JP2588832B2 - Method for manufacturing artificial stone made of concrete - Google Patents

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 pseudo-stone block made of concrete, which has a surface texture similar to that of natural stone and can facilitate construction work of a structure.

[0002]

BACKGROUND OF THE INVENTION Hitherto, it has been widely practiced to construct river and coastal structures by combining cast-in-place concrete and concrete blocks.

[0003] However, river and coastal structures constructed using such cast-in-place concrete or concrete blocks are often incompatible with the surrounding environment due to the lack of artificial feeling, and these days, various methods are used. Using the obtained natural stone, a device has been devised to make it as harmonious as possible with the surrounding environment.

There are two methods commonly used to obtain such natural stones, one of which is industrial waste generated along with the construction of the structure at the place where the structure is to be constructed. One method is to reuse natural stone as an object, and the other is to transport it from a place away from the place where the structure is being constructed.

However, in the former case, it is often difficult to obtain a required amount of natural stone having a shape and dimensions required for constructing a structure. In addition, transporting natural stones from a remote place such as the latter requires a great deal of expense.

On the other hand, in order to construct a structure using these natural stones, not only special techniques are required, but also there are many human-powered operations in which construction machines and the like cannot be used. At present, the number of technicians who can construct structures using natural stones is becoming scarce and aging.

On the other hand, a variety of artificial stone blocks and the like have been proposed and used in which a female mold is formed from a synthetic resin material or the like using natural stone as a matrix, and concrete is cast into the female mold. However, there were many points that needed to be improved in terms of surface texture including reproducibility such as the fine texture of natural stone.

[0008]

Accordingly, in the present invention,
Using a male mold of a predetermined shape as a master, form a base mold with a material such as FRP, and in parallel with this, form a male rubber mold via a rubber mold taken from natural stone of any shape to be a mother And cut and paste the male rubber mold on the surface of the mortar mass slightly smaller than this natural stone to form a primary male mold,
An elastic female mold formed by forming an original male mold composed of a mortar mass with the primary female mold to which the primary male mold has been transferred, and applying an elastic material such as rubber to the outer surface of the original male mold and transferring the outer surface shape thereof. Then, a holding resin form is formed by applying and curing a synthetic resin agent on the outer surface of the elastic female form, and further, the elastic female form is set in the holding form and the base portion is formed. The method of mounting the formwork, casting concrete into the pseudo-stone formwork thus formed, and hardening it, and manufacturing the pseudo-stone block made of concrete, the surface texture including the fine texture of natural stone And to facilitate the construction work of the structure and the like.

In this case, a resin clay is adhered to the outer surface of the original male mold to a substantially uniform thickness, and the resin clay is cured with a resin polymer to form a spacer. The holding mold is formed by applying and curing a synthetic resin material, while the FRP resin is formed on the inner surface of the provisional female mold formed by applying an elastic material such as silicone rubber to the outer surface of the original male mold. A secondary male mold is formed by applying and curing a synthetic resin material such as the above, and then a secondary male mold is set in the holding mold frame that has been turned, and the holding mold frame and the secondary male mold are combined. The use of an elastic female mold having an approximately uniform thickness by hardening an elastic material such as silicon rubber supplied between the two can improve the durability of the elastic female mold.

[0010] As a method of placing concrete in the elastic female mold, a press-in method can be used without inconvenience in addition to a normal pouring method.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the method for manufacturing a pseudo-stone block according to the present invention, a mold is divided into three parts, a base part form, an elastic female form, and a holding form, and a plane is formed by the base part form. Since it is set to a predetermined shape, not only manufacturing but also construction work of a structure with a pseudo stone block can be easily performed, and natural stone is formed through an elastic female mold made of mortar lump and rubber material. Since the outer surface is faithfully transferred, the reproducibility of the surface texture including the fine texture of the natural stone can be drastically improved.

In the case of using an elastic female mold having a substantially uniform thickness formed by supplying an elastic material such as silicon rubber into the gap between the holding mold and the secondary male mold and curing the material, In addition to improving the durability of the formwork itself, the versatility of the base part formwork and the holding formwork is improved, and by replacing only the elastic female formwork while keeping the base part formwork and the holding formwork common It is possible to produce pseudo stone blocks having the same planar shape but different surface textures.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the method for manufacturing a concrete pseudo-stone block according to the present invention will be described below in detail with reference to the accompanying drawings.

In the method for manufacturing a pseudo-stone block made of concrete according to the present invention, first, the shape and surface texture of the pseudo-stone block to be manufactured are determined, and then a natural stone A satisfying such conditions is used as a matrix. Former male type 10
Is formed (see FIG. 1).

When the original male mold 10 is concretely formed, as shown in FIG. 2, a rubber material is applied to the inside of a rubber mold 12 collected from natural stone A to produce a male rubber mold 14. Next, an appropriately divided male rubber mold 14 is cut and pasted on the surface of the mortar block 16 formed smaller than the natural stone to form a primary male mold 18. Then, a rubber material is applied again to the surface of the primary male mold 18 to produce a primary female mold 20. The mortar is cast on the primary female mold 20, and the mortar mass 22 is exposed on the outer surface. The joint portion of the male rubber mold 14 may be formed by engraving.

Next, the former male mold 10
An elastic material 24 such as silicone rubber, which is set to an appropriate viscosity, is applied to the outer surface using a trowel or the like, and a mesh member 26 such as a glass fiber non-woven fabric is adhered to reinforce the elastic material 24. By applying a second layer of the elastic material 24 on the upper surface 26, an elastic female mold frame 28 that accurately reproduces the outer surface shape of the original male mold 10 is formed.

When the elastic female mold frame 28 is formed, the elastic material 24 made of silicon rubber or the like having an appropriate viscosity enters all over the outer surface of the original male mold 10, and the texture is faithfully observed. Since the transfer is performed, the entire surface texture including the fine texture of the natural stone A is faithfully reproduced on the inner surface of the elastic female frame 28 via the original male mold 10.

Next, a holding frame 30 made of a synthetic resin for holding the shape of the elastic female frame 28 is formed by the same procedure as that of a general FRP product manufacturing method. One of the specific examples is, as shown in FIG.
An FRP resin and its hardener are mixed and applied to a mesh member such as a glass fiber non-woven fabric cut into about m squares, and a reinforcing material 32 formed by superposing a plurality of these is prepared. The holding mold frame bottom portion 30a is formed by sticking and curing while gradually overlapping along the ridge line of the elastic female mold frame 28 formed on the outer surface of the holding mold frame.
Then, an angle member 36 with a putty or the like inserted therebetween is arranged along the dividing line 34 of the form bottom 30a, and is integrally cured, and a bolt hole to be used at the time of assembly is formed in the angle member 36. . Next, the mold bottom 30a is released from the elastic female mold 28, cut along the dividing line 34, integrated with a bolt and nut inserted into a bolt hole, and attached to the elastic female mold 28 again. . Then, in this state, the reinforcing material 32 is superimposed little by little on the exposed portion other than the mold bottom portion 30a, and is then cured. In addition, the legs 38 are disposed and cured, whereby the synthetic resin holding mold 30 is cured. Form as

Next, the holding mold frame 30 assembled by the bolt and nut is turned to place the elastic female mold frame 2 at a predetermined position inside the holding mold frame 30.
After the base 8 is placed, the base mold 40 is further set on the elastic female mold 28, and concrete 42 is poured into the elastic female mold 28 and the base mold 40 and cured to form a pseudo stone block. 44 is manufactured.

The concrete artificial stone block 44 manufactured in this manner is an elastic female mold frame 2 made of silicon rubber or the like in which the outer surface of the natural stone A is faithfully transferred via the original male mold 10.
8, the surface texture including the fine texture peculiar to natural stone is faithfully reproduced, and the elastic female formwork 28 is formed from the original male mold 10 while the elastic female formwork 28 is formed. Since the holding mold frame 30 made of synthetic resin is formed on the outer side of the mold 28, the fabrication of the mold frame can be easily performed.
Since the plane of the base part form is set to a predetermined shape, the construction work of the structure by the pseudo stone block 44 can be easily and simply performed.

FIG. 4 shows another production process of the elastic female formwork 28 used in the production of the artificial stone block 44 made of concrete. That is, in this method, the former male type 1
In addition, a resin clay is stuck on the outer surface of the spacer 0 to a substantially uniform thickness, and the resin clay is cured with a resin polymer to provide a spacer forming member 46. A holding frame 30 made of synthetic resin is formed in advance.

On the other hand, the temporary female mold 48 is coated on the outer surface of the original male mold 10 with an elastic material such as silicone rubber.
The secondary male mold 50 is formed by applying a synthetic resin material such as FRP resin set to an appropriate viscosity on the inner surface of the provisional female mold frame 48 and curing the resin.

Next, after the synthetic resin holding mold frame 30 is turned and silicone rubber is applied inside the holding mold frame 30, a reinforcing material 52 such as glass wool is attached. Separately, silicone rubber is also applied to the outer surface of the secondary male mold 48, and a predetermined amount of silicone rubber 5 is placed in the holding mold 30.
After charging 4, the secondary male mold 50 is inserted into the holding mold 30 and fixed. At this time, the spacer forming member 4 is provided between the inner surface of the holding mold frame 30 and the outer surface of the secondary male mold 50.
6 is set in a state where a gap X substantially corresponding to the thickness dimension is formed, so that the silicone rubber 54 spreads evenly over the gap X, so that the elastic female mold 28 has a thickness dimension. Are formed as substantially the same form.

In the elastic female mold 28 thus formed, when manufacturing the pseudo stone block 44, the surface texture including the fine texture peculiar to the natural stone is faithfully reproduced as described above. Not only that, its thickness is almost the same, so it will not be damaged even if it is used repeatedly, so durability is improved. It is possible to reduce the number.

[0025]

As described above, according to the method for manufacturing a pseudo stone block made of concrete according to the present invention, a rubber or the like whose surface of natural stone is faithfully transferred through an original male mold made of mortar mass is used as a material. The reproducibility of the surface texture, including the fine texture of natural stone, can be drastically improved.

Further, since an elastic female mold having a substantially uniform thickness formed by supplying an elastic material such as silicone rubber into the gap between the holding mold and the secondary male mold and curing the same is used, Since the durability of the formwork is improved without the form frame being damaged from a portion or the like, the production cost of the pseudo stone block can be reduced.

Further, the artificial stone block obtained by the production method of the present invention has a surface texture very close to that of natural stone, so that it has less uncomfortable feeling than concrete exposed blocks and conventional artificial stone blocks, so that it can be used directly by people. It can be used without any inconvenience in maintenance of a hydrophilic space or in a place close to the viewpoint, and the plane can be set to a predetermined shape by the base formwork, making construction work of the structure easy and simple. Has various advantages.

The preferred embodiment of the method for manufacturing a concrete pseudo-stone block according to the present invention has been described with reference to the accompanying drawings. However, the present invention is not limited to this embodiment, and the spirit of the present invention is not limited thereto. It goes without saying that the implementation method can be variously changed without departing from the scope of the present invention.

[Brief description of the drawings]

FIG. 1 is a process explanatory view showing a preferred embodiment of the method for manufacturing a concrete artificial stone block according to the present invention.

FIG. 2 is an explanatory diagram of a production process of a former male mold used in producing the concrete artificial stone block shown in FIG.

FIG. 3 is an explanatory diagram of a manufacturing process of a holding mold used when manufacturing the concrete artificial stone block shown in FIG.

FIG. 4 is an explanatory view showing another production process of the elastic female formwork used when producing the concrete artificial stone block shown in FIG. 1;

[Explanation of symbols]

10 yuan male type, 12 rubber type, 14
Male rubber type, 16 mortar mass, 18 primary male type, 20 primary female type, 22 mortar mass, 2
4 elastic material, 26 mesh member, 28 elastic female formwork, 30 holding formwork, 32 reinforcing material, 34
Parting line, 36 angle members, 38 legs, 40 base formwork, 42 concrete, 4
4 artificial stone block, 46 spacer forming member, 48 provisional female formwork, 50 secondary male form, 52 reinforcing material,
54 silicon rubber,

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Wakiro Nishikori 2-7 Higashi-Nakkanuki-cho, Tsuchiura-shi, Ibaraki Nippon Tetorapod Co., Ltd. Applied Hydraulic Research Laboratory (72) Inventor Makoto Kuchinomachi 2 Higashi-Nakkanuki-cho, Tsuchiura-shi, Ibaraki -7 Inside the Applied Hydraulic Research Laboratory, Japan Tetrapod Co., Ltd. (72) Inventor Akira Furusawa 2-7-1, Nishishinjuku, Shinjuku-ku, Tokyo Inside Tetrapod Co., Ltd. (56) References JP-A-54-63120 JP, A) JP-A-3-82503 (JP, A)

Claims (2)

(57) [Claims] A male rubber mold is formed via a rubber mold taken from natural stone of an arbitrary shape to be a matrix, and the male rubber mold is cut and pasted on the surface of a mortar block slightly smaller than the natural stone to form a primary male mold. Was formed, and a primary male mold composed of a mortar mass was formed by the primary female mold to which the primary male mold was transferred, and an elastic material such as rubber was applied to the outer surface of the original male mold to transfer the outer surface shape. Forming an elastic female formwork,
Next, a holding mold is formed by applying and curing a synthetic resin agent on the outer surface of the elastic female mold. Further, the elastic female mold is set in the holding mold, and a separate base portion mold is formed. A method for producing a concrete pseudo-stone block, characterized in that concrete is poured into the pseudo-stone formwork thus formed and hardened. 2. A resin clay is attached to the outer surface of the former male mold to a substantially uniform thickness, and the resin clay is cured with a resin polymer to form a spacer.
The holding mold is formed by applying and curing a synthetic resin material such as resin, while the inner surface of the provisional female mold is formed by applying an elastic material such as silicone rubber to the outer surface of the original male mold A secondary male mold is formed by applying and curing a synthetic resin material such as FRP resin, and then the secondary male mold is set in the turned holding mold, and the holding mold and the secondary male are set. 2. A method for manufacturing a concrete pseudo-stone block according to claim 1, comprising using an elastic female formwork having a thickness dimension substantially equalized by hardening an elastic material such as silicon rubber supplied between said mold and said mold. Method.