (72) Inventor Kikuo Tachibana Taisho-ku, Osaka-shi 7-55 Minamienkajima, Cement Concrete Research Laboratory, Sumitomo Osaka Cement Co., Ltd. (72) Inventor Nobuyuki Tanaka 7-55 Minamienkajima, Taisho-ku, Osaka Sumitomo Osaka Cement Co., Ltd. Cement Conc Inside the REIT Research Institute (72) Inventor Masato Kotani 7-55 Minamienkajima, Taisho-ku, Osaka City Sumitomo Osaka Cement Co., Ltd. Cement Concrete Research Laboratory (72) Inventor Kiho Hayashi Minamienkajima, Taisho-ku, Osaka-shi 7-1-55 Sumitomo Osaka Cement Co., Ltd. Cement Concrete Research Laboratory F-term (reference) 4G053 AA07 BE12 EA26 EB02

Claims (3)

[Claims] At least a molding surface is elastically deformable, has a breaking elongation of at least 800%, a breaking strength of at least 10 kgf / cm ² and an Asker C hardness of 60.
Concrete is poured into the following formwork, and at the stage where the concrete has hardened to form a molded product that can be removed from the mold, the molding surface is formed between the outer surface of the molded product and the molding surface of the mold. A nozzle is inserted by utilizing elasticity, a compressed gas is introduced from the nozzle, and the introduced compressed gas is spread over a wide range at the boundary between the molding surface and the outer surface of the molded product by utilizing the elasticity of the molding surface. A method for producing a concrete product, comprising releasing the molded product from the mold by dispersing the molded product. 2. A mold according to claim 1, wherein said mold has a nozzle penetrating portion in which an internal structure extending from a molding surface to an outer surface is entirely made of a rubber-like material capable of being elastically deformed. The method for producing a concrete product according to claim 1, wherein the concrete product has a hollow needle shape. 3. An outer surface of a matrix is brought into contact with a thermoplastic material which is hardened at room temperature to become an elastically deformable object while being heated and melted, and the thermoplastic material is hardened at room temperature to form a mold body. 3. The method for manufacturing a concrete product according to claim 1, wherein said form is formed by manufacturing and holding a required portion on the outer surface side of said form by a shape-retaining means.