JP2979340B2 - 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 of the present invention includes:
A water-soluble auxiliary frame corresponding to the pattern to be expressed is arranged at a predetermined position inside a mold for molding a concrete molded body, and a dried concrete pattern material and a mold are provided inside or outside the auxiliary frame. Filling the entire remaining portion of the inside of the frame that does not contain the pattern material with a concrete base material, respectively, and using the water contained in the base material or the water supplied to one or both of the base material and the design material to obtain the water-soluble material. It is characterized in that the auxiliary frame is melted and the pattern material and the base layer material are solidified integrally.

<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 5 show a patterned concrete molding 1 manufactured according to the present invention, in this case a pavement block, and FIGS. 1 and 2 show four traffic sign patterns, FIG. 5 shows a single symbol 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 was manufactured by filling a pattern material into the inside of an auxiliary frame disposed in a mold as described later, and filling a base layer material to the outside of the auxiliary frame with 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 thin at a portion lining the pattern layer 2 and is thick at a portion exposed on the surface. The block shown in FIG. 2 fills the inside of the auxiliary frame arranged in the mold so as to be described later with the pattern material, and includes the outside of the auxiliary frame and the remaining portion of the inside of the mold not containing the pattern material. It was manufactured by filling the entire part with the base material.

In the block shown in FIG. 5, the pattern layer 2 forms the entire 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 the inside of the auxiliary frame arranged inside the mold as described later with the same thickness of the pattern material inside and outside the auxiliary frame, and the remaining portion of the inside of the mold that does not contain the pattern material It was manufactured by filling the entire substrate material. Note that the order of filling the pattern material and the base layer material is arbitrary in manufacturing any block.

Now, the present invention provides a concrete molded body having the pattern layer 2 exposed on a part of or the entire surface as illustrated in FIGS. A frame 5 is used, and the pattern layer 2 is formed of a dried concrete pattern material, and the base layer 3 is formed of a concrete base material. An auxiliary frame 5 for manufacturing the blocks shown in FIGS.
FIG. 4 is a plan view showing the auxiliary frame arranged inside the mold, FIG. 3 is a plan view, and FIG. 7 is an auxiliary frame 5 for manufacturing the block shown in FIG. The plan views arranged inside the mold are shown in FIG. 6, respectively.

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 material is mainly composed of cement powder, resin, and fine aggregate. If necessary, it contains pigment or coarse aggregate and one or both of various fibers, and even if it contains moisture from absolutely dry, it is not kneaded with water and can be easily loosened and supplied. The dried material for the base layer composition may be a water-mixed material for the base layer composition obtained by kneading with water, so-called ready-mixed concrete,
If necessary, mix the granite framing stone, crushed powder, slag, light-reflecting fine particles and other substances into both the pattern material and the base layer material, as well as setting hardening accelerators, waterproofing agents, swelling agents and other admixtures. May be mixed. Also, with the various fibers mentioned above,
Metal fibers, carbon fibers, synthetic fibers, glass fibers and the like.

In the method of the present invention, the auxiliary frame is made of Oplard or other water-soluble material. Since the auxiliary frame is melted in the mold, a cylindrical mold having both upper and lower surfaces opened or a mold having a bottom provided on the lower surface can be used.

In order to manufacture the block shown in FIG. 1, a T-shaped space partitioned by a partition inside an auxiliary frame 5 arranged in a mold 4 is used.
Inside 5a is a red dried pattern material 2R, two fan-shaped spaces 5b
The inside is filled with a blue dry pattern material 2B, and the outside of the auxiliary frame 5 is filled with a dried base material 3D or a hydrated base material 3W by the same thickness as shown in FIG. The order is arbitrary.), After filling, the auxiliary frame dissolves. The auxiliary frame is dissolved by moisture bound to one or both of the base material and the pattern material, but when the filled base material is dry, the base material 3D and the cement or resin of the pattern materials 2R and 2B are used. Water is supplied to the entire interior of the formwork so that the required water: cement ratio with respect to the total amount of the base material, and with the water content, or when the base material is watered, the water content of the base material 3W, and the pattern material 2R, 2B and the base material 3D or 3W are integrally solidified to produce a molded body.

In order to manufacture the block of FIG. 2, the spaces 5a and 5b inside the auxiliary frame 5 in the mold are filled with the dried pattern materials 2R and 2B thinner than the thickness of the block as shown in FIG. Dry the base material 3D on the outside of the auxiliary frame and on the pattern materials 2R and 2B
Or, the base layer material 3W with water was filled into a block having a required thickness, and after the auxiliary frame was removed, when the base layer material was dry, water was supplied to the entire inside of the mold and water was added. In the case of the base layer material 3W, the entire material is solidified with the moisture contained therein and removed, or as shown in FIG. 10, the dried base layer material 3D or
3W is thinly filled, and then the pattern materials 2R and 2B are filled in the spaces 5a and 5b inside the auxiliary frame, and the base material 3D or 3W is similarly set outside the auxiliary frame.
After the auxiliary frame is removed and the auxiliary frame is removed, when the base layer material is dry, a required amount of water is supplied to the entire inside of the mold, and when the base layer material is De-molds all materials together with the moisture contained in them.

In order to manufacture the block shown in FIG. 5, as shown in FIG. 11, the space 5c inside the auxiliary frame in the mold has a white dry pattern material 2W representing snow at the top of the mountain and a space 5d. The brown dry pattern material 2Br representing the mountain skin, the blue dry pattern material 2B representing the sea in the space 5e, and the dry sky blue pattern material 2S representing the sky outside the auxiliary frame from the block thickness. The base material 3D or the base material 3W which has been dried so as to form a block having a required thickness is filled into the entire inside of the formwork, or the inside of the formwork is firstly filled in reverse to the above. The whole is first filled with the base layer material 3D or 3W, and thereafter, the space 5c, 5d, 5e inside the auxiliary frame and the outside of the auxiliary frame are filled with the dried pattern material 2W, 2Br, 2B, 2S. Then, after the auxiliary frame is removed, when the filled base layer material is dry, a required amount of water is supplied to the entire inside of the mold, and when the base layer material 3W is hydrated, all the materials are contained in the water contained therein. And demold.

In any of the manufacturing methods of the above-described embodiments, the removal of the auxiliary frame 5 from the inside of the mold is performed after filling all the pattern materials and removing the auxiliary frame, as long as the pattern to be expressed is not impaired. It may be before or after filling the material 3D or 3W. For example, in the case of FIG. 8, if the auxiliary frame is removed after filling the pattern materials 2R and 2B, the pattern collapses. Therefore, the base material 3D or 3W is removed after filling the outside of the auxiliary frame, and in the case of FIG.
The auxiliary frame may be removed after filling R, 2B and the same amount of the base material 3D or 3W, or the base material may be removed after filling the base material on each material. In the case of Fig. 10, pattern material 2
R, 2B, the auxiliary frame is removed after filling all the base layer materials 3D or 3W, and in the case of FIG. 11, all of the pattern materials 2S, 2W, 2Br, 2B may be removed after filling, The base material 3D or 3W may be removed after filling the pattern material. When the auxiliary frame is removed in this manner, the pattern material and the pattern material and the base layer material in the portion separated by the wall 5 'of the auxiliary frame collapse and fill the trace of the removed wall of the auxiliary frame. In addition, when removing the auxiliary frame, one or both of the mold frame and the auxiliary frame are vibrated by a vibrator or an ultrasonic wave, and when the auxiliary frame is removed and the entire material is hardened, the material is pressed by a press. Of the auxiliary frame is forced, and it is possible to promote filling of the trace of the wall of the auxiliary frame.

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.

Further, when it is desired to dissolve the auxiliary frame as soon as possible, for example, it is possible to fill all the dried pattern materials and then supply water to humidify the pattern materials first, and then fill the base material. In this case, the subsequent water supply of the dried base material 3D is reduced,
In addition, the water content of the added base layer material 3W is reduced. Furthermore, if the hydrated base layer material 3W is filled before the pattern material, the auxiliary frame may be dissolved before the pattern material is filled. use.

Since the auxiliary frame melts and disappears in the mold, the auxiliary frame may have a depth equal to the filling thickness of the pattern material.

In the manufacturing method of the present invention, when the mold is placed on the table vibrator and a vibration is applied when filling each pattern material and the base layer material, the density of each material is increased and the material can be densely filled.

Also, as shown in FIG. 12, a bulky mat 6 which can be compressed, for example, an insane cloth, is laid on the inner surface of the bottom of the form 4 and the auxiliary frame 4 is placed thereon, Pattern material 2R,
2B and one or both of the base material 3D and 3W to be filled out of the auxiliary frame, or part or all of them, in this case, when a swelling agent is mixed with the pattern materials 2R and 2B, it takes a while until it hardens. As shown in FIG.
To expand. 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, if a material having water absorbency is used for the mat 6, excess water can be absorbed and water can be uniformly distributed to each material, so that the performance of the molded body can be improved in strength.

FIGS. 12 and 13 correspond to the embodiment of FIG. 8, but the same applies to the embodiments of FIGS. 9 and 11. Also,
In FIG. 10, since the pattern material is filled on the filled base layer 3D or 3W, for example, a swelling agent is mixed into this pattern material, and the pattern layer can be raised on the surface of the molded body without using a bulky mat. . 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 of the present invention, as shown in FIGS. 14 and 15, a plate or sheet 7 having pins or small pieces planted on the inner surface of the bottom of the mold, flocking, brushing, bristles, Sheet 8 having a pile, a loop, etc.) is laid beforehand and the auxiliary frame 3 is placed thereon.
The filled and dried pattern material or the base layer material 3D or 3W may be held by pins and small pieces 7 ', flocking, raising, bristles, and rims 8'. Thus, it is possible to prevent movement due to vibration or the like until each material is hardened, and it is possible to clearly express the boundary between differently colored pattern materials and the boundary between the pattern material and the base material 3D or 3W.

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, in the manufacturing method of the present invention, a part or the whole of the mold 4 is formed of a deformable material, and after filling each pattern material and the base layer material 3D or 3W, the mold is deformed to deform the inside of the mold. It is also possible to manufacture a molded body other than the block shape by solidifying the respective materials in the following. This will be hereinafter referred to as a case where a molded body having a pattern layer 2 similar to that shown in FIG. I will tell you.

FIGS. 16 to 18 show an embodiment for producing a cylindrical molded body, in which a mold 10 is a deformable peripheral frame 11 made of urethane rubber or the like, and a metal sheet for mounting the peripheral frame 11 thereon, It is composed of a rollable bottom sheet 12 such as a plastic sheet, paper, nonwoven fabric, knitted fabric, rubber sheet, etc., and a peripheral frame 11 is placed on the bottom sheet 12 and an auxiliary frame is provided at a predetermined position inside the peripheral frame 11. Place the dried pattern material 2R inside the auxiliary frame,
2B, and the outside of the auxiliary frame is filled with the dried base material 3D or the hydrated base material 3W (FIG. 16). When both materials are solidified, the surrounding frame 11 is covered with a rollable auxiliary sheet 13 similar to the bottom sheet 12 (FIG. 17). By supporting between the sheets 13 and rounding the entire peripheral frame 11 (FIG. 18), by keeping the two materials in a rolled state until they are hardened, a molded article having a cylindrical shape with the pattern layer 2 exposed at a required position on the peripheral surface is manufactured. can do.

FIG. 19 shows a mold 14 which fills the pattern material and the base layer material as shown in FIG. 16 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 in the case of being rounded or wound by the manufacturing method of FIG. 18 or FIG. 19, 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 10 with the pattern material and the base layer material as shown in FIG. 16, after solidification, the peripheral frame 11 is removed as shown in FIG. 20, and the inner shape of the cylinder forming body to be manufactured matches the inner shape, And wrapping it together with the bottom sheet 12 outside a mold 15 having flanges 15 ', 15' at both ends, and keeping the material in that state until both materials are hardened (see FIG. 21), to produce a cylindrical molded body Can also. Of course,
As in the case of FIG. 19, 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 outer periphery of the mold 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 for manufacturing a tubular formed body, a molded body other than a cylindrical shape can also be manufactured by partially or entirely deforming a mold.

For example, as shown in FIG.
After filling, as shown in FIG. 22, an upper die having a concave portion 16 on the upper surface and placing it 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 formed. Pressing is applied from above by 20 (FIG. 23), whereby the upper surface is pressed by the convex portion 19 to be 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 bottom sheet located on the concave portion 16 flat until it is pressurized by the upper die 20, and when the press of the upper die 20 starts. The bottom sheet pushed into the recess and the material thereon spills around from the upper edge of the recess. Incidentally, the lower mold 18 may be made of a plastic material such as viscosity, in which case the upper surface of the lower mold made of a plastic material is depressed by pressing the upper mold, so that the concave portion 16 is formed,
Filling the gel 17 therein can be omitted.

Furthermore, as shown in FIG. 16, after filling the pattern material and the base layer material into the mold frame 10, the mold material 10 is placed on a lower mold 21 having an uneven upper surface as shown in FIG. Push (25th
(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 deformable by a bottom wall. It may have a closed bottom.

As described above, when manufacturing by partially or entirely deforming the mold, the mold may be deformed after the auxiliary frame 3 starts melting.

In each of the embodiments shown in FIGS. 8, 9 and 10, the auxiliary frame is filled with the dried pattern material.
Fill the outside of the auxiliary frame and a part of the space inside the auxiliary frame with the dried pattern material, and fill the remaining all of the formwork with the dried concrete base material or the hydrated concrete base material and mold. The body can also be manufactured.

Further, the filling of the dried pattern material and the dried base layer material can be performed in a fine dot shape by a robot without manual operation.

Further, when the pattern material and the base layer material inside the mold are solidified together, the inside of the mold may be pressurized by a press device, and when filling the material or removing the product from the mold. One or both of the mold frame and the auxiliary frame may be vibrated by a vibrator or ultrasonic waves.

In addition, when a mat having water absorbency is used as shown in FIGS. 12 and 13, the excess water can be absorbed, or the water supplied to a portion of the material where the moisture is insufficient can be re-supplied, so that the molded body can be formed. Since the water content of the whole is made uniform and the water: cement ratio on the surface is made small, the performance of concrete is improved in terms of strength.

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.

And, inside the form to be molded, reinforcing materials such as rebar, lath net, expanded metal, various ropes and wires, etc. are incorporated in addition to the various fibers and fibers such as the above-mentioned metals and fibers to form a strong molding. The body can be manufactured. Further, when the reinforcing material is laid on the previously filled base layer material (or pattern material) and the pattern material (or base material) is filled thereon, the filled upper and lower materials can be prevented from shifting. At the same time, the bond between the pattern layer and the base layer can be reinforced 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 inside of the auxiliary frame inside the mold or inside the mold outside the auxiliary frame, it can be filled with a gap without gaps, and the auxiliary layer which has been removed or disappeared. Since the traces of the frame are filled by the collapse of the pattern material or the base layer material, 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]

1 and 2 are perspective views illustrating a patterned concrete molded product manufactured according to the present invention. FIG. 3 is a plan view of a mold frame and an auxiliary frame for manufacturing one of the molded products. 4
FIG. 3 is a perspective view of the auxiliary frame of FIG. 3, FIG. 5 is a perspective view illustrating another patterned concrete molded body manufactured according to the present invention, and FIG. 6 is a mold for manufacturing the molded body. FIG. 7 is a plan view of the auxiliary frame, FIG. 7 is a perspective view of the auxiliary frame of FIG. 6, FIG. 8 is a cross-sectional view showing a manufacturing state of the molded body of FIG. 1, FIG. 9 and FIG. Sectional view showing the state of production of the molded body, eleventh
FIG. 12 is a cross-sectional view showing a manufacturing state of the molded body of FIG. 5, FIG. 12, FIG. 13, FIG. 14, FIG. 15 is a cross-sectional view showing another manufacturing state of the molded body of FIG. FIG. 17, FIG. 17, and FIG.
FIG. 19 is also a perspective view showing the state of manufacture of another cylinder forming body,
FIGS. 20 and 21 are also perspective views showing the production state of another cylinder forming body, FIGS. 22 and 23 are also perspective views and sectional views showing the production state of another molded body, and FIGS. 24 and 25. The figure is also a perspective view and a cross-sectional view 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 dry base material, 3W is a base material with water, 4 is a formwork, 5 is an auxiliary frame, 5 'is its wall, 6 is a bulky mat, and 7 and 8 are boards Or a sheet, 10 is a mold, 11 is its surrounding frame, 12 is a bottom sheet, 13 is an auxiliary sheet, 14 and 15 are cylindrical molds, 15 'is a collar, 16 is a recess, 17 is a gel, and 18 is a lower mold. , 19 are convex, 20 is an upper mold, 21 is a lower mold, and 22 is an elastic plate.

Claims (1)

(57) [Claims] A water-soluble auxiliary frame corresponding to a pattern to be expressed is disposed at a predetermined position inside a mold for molding a concrete molded body, and dried concrete is provided inside and / or outside the auxiliary frame. The pattern material, the entire remaining portion of the inside of the formwork not containing the pattern material is filled with a concrete base material, and the moisture contained in the base material, or the water supplied to one or both of the base material and the pattern material And dissolving said water-soluble auxiliary frame, and solidifying said pattern material and base layer material integrally.