JP3005771U - Lightweight block - Google Patents

Abstract

(57) [Summary] [Purpose] The stone layer is provided on both the front and back sides, is lightweight and easy to handle, and there is no risk of the stone layer peeling off.
(EN) Provided is a lightweight block which can be constructed easily and can be easily manufactured without using a special molding die or method. [Structure] Stone material 2 is bonded and integrated on both front and back sides of core material 1 made of foam, which has an elegant appearance and is water resistant.
It is possible to obtain a lightweight block A which is excellent in physical properties such as durability and shape retention and is lightweight and easy to carry and handle. Convex parts 5a, 5b
And the recesses 6a and 6b are fitted so that the blocks are
By connecting in the height direction, the construction work can be performed very easily, and the blocks can be connected more securely. The fitting convex portions 5a, 5b and the concave portions 6a, 6b can be easily formed by shifting the joining position of the stone material 2 to the core material 1 in an arbitrary direction.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a lightweight block having stone layers such as natural stone or tiles on the front and back surfaces of the block body.

[0002]

[Prior art]

 A block made of natural stone has been known for a long time, which is made by cutting a natural stone material into a predetermined size and forming a through hole in the vertical direction to form a block. Although such natural stone blocks have an aesthetically pleasing appearance and superior physical properties such as water resistance and durability compared to concrete blocks, the natural stone material is extremely heavy (usually about 24 to 25 kg). It had the drawbacks that it was difficult to handle the claws, etc. during processing, transportation, and construction, and that it could only be manufactured at the site equipped with a large stone cutter. In order to eliminate such drawbacks, there are some blocks in which a stone block with a specified thickness is attached to the concrete block, and both sides of the block are made of natural stone or stone layers such as tiles, but at the concrete block manufacturing stage, especially the steam curing process. Since there is a warp of about 1 to 2 mm, there is a drawback that the stone material cannot be adhered closely. As a countermeasure, it is conceivable to fill the gap between the stone and concrete block with mortar, but in this case, it takes a long time to dry, so mass production is difficult, or there is a gap somewhere somewhere. Water may enter through the gaps, and the water may freeze in winter, which may cause damage or peeling of the stone layer.

On the other hand, Japanese Unexamined Patent Publication No. 64-17952 discloses the problem of the block of natural material type or concrete type by sticking a surface material made of stone on the surface of a core material made of foamed resin. Dissolved lightweight blocks are disclosed. However, in this prior art, the block members are joined by joining rods fitted in the vertical through holes, and workability is improved by using the joining rods for joining in the height direction. However, no special engagement means was provided for the connection in the width direction, and the same work as in the past was required. As a countermeasure for this, it is possible to form a step for engagement in the width direction of the block body, but in that case, a special forming die having a concave portion and a convex portion for forming the step portion is used and the die cutting is performed. It is necessary to design the mold in consideration of the above, and it has a drawback that it takes time and effort to manufacture and the manufacturing cost increases.

[0004]

[Problems to be solved by the device]

 The present invention has been made in view of the above-mentioned conventional circumstances, and its purpose is to provide a stone layer such as natural stone or tile on the front and back sides, which is lightweight and easy to handle, and the stone layer peels off. It is to provide a new lightweight block that does not have such a fear, and that the construction work of the structure is extremely easy, and can be easily manufactured without using a special molding die or method. .

[0005]

[Means for Solving the Problems]

 In order to achieve the above object, the lightweight block of the present invention is a lightweight block made by joining stone materials cut to a predetermined thickness to both the front and back surfaces of a core material formed of foam and having through holes in the vertical direction. In the block, the joining position of the stone material with respect to the core material is shifted in an arbitrary direction to form a convex portion and a concave portion for coupling fitting of the blocks in the horizontal width direction and the vertical height direction of the block body. It is characterized by

[0006]

[Action]

 According to the above configuration, the stone material is bonded and integrated on both the front and back surfaces of the foam core material, and the bonding strength of the stone material to the core material is extremely strong. At the same time, it has excellent physical properties such as water resistance, durability, and shape retention, and it is lightweight and can be obtained as a lightweight block that is easy to transport and handle. Also, when constructing a structure, insert a core rod (round steel) for joining into the through hole provided in the core material, and fit the convex part and the concave part for coupling and fitting the blocks to each other in the width direction. Also, since they are connected in the height direction, the construction work can be performed very easily, and the blocks can be connected more reliably. Moreover, in the joined blocks, the joint surface between the core materials and the joint portion are deviated from each other (see FIGS. 2 and 3). Therefore, even if rainwater or the like intrudes from the joint portion, the joint surface may be different. It is unlikely to get around. Further, the fitting convex portion and concave portion can be easily formed by shifting the joining position of the stone material to the core material in an arbitrary direction.

[0007]

【Example】

 FIG. 1 shows an embodiment of a lightweight block according to the present invention, in which 1 is a core material made of foam, 2 and 2 are stone materials which are bonded to both front and back surfaces of the core material, and the core material 1 has a width direction substantially equal to that of the stone material. A vertical through hole 3 is formed in the central portion. Further, semi-circular vertical grooves 3a, 3a are provided at the left and right outer end portions of the core material 1, and the core materials 1, 1 of the blocks A, A joined together in the width direction as shown in FIG. A through hole 3'in the vertical direction is formed between the joint surfaces 10 of each other. Examples of the foam constituting the core material 1 include urethane foam, polyurethane foam, polystyrene foam, polyethylene foam, and the like. In this embodiment, urethane foam is used. Examples of the material forming the stone material 2 include natural stones and tiles. In the present embodiment, thin plate-shaped natural stones are used (the drawing shows marble). Further, a notch step portion 4 is formed at one edge portion (the lower edge portion is shown in the drawing) of the stone material 2 in the height direction, and is joined in the width direction when a structure, for example, a block wall is constructed. The blocks A, A, ... Are continuous with the stepped portions 4, 4, ... And can give decorativeness and aesthetics.

The stone material 2 may be joined to the core material 1 by applying an adhesive or the like on both front and back surfaces of the preformed core material 1, but in the present embodiment, the following method is adopted. First, fix the two stones 2 and 2 so that they do not move with a certain space between them, and then, the part between the stones 2 and 2, that is, the part that becomes the core 1 is formed by the mold material. The core material is enclosed between the stone materials 2 and 2 by enclosing it so that the two-part urethane is injected into the voids surrounded by the mold material to foam it and completely drying it while applying pressure and then removing the mold material. At the same time that the core material 1 is formed, the stone materials 2 and 2 are joined to both the front and back surfaces of the core material 1 with a strong adhesive force with no gap between the surfaces and the core material 1 to obtain the lightweight block A of this embodiment.

When molding the core material 1, the joining positions of the stone materials 2 and 2 with respect to the core material 1 are shifted in any direction. In this embodiment, as shown in FIG. For fitting the blocks together in the left-right width direction and the vertical height direction by shifting the molding position of the core 1 so that the end surface and one end surface in the vertical height direction project by a predetermined amount. The convex portions 5a and 5b and the concave portions 6a and 6b are formed.

In molding the core material 1, the mold material is set so that the widthwise and heightwise dimensions of the core material 1 are larger than the stone material 2 by a predetermined dimension (for example, about 10 mm). The protrusions 5a, 5b are made larger than the recesses 6a, 6b by the protrusion so that when the blocks A, A are joined together, the joint gap 7a is formed between the opposite edges of the stones 2, 2. , 7b are secured (see FIGS. 2 and 3). A well-known joint material 8 is filled in the joint gaps 7a and 7b. However, in this embodiment, since the core material 1 is urethane foam, an acrylic resin caulking material is used for the joint material 8 to form the core material. 1. Prevent deterioration and protect from ultraviolet rays. In addition, as is clear from FIGS. 2 and 3, in the joined blocks A and A, the joint surface 10 of the core materials 1 and 1 and the joint portion 9 are displaced from each other, and by any chance, from the joint portion 9 Even if rainwater or the like enters, it is extremely unlikely that it will enter the joint surface 10. Therefore, as compared with a structure in which the joint surface 10 of the core materials 1 and 1 and the joint portion 9 are located in the same line (for example, Japanese Patent Laid-Open No. 64-17952 mentioned as the prior art), rainwater or the like is bonded. It is extremely unlikely that it will enter the through holes 3 and 3'through the surface 10 and reduce the joining force between the blocks A and A, in other words, the durability and strength of the structure.

The lightweight block A of the present embodiment having the above-mentioned structure has the stone materials 2 and 2 adhered firmly and firmly to both the front and back surfaces of the core material 1 made of a foam, thereby providing an elegant appearance. In addition to having physical properties such as water resistance, durability, and shape retention, a lightweight block that is lightweight and easy to carry and handle can be obtained. Further, when constructing a structure such as a block fence, as shown in FIGS. 2 and 3, the core rod (round steel) 11 for joining is inserted through the through holes 3 and 3 ′, and the joint fitting is performed. The blocks A, A are connected to each other in the width direction and the height direction by fitting the convex portions 5a, 5b and the concave portions 6a, 6b, and the mortar 12 is filled in the through holes 3, 3 '. Therefore, in combination with the light weight of the block A, the construction work can be performed very easily, and the blocks A and A can be more reliably connected to each other. In addition, since the joint surfaces 10 of the core materials 1 and 1 and the joint portions 9 of the joined blocks A and A are displaced from each other, even if rainwater or the like intrudes from the joint portions 9, the above-mentioned joints will not occur. It is less likely to go around the surface 10 and is advantageous for improving the durability and strength of the structure. Further, the fitting convex portions 5a, 5b and the concave portions 6a, 6b can be easily formed by shifting the joining positions of the stone materials 2, 2 with respect to the core material 1 in an arbitrary direction, and a special molding die. Since there is no need to use a manufacturing method or a method, there is no fear that it will take time and effort to manufacture or increase manufacturing cost.

It is needless to say that the notch step portion 4 described above does not necessarily have to be provided, and the same effect as above can be obtained in the embodiment shown in FIG. Also, as shown in FIG. 2, the block A located at the bottom of the structure does not need to have the recess 6b in the height direction, and although not shown, the block located at the top of the structure has a high height. Similarly, it is not necessary to provide the convex portion 5b in the depth direction, and similarly, the block located at the outermost end of the structure does not need to have the convex portion 5a or the concave portion 6a in the width direction. It is molded and appropriately used as needed.

[0013]

[Effect of device]

 Since the lightweight block of the present invention is constructed as described above, it has the following effects. Since stone blocks are closely and firmly bonded and integrated on both sides of the foam core material to form blocks, the disadvantages of traditional products in which stone materials are stuck to natural stone blocks or concrete blocks are eliminated, and it is elegant. It is possible to obtain a lightweight block that has excellent aesthetics and excellent physical properties such as water resistance, durability and shape retention, and is lightweight and easy to transport and handle. Since the block main body is provided with fitting protrusions and recesses in the left-right width direction and the vertical height direction, blocks can be easily connected in both the height direction and the width direction when constructing a structure. Therefore, combined with the advantage of being lightweight, the construction work of the structure is very simple. Further, the fitting of the convex portion and the concave portion can further secure the mutual connection of the blocks.

In the joined blocks, the joint surface of the core materials and the joint portion are displaced from each other (see FIGS. 2 and 3), and even if rainwater or the like enters from the joint portion, the joint surface does not reach the joint surface. There is a low possibility that it will go around, and there is very little risk that rainwater, etc. will enter the through-holes through the joint surface and reduce the joint force between the blocks, in other words, the durability and strength of the structure. Therefore, compared with a structure in which the joint surface of the core material and the joint portion are located in the same line (for example, Japanese Patent Laid-Open No. 64-17952, which has been cited as the prior art), the durability and strength of the structure can be improved. This is advantageous for improvement. The fitting convex portion and concave portion can be easily formed by displacing the joining position of the stone material with respect to the core material in an arbitrary direction, and since no special molding die or method is used, it is troublesome to manufacture. There is no fear that the cost will increase and the manufacturing cost will increase.

[Brief description of drawings]

FIG. 1 is a perspective view showing an embodiment of a lightweight block according to the present invention.

FIG. 2 is a vertical cross-sectional side view showing a state in which the lightweight blocks shown in FIG. 1 are vertically joined together.

3 is a cross-sectional plan view showing a state in which the lightweight blocks shown in FIG. 1 are laterally joined together.

FIG. 4 is a perspective view showing another embodiment of the lightweight block according to the present invention.

[Explanation of symbols]

 A: Light weight block 1: Core material 2: Stone material 3, 3 ': Through hole 4: Notch step 5a: Width convex portion 5b: Height convex portion 6a: Width concave portion 6b: Height direction Recess 8: Joint material

Claims (1)

[Scope of utility model registration request] 1. A lightweight block made by joining a stone material cut to a predetermined thickness to both the front and back surfaces of a core material formed of foam and having through holes in the vertical direction, the stone material corresponding to the core material. The light weight block is characterized in that the joint position of the block is shifted in an arbitrary direction, and a convex portion and a concave portion for coupling fitting of the blocks are formed in the left-right width direction and the vertical height direction of the block main body.