JP2984902B2 - Method for manufacturing female mold for decorative panel molding and method for manufacturing decorative panel - 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 female mold for forming a decorative panel which can easily form a large decorative panel, especially a concrete decorative panel forming a pseudo-rock or a masonry pattern, and a method of using the female mold. And a method for manufacturing a concrete decorative panel.

[0002]

2. Description of the Related Art Concrete panels imitating natural stone piling stones and bedrock are frequently used as construction materials and earth wood for enhancing decorativeness. In particular, since glass fiber reinforced concrete (hereinafter, referred to as GRC) is capable of producing a thin and high-strength panel due to its characteristics, decorative panels using GRC have recently been used. Conventionally, as a method for forming artificial natural objects such as artificial rock made of concrete, for example, Japanese Patent Application Laid-Open Nos. Hei 6-26020 and Hei 7-9800 have been proposed. The method of manufacturing a decorative panel can be roughly summarized into the following three points.

[0003] 1) A method of directly applying a resin such as silicon which is excellent in releasability and having high reproducibility and reproducibility to natural rock surface, peels the resin, and directly uses it as a female mold to form a decorative panel such as a concrete panel. 2) In the case of a stone masonry type, a method in which natural flat stones are combined in a flat plate shape, a female mold is manufactured by flowing a release resin such as soflan, foamed resin or the like on the upper surface thereof, and a decorative panel is manufactured using the female mold. 3) A method in which concrete is directly sprayed on a foundation formed by a wire mesh or the like to form a natural stone pattern or the like.

[0004]

In the above prior art, the method 1) uses a natural rock surface as a prototype and directly transfers it with a silicone resin or the like and uses it as a female mold.
m ² about small-scale female not only obtained. Therefore, there is a drawback that the decorative panel obtained by using the female mold can be manufactured only on the same scale. With the panels obtained in this way, when assembling a large-scale rock surface, the area per piece is small, so the finished surface becomes a patchwork of countless small pieces, and the problem that the joint treatment is difficult there were.

In the method 2), the combination of natural slabs is used as a female prototype, so that the production of the prototype is very complicated, the types are limited, and there is a tendency to form a pattern. Are difficult to form and generally have the disadvantage of being poorly changed. Further, the method 3) has a problem that it is difficult to imitate and imitate a natural object such as a natural stone or the like, requires skill, is not reproducible, and is inefficient.

Moreover, in the conventional methods 1) and 2),
When removing the female mold from the original mold, it was impossible to pour or inject resin or the like without going through a complicated process of completely drying the original mold, then applying a release agent and then drying.
Therefore, there is a problem that it takes a long time of several hours to 24 hours to produce the female mold.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems of the conventional method of manufacturing a decorative panel. A female mold having an arbitrary size can be easily manufactured in a short time, and the pattern can be modified. And a method of manufacturing a decorative panel such as a concrete panel capable of manufacturing a large, varied, highly decorative panel in a short time without complicated steps. The purpose is to:

[0008]

According to the present invention, there is provided a method for manufacturing a female mold for decorative panels, such as a concrete panel having a three-dimensional pattern such as a stone pattern or a rock pattern. 1 unit primary prototype with female design
Or a step of producing a plurality of types, a step of producing a secondary prototype having a male pattern of an arbitrary size on a plastic material using the unit primary prototype, and a process of producing a female mold from the secondary prototype. It is characterized by the following. By adopting wet raw stucco or clay as the plastic material and spraying and curing urethane elastomer on the surface of the secondary prototype made of wet raw stucco or clay in the female mold making process, it is very short. A female mold can be manufactured in time.

The method of manufacturing a decorative panel according to the present invention is a method of manufacturing a concrete decorative panel having a three-dimensional design such as a masonry pattern or a rock pattern, wherein one or more unit primary prototypes having a female design are provided. Seed manufacturing step, manufacturing a secondary mold having a male pattern of an arbitrary size on a plastic material using the unit primary mold, manufacturing a female mold from the secondary mold, the female mold Characterized in that it comprises a step of injecting a molding material such as concrete into the mold, curing, and releasing the mold.
By fabricating the female mold at the stage, a large decorative panel having a three-dimensional pattern such as a masonry pattern or a bedrock pattern can be obtained, and the problems of the small-scale and uniform conventional technology have been solved.

[0010] By manufacturing the decorative panel from concrete, especially glass fiber reinforced concrete, a thin and strong panel can be obtained. Also, the unit primary prototype can be easily manufactured by directly transferring the surface of natural rock surface, natural stone, or another natural or artificial modeled object with a small piece of silicon resin or the like.

[0011]

[Function] Since a secondary prototype is manufactured by working a plastic material such as uncured raw plaster or clay in a wet state, the unit primary prototype obtained by transferring from natural rock surface is arbitrarily repeated, and By freely working, it is possible to manufacture a large secondary prototype in which various types of masonry patterns and the like are formed. In addition, since this secondary prototype is a male type, it has a concavo-convex pattern similar to the panel of the final product. At this stage, the finished state of the final product can be visually recognized, and the desired design can be easily obtained. Can be modified. In addition, the secondary prototype does not cure even when dried, and can be regenerated and reused, so that manufacturing costs can be reduced.

[0012] A decorative panel such as a large GRC decorative panel having a unique pattern made by combining a natural stone pattern and the like with a large female mold obtained from the secondary prototype can be easily manufactured. Therefore, by using the concrete decorative panel, the joint processing can be easily performed, and a large wall or a retaining wall, or a pseudo rock can be constructed in a short time. In addition, since a complicated process such as applying a release agent to the prototype and drying it is not required when producing the female mold, the female mold can be produced from the secondary prototype in a short time of about several minutes.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a female mold for forming a decorative panel and a method for manufacturing a GRC decorative panel according to an embodiment of the present invention will be described below in detail in the order of steps with reference to the drawings. (1) By directly applying and transferring a resin having viscosity and reproducibility such as silicone resin to natural skin such as natural rocks and stones, or to the surface of other molded objects as necessary.
The unit primary prototype 1 having the female pattern shown in FIG. 1 is obtained. The unit primary prototype 1 produces one type or a plurality of types having different surface shapes as necessary. However, when producing a large-scale secondary prototype using the unit primary prototype, it must be used repeatedly. Therefore, if one of the same type is manufactured, it will be enough.

(2) FIG. 2 shows a large secondary prototype 2 made of a plastic material, especially raw plaster or clay, using the primary prototype 1 described above.
Is produced. Since the secondary prototype 2 is a raw plaster or a clay, it can be easily transferred simply by pressing the primary prototype 1 against its surface, and by repeatedly using one or more primary prototypes as appropriate, for example, , it is possible to shape the stone-piling pattern with a joint 5 _1, it is possible to create any of the male pattern of large-scale. In addition, since it is possible to freely add modeling as needed, it is possible to create a custom-made unique pattern combining natural stone patterns having a unique shape.

Further, since this secondary prototype is a male pattern, it has the same concavo-convex pattern as the panel of the final product. At this stage, the finished design of the final product can be visually recognized, and a desired design can be obtained. So that it can be easily modified. Therefore, it is possible to reduce the need for re-creation due to inadequate design after the panel is produced, and to efficiently produce the female mold and the product without wasting. Further, even if it is dried, it can be regenerated and reused by adding water, so that the production cost can be reduced.

(3) Next, the secondary prototype 2 obtained in the previous step
There remains wet, a super hardened urethane elastomer 1~5mm about sprayed onto the surface to make a coating film, by demolding it, as shown in FIG. 3, protruding joint 5 ₁ part of the male part 5 _A female mold 3 of ₂ is obtained. By spraying the urethane elastomer onto the surface while the secondary prototype 2 is still wet, it cures in a short time of about several minutes due to the unsaturated reaction between the urethane elastomer and water. Therefore, it is possible to release the mold in a very short time as compared with the case requiring 8 to 24 hours.

[0017] (4) on the mold surface of the thus female 3 obtained by applying spraying GRC direct spray or premix method, large format GRC decorative panel 4 having a joint 5 ₃ is obtained . As the GRC decorative panel, for example, a large-sized panel having a wall thickness of 15 mm to 30 mm is obtained, and the large-sized panels are continuously combined to form a retaining wall, whereby a retaining wall having a natural masonry pattern can be obtained.

The preferred embodiment of the present invention has been described above.
The present invention is not limited to the above embodiment. For example, in the above embodiment, the GRC decorative panel was manufactured from the obtained female mold. However, the present invention can be applied to the manufacture of a normal concrete decorative panel or a synthetic resin decorative panel using the female mold obtained in the present invention. Needless to say. Further, it is needless to say that the concrete decorative panel is not limited to a planar shape, and can be formed into various three-dimensional shapes depending on the application.

[0019]

The present invention has the above-described configuration,
It has the following special effects. According to the female mold manufacturing method of the present invention, a female mold of an arbitrary size such as a natural stone pattern can be obtained, and the pattern can be easily modified, etc., and it is very flexible. And rock or various designs can be arbitrarily formed. According to the third aspect, the production of the female mold from the original mold, which conventionally required 8 to 24 hours, can be completed in only a few minutes.

Further, according to the present invention, a large-scale concrete decorative panel can be obtained, so that joints can be easily processed and a highly decorative retaining wall or the like can be constructed in a short time at low cost. In addition, by manufacturing the concrete decorative panel with glass fiber reinforced cement, a lightweight, strong, and fine pattern can be reproduced, and a decorative panel with a pattern closer to a natural object can be obtained.

[Brief description of the drawings]

FIG. 1 shows a unit primary prototype according to an embodiment of the present invention;
(A) is a plan view and (b) is a cross-sectional view.

FIG. 2 shows a secondary prototype according to an embodiment of the present invention, and (a)
Is a plan view, and (b) is a cross-sectional view along AA.

FIGS. 3A and 3B show a female mold according to an embodiment of the present invention, wherein FIG. 3A is a plan view and FIG.

4A and 4B show a GRC decorative panel according to an embodiment of the present invention, wherein FIG. 4A is a plan view and FIG.

[Explanation of symbols]

1 Unit Primary prototype 2 Secondary prototype 3 Female type 4 GRC decorative panel

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-6-114811 (JP, A) JP-A-8-39527 (JP, A) JP-A-6-143216 (JP, A) JP-A-54-1979 63120 (JP, A) JP-A-7-9800 (JP, A) JP-A-6-26020 (JP, A) JP-A-5-169409 (JP, A) JP-A-4-118425 (JP, A) (58) Fields investigated (Int.Cl. ⁶ , DB name) B28B 1 / 14,1 / 16 B28B 7/16 E02B 3/14 E02D 29/02 302 E04F 13/08

Claims (6)

(57) [Claims] 1. A method for producing a female mold for decorative panel molding such as a concrete panel having a three-dimensional pattern such as a stone pattern or a rock pattern, wherein the unit primary prototype having the female pattern is
Or a step of producing a plurality of types, a step of producing a secondary prototype having a male pattern of an arbitrary size on a plastic material using the unit primary prototype, and a process of producing a female mold from the secondary prototype. A method for producing a female mold of a decorative panel. 2. The method according to claim 1, wherein the plastic material is wet raw stucco or clay. 3. The decorative panel according to claim 2, wherein in the female mold making step, a urethane elastomer is sprayed on a surface of a secondary mold made of wet raw stucco or clay to be cured, and the mold is removed. Female mold manufacturing method. 4. A method for producing a decorative panel having a three-dimensional pattern such as a stone pattern or a rock pattern, the method comprising: producing one or more types of unit primary prototypes having a female pattern;
Manufacturing a secondary mold having a male pattern of an arbitrary size on a plastic material using a secondary mold, manufacturing a female mold from the secondary mold, injecting a molding material into the female mold, and removing after curing; A method for producing a concrete decorative panel, comprising a step of molding. 5. The method for manufacturing a decorative panel according to claim 4, wherein the molding material is concrete. 6. The method according to claim 1, wherein the concrete is glass fiber reinforced concrete.