【０００１】
【発明の属する技術分野】
本発明は、コンクリート二次製品等の水硬性材料成形品（水硬性成形品と称する）の製造方法に関し、特に、内側に玉石等の外観材又は凹凸面を有する成形品を製造するに適した製法に関する。
【０００２】
【従来の技術】
従来のコンクリート製Ｕ字溝ブロックは、脱型上、その内面はコンクリートの地肌平坦面であることから、人工的で無味乾燥の色彩が強く、とりわけ山間部や田園地帯に設置するには、景観や生態系に不釣り合いである。しかしながら、製造容易・廉価で、しかも施工容易で強度・耐久性に富むことから、依然として多用されているのが実状である。
【０００３】
これに代わる物としては、自然水路の土壌堤の復元や玉石積みなどを採用する例も見受けられるが、旧技術への復古又は逆行に過ぎない面があり、また職人不足や人手と工費の相当の負担増を強いられるため、観光地等における観光客誘致目的等の一定目的にしか採用できていないのが現実である。
【０００４】
【発明が解決しようとする課題】
例えば、人工物の風合いを幾分でも緩和するため、内側に玉石張りのコンクリート製Ｕ字溝を製造する場合、通例現場では生コンクリート打設と玉石等の布置作業とを要し、人手と施工費用の相当の負担と共に、長期の施工期間を招く。また生コンクリートを打設した未硬化軟弱状凸面に玉石等を嵌め込むらな未だしも、Ｕ字溝の場合にはその内側凹面に玉石等を嵌め込む必要性から、溝内部の狭空間では作業自体がやり難い。更に、丈寸法長尺（例えば１ｍ以上）である凸面又は凹面に玉石等を嵌め込む作業では、生コンクリートの打設と玉石等の嵌め込みとを交互に繰返す積み上げ工法となることから、施工期間の長期化及び打設時点を異にするコンクリート質相互の境界部水和結合力の不足を招く。１回の生コンクリート打設で済ませる場合は、多人数による玉石の嵌め込み作業の迅速化を要するため、職人芸ならずば到底現実的ではない。
【０００５】
通常のＵ字溝ブロックの内側面を徐々に叩き砕いて凹凸粗面化の後処理を施す方法もあるが、厚肉壁として予め成形する必要があり、また大きな凹凸を形成するにはいわば彫刻作業となるため、生産性に到底見合わない。
【０００６】
他方、特許公報には特開２００２−２１０７１６（敷石ブロック製造方法及びそのブロック）が開示されているものの、この製法は平坦状ブロックの用途に限られ、Ｕ字溝ブロック等の凹部又は凸部に玉石等が突出したブロックの製造には採用できないばかりか、堅めの糊等から成る可塑材を水平姿勢の型板上に手作業でテコ塗りする必要があり、ブロックの生産性及び品質平準化を確保できない。
【０００７】
そこで、本発明の第１の課題は、上記問題点を解決するものであり、工場内において１回の生成形材料の打ち込みで済ませることが可能であって、製造容易で現場施工期間を短縮でき、幅狭い凹部等にも玉石等の外観材を容易に装定できる、水硬性成形品の製造方法を提供することにある。
【０００８】
また、本発明の第２の課題は、工場内において１回の生成形材料の打ち込みで済ませることが可能であって、製造容易で現場施工期間を短縮でき、幅狭い凹部等にも凹凸面を具有できる、水硬性成形品の製造方法を提供することにある。
【０００９】
【課題を解決するための手段】
第１の発明として、表面に外観材を一体的に具備する水硬性成形品の製造方法においては、先ず、主として塑性材（可塑材）から成る適宜厚さの被覆層を少なくとも有する第１の型を準備する（型取り工程）。この被覆層を構成する塑性材としては、加水混練した生粘土，生紙粘土や樹脂製粘着材等を用いることができる。切り藁，籾殻等の繊維や連結片等のバインダー或いは種々の添加材を混ぜ込んだものでも良い。材料費削減のためには生粘土を用いる。被覆層は単層に限らず、柔軟複層構造とすることもできる。
【００１０】
次いで、被覆層の表面に対し玉石，岩石，砕石，木材等の外観材を押し込んで未埋没状態として外観材を被覆層で姿勢保持せしめる（外観材装着工程）。被覆層の表面に外観材を押し込むと、外観材が被覆層の塑性材に密着しながら徐々に沈み込むため、大気圧封着力又は粘着力により、重量のある外観材を表面凸状又は凹状の被覆層の適宜箇所に適宜姿勢で確実に装定することができる。被覆層は重量のある複数の外観材の相互姿勢を例えば傾斜面でも保持できる程の厚さが必要であるが、厚めの被覆層でも充分な定着力が得られない場合は、その被覆層の上に金属製又は縄製などのネット（メッシュ）を被せた後、外観材を網目を介して被覆層に埋め込み、ネット材で外観材を一部支持しそのずれ動きを相互に拘束しても良い。また、ネット材又はそれによる塑性材の膨れ部分が外観材嵌め込み位置の見当となる。その際、表面側にネットが予め付着した可撓性板状体を準備し、その裏面側を型基体に被着するのが望ましい。ネットが裏打ち機能を果たし可撓性板状体を取り扱う際の型崩れを抑制できるからである。なお、外観材としては立体的外観材を用いて外観材同士が互いに密に接触するように組み込み装着するのが望ましい。成形体の強度化を図ることができるからである。
【００１１】
次いで、第１の型に対して第２の型を合わせ（型合わせ工程）、被覆層と第２の型との間に画成されたキャビティ内に生コンクリート材料（モルタルも含む），生石膏，生漆喰等の生水硬性材料を充填する（材料充填工程）。なお、第１の型と第２の型との離間距離が充分ならば、必要に応じて、型合わせ工程を外観材装着工程の前に施しても良い。また外観材は第２の型に接触していても構わない。
【００１２】
このように、主として塑性材から成る適宜厚さの被覆層は、製造工程中では重量のある外観材の姿勢を保持するための支持機能と水硬性材料から外観材の片側面（外観面）を隠すためのマスク機能とを有すると共に、成形品取出工程では被覆層を剥離・除去又は突き崩すことができるため、抜型容易化を実現でき、特に、内側に突出した立体状外観材を具備する水硬性成形品をも容易に製造できる。勿論、１回の生成形材料の打ち込みで済ませることができる。外観材を被覆層に対して未埋没状態で装定してあるため、その外観材の周囲に塑性材の隆起部（膨出部）が形成され、材料充填工程では水硬性材料が被覆層内に深く進入する恐れがなく、むしろ、外観材の周囲の水硬性材料が窪んで外観材が際立つ成形品を歩留まり良く得ることができる。外観材が被覆層に対して未埋没状態であるため、材料充填以降では外観材が被覆層と水硬性材料との双方に対するいわば鋲着効果を発揮し、成形品取出工程では外観材間の隙間に塑性材を挟んで成形品を取り出すことができる。施工時等では外観材間の隙間に残る塑性材をそのまま動植物用地等として利用でき、環境適合型成形品を実用的に提供できる。
【００１３】
ここで、型取り工程及び成形品取出工程を更に容易にするため、第１の型は、型基体とこの表面に付着した被覆層とを有する構成とする。塑性材の量を節約できると共に型基体の表面に塑性材を被覆する処理だけで型取りを済ませることができる。また、外観材装着工程では外観材を型基体に当たるまで押し込めば良いため、型基体が外観材を半埋没状態に留めるためのストッパー機能を発揮すると共に、外観材群の突出レベルを整合化できる。成形品取出工程では型基体と第２の型を脱型すれば、成形品に塑性材が付着したまま取り出しても良く、付着した塑性材自体を動植物用地や魚床等の用途に一層役立てることができる。
【００１４】
また、外観材としての瓦と、塑性材としての生粘土と、水硬性材料としての生コンクリート材料（モルタルも含む）或いは生漆喰などを用い、生粘土被覆層に瓦を差し込んで整列配置した場合、擁壁背面がコンクリート質で固められた高強度の瓦積み擁壁ブロックを容易に得ることができる。
【００１５】
更に、外観材は透水性固体とし、型合わせ工程では第２の型を透水性固体に接触させて配置すると、材料費が廉価で高強度の部分的透水性成形品を得ることができる。
【００１６】
第２の発明として、表面に凹凸面を具有する水硬性成形品の製造方法は、主として塑性材から成り表面に凹凸を形成した被覆層が型基体の表面に付着した第１の型を準備する型取り工程と、第１の型に対して第２の型を合わせる型合わせ工程と、次いで被覆層と第２の型との間に画成されたキャビティ内に生水硬性材料を充填する材料充填工程とを含む。成形品取出工程では被覆層を剥離・除去又は突き崩すことができるため、表面に凹凸面を具備する水硬性成形品を提供できる。勿論、１回の生成形材料の打ち込みで済ませることができる。
【００１７】
特に、上記いずれの発明においても、型取り工程としては、主として塑性材から成る概ね可撓性板状体を準備する工程と、可撓性板状体の面を型基体の面に被着する工程とを有する。予め均質且つ厚さ均一の可撓性板状体を得ることができるから、これを型基体の面に被着させることにより、型基体表面に塑性材を手作業でコテ塗りして被覆層を確保する場合に比し、略均一厚さの被覆層を凹凸部上にも簡単に確保でき、成形品の形態及び用途が広く、しかも歩留まり良く生産性を高めることができる。また、可撓性板状体を予め準備するものであるから、複数枚の可撓性板状体を重ね合わせることにより必要な肉厚又は柔軟複層構造の被覆層も容易に得ることができる。
【００１８】
この可撓性板状体を型基体（被着対象）の面に被着するために用いる可撓性板状体の取扱機としては、可撓性板状体を載せ置くための複数本の左側櫛歯状フィンガーと複数本の右側櫛歯状フィンガーとを支持し、少なくとも両者を互いに略水平方向に離接動作せしめるフィンガー駆動手段を備えている。この取扱機によれば、櫛歯状フィンガーを用いているため、重量のある広面積の可撓性板状体をも型崩れなく分布的に支持でき、また型基体の真上で左側櫛歯状フィンガーと複数本の右側櫛歯状フィンガーを相離間方向に引き抜くことにより、可撓性板状体自身の撓曲変形を利用して可撓性板状体を型基体の面に被着でき、型取り工程の省力化及び迅速化を図ることができる。
【００１９】
上記塑性材を生粘土とし、上記水硬性材料をコンクリート材料とし、第１の型を雄型とした場合には、材料費が廉価で、内側に外観材又は凹凸面を有するＵ字溝等のコンクリート製溝ブロックを容易に製造することができる。
【００２０】
【発明の実施の形態】
次に、本発明の実施形態に係るコンクリート製Ｕ字溝ブロックの製造方法を添付図面に基づいて説明する。
【００２１】
【第１実施例】
図１は第１実施例により得られたＵ字溝ブロックを示す縦断面図、図２乃至図８はＵ字溝ブロックの製造方法に係る第１実施例を示す工程縦断面図である。
【００２２】
本実施例により得られたＵ字溝ブロックは、外側コンクリート質１の内側に立体状固体外観材としての概ね球塊状の天然玉石２を一体的に具備し、外側コンクリート質１と隣接した玉石２，２間には粘土塊３が付着して残る。
【００２３】
第１実施例に係る製造方法は、先ず、図２に示す如く、形成すべきＵ字溝ブロックの溝幅寸法より狭い幅寸法の突条部４ａを持つ支持台４に沿って断面Ｕ字状の下型（内型，雄型）基体５を被せてこれを固定する。
【００２４】
次いで、主として加水混練済みの生粘土から成る適度柔軟な生板（未固化で可撓性のある粘土板）６を生板被覆機の左右の櫛歯状フィンガー７ａ，７ｂの上に載せて支持しながら、下型基体５の真上位置まで持ち来たす。なお、この生板６は、真空式土練機等で原土（配合粘土或いは水ひ粘土）を抜気混練し、ロール掛け処理等で引き延ばしてプレート状に成形し、それを所定寸法に切断して得ることができる。抜気処理は生板６が撓曲変形する際のひび割れ等を抑制する。
【００２５】
ここで例えば、深さ０．６ｍ，幅０．６ｍ，長さ１．８ｍのＵ字溝ブロックを得る場合に用いる生板６の広さは約１坪（３．３ｍ２）で、また玉石２の突出長を５ｃｍとすると、生板６の厚さも５ｃｍ程度を必要とし、生粘土体積が０．１６５で、生粘土の比重１．５とすると、生板６の重量は約２５０ｋｇとなる。このような重量のある面積の広い生板６を人手だけで取り扱うことは到底不可能である。
【００２６】
そこで、この生板６全体を載置して下型基体５の表面に被着処理するために用いる生板被覆機（可撓性板状体取扱機）を用いる。この生板被覆機は、複数本の左側櫛歯状フィンガー７ａと複数本の右側櫛歯状フィンガー７ｂとを有し、両者を互い違いに挿間可能に差し延べ支持し、両者を互いに略水平方向に離接動作せしめる共に昇降動作せしめるフィンガー駆動手段（図示せず）を備えている。櫛歯状フィンガー７ａ，７ｂは、生板６の下面への深い食い込みを抑制し程度に滑動するように、天地反転姿勢のスキー板の如き先端彎曲状の板として形成するのが望ましい。下型基体５を支持する支持台４を昇降可能に構成する場合には、上記離接動作せしめるようにフィンガー駆動制御手段を構成するだけでも良い。なお、フィンガー駆動手段は両櫛歯状フィンガー７ａ，７ｂを同期又は個別に傾動せしめる機能を備えていても良い。
【００２７】
次いで図３に示す如く、櫛歯状フィンガー７ａ，７ｂを徐々に降下させながら互いに離反する水平方向へ徐々に引き抜き、生板６のやや撓んだ中央部下面を下型基体５の頂上面に接触させて粘着し、引き続き図４に示す如く、櫛歯状フィンガー７ａ，７ｂを更に降下させながら互いに離反する水平方向へ徐々に引き抜き、重量のある生板６自身の撓みを利用して、生板６の下面を下型基体５のコーナーから上部側面に亘って撓曲変形で徐々に接触させて粘着面積を拡大しつつ、最後に、櫛歯状フィンガー７ａ，７ｂを徐々に降下させながら完全に引き抜くと、図５に示す如く、生板６の端部下面が下型基体５の下部側面に貼り付き、下型基体５の表面は密着状態で生粘土被覆層１６に覆われる。なお、粘着力を増強するには、被着前に、予め生板６又は下型基体５の表面に対し散水等を施し、生板６下面を湿潤状態にしておくと良い。生粘土被覆層１６に風圧等の圧迫力を加えながら被着しても良い。また、生板被覆工程の前に、下型基体５の表面に柔軟な境界フィルム等を覆っても良い。
【００２８】
上記の型取り工程により生粘土被覆層１６を型材とする第１の型が形成されるが、この後、図６及び図７に示す如く、生粘土被覆層１６の上部中央表面から隅部表面を介して下部側面の表面に対し、順次、玉石２を下型基体の表面に当たる程度まで押し込み未埋没状態とし、玉石２を生粘土被覆層１６で姿勢保持せしめ、玉石２を密に並べる（外観材装着工程）。この押し込み過程においては、玉石２，２間で挟まれた生粘土が生板６の表面レベルより外側へ幾分膨出する。なお、外観材装着工程の前に、生粘土被覆層１６の表面に散水等を施し、生板６の表層を湿潤状態と成すことにより、玉石２の押し込み抵抗を軽減できる。この時点の散水処理を省き、比較的厚めの生板被覆層に対する外観材装着工程を遂行するには、型取り工程において、相対的に硬質下層と軟質上層とから成る柔軟２層構造（柔軟複層構造）の生板６を張り合わせ等で予め得ると良い。硬質中層の上下面に相対的に軟質上層と軟質下層を付着した３層構造の生板６を準備しても良い。撓曲変形の際に適度な靭性と粘着性を備えた生板６を得ることができる。被覆機で生板６を水槽に浸漬させてから被覆しても良い。また、玉石２を濡らしておいても良い。必要な場合、生粘土被覆層１６の表面に型押し等で凹凸面を付与しても良い。更に、複数枚の生板６を重ね合わせて被覆層１６の肉厚を確保しても良い。なお、生粘土被覆層１６の厚さは外観材（玉石２）の平均外径の約半分程度を目安とする。
【００２９】
この外観材装着工程の後、図７に示す如く、生粘土被覆層１６のうち下型基体５の下端レベルより下方へはみ出た垂下部分を切断除去し、そこに端部取付型８ａ，８ｂを設置する。玉石２，２間の生粘土膨出部分に砂礫，小石等の小骨材や小さ目の外観材（小玉石等）を押し当てても良い。生粘土被覆層１６が適度に乾燥固化した後、次いで図７に示す如く、第２の型としての上型（外型，雌型）９を型合わせする（型合わせ工程）。
【００３０】
次いで、玉石２と上型９とで画成されたキャビティ１０内に生コンクリート材料（泥濘状，スラリー状）１１を充填する（成形材料充填工程）。バイブレーション（加振）を施しても良い。その際、浮水が上昇するため、生粘土被覆層１６の下端側が過水軟化するのを防止でき、下端部位置の玉石２の外観表面におけるセメントミルクの殻状固化を抑制できる。なお、生コンクリート材料としてはセメントと砂を混錬したモルタルも含む。
【００３１】
そして、生コンクリート材料１１の養生硬化後、脆くなった被覆層１６を突き崩すなどして下型基体５を抜型する。生粘土被覆層１６が玉石等の外観材で覆い尽くされる場合には、被覆層１６の未固化状態で生コンクリート材料１１を充填しても良い。そして、上型９を抜型し、溝内面に玉石２を有するＵ字溝ブロックを取り出す（成形品取出工程）。
【００３２】
外観材装着工程において、生粘土被覆層１６の表面に玉石２を押し込むと、玉石２が生粘土に密着しながら徐々に沈み込むため、大気圧封着力又は粘着力により、玉石２を生粘土被覆層１６の適宜箇所に適宜姿勢で確実に装定することができる。この生粘土被覆層１６は、製造工程中では重量のある玉石２の姿勢を保持するための支持機能と生コンクリート材料１１から玉石２の外観面を隠すためのマスク機能とを有する。更に、成形品取出工程では玉石２が下型基体５に接触すると共に被覆層１６を剥離・除去又は突き崩すことができるため、脱型容易化を実現できる。
【００３３】
生コンクリート材料１１の初期養生期間においては水和結合によりコンクリート材料１１が多少発熱するため、生粘土被覆層１６の乾燥固化を速めることができ、その乾燥固化による収縮により、被覆層１６に多少のひび割れが生じ、抜型容易化に寄与する。逆に、打撃や加振を施しながら下型基体５と被覆層１６との境界面に対し透水処理や噴風処理を施し、下型基体５を早期に脱型しても良い。このため、本例製法は内側に突出した立体状の玉石２を具備するＵ字溝ブロックの製造にとりわけ適している。勿論、１回の生コンクリート材料１１の打ち込みで済ませることができる。
【００３４】
玉石２を生粘土被覆層１６に対して未埋没状態で装定してあるため、その玉石２の周囲に生粘土の隆起部（膨出部）が形成され、材料充填工程では生コンクリート材料１１が生粘土被覆層１６内に深く進入する恐れがなく、むしろ、玉石２の周囲の成形材料が窪んで玉石２が際立つＵ字溝ブロックを歩留まり良く得ることができる。玉石２が生粘土被覆層１６に対して未埋没状態であるため、成形時では玉石２自体が生粘土被覆層１６と生コンクリート材料１１との双方に対するいわば鋲着効果を発揮し、成形品取出工程では玉石２，２間の隙間に粘土塊３を挟んで成形品を取り出すことができる。施工時等では玉石２，２間の隙間に残る粘土塊３をそのまま動植物用地等として利用でき、環境適合型成形品を実用的に提供できる。
【００３５】
なお、設置されたＵ字溝ブロック内に水が流れると、溝内面に付着した粘土層が自然に洗掘されるので、玉石２間に適度な粘土が粘着したまま残る。特に、玉石２，２間の生粘土膨出部分に玉石や小骨材を被せる外観材装着工程を採用する場合には、洗掘作用があっても、粘土塊３が玉石２等に囲まれているため、安息魚床等を確実に提供できる。
【００３６】
第１の型としての下型は、下型基体５とこの表面に粘着した生粘土被覆層１６とから成るため、生粘土量を節約できると共に下型基体５の表面に生粘土を被覆する処理で型取りを済ませることができる。また、外観材装着工程では玉石２を下型基体５に当たるまで押し込めば良いため、玉石群の突出レベルを整合化でき、Ｕ字溝ブロックの内寸法を歩留まり良く規格化できる。
【００３７】
型取り工程としては、生板６を準備する工程と、この生板６を下型基体５の表面に被着する被覆工程とを有するため、下型基体５の表面に生粘土を手作業でコテ塗りして被覆層１６を確保する場合に比し、歩留まり良く量産性を高めることができる。
【００３８】
なお、立体状外観材として、例えば素焼き等の凹状物体を用い、その開口側を被覆層１６に向けて押し込んだ場合には、この凹部内に適度な粘土を確保した状態で安息魚床を提供できる。また、透水性固体を外観材として用いて透水性固体と上型９とを接触するように位置決めする場合には、部分的透水性のＵ字溝ブロックを得ることができる。
【００３９】
【第２実施例】
図９及び図１０は第２実施例に係る工程断面図である。本例は溝内面に凹凸のあるＵ字溝ブロックの製造方法に関し、第１実施例における図２乃至図５に示す型取り工程をそのまま援用している。
【００４０】
図９に示す如く、生粘土被覆層１６の表面に対して型押し等により凹凸面Ｓを付与する。生粘土被覆層１６の乾燥固化後、図１０に示す如く、上型９を型合わせして、生粘土被覆層１６と上型９と間に画成されたキャビティ内に生コンクリート材料１１を充填する。そして養生硬化後、内側に凹凸面を備えるＵ字溝ブロックを取り出す。なお、材料充填工程の前に、凹凸面Ｓの上に砂礫，小石等の細骨材を被着しても良い。
【００４１】
成形品取出工程では被覆層１６を剥離・除去又は突き崩すことができるため、表面に凹凸を有するＵ字溝ブロックを提供できる。勿論、１回の生コンクリート材料１１の打ち込みで済ませることができる。
【００４２】
本例の型取り工程は第１実施例のそれとほぼ同じであり、生板６を準備する工程と、この生板６を下型基体５の表面に被着する被覆工程とを有するため、下型基体５の表面に生粘土を手作業でコテ塗りして被覆層１６を確保する場合に比し、歩留まり良く量産性を高めることができる。
【００４３】
なお、生板６の被覆後にその表面に凹凸面Ｓを付与するのではなく、被覆前の生板６の上面に予め凹凸面Ｓを付与しておいても良い。
【００４４】
上記各実施例では凹部に外観材又は凹凸面を有するＵ字溝ブロックの製法に本発明を適用した例を説明したが、その他、凹部を持つ成形品は勿論のこと、凸部又は平坦部に外観材又は凹凸面を有する成形品の製法にも適用できることは云う迄もない。また、外観材としては、大小の玉石，岩石，軽石，鉱石，貝殻，ガラス，木材，金属材，木炭，瓦，焼き物，透水性固体等，その他の立体状外観材を用いるのが適し、石墨や黄鉄鉱などの鉱物を外観材に用いる場合には電磁波遮蔽用建材をも容易に得ることができる。
【００４５】
【発明の効果】
以上説明した様に、第１の発明では、主として塑性材から成る被覆層を脱型容易な型材として用いるばかりか、外観材に対する姿勢保持材とその外観面のマスク材としても利用しているため、工場内において１回の生成形材料の打ち込みで済ませることが可能であって、製造容易で現場施工期間を短縮でき、幅狭い凹部等にも玉石等の外観材を一体的に装定した水硬性成形品を提供できる。また第２の発明では、主として塑性材から成る被覆層を有する型を用いているため、工場内において１回の生成形材料の打ち込みで済ませることが可能であって、製造容易で現場施工期間を短縮でき、幅狭い凹部等にも凹凸面を具備した水硬性成形品を提供できる。
【００４６】
特に、いずれの発明においても、型取り工程としては、主として塑性材から成る可撓性板状体を準備する工程と、この可撓性板状体を型基体の表面に被着する工程とを有する。予め厚さ均一の可撓性板状体を得ることができるから、これを型基体の面に被着させることにより、型基体表面に塑性材を手作業でコテ塗りして被覆層を確保する場合に比し、略均一厚さの被覆層を凹凸部上にも簡単に確保でき、成形品の形態及び用途が広く、しかも歩留まり良く生産性を高めることができる。また、可撓性板状体を予め準備するものであるから、複数枚の可撓性板状体を重ね合わせることにより必要な肉厚又は柔軟複層構造の被覆層も容易に得ることができる。
【００４７】
また、表面側にネットが予め付着した可撓性板状体の裏面側を型基体に被着させる場合には、可撓性板状体を取り扱う際の型崩れを抑制でき、表面側の網目又はそれによる膨れ部分が外観材の嵌め込みの際の見当となる。
【００４８】
更に、本発明の可撓性板状体の取扱機を用いれば、重量のある広面積の可撓性板状体をも型崩れなく分布的に支持でき、また可撓性板状体自身の撓曲変形を利用して可撓性板状体を被着対象の面に被着でき、型取り工程の省力化及び迅速化を図ることができる。
【図面の簡単な説明】
【図１】本発明の第１実施例に係る製造方法により得られたＵ字溝ブロックを示す縦断面図である。
【図２】第１実施例における型取り工程での下型基体の設置状態を示す工程縦断面図である。
【図３】第１実施例における型取り工程での下型基体の頂上面への生板被覆状態を示す工程縦断面図である。
【図４】第１実施例における型取り工程での下型基体側面への生板被覆状態を示す工程縦断面図である。
【図５】第１実施例における型取り工程での生板被覆完了状態を示す工程縦断面図である。
【図６】第１実施例における玉石装着工程の途中状態を示す工程縦断面図である。
【図７】第１実施例における玉石装着工程の完了後の型合わせ状態を示す工程縦断面図である。
【図８】第１実施例における材料充填工程の完了状態を示す工程縦断面図である。
【図９】第２実施例における凹凸面付与状態を示す工程縦断面図である。
【図１０】第２実施例における材料充填工程の完了状態を示す工程縦断面図である。
【符号の説明】
１…外側コンクリート質
２…玉石
３…粘土塊
４…支持台
４ａ…突条部
５…下型（内型，雄型）基体
６…生板
７ａ，７ｂ…櫛歯状フィンガー
８ａ，８ｂ…端部取付型
９…上型（外型，雌型）
１０…キャビティ
１１…生コンクリート材料
１６…生粘土被覆層
Ｓ…凹凸面[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method for producing a hydraulic material molded article (referred to as a hydraulic molded article) such as a secondary concrete product, and is particularly suitable for producing a molded article having an exterior material such as a boulder or an uneven surface inside. Related to manufacturing method.
[0002]
[Prior art]
Conventional U-shaped groove blocks made of concrete can be removed from the mold and the inside surface is a flat surface of concrete, so it is artificial and tasteless and has a strong color, especially in mountainous and rural areas. And is disproportionate to the ecosystem. However, since they are easy to manufacture and inexpensive, easy to construct, and have high strength and durability, they are still frequently used.
[0003]
As an alternative to this, there are cases where the restoration of soil dikes in natural waterways or the use of cobblestones are adopted, but this is only a retroactive or retrograde process to the old technology, and there is also a shortage of craftsmen and considerable labor and labor costs. In reality, it can only be used for certain purposes such as the purpose of attracting tourists at tourist spots.
[0004]
[Problems to be solved by the invention]
For example, when manufacturing a U-shaped groove made of cobblestone on the inside in order to alleviate the texture of the artifact to some extent, it is usually necessary to cast concrete and lay cobble stones at the site, Along with a considerable burden of costs, it leads to a long construction period. In addition, even though it is not possible to insert cobblestones etc. into the uncured soft convex surface where fresh concrete is cast, in the case of a U-shaped groove, it is necessary to insert cobblestones etc. into the inner concave surface, so in a narrow space inside the groove The work itself is difficult. Furthermore, the work of inserting a cobblestone or the like into a convex or concave surface having a long length (for example, 1 m or more) is a stacking method in which the placing of fresh concrete and the insertion of a cobblestone are alternately repeated. This leads to a prolonged period and a shortage of hydration bonding force at the boundary between the concrete materials at different time points. In the case of finishing with a single piece of ready-mixed concrete, it is necessary to speed up the work of inserting cobble stones by a large number of people.
[0005]
There is also a method in which the inner side surface of a normal U-shaped groove block is gradually beaten and crushed to perform post-treatment for roughening the surface. However, it is necessary to form the wall as a thick wall in advance, and to form large unevenness, it is necessary to use engraving. Since it is an operation, productivity is hardly worth it.
[0006]
On the other hand, although Japanese Patent Application Laid-Open No. 2002-210716 (paving stone block manufacturing method and its block) is disclosed in the patent gazette, this manufacturing method is limited to the use of a flat block, and is applied to a concave or convex portion such as a U-shaped groove block. Not only can it not be used for the production of blocks with cobblestones, but also it is necessary to manually apply a plastic material made of hard glue etc. on a template in a horizontal position, which will improve the productivity and quality leveling of the blocks. I can't secure it.
[0007]
Therefore, a first object of the present invention is to solve the above-mentioned problems, and it is possible to complete a single injection of the formed material in a factory, and it is easy to manufacture and the on-site construction period can be shortened. Another object of the present invention is to provide a method for manufacturing a hydraulic molded product, in which an external appearance material such as a cobblestone can be easily mounted even in a narrow recess or the like.
[0008]
Further, the second problem of the present invention is that it is possible to complete a single forming material injection in a factory, it is easy to manufacture, and it is possible to shorten the on-site construction period. It is an object of the present invention to provide a method for producing a hydraulic molded product that can be provided.
[0009]
[Means for Solving the Problems]
As a first invention, in a method of manufacturing a hydraulic molded product having a surface integrally provided with an appearance material, first, a first mold having at least a coating layer of an appropriate thickness mainly made of a plastic material (plastic material) is provided. Is prepared (molding process). As the plastic material constituting the coating layer, a raw clay kneaded with water, a raw paper clay, a resin adhesive, or the like can be used. Fibers such as cut straw and rice hulls, binders such as connecting pieces, or various additives may be mixed. Raw clay is used to reduce material costs. The coating layer is not limited to a single layer, and may have a flexible multilayer structure.
[0010]
Next, an appearance material such as a boulder, a rock, a crushed stone, or wood is pushed into the surface of the coating layer so that the appearance material is not buried, and the posture of the appearance material is held by the coating layer (appearance material mounting step). When the appearance material is pushed into the surface of the coating layer, the appearance material gradually sinks while being in close contact with the plastic material of the coating layer, so that the atmospheric appearance sealing force or adhesive force causes the heavy appearance material to have a convex or concave surface. It can be securely mounted at an appropriate position in an appropriate position of the coating layer. The coating layer needs to be thick enough to hold the mutual attitude of a plurality of heavy exterior materials, for example, even on an inclined surface, but if a thicker coating layer does not provide sufficient fixing power, the After covering a net (mesh) made of metal or rope on top, embed the appearance material into the coating layer via a mesh, partially support the appearance material with the net material, and restrain the displacement movement of each other. good. In addition, the swelling portion of the net material or the plastic material resulting therefrom serves as an indication of the fitting position of the appearance material. At this time, it is desirable to prepare a flexible plate-like body having a net adhered to the front surface side, and to adhere the back surface to the mold base. This is because the net performs a backing function and can suppress the shape collapse when handling the flexible plate. It is desirable that a three-dimensional appearance material is used as the appearance material and that the appearance materials are incorporated and mounted so that they are in close contact with each other. This is because the strength of the molded body can be increased.
[0011]
Next, the second mold is matched with the first mold (mold matching step), and the ready-mixed concrete material (including mortar), the fresh gypsum, and the like are placed in the cavity defined between the coating layer and the second mold. Filling with raw hydraulic material such as raw plaster (material filling step). If the distance between the first mold and the second mold is sufficient, the mold matching step may be performed before the appearance material attaching step, if necessary. Further, the appearance material may be in contact with the second mold.
[0012]
As described above, the coating layer having an appropriate thickness, which is mainly made of a plastic material, has a supporting function for maintaining the posture of the heavy external material during the manufacturing process and one side (the external surface) of the external material from the hydraulic material. In addition to having a mask function for hiding, the coating layer can be peeled / removed or crushed in the molded product taking-out step, so that die removal can be facilitated, and in particular, water having a three-dimensional appearance material protruding inward can be realized. Hard molded products can also be easily manufactured. Needless to say, it is possible to perform only one injection of the formed material. Since the appearance material is mounted on the coating layer in an unburied state, a raised portion (bulging portion) of a plastic material is formed around the appearance material, and the hydraulic material is filled in the coating layer in the material filling step. Therefore, a molded product in which the hydraulic material around the appearance material is depressed and the appearance material stands out can be obtained with a high yield. Since the appearance material is not buried in the coating layer, after the material is filled, the appearance material exerts a so-called tack effect on both the coating layer and the hydraulic material, and a gap between the appearance materials in the molded product removal process. A molded product can be taken out with a plastic material interposed therebetween. At the time of construction or the like, the plastic material remaining in the gaps between the appearance materials can be used as it is for animals and plants, and an environmentally compatible molded product can be provided practically.
[0013]
Here, in order to further facilitate the mold taking step and the molded product taking out step, the first mold is configured to have a mold base and a coating layer attached to the surface of the mold base. The amount of the plastic material can be saved, and the mold can be completed only by coating the surface of the mold base with the plastic material. In addition, in the appearance material mounting step, the appearance material only needs to be pushed in until it hits the mold base, so that the mold base exhibits a stopper function for keeping the appearance material in a semi-buried state, and the projection level of the appearance material group can be matched. If the mold base and the second mold are removed from the molded product in the molded product removal process, the molded product may be taken out with the plastic material adhered thereto, and the adhered plastic material itself is further useful for uses such as land for animals and plants, fish beds, and the like. Can be.
[0014]
When tiles are used as exterior materials, raw clay as a plastic material, and raw concrete material (including mortar) or hydraulic plaster as a hydraulic material, and tiles are inserted into the raw clay coating layer and aligned. Thus, a high-strength tiled retaining wall block in which the back surface of the retaining wall is made of concrete and can be easily obtained.
[0015]
Furthermore, if the exterior material is a water-permeable solid and the second mold is placed in contact with the water-permeable solid in the mold matching step, a partially water-permeable molded article with low material cost and high strength can be obtained.
[0016]
As a second invention, a method for manufacturing a hydraulic molded product having an uneven surface on the surface is to prepare a first mold having a coating layer mainly made of a plastic material and having an uneven surface attached to the surface of a mold base. A molding step, a mold matching step of matching the second mold to the first mold, and then filling the cavity defined between the coating layer and the second mold with the hydraulic material. And a filling step. Since the coating layer can be peeled, removed, or crushed in the molded product removal step, a hydraulic molded product having an uneven surface can be provided. Needless to say, it is possible to perform only one injection of the formed material.
[0017]
In particular, in any of the above-described inventions, the molding step includes a step of preparing a substantially flexible plate-like body mainly made of a plastic material and a step of applying the surface of the flexible plate-like body to the surface of the mold base. And a process. Since a flexible plate having a uniform thickness and a uniform thickness can be obtained in advance, this is applied to the surface of the mold base, and a plastic material is manually ironed on the surface of the mold base to form a coating layer. As compared with the case where the coating layer is secured, a coating layer having a substantially uniform thickness can be easily secured even on the uneven portion, the form and use of the molded product are wide, and the productivity can be improved with high yield. In addition, since the flexible plate is prepared in advance, it is possible to easily obtain a coating layer having a necessary thickness or a flexible multilayer structure by overlapping a plurality of flexible plates. .
[0018]
As a handling machine for the flexible plate used for attaching the flexible plate to the surface of the mold base (object to be attached), a plurality of flexible plates for placing the flexible plate are placed. Finger driving means is provided for supporting the left comb-shaped finger and the plurality of right comb-shaped fingers, and for moving at least both of them in a substantially horizontal direction. According to this handling machine, since the comb-shaped fingers are used, even a heavy, wide-area flexible plate-like body can be supported in a distributed manner without shape collapse. By pulling out the flexible finger and the plurality of right comb-shaped fingers in the direction of separation, the flexible plate can be attached to the surface of the mold base by using the bending deformation of the flexible plate itself. In addition, the labor and speed of the molding process can be reduced.
[0019]
When the plastic material is raw clay, the hydraulic material is a concrete material, and the first mold is a male mold, the material cost is low, and a material such as a U-shaped groove having an exterior material or an uneven surface on the inside is inexpensive. Concrete groove blocks can be easily manufactured.
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
Next, a method for manufacturing a concrete U-shaped groove block according to an embodiment of the present invention will be described with reference to the accompanying drawings.
[0021]
[First embodiment]
FIG. 1 is a vertical sectional view showing a U-shaped groove block obtained by the first embodiment, and FIGS. 2 to 8 are process vertical sectional views showing a first embodiment according to a method of manufacturing a U-shaped groove block.
[0022]
The U-shaped groove block obtained by this embodiment is provided with a substantially spherical natural cobblestone 2 as a three-dimensional solid external appearance material integrally with the inside of the outer concrete material 1, and the cobblestone 2 adjacent to the outer concrete material 1. , 2 are left with a clay mass 3 attached thereto.
[0023]
In the manufacturing method according to the first embodiment, as shown in FIG. 2, first, as shown in FIG. 2, a U-shaped cross section is formed along a support 4 having a ridge 4a having a width smaller than the groove width of a U-shaped groove block to be formed. The lower mold (inner mold, male mold) base 5 is put on and fixed.
[0024]
Next, a moderately flexible raw plate (unsolidified and flexible clay plate) 6 mainly made of raw clay kneaded with water is placed on and supported by the left and right comb-like fingers 7a and 7b of the raw plate coating machine. Then, it is brought to a position directly above the lower mold base 5. In addition, this raw plate 6 is obtained by deaeration and kneading of the original soil (mixed clay or hydrocephalus clay) with a vacuum kneading machine or the like, stretched by rolling or the like, formed into a plate shape, and cut into predetermined dimensions. Can be obtained. The degassing process suppresses cracks and the like when the raw plate 6 is bent and deformed.
[0025]
Here, for example, the width of the raw plate 6 used to obtain a U-shaped groove block having a depth of 0.6 m, a width of 0.6 m, and a length of 1.8 m is about 1 tsubo (3.3 m). 2 ), If the protruding length of the cobblestone 2 is 5 cm, the thickness of the raw plate 6 also needs to be about 5 cm, and if the raw clay volume is 0.165 and the specific gravity of the raw clay is 1.5, the weight of the raw plate 6 Is about 250 kg. It is almost impossible to handle such a heavy raw board 6 having a large area by hand alone.
[0026]
Therefore, a raw plate coating machine (flexible plate-like body handling machine) which is used for placing the whole raw plate 6 and applying a coating treatment to the surface of the lower mold base 5 is used. This raw plate coating machine has a plurality of left comb-shaped fingers 7a and a plurality of right comb-shaped fingers 7b, and extends and supports them alternately so that they can be inserted alternately. There is provided a finger driving means (not shown) for making the moving and separating operations and the raising and lowering operation. The comb-shaped fingers 7a and 7b are preferably formed as curved plates such as skis in an upside-down posture so as to suppress deep penetration into the lower surface of the raw plate 6 and to slide to the extent. When the support base 4 supporting the lower mold base 5 is configured to be able to move up and down, it is only necessary to configure the finger drive control means so as to perform the above-mentioned separation and contact operation. The finger driving means may have a function of synchronizing or individually tilting the two comb-tooth fingers 7a, 7b.
[0027]
Next, as shown in FIG. 3, the comb-shaped fingers 7 a and 7 b are gradually lowered and gradually pulled out in the horizontal direction away from each other, so that the lower surface of the slightly bent central portion of the raw plate 6 is placed on the top surface of the lower mold base 5. Then, as shown in FIG. 4, the comb teeth 7a and 7b are further pulled down and gradually pulled out in the horizontal direction away from each other while further descending, as shown in FIG. The lower surface of the plate 6 is gradually contacted from the corner of the lower mold base 5 to the upper side surface by bending deformation to enlarge the adhesive area, and finally, the comb-shaped fingers 7a and 7b are completely lowered while being gradually lowered. As shown in FIG. 5, the lower surface of the end portion of the green plate 6 is stuck to the lower side surface of the lower mold base 5, and the surface of the lower mold base 5 is covered with the raw clay coating layer 16 in close contact, as shown in FIG. In order to increase the adhesive strength, it is preferable that the surface of the raw plate 6 or the lower mold base 5 is subjected to water spraying or the like before the application, so that the lower surface of the raw plate 6 is in a wet state. The raw clay coating layer 16 may be applied while applying a pressing force such as wind pressure. Further, before the green plate covering step, the surface of the lower mold base 5 may be covered with a flexible boundary film or the like.
[0028]
The first die using the raw clay coating layer 16 as a molding material is formed by the above-described molding step. Thereafter, as shown in FIGS. The cobble stones 2 are sequentially pushed to the surface of the lower side surface to the extent that they hit the surface of the lower mold base to be in a non-buried state. Material mounting process). In this indentation process, the raw clay sandwiched between the boulders 2 and 2 slightly swells outside the surface level of the raw plate 6. Before the appearance material mounting step, the surface of the raw clay coating layer 16 is sprayed with water, etc., so that the surface layer of the raw plate 6 is in a wet state, whereby the pushing resistance of the cobblestone 2 can be reduced. In order to omit the water sprinkling process at this time and to perform the appearance material attaching step on the relatively thick green plate covering layer, in the molding step, a flexible two-layer structure (relatively flexible layer) composed of a relatively hard lower layer and a soft upper layer is used. It is preferable to obtain a raw plate 6 having a layer structure) in advance by laminating or the like. A raw plate 6 having a three-layer structure in which a soft upper layer and a soft lower layer are relatively attached to the upper and lower surfaces of the hard middle layer may be prepared. A green plate 6 having appropriate toughness and adhesiveness at the time of bending deformation can be obtained. The raw plate 6 may be immersed in a water tank with a coating machine before coating. Further, the cobblestone 2 may be wet. If necessary, an irregular surface may be provided on the surface of the raw clay coating layer 16 by embossing or the like. Further, the thickness of the coating layer 16 may be ensured by stacking a plurality of raw plates 6. Note that the thickness of the raw clay coating layer 16 is about a half of the average outer diameter of the appearance material (cobblestone 2) as a guide.
[0029]
After the appearance material mounting step, as shown in FIG. 7, the hanging portion of the raw clay coating layer 16 protruding below the lower end level of the lower mold base 5 is cut and removed, and the end mounting dies 8a and 8b are mounted thereon. Install. Small aggregates such as gravel and pebbles and small external appearance materials (such as pebbles) may be pressed against the portion of the raw clay swelling between the boulders 2 and 2. After the raw clay coating layer 16 is appropriately dried and solidified, the upper mold (outer mold, female mold) 9 as the second mold is then matched as shown in FIG. 7 (mold matching step).
[0030]
Next, a ready-mixed concrete material (mud-like or slurry-like) 11 is filled into the cavity 10 defined by the boulder 2 and the upper die 9 (molding material filling step). Vibration (vibration) may be applied. At that time, since the floating water rises, the lower end side of the raw clay coating layer 16 can be prevented from being softened by water, and the solidification of the cement milk on the appearance surface of the cobblestone 2 at the lower end portion can be suppressed. Note that the ready-mixed concrete material also includes mortar obtained by kneading cement and sand.
[0031]
Then, after curing of the ready-mixed concrete material 11, the brittle coating layer 16 is crushed and the lower mold base 5 is removed. When the raw clay coating layer 16 is covered with an appearance material such as a cobblestone, the raw concrete material 11 may be filled in a state where the coating layer 16 is not solidified. Then, the upper die 9 is removed, and a U-shaped groove block having the cobblestone 2 on the inner surface of the groove is taken out (molded product taking out step).
[0032]
In the appearance material mounting step, when the cobblestone 2 is pushed into the surface of the raw clay coating layer 16, the cobblestone 2 gradually sinks while being in close contact with the raw clay, so that the cobblestone 2 is coated with the raw clay by the atmospheric pressure sealing force or adhesive force. It can be securely mounted at an appropriate position on the layer 16 at an appropriate position. The raw clay coating layer 16 has a supporting function for maintaining the posture of the heavy boulder 2 during the manufacturing process and a mask function for hiding the appearance surface of the boulder 2 from the ready-mixed concrete material 11. Further, in the molded product removal step, the cobblestone 2 comes into contact with the lower mold base 5 and the coating layer 16 can be peeled, removed, or crushed, thereby facilitating removal of the mold.
[0033]
During the initial curing period of the ready-mixed concrete material 11, the concrete material 11 generates a little heat due to hydration bonding, so that the dry-solidification of the fresh-clay coating layer 16 can be accelerated. Cracks occur, which contributes to easier die removal. Conversely, a permeation process or a blowing process may be performed on the interface between the lower mold base 5 and the coating layer 16 while performing impact or vibration, and the lower mold base 5 may be released from the mold at an early stage. For this reason, the manufacturing method of this example is particularly suitable for manufacturing a U-shaped groove block provided with a three-dimensional cobblestone 2 projecting inward. Needless to say, it can be completed by one shot of the ready-mixed concrete material 11.
[0034]
Since the cobblestone 2 is mounted on the raw clay coating layer 16 in an unburied state, a raised portion (bulging portion) of the raw clay is formed around the cobblestone 2, and the raw concrete material 11 is formed in the material filling step. There is no danger of penetrating deep into the raw clay coating layer 16, but rather a U-shaped groove block in which the molding material around the cobblestone 2 is depressed and the cobblestone 2 stands out can be obtained with good yield. Since the cobblestone 2 is not buried in the raw clay coating layer 16, at the time of molding, the cobblestone 2 itself exerts a so-called tacking effect on both the raw clay coating layer 16 and the raw concrete material 11, so that the molded product is taken out. In the process, a molded product can be taken out with the clay mass 3 interposed between the cobblestones 2 and 2. At the time of construction or the like, the clay mass 3 remaining in the gap between the cobblestones 2 can be used as it is as a land for animals and plants, and an environmentally compatible molded product can be provided practically.
[0035]
When water flows into the installed U-shaped groove block, the clay layer attached to the inner surface of the groove is naturally scoured, so that an appropriate amount of clay remains between the cobblestones 2. In particular, in the case of adopting an appearance material attaching step of covering the swelled portion of the raw clay between the cobblestones 2 and 2 with a cobblestone or a small aggregate, the clay mass 3 is surrounded by the cobblestone 2 or the like even if there is scouring action. Therefore, it is possible to reliably provide a resting fish bed and the like.
[0036]
The lower mold as the first mold is composed of the lower mold base 5 and the raw clay coating layer 16 adhered to the surface thereof, so that the amount of fresh clay can be saved and the surface of the lower mold base 5 is coated with fresh clay. Can finish the mold. In addition, in the appearance material mounting step, the cobblestone 2 may be pushed until it hits the lower mold base 5, so that the protruding level of the cobblestone group can be matched, and the inner dimensions of the U-shaped groove block can be standardized with high yield.
[0037]
Since the molding step includes a step of preparing the raw plate 6 and a coating step of applying the raw plate 6 to the surface of the lower die base 5, the raw clay is manually applied to the surface of the lower die base 5. Compared with the case where the coating layer 16 is secured by ironing, mass productivity can be improved with a high yield.
[0038]
When a concave object such as unglazed material is used as the three-dimensional appearance material and the opening side is pushed toward the covering layer 16, a resting fish bed is provided in a state in which appropriate clay is secured in the concave portion. it can. When positioning the water-permeable solid and the upper mold 9 so as to be in contact with each other by using the water-permeable solid as an appearance material, a partially water-permeable U-shaped groove block can be obtained.
[0039]
[Second embodiment]
9 and 10 are process sectional views according to the second embodiment. This example relates to a method of manufacturing a U-shaped groove block having an uneven surface on the inner surface of the groove, and the molding step shown in FIGS. 2 to 5 in the first embodiment is directly used.
[0040]
As shown in FIG. 9, an uneven surface S is provided on the surface of the raw clay coating layer 16 by embossing or the like. After the dry clay coating layer 16 is dried and solidified, the upper mold 9 is matched and the fresh concrete material 11 is filled in the cavity defined between the raw clay coating layer 16 and the upper mold 9 as shown in FIG. I do. Then, after curing and curing, the U-shaped groove block having an uneven surface on the inside is taken out. Before the material filling step, fine aggregates such as gravel and pebbles may be applied on the uneven surface S.
[0041]
Since the coating layer 16 can be peeled / removed or crushed in the molded product removal step, a U-shaped groove block having unevenness on the surface can be provided. Needless to say, it can be completed by one shot of the ready-mixed concrete material 11.
[0042]
The molding process of this embodiment is almost the same as that of the first embodiment, and includes a process of preparing a green plate 6 and a coating process of applying the green plate 6 to the surface of the lower mold base 5. Compared with the case where the raw material clay is manually ironed on the surface of the mold base 5 to secure the coating layer 16, the mass productivity can be improved with a high yield.
[0043]
In addition, the uneven surface S may be provided on the upper surface of the raw plate 6 before coating, instead of providing the uneven surface S on the surface of the raw plate 6 after coating.
[0044]
In each of the above embodiments, the example in which the present invention is applied to the method of manufacturing the U-shaped groove block having the appearance material or the uneven surface in the concave portion has been described, but in addition to the molded product having the concave portion, the convex portion or the flat portion It goes without saying that the present invention can also be applied to a method for producing an appearance material or a molded article having an uneven surface. Also, it is suitable to use other three-dimensional appearance materials such as large and small boulders, rocks, pumice stones, ores, shells, glass, wood, metal materials, charcoal, tiles, pottery, permeable solids, etc. When a mineral such as pyrite or pyrite is used as the exterior material, a building material for shielding electromagnetic waves can be easily obtained.
[0045]
【The invention's effect】
As described above, in the first invention, the coating layer mainly made of a plastic material is used not only as a mold material that can be easily removed, but also as a posture holding material for the appearance material and a mask material for the appearance surface. It is possible to complete the molding material only once in the factory, it is easy to manufacture and the construction period can be shortened. A hard molded product can be provided. Further, in the second invention, since a mold having a coating layer mainly composed of a plastic material is used, it is possible to perform only one injection of the formed material in the factory, and it is easy to manufacture and the on-site construction period is shortened. It is possible to provide a hydraulic molded product which can be shortened and has an uneven surface even in a narrow recess or the like.
[0046]
In particular, in any of the inventions, the molding step includes a step of preparing a flexible plate-like body mainly made of a plastic material and a step of applying the flexible plate-like body to the surface of the mold base. Have. Since a flexible plate-like body having a uniform thickness can be obtained in advance, this is adhered to the surface of the mold base, and a plastic material is manually ironed on the surface of the mold base to secure the coating layer. As compared with the case, a coating layer having a substantially uniform thickness can be easily secured even on the uneven portion, the form and use of the molded product are wide, and the productivity can be improved with high yield. In addition, since the flexible plate is prepared in advance, it is possible to easily obtain a coating layer having a necessary thickness or a flexible multilayer structure by overlapping a plurality of flexible plates. .
[0047]
Further, when the back side of the flexible plate having the net adhered to the front surface side is adhered to the mold base, it is possible to suppress the shape collapse when handling the flexible plate, and the mesh on the front side can be suppressed. Alternatively, the swollen portion resulting therefrom serves as a register when the appearance material is fitted.
[0048]
Further, by using the handling machine of the flexible plate-shaped body of the present invention, a heavy and large-area flexible plate-shaped body can be supported in a distributed manner without shape collapse, and the flexible plate-shaped body itself can be supported. The flexible plate can be attached to the surface to be attached by using the bending deformation, and the labor and speed of the molding process can be reduced.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view showing a U-shaped groove block obtained by a manufacturing method according to a first embodiment of the present invention.
FIG. 2 is a vertical cross-sectional view showing a setting state of a lower mold base in a molding step in the first embodiment.
FIG. 3 is a vertical cross-sectional view showing a state in which a raw sheet is coated on a top surface of a lower mold base in a molding step in the first embodiment.
FIG. 4 is a vertical cross-sectional view showing a state in which the side surface of a lower mold base is covered with a raw plate in a molding step in the first embodiment.
FIG. 5 is a vertical cross-sectional view of a process of the first embodiment, showing a completed state of raw sheet covering in a molding process.
FIG. 6 is a process vertical cross-sectional view showing an intermediate state of a boulder mounting process in the first embodiment.
FIG. 7 is a process longitudinal sectional view showing a mold matching state after completion of the boulder mounting process in the first embodiment.
FIG. 8 is a process vertical sectional view showing a completed state of a material filling process in the first embodiment.
FIG. 9 is a vertical cross-sectional view showing a process in a second embodiment, showing a state of providing an uneven surface.
FIG. 10 is a process vertical sectional view showing a completed state of a material filling step in the second embodiment.
[Explanation of symbols]
1: Outside concrete
2. Cobblestone
3… Clay lump
4 ... Support
4a ... ridge
5. Lower type (inner type, male type) base
6 ... Raw board
7a, 7b ... comb-shaped fingers
8a, 8b ... end mounting type
9 Upper type (outer type, female type)
10. Cavity
11: Ready-mixed concrete material
16: Raw clay coating layer
S: Uneven surface
