JP2929135B2 - Method of manufacturing patterned concrete molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial application field> The present invention relates to pavement blocks to be spread and fixed on sidewalks and roadways, and other patterned concrete products, and structures such as walls, ceiling slabs, and soil between buildings. The present invention relates to a method for producing a concrete molded article such as a product.

<Conventional technology> For example, when a traffic sign pattern such as a pedestrian crossing or a stop is to be expressed on a part of the surface of a pavement block, or when a pattern is to be expressed on the entire surface, the conventional method is to paint with paint or other paint. Did not.

<Problems to be solved by the invention> However, the pattern drawn on a part of or the entire surface of the pavement block is rubbed with the bottom of footwear of a person walking on it, or a wheel of a car running on it, It wears out in a short period of time and needs to be repainted frequently, which is very time-consuming.

Therefore, the present invention has been developed for the purpose of expressing a pattern appearing on a part or the whole surface of a concrete molded body in a Kintaro candy style by a pattern layer made of a dried pattern material having a predetermined thickness.

<Means for Solving the Problems> The method for producing a patterned concrete molded product according to claim 1 is characterized in that a cylindrical small section having a constant height is formed at a predetermined position inside a mold for molding a concrete molded product. A water-insoluble cell densely packed body arranged adjacently is arranged, and a part or the whole of the small section of the cell densely packed body is a dry concrete pattern material, and the entire remaining portion of the inside of the formwork that does not contain the above pattern material. While filling each with a concrete base layer material, removing the cell dense body from the inside of the mold, and removing the pattern material with the moisture contained in the base layer material or the water supplied to one or both of the base layer material and the pattern material. It is characterized by solidifying the base layer material integrally.

A method for producing a patterned concrete molded product according to claim 2, wherein a water-soluble cell in which cylindrical small sections of a fixed height are arranged adjacently at a predetermined position inside a mold for molding the concrete molded product. A dense body is arranged, and a part or all of the small section of the cell dense body is filled with a dried concrete pattern material, and a concrete base material is filled in the entire remaining portion of the formwork that does not contain the pattern material. Dissolving the water-soluble cell dense body with water contained in the base layer material, or water supplied to one or both of the base layer material and the pattern material, and solidifying the pattern material and the base material integrally. I do.

<Examples> Examples of the method for producing a patterned concrete molded product of the present invention will be described below with reference to the drawings.

1, 2 and 3 show a patterned concrete molded article 1 manufactured according to the present invention, here a pavement block, and FIGS. 1 and 2 show a traffic sign pattern, and FIG. It represents a pattern.

1 comprises a pattern layer 2 and a base layer 3 having the same thickness, and the pattern layer 2 is exposed on a part of the surface of the block. This block fills a part of the subdivision of the cell densely arranged in the formwork with the pattern material as described later,
It was manufactured by filling the remainder of the subsection with the base material at the same thickness as the pattern material. On the other hand, in the block of FIG. 2, the pattern layer 2 is also exposed on a part of the surface of the block, but the back surface of the block is formed only of the base layer 3. That is, the thickness of the base layer 3 is small at the portion lining the pattern layer 2 and thick at the portion exposed on the surface.
The block of FIG. 2 fills a part of the small section of the cell densely packed body arranged in the formwork with the pattern material as will be described later, includes the rest of the small section, and contains the pattern material inside the formwork. It was manufactured by filling the entire remaining portion with the base material.

In the block shown in FIG. 3, the pattern layer 2 forms the whole surface, the back layer is formed with the base layer 3, and the base layer is not exposed on the surface of the block. This block fills all of the subdivisions of the cell clusters arranged in the formwork with the pattern material as described later, and fills the entire remaining portion of the form inside the formwork without the pattern material with the base material. It was manufactured.
Note that the order of filling the pattern material and the base layer material is arbitrary in manufacturing any block.

In the present invention, a concrete molded body having the pattern layer 2 exposed on a part of or the entire surface as illustrated in FIGS. The pattern is formed using a dry concrete pattern material, and the base layer 3 is formed from a concrete base material. The cross-sectional shape of the cylindrical small section is preferably the same square or honeycomb shape (hexagon), and the size is 1 to 10 mm on one side
The degree and height are at least the same as or higher than the thickness of the pattern layer to be formed.

In addition, the pattern material of the dried concrete is a cement powder or a resin, or a mixture thereof with a pigment or a fine aggregate, and is not kneaded with water even if it contains moisture even from absolutely dry. The material for the pattern layer that can be easily unraveled and supplied, and the concrete base layer material is mainly composed of cement powder, resin and fine aggregate. A base layer that contains one or both of pigments and coarse aggregates and various fibers as necessary, and is not kneaded with water even if it contains moisture from absolutely dry, and can be easily loosened and supplied. It may be a dry material for construction or a hydrated material for construction of the base layer made by mixing with water, so-called ready-mixed concrete. , Slag, light Or a mixture of fine other substances that morphism, condensation curing accelerators, waterproofing agents, sometimes mixing swelling agent other admixtures. The above-mentioned various fibers are metal fibers, carbon fibers, synthetic fibers, glass fibers and the like.

In the manufacturing method according to the first aspect of the present invention, in order to manufacture a molded body, the above-mentioned cell dense body 5 made of a metal plate, plastic, rubber, wood, paper, nonwoven fabric, or other water-insoluble material is used. The dense cell body has a cylindrical shape in which the lower surface is opened in addition to the upper surface for removal from the inside of the mold.

In order to manufacture the block shown in FIG. 1, as shown in FIG. 5, a cell dense body 5 having substantially the same height as the depth of the mold is arranged in the mold 4, and a large number of the cell dense bodies are formed. During the subdivision, a red dry pattern material 2R inside a small subdivision expressing the ring of the pattern and a straight line crossing the inside of the ring diagonally, the inside of the ring separated by the diagonal straight line Blue dry pattern material inside some other sub-section representing two nearly semi-circles of
2B, the dried base material 3D or the hydrated base material 3W is filled in the same thickness as the outside of the ring (the filling order of each material is arbitrary). And when the filled base material is dry, mold so that the required water: cement ratio is achieved with respect to the base material 3D and the total amount of cement and resin of the pattern materials 2R and 2B. Water is supplied to the entire inside of the frame, and with the moisture, or when the base material is watered, the moisture contained in the base material 3W is used to solidify the pattern materials 2R, 2B and the base material 3D or 3W together to form a molded body. Is manufactured and released from the mold 4 when it is hardened.

In order to manufacture the block of FIG. 2, as shown in FIG. 6, a dried pattern material 2R, 2B having a thickness smaller than the thickness of the block is applied to a part of a small section of the cell dense body 5 in the formwork as shown in FIG. And then filling the remaining small sections and the dried base material 3D or the hydrated base material 3W on the pattern materials 2R and 2B into blocks of the required thickness, Along with removing, when the base material is dry, water is supplied to the entire inside of the mold, and when the base material 3W is hydrated, all the materials are solidified with the moisture contained therein and the mold is removed, or Seventh
As shown in the figure, dry base material 3D
Alternatively, the base material 3W which has been hydrated is thinly filled, and thereafter, the pattern materials 2R and 2B are used for the small sections addressed to a part of the cell dense body, and the base material 3D or 3W is similarly used for the remaining small sections. In order to remove the dense cell body, when the base layer material is dry, a required amount of water is supplied to the entire inside of the mold. The material is solidified and removed from the mold.

In order to manufacture the block of FIG. 3, as shown in FIG. 8, during the subdivision of the densely packed cells in the formwork, a white dry pattern material 2W is applied to the portion representing the snow at the top of the mountain, Filled with brown dry pattern material 2Br in the mountain surface area, blue dry pattern material 2B in the sea area, and dry sky blue pattern material 2S in the sky area thinner than the block. Then, dry the base material 3D or the hydrated base material 3W so as to form a block of a required thickness over the entire interior of the mold, or first fill the entire interior of the mold with the reverse of the above. Is filled with the base material 3D or 3W, and then the dried pattern material 2W, 2Br, 2
B, 2S are similarly filled. Then, while removing the cell dense body from the inside of the mold, when the filled base layer material is dry, a required amount, water is supplied to the entire inside of the mold, and when the base layer material 3W is added, it is included. All materials are solidified with water and demolded.

In the drawings, the size of the cell dense body is adjusted to the inner shape of the mold, but it is sufficient that the size is slightly larger than the outer shape of the pattern to be expressed, and it is not always necessary to match the inner shape of the mold. The filling of each pattern material into the small section 5 'can be performed manually or by a robot. However, for accurate and quick filling, it is the same size as the dense cell body and has an opening corresponding to the pattern. However, it is better to use a closed mask except for the opening.

Since the pattern of the molded body in FIGS. 1 and 2 is composed of a red pattern and a blue pattern, as shown in FIG. 4, a mask MR having an opening R corresponding to the red pattern and a blue pattern are formed. A mask having a corresponding opening B is used for MB. Both masks have the same outer shape as the cell dense body 5, and when accurately overlapped on the cell dense body 5, the respective openings R and B can express the respective patterns of red and blue.

Therefore, one of the masks, for example, MR is first superimposed on the cell dense body, the red pattern material 2R is filled into the required small sections through the opening R, and then the mask MR is removed, and the mask MB is replaced with the cell dense. 2B of blue pattern material through the opening B
May be filled in other required small sections, and the mask MB may be removed.

The removal of the cell dense body 5 from the inside of the formwork can be performed by filling all the pattern materials into the necessary small sections, and then removing the cell dense body so long as the pattern to be expressed is not impaired.
It may be before filling 3W or after filling. For example, the fifth
In the case of the figure, removing the cell dense body after filling with the pattern materials 2R and 2B destroys the pattern, so the base layer material 3D or 3W is removed after filling, and in the case of FIG. 6, the pattern materials 2R and 2B and the same. The thick base material 3D or 3W may be removed after filling, or the base material may be removed on top of each material after filling. In the case of FIG. 7, the pattern materials 2R and 2B and the 3D or 3W
After filling, and in the case of FIG. 8, pattern materials 2S, 2W,
All of 2Br and 2B may be removed after filling, or the base layer material 3D or 3W may be removed after filling each pattern material. When the cell cluster is removed in this manner, the pattern material and the pattern material and the base layer material in the portion separated by the wall that separates the small sections collapse, and fill the traces of the partition wall of the removed cell cluster. When removing the cell compact, one or both of the mold and the cell compact may be vibrated by a vibrator or an ultrasonic wave, or a press may be used to remove the cell compact and harden all materials. Pressing is preferable because the collapse of the material is forced and the filling of the trace of the partition wall of the cell dense body can be promoted.

And if the filling is dry base material 3D,
An appropriate amount of water is supplied to the entire interior of the formwork so that the required water: cement ratio is achieved with respect to the total amount of cement and resin contained in the base layer material and each pattern material, but this water supply is used to adjust the movement of each material. If necessary, a part of the water may be supplied first. In the case where the base material 3W is filled with water, since each pattern material is mainly humidified by the water contained in the base material 3W, the water in the water: cement ratio of the base material 6W is increased in anticipation of this. Put. Of course, when it is not sufficient to humidify the pattern material only with the moisture of the base layer material 6W, additional water may be supplied.

The depth of the cell dense body 5 may be equal to the thickness of the layer filled with the pattern material. However, if the cell dense body 5 is placed so as to protrude from the upper surface of the formwork 4 as shown in the figure, it can be easily removed.

In order to produce a molded article by the production method according to the second aspect, a dense cell body made of a material soluble in water, such as an oblate, is used. The cell dense body is not limited to a cylindrical one having both upper and lower surfaces opened because it is melted in the mold, but a lower surface closed at the bottom can also be used.

In the embodiment of the molded article shown in FIGS. 1, 2 and 3 according to the second aspect of the present invention, the step of removing the cell dense body from the inside of the mold is not necessary, and the other steps are described above. In the same manner as in the first embodiment, the traces of the dissolved and disappeared cell clusters are filled with the pattern material which has been in contact with the wall of the cell cluster, and the pattern material and the base layer material. Vibration or pressure may be applied to promote collapse.

Further, when it is desired to dissolve and place the cell dense body as soon as possible, for example, after filling all the dried pattern materials, water may be supplied to humidify the pattern materials first, and then the base material may be filled.
In this case, the water supply amount of the dried base material 3D after that is reduced, and the water content of the added base material 3W is reduced. Furthermore, if the hydrated base layer material 3W is filled before the pattern material, the cell dense body may be dissolved before the pattern material is filled. Use the collective.

Then, since the cell dense body dissolves and disappears in the mold, it only has to have a depth equal to the filling thickness of the pattern material, and it is not necessary to protrude upward from the upper surface of the mold.

In any of the above-described claim 1 and claim 2, the mold is placed on a table vibrator,
When vibration is applied when filling each pattern material and the base layer material, the density of each material increases, and the material can be densely filled.

Similarly, in both the manufacturing methods of claims 1 and 2, a compressible bulky mat 6 such as a non-woven fabric is laid on the inner surface of the bottom of the mold 4 as shown in FIG. The cell dense body 4 is placed thereon, and the dry pattern material 2R, 2B to be filled and the base material 3D or 3W to be filled, or part or all of both, here, the pattern material
When the swelling agent is mixed with 2R and 2B, the material in which the swelling agent is mixed until it hardens expands the mat 6 by compressing it as shown. Therefore, the surface of the pattern layer or the base layer is raised from the surface of the molded body to make the pattern three-dimensional. Also, in the figure, the upper surface of the mold is open, but if the upper surface is closed with a heavy lid, the material expands only toward the mat 6, so that a more three-dimensional pattern can be obtained. Further, when a material having water absorbency is used for the mat 6, excess water is absorbed, and water is uniformly distributed to each material, so that the performance of the molded body can be improved in strength.

FIG. 9 corresponds to the embodiment of FIG. 5, but the same applies to the embodiments of FIGS. In FIG. 8, since the pattern material is filled on the filled base layer material 3D or 3W, for example, an expander is mixed with the pattern material, and the pattern layer is formed on the surface of the molded body without using a bulky mat. You can excite. In this case, if a water-absorbing mat is laid on the inner surface of the bottom of the mold, the performance of the molded body can be improved in strength as described above.

Further, in the manufacturing method according to any one of claims 1 and 2, as shown in FIGS. 10 and 11, a plate or sheet 7 having pins or small pieces planted on the inner surface of the bottom of the formwork. , Flocking, brushed,
A sheet 8 having hairs and wrinkles (pile, loop, etc.) is laid beforehand, and a cell dense body 5 is placed thereon, and the filled dry pattern material or the base material 3D or 3W is applied to a pin or a small piece 7 '. , Flocking, raising, bristles, and wrinkles 8 '. Until each material is hardened, it can be prevented from moving due to vibration, etc., and the border between different color pattern materials,
The boundary between the pattern material and the base material 3D or 3W can be clearly expressed.

If the above pins, small pieces, flocking, brushed, bristled, and linna are made water-soluble together with the sheet or plate, they can be dissolved and disappear until the respective materials are hardened, thereby eliminating the trouble of peeling off from the molded body. It is desirable to make them water-soluble or water-insoluble depending on the required holding state.

Further, part or all of the mold 4 is made of a deformable material by any of the manufacturing methods of claims 1 and 2, and the mold is filled with each pattern material and the base material 3D or 3W. It is also possible to manufacture a molded body other than the block shape by solidifying the respective materials inside the deformed and deformed formwork, and the same pattern layer 2 as shown in FIG. A description will be given of the case where a molded article having the above-mentioned method is manufactured.

12 to 14 show an embodiment of manufacturing a cylindrical molded body, a deformable peripheral frame 11 made of urethane rubber or the like, and a metal sheet for mounting the peripheral frame 11 thereon, A plastic sheet, paper, non-woven fabric, knitted fabric, rubber sheet, etc., and a rollable bottom sheet 12, and a peripheral frame 11 is placed on the bottom sheet 12, and a predetermined position inside the peripheral frame 11 is described later. A deformable cell dense body is arranged, and as in the case of FIG. 5, dried pattern materials 2R and 2B and dried base material 3D
Alternatively, a filled base layer material 3W is filled (FIG. 12). When both materials are solidified, the surrounding frame 11 is covered with a rollable auxiliary sheet 13 similar to the bottom sheet 12 (FIG. 13). By supporting between the sheets 13 and rounding the entire peripheral frame 11 (FIG. 14), by keeping the two materials in a rolled state until they solidify, a cylindrical shaped body with the pattern layer 2 exposed at a desired position on the peripheral surface is manufactured. can do.

FIG. 15 shows a mold 14 which fills the pattern material and the base material as shown in FIG. 12 and solidifies after solidification. The mold 14 corresponds to the inner shape of the cylinder to be manufactured. ) And kept in that state until both materials are consolidated to produce a cylindrical molded body. In this case, since the surfaces of the two materials 2R, 2B and 3D or 3W exposed on the open upper surface of the peripheral frame 11 contact the outer surface of the mold 14, the auxiliary sheet 13 can be omitted, and the mold 14 has a polygonal shape. Can be used to produce a cylinder-shaped body having a polygonal cross section.

When the two side edges of the peripheral frame 11 are adjacent to each other when rounded or rolled by the manufacturing method of FIGS. 14 and 15 described above, a seam of space occurs between the side edges of the base layer material, so that both side edges are Overlap and slightly overlap the inside and outside, the base material is doubled inside and outside at the seam, or cut off each side edge of the peripheral frame 11,
The exposed base material at each side edge is abutted so that no space is created at the seam.

Similarly, after filling the mold material 10 with the pattern material and the base layer material as shown in FIG. 12, after solidification, the peripheral frame 11 is removed as shown in FIG. And wrapping it together with the bottom sheet 12 outside a mold 15 having flanges 15 ', 15' at both ends, and keeping the state until both materials are hardened (see FIG. 17) to produce a cylindrical molded body Can also. Of course,
The width of the inner shape of the peripheral frame 11 is set so as to correspond to the length of one circumference of the mold 15 similar to the case of FIG. 15, and the length thereof is made equal to the interval between the flanges 15 ', 15'. Also in this case, the auxiliary sheet 13 can be omitted, and a cylinder-shaped body having a polygonal cross section other than the cylinder can be manufactured by using a polygonal one for the mold 15.

Although the above is a method of manufacturing a cylinder-formed body, a molded body other than a cylinder can be manufactured by partially or entirely deforming a mold.

For example, as shown in FIG.
After filling, as shown in FIG. 18, the upper die having a concave portion 16 on the upper surface, placed on a lower die 18 filled with a gel 17 in the concave portion, and having a convex portion 19 corresponding to the concave portion 16 is provided. Pressing is applied from above by 20 (FIG. 19), whereby the upper surface is pressed by the convex portion 19 and dented, and the lower surface is pressed by the concave portion 16 to produce a molded product which swells downward. In this case, it is not necessary that the peripheral frame 11 be deformable because the part deformed by the mold is a part of the bottom sheet 12. Further, the gel 17 filled in the concave portion is for keeping the portion of the traveling sheet located on the concave portion 16 flat until the upper mold 20 presses, and when the press of the upper mold 20 starts. The bottom sheet pushed into the recess and the material thereon spills around from the upper edge of the recess. The lower mold 18 may be made of a plastic material such as clay.In this case, since the upper surface of the lower mold made of the plastic material is depressed by pressing the upper mold, a recess 16 is formed, and the gel 17 is formed therein. Filling can be omitted.

Furthermore, as shown in FIG. 12, after filling the pattern material and the base layer material into the mold frame 10, the mold frame 10 is placed on a lower mold 21 having an uneven upper surface as shown in FIG. 20, and a flat elastic plate 22 is used from above. Push (21st
(See FIG.), Whereby the mold 10 and the materials filled therein can be regarded as the uneven upper surface of the lower mold 21 and deformed to produce a tile-shaped, eight-bridge-shaped or the like. The mold 10 in this case may be constituted by the deformable peripheral frame 11 described above and a bottom sheet 12 laid under the bottom, but the bottom surface of the deformable peripheral frame is formed by a deformable bottom wall. It may have a closed bottom.

As described above, when manufacturing by deforming part or all of the mold, if the cell dense body 3 is deformable even if it is water-insoluble, the cell dense body is removed after deforming the mold. You may. However, when the cell mass is insoluble in water and cannot be deformed, the cell mass is removed from the mold before the mold is deformed. When the cell cluster is water-soluble, the mold may be deformed after the cell cluster starts dissolving.

In order to make the cell densely deformable, for example, a partition wall for partitioning a single cylindrical small section may be cut from the top or bottom, and each partition wall may be partially separated and separated.

The present invention relates to a building constructed by pouring ready-mixed concrete on site, for example, a ceiling slab, which is a building body of a building, in addition to the blocks, cylindrical and polygonal tubular forming bodies, and plate-like forming bodies described above. It is also possible to manufacture a ceiling slab in which the pattern layer is exposed on the upper surface or lower surface by applying the method to the molding.

In addition to the various fibers and fibers such as the above-mentioned metals and fibers, reinforcing materials such as reinforcing bars, lath nets, expanded metal, and various ropes and wires are incorporated into the inside of the mold to be molded, and the molding with high strength is performed. The body can be manufactured.
Further, the reinforcing material is laid on the previously filled base material (or pattern material), and the pattern material (or base material) is placed thereon.
When filled, it is possible to prevent the filled upper and lower materials from shifting and moving, and to reinforce the bond between the pattern layer and the base layer at the interface.

<Effect of the Invention> According to the present invention, it is possible to easily manufacture a concrete molded body that expresses a pattern by exposing the pattern layer to a part or the entire surface of the molded body in a Kintaro candy style. And even if the surface of the molded body is worn, the expressed pattern does not disappear or become unsightly.

In addition, since the pattern layer is formed of a dry pattern material filled in the small section of the cell dense body in the formwork, it can be filled with a gap without gaps, and the trace of the removed or lost cell dense matter can be filled in with the pattern. Since the material and the base layer material are collapsed and filled, the boundary between the pattern layer and the base layer can be expressed finely, and a molded article having a very clear pattern can be obtained.

Furthermore, since the pattern material is dry, if it is incorrectly filled, it can be easily removed and repaired using a vacuum cleaner-type tool.

[Brief description of the drawings]

FIGS. 1, 2 and 3 are perspective views illustrating a patterned concrete molded body manufactured according to the present invention, and FIG. 4 is a perspective view of a mold and a cell dense body for manufacturing the same. FIG. 5 is a cross-sectional view showing a manufacturing state of the molded body of FIG. 1,
6 and 7 are cross-sectional views showing the manufacturing state of the molded body of FIG. 2, FIG. 8 is a cross-sectional view showing the manufacturing state of the molded body of FIG. 3, FIG. 9, FIG. 1 is a cross-sectional view showing another manufacturing state of the molded body of FIG. 1, FIG. 12, FIG. 13, and FIG. 14 are perspective views for explaining a manufacturing state of a cylindrical molded body in order. FIG. 15 is also a perspective view showing the production state of another cylinder-forming body, FIGS. 16 and 17 are perspective views showing the production state of another cylinder-forming body, and FIGS. 18 and 19 are other moldings. 20 and 21 are a perspective view and a sectional view, respectively, showing a manufacturing state of another molded body. In the figure, 1 is a molded body, 2 is a pattern layer, 2R, 2B, 2W, 2S, 2Br
Is a pattern material, 3 is a base layer, 3D is a dried base material, 3W is a hydrated base material, 4 is a mold, 5 is a densely packed cell, 6 is a bulky mat, 7 and 8 are plates or sheets, 10 is Formwork, 11 is its surrounding frame, 12 is the bottom sheet, 13 is the auxiliary sheet, 14 and 15 are cylindrical molds, 15 'is a collar, 16 is a recess, 17 is a gel, 18 is a lower mold, 19
Denotes a convex type, 20 denotes an upper type, 21 denotes a lower type, and 22 denotes an elastic plate.

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B28B 3/02

Claims (2)

(57) [Claims] 1. A water-insoluble cell dense body in which cylindrical small sections of a certain height are arranged adjacent to each other at a predetermined position inside a mold for molding a concrete molded body. A part or all of the sub-division is filled with a dried concrete pattern material, and the entire remaining part of the formwork that does not contain the pattern material is filled with a concrete base material,
The cell dense body is removed from the inside of the mold, and the pattern material and the base material are solidified integrally with the water contained in the base material or the water supplied to one or both of the base material and the pattern material. Method for producing a patterned concrete molded body. 2. A water-soluble cell cluster in which cylindrical small sections of a certain height are arranged adjacent to each other at a predetermined position inside a mold for molding a concrete molded body. Part or all of the subdivision is filled with a dried concrete pattern material, and the entire remaining portion of the formwork that does not contain the pattern material is filled with a concrete base material, and the moisture contained in the base material or the base material And dissolving the water-soluble densely packed cells with water supplied to one or both of the pattern material and the pattern material, and solidifying the pattern material and the base layer material integrally.