JP2002200614A - Concrete artificial wood whose whole periphery is molded into uneven state of natural wood, and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make the whole of an artificial wood extremely lightweight while increasing bending strength and to mold a three-dimensional surface pattern into an ideal shape extremely near to natural wood. SOLUTION: Concrete artificial wood of which the whole periphery is molded into the uneven state of natural wood has plastic foam as a core material 6 and a GRC layer 7 wherein reinforcing fibers are embedded in cement is provided to the surface of the whole periphery of the core material 6. The GRC layer 7 is molded into the uneven shape of natural wood.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a concrete pseudo-wood in which the entire circumference is formed into an uneven shape of natural wood.

[0002]

2. Description of the Related Art Natural wood having a three-dimensional uneven pattern on its surface has a unique aesthetic property that cannot be realized by artificially processed one. In the present specification, the term "natural wood" is used in a broad sense, including unnatural wood whose surface is not processed, and wood whose surface is naturally uneven after processing, such as used sleepers. Natural wood is used for various purposes such as parks and gardens, utilizing its unique aesthetics. For example, natural wood is used as a support for supporting a tree, a fence of a flower bed, a support for fixing a water tap, and the like. The natural wood used in this application has a beautiful natural aesthetic, but does not have sufficient durability for outdoor use.
For the purpose of overcoming this drawback, a concrete pseudo-wood made of concrete has been developed.

[0003]

SUMMARY OF THE INVENTION
It is extremely durable because it does not corrode like natural wood. However, the concrete artificial wood has a drawback that it becomes extremely heavy because the whole is made of concrete. Also, it is difficult to achieve sufficient bending strength,
There is a disadvantage that a thin and long product cannot be manufactured. The bending strength can be increased by burying a reinforcing bar inside. However, even with this structure, when a long and thin product is manufactured, it is not always possible to obtain a sufficient bending strength, and when a bending force acts, there is a disadvantage that cracks are easily generated in the concrete on the surface.

[0004] In addition, the concrete artificial wood has a drawback that it is difficult to form an uneven pattern on the surface very close to that of a natural wood, and when observed microscopically, fine irregularities are formed. This is because the aggregate filled in the mortar makes the surface a fine uneven surface. For this reason, when a natural wood having a smooth uneven surface, such as a used sleeper, is formed, the surface becomes a rough uneven surface and there is a disadvantage that it cannot be formed into a beautiful uneven surface.

[0005] The present invention has been developed for the purpose of solving such a drawback. An important object of the present invention is to make the entire structure extremely lightweight while increasing the bending strength, and furthermore, it is possible to form a three-dimensional pattern on the surface into an ideal shape very close to that of a natural tree. And a method for producing the same.

[0006]

According to a first aspect of the present invention, there is provided a concrete artificial wood in which the entire circumference is formed into an uneven shape of a natural wood, wherein a plastic foam is used as a core material 6 and the core material is made of a plastic material. A GRC layer 7 in which reinforcing fibers are embedded in cement is provided on the surface of the entire circumference of 6. The surface of the GRC layer 7 is formed into an uneven shape of a natural tree.

According to a second aspect of the present invention, there is provided a method of manufacturing a concrete pseudo-wood, wherein the upper and lower sides are closed by opening and closing the periphery and the bottom, and the bottom and the periphery are formed by a rubber-like elastic body 4 so as to form the unevenness of the natural wood. A first application step of embedding reinforcing fibers on the inner surface of the formwork 2 to be applied and applying the cement paste 5 to a predetermined thickness, and the cement paste 5 applied in the first application step is in an uncured state. A core material inserting step of inserting the core material 6 into the inside of the mold frame 2 to which the paste 5 is applied; and a cement paste by embedding reinforcing fibers on the upper surface of the core material 6 inserted into the mold frame 2 in the core material inserting step. 5 in a second application step of applying the cement paste 5 applied in the second application step in an uncured state,
A closing step of closing the opening of the mold 2 with an upper mold 3 having a lower surface of an irregular shape of natural wood, and holding the opening of the mold 2 with the upper mold 3 so that the cement paste 5 In a hardening step of advancing the hardening reaction and, after the hardening step, a demolding step of demolding the upper mold 3 and the mold frame 2, a concrete mock-up in which the entire circumference is formed into an uneven shape of natural wood is manufactured.

In this manufacturing method, a plastic foam is preferably used as the core material 6. The use of the core material 6 made of a plastic foam makes it possible to make concrete artificial wood extremely light. The rubber-like elastic body 4 on the inner surface of the mold 2 preferably uses silicone rubber. More preferably, an upper mold 3 having an inner surface made of a rubber-like elastic body 4 is used. The concrete dummy is formed, for example, in the shape of a used sleeper.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. However, the following examples illustrate concrete artificial wood and a method of manufacturing the same to embody the technical idea of the present invention, and the present invention does not specify concrete artificial wood and a method of manufacturing the same as follows. .

Further, in this specification, in order to make it easier to understand the claims, the numbers corresponding to the members shown in the embodiments will be referred to as “claims” and “ In the column of “means”. However, the members described in the claims are not limited to the members of the embodiments.

The concrete artificial wood 1 shown in FIG. 1 has an outer shape shaped like a used sleeper. The sleeper is made of hard wood processed into an elongated rectangular column shape, but the surface of the used sleeper is weathered, and the four surfaces on the entire circumference have irregularities or cracks due to the grain. Since wood has hard winter eyes and soft summer eyes alternately, when exposed to the wind and rain for many years like a sleeper, the summer eyes become concave and the winter eyes protrude and become uneven. Further, the surface may be uneven due to warpage or cracking of the whole.

A concrete pseudo-wood having irregularities on all four sides of the entire circumference is manufactured as shown in FIG. 2 in the following steps. First Application Step In this step, the cement paste 5 is applied to the inner surface of the mold 2 to a predetermined thickness while reinforcing fibers are embedded. The thickness of the cement paste 5 to be applied is determined in consideration of the size and strength of the concrete artificial wood, but in the case of used sleepers, it is 1 to 5 cm, preferably 2 to 4 cm. The reinforcing fibers can be kneaded with the cement paste 5 and applied together, or the reinforcing fibers can be applied after the cement paste 5 is applied, and then the cement paste 5 can be applied and embedded. As the reinforcing fibers, all alkali-resistant fibers, for example, glass fibers are used.

The formwork 2 is a box-shaped form that is open at the top and closes the periphery and bottom. The box-shaped formwork 2 has a rubber-like elastic body 4 on the bottom surface and the periphery of the box-shaped formwork so as to have a concave and convex shape of natural wood. Formwork 2
Preferably, the bottom surface and all peripheral surfaces around the bottom surface have irregularities. The mold 2 can be formed into an uneven shape of natural wood on the entire circumference and both end faces. The concrete pseudo-wood produced by the formwork 2 can have all the surfaces including the entire circumference and the both end surfaces of the four surfaces in an uneven shape of the natural wood. However, as for the formwork, the peripheral surfaces that form both end surfaces of the concrete pseudo-wood can be flat. The formwork 2 for molding a sleeper may have a bottom surface and both side surfaces in an uneven shape of the sleeper, and the peripheral surface of the formwork 2 for forming both end surfaces of the sleeper may be flat. The concrete pseudo-wood molded by the formwork 2 has a flat shape with no irregularities at both end surfaces.

Core Material Inserting Step This step is a step in which, when the cement paste 5 applied in the first application step is uncured, the core material 6 is inserted into the mold 2 to which the cement paste 5 is applied. is there. Core material 6
The most suitable is a plastic foam such as styrene foam. As the plastic foam, one having closed cells is cut into a predetermined shape so as not to be impregnated with the cement paste 5, and a plastic foam having irregularities due to countless cells is used. The core material 6 is light and adheres well to the cement paste 5. This is because the cement paste 5 penetrates into unevenness due to countless bubbles and is firmly connected. The core material 6 is inserted into the inside of the cement paste 5 being applied, is in close contact with the inner surface of the cement paste 5, and has such a size that no gap is formed.

Second Coating Step The reinforcing fiber is further embedded on the upper surface of the core material 6 put in the mold frame 2 in the core material fitting step, and the cement paste 5 is applied. Also in this second application step, the cement paste 5 applied in the first application step is applied with the cement paste 5 in an uncured state. Also in this step, the cement paste 5 in which the reinforcing fibers are kneaded is applied, or the reinforcing fibers and the cement paste 5 are mixed.
Are separately applied to the surface of the core material 6. The amount of the cement paste 5 to be applied, that is, the thickness is an optimal value in consideration of the degree of unevenness of the natural wood so that the upper mold 3 is pressed in the next step so that the cement paste 5 can enter the unevenness of the upper mold 3. And In the case of sleepers, it is 1-5 cm, preferably 2-4 cm. The cement paste 5 applied in the second application step is connected to the cement paste 5 applied in the first application step.

Closing Step When the cement paste 5 applied in the second applying step is uncured, the opening of the mold 2 is closed with the upper mold 3. Upper mold 3
Has an uneven shape on the lower surface of natural wood. This upper mold 3
Also, the lower surface of the rubber-like elastic body 4 such as silicon rubber has an uneven shape of natural wood. When the sleeper is made of natural wood, the sleeper has a surface shape. When the upper mold 3 is pressed and pressed, the cement paste 5 applied to the upper surface of the core 6 in the second application step is formed into a shape along the irregularities of the upper mold 3, and the excess cement paste 5 is extruded. . In this state, the entire surface of the core material 6 is surrounded by the cement paste 5, and the entire surface of the cement paste 5 is formed into a natural tree shape by the mold 2 and the upper mold 3.

Hardening Step The opening of the mold frame 2 is kept closed by the upper mold 3, and the hardening reaction of the cement paste 5 is advanced. This process is continued until the cement paste 5 hardens and does not deform. In the case of GRC with embedded reinforcing fibers,
The curing process takes about one day.

Demolding Step After the cement paste 5 is cured in the curing step, the upper mold 3
And the mold 2 are removed from the mold, and the molded concrete artificial wood 1 is taken out. In demolding, after removing the upper mold 3, the mold 2 is opened to separate the artificial wood 1 from the mold 2. Formwork 2
As shown in the figure, the concrete artificial wood 1 can be easily removed from the structure as a structure that opens on both sides.

In the above steps, as shown in the cross-sectional view of FIG. 3, a plastic foam is used as the core material 6 and the reinforcing fiber is embedded in cement on the entire surface of the core material 6.
The layer 7 is further provided, and the concrete artificial wood 1 in the form of a used sleeper or the like, in which the surface of the GRC layer 7 is formed into an uneven shape of natural wood, is manufactured. In the same way,
Instead of used sleepers, it is also possible to produce concrete mushrooms with uneven shapes like natural tree branches.

[0020]

The concrete pseudo-wood of the present invention has features that the whole can be made extremely lightweight while increasing the bending strength, and that the three-dimensional pattern on the surface can be formed into an ideal shape very close to a natural wood. That is, the concrete pseudo-wood of the present invention has a plastic foam as a core material, and a GRC layer in which reinforcing fibers are embedded in cement is provided on the entire surface of the core material. This is because it is formed into a tree shape. The concrete artificial wood of this structure uses a plastic foam as a core material, and a GRC layer in which reinforcing fibers are embedded in cement is provided on the surface of the core material. Can be lightweight. Further, the GRC layer in which the reinforcing fibers are embedded in the cement can not only increase the strength but also provide a smooth uneven surface without fine unevenness on the surface as compared with the conventional mortar. Therefore, GRC
The surface of the layer can be formed into an uneven shape of natural wood, and the uneven pattern on the surface can be made very close to that of natural wood.

Further, the method of the present invention for producing a concrete pseudo-wood has a simple manufacturing process by which a concrete pseudo-wood having a high bending strength, an extremely light weight as a whole, and a three-dimensional pattern very close to that of a natural wood is obtained. The feature is that it can be manufactured efficiently. That is, the production method of the present invention is applied to a first application step of applying a cement paste to a predetermined thickness on an inner surface of a formwork having a rubber-like elastic body and an uneven shape of a natural tree on a bottom surface and a periphery thereof, and A step of inserting a core material into the mold in a state in which the cement paste is uncured, a second application step of applying a cement paste to the upper surface of the core material put in the mold, and an opening of the mold. A closing step in which the lower surface is closed with an upper mold having an uneven shape of natural wood, a curing step in which the opening of the mold is closed with the upper mold, and a curing reaction of the cement paste proceeds, and a curing step. This is because concrete pseudo wood is manufactured later in the upper mold and the mold removing step of removing the mold.

[Brief description of the drawings]

FIG. 1 is a perspective view of a concrete artificial tree according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view showing a manufacturing process of a concrete artificial wood according to an embodiment of the present invention.

FIG. 3 is a sectional view of a concrete artificial tree according to an embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Concrete artificial wood 2 ... Form 3 ... Upper mold 4 ... Rubber-like elastic body 5 ... Cement paste 6 ... Core material 7 ... GRC layer

Claims (6)

[Claims] 1. A plastic foam is used as a core material (6), and a GRC layer (7) in which reinforcing fibers are embedded in cement is provided on the entire surface of the core material (6). 7) A concrete artificial wood in which the entire surface of the surface of the natural wood is formed into an uneven shape. 2. A reinforcing fiber is provided on the inner surface of a formwork (2) which is open at the upper side and closes the periphery and the bottom surface, and the bottom surface and the periphery are made of a rubber-like elastic body (4) and formed into an uneven shape of natural wood. A first application step of embedding and applying a cement paste (5) to a predetermined thickness; and applying the cement paste (5) in an uncured state to the cement paste (5) applied in the first application step. Formwork
A core material insertion step of inserting the core material (6) into the inside of (2), and a reinforcing fiber is buried on the upper surface of the core material (6) put in the formwork (2) in the core material insertion step, and cement paste ( In the second application step of applying 5), the cement paste (5) applied in the second application step is in an uncured state, and the opening of the mold (2) is made to have a concave and convex shape of a natural wood on the lower surface. A closing step of closing with the upper mold (3), and holding the opening of the mold (2) with the upper mold (3) in a closed state,
The entire circumference consisting of a hardening step to advance the hardening reaction of the cement paste (5) and a demolding step of demolding the upper mold (3) and the mold (2) after the hardening step is formed into an uneven shape of natural wood. The method of manufacturing the concrete artificial wood being molded. 3. The method according to claim 1, wherein a plastic foam is used as the core material (6). 4. A concrete artificial wood in which the entire circumference is formed into an uneven shape of a natural wood according to claim 1, wherein a mold frame (2) in which the rubber-like elastic body (4) on the inner surface is made of silicon rubber is used. Production method. 5. The method according to claim 1, wherein an upper die (3) having an inner surface made of a rubber-like elastic body (4) is used. 6. The method according to claim 1, wherein the artificial wood is formed into an outer shape of a used sleeper.