JP2002234038A - Shaped article and method for manufacturing shaped article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture a shaped article such as an imitation rock at a low cost by forming the shape and construction of the shaped article without depending upon the welding of a reinforcing bar, in the manufacture of the shaped article such as the imitation rack and at the same time, usefully recycle used PET bottles. SOLUTION: Used PET bottles of various kinds and shapes are put into a net bag of a polyester fiber and irregularities and protrusions similar to the form of the rock to be shaped are formed by tying the specified spots of the net bag of a polyester fiber and further, an expanded polyurethane resin is injected through the net bag. Thus the periphery of the PET bottle is coated with the expanded polyurethane resin. Finally a colored solid polyurethane resin is applied to the surface layer of the expanded polyurethane resin layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a shaped article and a method for manufacturing the shaped article. More specifically, the present invention relates to a shaped article using a plastic bottle, for example, a used PET bottle as a core material for imparting a shape, and a method of manufacturing the shaped article.

[0002] The term "sculpture" used in the present invention broadly means an article manufactured in a specific or abstract shape that gives an aesthetic impression through visual sense. There are decorative objects on wall surfaces, object ornaments such as parks and pavements, and playground equipment such as amusement parks and kindergartens. Hereinafter, the prior art and the present invention will be described using a pseudo rock as an example.

[0003]

2. Description of the Related Art So-called artificial rocks that resemble natural rocks include artificial stones made by dispersing natural rocks, mainly granite and andesite crushed stones, as seed stones in concrete or mortar, and replacing cement with cement as a binder. These are roughly classified into those using a thermosetting polyester resin or epoxy resin. At present, the use of the latter pseudo-rock made of resin is expanding due to the advantages of factory production and various properties such as waterproofness and acid resistance.

[0004] Conventional pseudo rocks are roughly classified into two as described above. The present invention is characterized in that a plastic bottle is used as a core material for imparting the shape of the pseudo rock, and the outer layer material is as follows. , Mortar, resin, etc., it is a new pseudo rock that does not belong to any of the above-mentioned classifications.

Conventionally, when simulated rock is manufactured using mortar or concrete as an outer layer material, in order to maintain strength and its shape, a steel frame is welded to form a predetermined shape, and a metal lath is attached thereto. , Mortar or concrete, and painted.

[0006] Also, in the case of producing a pseudo rock using FRP as the outer layer material, a steel frame is welded, cut in accordance with the shape of the formed FRP part, fixed to the steel frame, and the joint portion is made of an unsaturated polyester resin. After embedding, it was painted.

[0007] For the welding of steel frames required for conventional artificial rock production, a qualified person with sufficient knowledge and experience concerning welding according to JIS Z 3801 "Testing methods in welding technology certification and its criteria", suitable for welding. It is necessary to select and pre-process steel frames, select welding materials (welding rods, welding wires, fluxes, shielding gases), use welding machines with sufficient functions, etc., and this greatly increases the overall cost. Was a factor.

[0008] In the case of shaped objects, not only large works such as public works, which require a large budget and construction period, but also, for example, there is a case where it is desired to produce only one artificial rock as in a private facility such as a kindergarten. In some cases, repair work must be urgently performed in small units. In such a case, it is extremely irrational to perform the conventional technique involving the welding work of the steel frame described above.

[0009]

Accordingly, the main problem to be solved by the present invention is to produce a modeled object such as a pseudo-rock, without involving a welding work on steel frames, and by changing the concrete or abstract shape and structure of the modeled object. It could not be granted.

Another problem to be solved by the present invention is that it was not possible to easily and inexpensively produce a shaped article such as a pseudo-rock even in a small unit of construction and a short construction period.

Still another problem to be solved by the present invention is to provide a concrete product with a concrete or abstract shape and structure by using plastic products to be discarded, to perform small-scale construction and a short construction period. However, it is not possible to easily and inexpensively produce a shaped article such as artificial rock. Another problem to be solved by the invention will be clarified sequentially below.

[0012]

In order to solve the above-mentioned problems, the present inventor firstly replaces a method of imparting the shape and structure of a modeled object by welding a steel frame with an article having a predetermined shape and structure. Were arranged in advance in a desired shape and structure to form a three-dimensional structure, and the surface and the space between the articles were sprayed or laid with mortar or resin, molded, molded, and then painted.

As a result of examining various objects for imparting the shape and structure of the formed object, it was found that plastic bottles of various sizes and various shapes can achieve the intended purpose.

Accordingly, the present invention, which is a means for solving the tentative problem, is directed to a mesh bag containing a plastic bottle formed by filling a plastic bottle into a mesh bag made of an arbitrary material and forming a shaped object. It is a modeled object which is entirely covered with a hardening material to form a hardened layer.

Further, the present invention, which is a means for solving the tentative problem, is a method for manufacturing a molded article, wherein a plastic bottle is filled in a meshed bag made of an arbitrary material, A predetermined portion of the meshed bag filled with is tied with a tying string to form irregularities and projections in accordance with the shape of the shaped object to be manufactured, and In a meshed bag filled with a plastic bottle with irregularities and projections formed according to the shape, a curable material is filled around the plastic bottle through the mesh and cured, and the surface layer of the cured curable material This is a method for producing a shaped article including applying and curing a colored surface coating material.

Further, the present invention, which is a means for solving the tentative problem, is a method of manufacturing a molded object on the wall surface of a building, wherein a plastic bottle is formed according to the shape of the molded object to be formed on the wall surface of the building. It was arranged and fixed to the wall by any means, the entire periphery of the plastic bottle fixed to the wall was covered and fixed with a meshed bag made of any material, and the plastic bottle was covered and fixed. Injecting the curable material through the mesh of the meshed bag and curing it around the plastic bottle, and applying and curing a colored surface coating material on the surface layer of the cured curable material. This is a method for manufacturing a molded article.

What is the most effective plastic bottle used in the present invention? PE in terms of hardness, shape maintenance, etc.
It is a T bottle, a so-called PET bottle. In particular, the use of used PET bottles meets the purpose and spirit of the present invention from the viewpoint of resource recycling. Therefore, a PET bottle will be described below as a typical example of a plastic bottle.

There are mainly two methods for forming the shape and structure of a predetermined model using a PET bottle. That is, the first method is to form a PET bottle on a wall surface of various buildings, for example, a wall surface of a building, a highway slope, a revetment wall, etc., by fixing a PET bottle to the wall surface by any fixing means. Form the desired shape and structure, cover the whole with a net, put mortar, unsaturated polyester resin, foamed polyurethane resin, epoxy resin, etc. on top of it and spray solid colored polyurethane on the surface layer is there.

A second method of forming the shape and structure of a predetermined model using a PET bottle is not a model fixed in advance on the wall surface of a building, but a model that exists independently such as a pseudo-rock. It is a method of manufacturing a product. in this case,
Put the number of PET bottles according to the size of the bag and the size and shape of the artificial rock to be manufactured into a net-made bag of a predetermined size, bind the entrance of the bag, and bind it with a string to manufacture it. A method of forming irregularities or projections according to the shape of the pseudo rock, spraying a foamed polyurethane resin to an arbitrary thickness to give a rock-like weight feeling, then spraying a colored surface polyurethane resin, and applying a finish coloring as desired It is.

In the present invention, a bag for putting a PET bottle is
The material of the bag is not particularly limited as long as it is a bag in which a mesh into which a coating material such as mortar or resin enters is formed. That is, any material such as iron, aluminum or other metal bags, various synthetic resin or rubber bags, or natural fiber bags can be used.

The PET bottle used in the present invention is a used PET bottle, but it is better to mix and use various kinds of shapes than to use the same shape. In addition, PET bottles have high hardness, and when crushed, a large number of acute-angled surfaces are formed. When a PET bottle is crushed to form a large number of acute-angled surfaces when or after being put into a bag, the surface shape is reduced. This is effective because a detailed design is formed.

In the present invention, the first method described above, ie, P
A method in which an ET bottle is fixed to a wall surface of a building, the surface of which is covered with a net, and a coating material is applied to the surface layer, and a second method, namely, a PET bottle is put in a net bag, and the surface layer is placed. The coating material used in the method of coating the coating material on the substrate is not particularly limited. That is, after infiltrating from a net such as mortar, dolomite plaster, stucco, tatami (Sanpei) soil, unsaturated polyester resin, polyurethane resin, epoxy resin and the like, the PET bottle is completely covered, cured, and durable. A coating material having excellent properties such as waterproofness can be used.

[0023]

Preferred embodiments of the present invention are described below with reference to the drawings.
A preferred embodiment of the present invention will be described with reference to examples. FIG. 1 is an explanatory view showing a procedure of an embodiment for producing a pseudo rock according to the present invention. As shown in FIG. 1, a variety of shapes of used P
17 ET bottles 2 were put.

Then, as shown in FIG. 2, a string of polyester fibers was bound at a plurality of places to form irregularities and projections in the shape of a pseudo rock to be formed.

Next, as shown in FIG. 3, the periphery of the PET bottle 2 is passed through the mesh of the net bag 1 to a maximum thickness of 70 mm.
mm, and a minimum thickness of 30 mm.

Finally, as shown in FIG. 4, a colored solid polyurethane layer 5 is formed on the surface of the foamed polyurethane layer 4.
To produce the target artificial rock.

FIG. 5 is a cross-sectional view taken along a plane LM in FIG. 1-D. The foamed polyurethane foam covers the periphery of the PET bottle 2 through the mesh of the bag 1 and firmly fixes the bottle 2, and the foamed polyurethane layer 4 has a maximum thickness of 70 m.
m, a thickness of at least 30 mm was used to express a heavy rock shape.

[0028]

As described above, the artificial object such as the pseudo rock of the present invention is used as a material for forming the shape and structure of the object.
Since a used plastic bottle, for example, a PET bottle, is used, unlike a conventional technique of welding a steel frame to form a shape and structure of a molded article, it can be easily manufactured at a low cost and use a steel frame. As a result, the completed model is light in weight, the load on the wall or the like is small, the application can be expanded, and the effective reuse of used plastic bottles is possible.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a state in which a PET bottle is put in a net bag.

FIG. 2 is a cross-sectional view showing a state where a PET bottle is put in a net bag and bound with a string to form a rock shape.

FIG. 3 is a cross-sectional view showing a state in which a PET bottle is put in a net bag, bound with a string to form a rock, and the surface thereof is covered with a polyurethane foam resin layer.

FIG. 4 is a cross-sectional view showing a state in which a PET bottle is put in a net bag, bound with a string to form a rock, the surface of which is covered with a foamed polyurethane layer, and the surface layer is sprayed with colored solid polyurethane. .

FIG. 5 is a sectional view taken along plane LM in FIG. 1-D.

[Explanation of symbols]

 Reference Signs List 1 net bag 2 PET bottle 3 tying strap 4 foamed polyurethane layer 5 colored solid polyurethane layer LM surface

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yu Matsumoto 2-2-11, Matsuhamacho, Fukuyama City, Hiroshima Prefecture Inside Hiroshima Kasei Co., Ltd. (72) Inventor Takahide Akiyama Esna, 15-15 Higashi 2-chome, Shibuya-ku, Tokyo・ Building Inside Planning Tension Co., Ltd. (72) Inventor Masakazu Okubo 417th Shimoda, Hino-shi, Tokyo F-term (reference) 4F204 AA42 AD05 AD07 AD16 AG03 AG20 EA01 EA03 EB01 EB11 EF01 EF05 EF37 EW37

Claims (8)

[Claims] 1. A reticulated bag made of a desired material is filled with a plastic bottle, and the entire reticulated bag in a plastic bottle formed in the shape of a molded article is covered with a curable material to form a cured layer. Sculpture. 2. The molded article according to claim 1, wherein a surface layer coating material is further applied to a surface layer of the cured layer. 3. The molded article according to claim 1, wherein the plastic bottle is a used polyethylene terephthalate bottle. 4. A method for manufacturing a shaped article, wherein a plastic bottle is filled in a meshed bag made of an arbitrary material, and a predetermined portion of the meshed bag filled with the plastic bottle is bound. Forming irregularities and projections according to the shape of the modeled object to be manufactured by binding with a string, and forming plastic with irregularities and projections according to the shape of the modeled object to be manufactured by binding with the binding string A curable material is filled into a meshed bag filled with a bottle, filled around the plastic bottle through the mesh and cured, and a colored surface coating material is applied and cured on the surface of the cured curable material. A method for producing a shaped article including the same. 5. A method for producing a shaped object on a wall of a building,
Plastic bottles are arranged according to the shape of the object to be formed on the wall of the building and fixed to the wall by any means, and the entire periphery of the plastic bottle fixed to the wall is made of any material Coating and fixing with the manufactured meshed bag, injecting the curable material through the mesh of the meshed bag with the plastic bottle coated and fixed, and curing around the plastic bottle; A method for producing a modeled object on a wall surface of a building, comprising applying and curing a colored surface coating material on the surface layer of the above. 6. The method according to claim 4, wherein the plastic bottle is a used polyethylene terephthalate bottle. 7. The method according to claim 4, wherein the curable material is a foamed polyurethane. 8. The method according to claim 4, wherein the surface coating material is polyurethane.