JP3044028B1 - Method for producing building material having brick on substrate surface and block with surface brick - Google Patents

Abstract

An object of the present invention is to provide a method of manufacturing a block having a brick surface. SOLUTION: An adhesive brick 11 is supplied to a large number of brick dies 8 in a molding die 7, and a large number of bricks 5 are provided at predetermined intervals.
Are simultaneously molded, and then the foamed resin block base 1 having the brick adhesive layer 4 is placed in a molding die 7 and pressed to adhere the bricks 5 to the brick adhesive layer 4 at the same time. A block with a brick 5 is formed by forming, removing, and curing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a building material having a brick on a surface of a substrate suitable for use as, for example, a block for forming a fence or a pillar, an interior or exterior panel, and particularly to a fence or a pillar. It relates to a block with a surface brick suitable for forming.

[0002]

2. Description of the Related Art There is known a method of manufacturing a brick which supplies a colored brick material such as a colored mortar to a brick mold, forms (molds), cures and cures after demolding. To facilitate molding and demolding, use a brick made of synthetic rubber, such as urethane rubber or silicon rubber, or aluminum, etc., with deaeration holes, and use a thermoplastic resin on the molding surface of the brick. A colored brick material is supplied to a brick mold by laying and arranging a film or sheet of silicone resin or the like, applying heat molding as necessary, and sucking the vacuum through the deaeration holes. It is supposed to perform.

[0003]

In this case, individual bricks having a preferable shape can be obtained. However, the use of individual bricks requires individual installation by, for example, on-site construction on concrete blocks or base panels. As with bricks made of ceramic bricks, there is a merit of reducing the cost of bricks, but there is no further merit.

[0004] The present invention has been made in view of such circumstances, and a solution to the problem is that, first, in addition to the molding of the brick, a block having the brick on the surface in a series of steps together with this , Panels, etc., for example, fences and gate posts can be formed immediately, interior and exterior can be formed immediately,
Another object of the present invention is to provide a method of manufacturing a building material having a brick on its base surface, which enables efficient and reliable manufacture of a building material capable of saving labor on site work. It is an object of the present invention to provide a block with a surface brick which is suitable for forming and enables labor saving of the above-mentioned field construction.

[0005]

Means for Solving the Problems According to the first object, the present invention provides a method of simultaneously forming a large number of bricks at predetermined intervals and supplying blocks, panels, and other bases before releasing the bricks. A large number of uncured bricks are simultaneously adhered to the adhesive layer, and joints are simultaneously formed by the adhesive layer according to the spacing of the bricks, and are then removed from the mold, cured and cured to obtain a final product with a base (base). A building material usable as a product is manufactured. That is, the invention according to claim 1 is applied to each brick mold using a colored mortar using a mold having a large number of brick molds arranged at predetermined intervals. A brick forming step of supplying a colored brick material such as a kneaded material of a material and a binder and simultaneously forming a large number of bricks at predetermined intervals, and an uncured bridging of a mortar-based or resin-based adhesive layer formed on the surface. A substrate placement and bonding step of simultaneously placing a plurality of bricks at the above-mentioned predetermined intervals by pressing and placing a base on a molding die and simultaneously forming joints with the above-mentioned adhesive layer according to the brick spacing; Claims: 1. A method for producing a building material having a brick on a surface of a substrate, comprising: a demolding step of simultaneously releasing the brick adhered to the substrate through the mold; and a curing step of curing and curing the brick and the adhesive layer. In the invention described in Item 2, the color tone of the brick is set to have a feeling of old color of a used brick, a feeling of unevenness in the burning of bricks, and the like. 2. The method according to claim 1, further comprising the step of applying or spraying an inorganic pigment having a color tone different from that of the colored brick material on the brick mold. The invention according to claim 3 is to prevent bricks from being applied to joints by the adhesive layer, clarify the boundary between the joints and the bricks, and improve the surface appearance thereof. In addition, this is to supply the colored brick material in the brick forming process, the brick type part is a mortar transmission part such as a through-hole, mesh shape, band shape, parallel line shape, and the peripheral rib part that defines the brick type is a masking part. 3. The method according to claim 1 or 2, wherein the jig is arranged in a molding die, and the jig is leveled by a leveling tool so that the bricks are uniformly formed on a large number of brick molds at predetermined intervals. According to a fourth aspect of the present invention, there is provided a method for manufacturing a building material having a brick on the surface of a substrate, wherein the colored brick material is adapted to a brick type to prevent collapse of the brick shape, generation of voids, holes, and the like. 4. The substrate according to claim 1, wherein the substrate placement and pressurizing step is performed by applying vibration to the mold after or after the substrate is placed. According to a fifth aspect of the present invention, there is provided a method of manufacturing a building material having a brick on its surface, wherein the base is made of an organic or inorganic block so as to have a base in a preferred form according to the use of the building material. Alternatively, the present invention provides a method for producing a building material having a brick on the surface of a substrate according to any one of claims 1, 2, 3, and 4, wherein the invention is provided as a panel. A block base made of a foamed resin, a mortar-based or resin-based adhesive layer formed on the surface of the block base, and a predetermined adhesive bonded to the adhesive layer by partially exposing the adhesive layer as a joint. Colored mortar with multiple spaces, inorganic A brick formed by molding a colored brick material such as a kneaded product of a material and a binder, and simultaneously forming a plurality of bricks formed by molding a plurality of colored mortars at predetermined intervals using a molding die corresponding to an arrangement position on the block base; A block with a surface brick, wherein the block is attached to the adhesive layer by simultaneously bonding the uncured adhesive layer to the uncured adhesive layer of the block substrate while the brick is in an uncured state;
These are the means of solving the above-mentioned problems as the gist of the invention.

A brick mold and a mold for forming a brick show a state in which a film is arranged or sucked in the following embodiment. In the present invention, the brick mold and the mold are a film and a mold. If used,
This is used to mean both types that do not use them,
Mortar such as colored mortar is used to include fresh concrete or concrete containing aggregate.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail with reference to the drawings, wherein A is a block with a surface brick, and the block A is a block base 1 made of a foamed resin; And a mortar-based or resin-based adhesive layer 4 formed on the surface of the substrate 1 and a large number of colored mortars, inorganic materials, and binders which are partially exposed and bonded to the adhesive layer 4 with the adhesive layer 4 partially exposed as joints 6. The brick 5 is formed by molding a colored brick material such as a kneaded material. The concrete 5 is filled with concrete through the filling hole 2 of the block base 1 through a reinforcing bar and installed at the site as in the case of a concrete block. At this time, the bricks 5 formed by molding a large number of colored brick materials at the predetermined intervals are arranged on the block base 1. Simultaneous molding is performed using a molding die 7 corresponding to the placement position, and the adhesion to the adhesive layer 4 is simultaneously bonded to the uncured adhesive layer 4 of the block base 1 while the brick 5 is in an uncured state. By doing it.

That is, if this is explained by a manufacturing method,
The block A is formed by using a molding die 7 in which a large number of brick dies 8 are arranged at predetermined intervals, and coloring mortar,
A brick forming step of supplying a colored brick material 11 such as a kneaded material of an inorganic material and a binder and simultaneously forming a large number of bricks 5 at predetermined intervals, and a step of forming a mortar-based or resin-based adhesive layer 4 formed on the surface with an uncured brick. A substrate disposing / adhering step of disposing the substrate 1 on the molding die 7 on the 5th side and pressurizing to simultaneously adhere a large number of bricks 5 at the predetermined intervals and simultaneously form joints 6 by the adhesive layer 4 corresponding to the intervals of the bricks 5; It is manufactured by a manufacturing method including a demolding step of simultaneously releasing the bricks 5 adhered to the substrate 1 from the mold 7 via the adhesive layer 4 and a curing step of curing and curing the bricks 5 and the adhesive layer 4. .

In this embodiment, the molding die 7 in the brick molding step is made of a synthetic rubber such as urethane rubber or silicone rubber, and has a large number of brick dies (cavities) 8 at predetermined intervals.
The brick mold 8 is set up as a recess, and the outer periphery of the brick mold 8 is raised and protruded as a rib 9. At this time, as the molding die 7, a used brick type brick die 8 molded from a used brick is used, and a large number of bricks 5 are simultaneously molded in the used brick type.

The molding die 7 of this embodiment uses a thermoplastic resin film 10, which is vacuum-sucked and adhered to the molding surface, and supplies a colored brick material 11 to the brick mold 8 via the film 10. In this example, the thermoplastic resin film 10 is coated and preliminarily formed by heating the film 10 and, for example, placed and fixed on a table 16 provided with a suction device. Immediately after being placed in the heated state on the molding surface of the molded mold 7, a large number of brick molds 8 are covered with a single film 10 by vacuum suction from the degassing holes so as to be in close contact with this. At this time, the vacuum suction continues until the demolding step described below,
The deformation and displacement are prevented.

The colored brick material 11 is a kneaded material of an inorganic material and a binder. As the inorganic material, for example, a crushed powder of a ceramic tile, a roof tile, or the like is used. Pigments or other inorganic pigments such as color powders, and kneaded them with an appropriate binder such as a silicon-modified acrylic emulsion. At this time, the inorganic pigments are The color of the pulverized material is adjusted so as to give a brick color tone, for example, by using a plurality of colors of an appropriate pigment such as red, black, and white. These pigments are added and kneaded with a plurality of colors at the same time to obtain a colored brick material 11, or a single or a plurality of colors are added and kneaded to obtain a colored brick material 11 of a plurality of colors. The brick 5 is used in such a manner that the brick 5 has a patchy color tone, or the brick 5 is formed by any method.

In the present embodiment, as a pre-step of the brick forming step, the brick mold 8 is used. In this embodiment, the colored brick material 11 is added to the brick mold 8 via the formed film 10.
A pigment disposing step of applying or dispersing an inorganic pigment having a color tone different from that of the brick. In this example, the inorganic pigment adheres to the surface of the colored brick material 11 (the surface of the brick 5) supplied to the brick mold 8 in the brick molding step. As a result, the color tone of the colored brick material 11 as well as the old color feeling of the used brick is highly reproduced and the appearance thereof is improved, for example, by appropriately using a material such as black, yellow, or white. is there.

In the present embodiment, the colored brick material 11 is supplied such that the colored brick material 11 is filled into the brick mold 8 through the film 10 in a single color or in a plurality of colors in a partially patchy manner. In this example, the colored brick material 11 of each brick mold 8 is pressurized, and in this example, the surface is coated with the inorganic pigment.

At this time, the supply of the colored brick material 11 in the brick forming step in the present embodiment is performed by changing the brick mold 8 portion into a mortar transmitting portion 13 having a through hole, a mesh shape, a band shape, a parallel line shape, and the like. A jig 12 is used as a masking portion 14 to define the outer peripheral rib 9, and the jig 12 is arranged on a molding die 7 and leveled by a leveling tool, so that a large number of brick dies 8 are provided at predetermined intervals. To do it.

That is, the supply of the colored brick material 11 in the brick mold 8 is performed by placing the colored brick material on the ribs 9 (the film 10 on the surface in this example) defining the respective brick molds 8 on the periphery of the brick mold 8. The material 11 may remain. In this case, the material is adhered to the adhesive layer 4, so that the boundary of the colored brick material 11 is not drawn and the brick 5 protrudes from the joint 6 or the brick 5 covers the joint 6. However, the jig 12 is used, the jig 12 is placed on the mold 7 and arranged, and a predetermined amount supplied onto the jig 12 by a leveling tool 15, for example, a spatula, a brush or the like. The masking portion 14 prevents the colored brick material 11 from adhering to the ribs 9 and the mortar transmitting portion 13 allows the colored brick material 11 to be applied to each brick mold 8 by leveling the colored brick material 11. Prompting a first feed distribution, it is possible to perform a smooth filling delivery to ensure for each brick type 8.

In this embodiment, the jig 12 is a frame in which a masking portion 14 is formed by cutting a metal plate, and a mortar transmitting portion 13 is provided with a metal mesh material. The leveling device 15 is, for example, a metal mesh. Mortar transmission part 1
It is based on a brush with a thickness that matches the eyes
Thus, the filling and supply of the colored brick material 11 to the brick mold 8 and the prevention of the adhesion to the ribs 9 (in the present embodiment, the film 10 on the surface) can be efficiently and reliably performed. The formation of the brick 5 and the joint 6 of the color tone can be performed with good appearance as in the case where the brick 5 is individually stretched and the joint 6 is finished thereafter.

The brick 6, that is, the colored brick material 11 in the brick forming step is formed by simultaneously molding a large number of the prescribed bricks using the molding die 7. For example, in the present embodiment, the colored brick material 11 is formed. Material 11
After the supply of the jig 12, the jig 12 is removed from the molding die 7, and the whole of the brick dies 8 of the molding die 7 is simultaneously or individually for each single or plural brick dies 8 using a panel, a cloth, a pressing jig or the like. This is done by manually or mechanically pressing the colored brick material 11 as appropriate to cause it to compact.

Substrate 1 Used in Substrate Arrangement Pressing Step
Is an organic or inorganic block or panel
In particular, the block base is made of an organic block. In this embodiment, the block base is formed by foaming a foamed resin, for example, a polystyrene resin at a foaming ratio of about 25 to 30 times, in order to reduce the weight of the block A. The block base 1 is provided with a non-penetrating filling hole 2 by covering it up and down or covering it so that it can be easily broken. The block base is formed by applying an adhesive such as a resin-based adhesive, a color powder in this example, and applying an appropriate thickness of, for example, a black resin mortar. 1, the adhesive layer 4 is placed on a mold 7 with the adhesive layer 4 facing the brick 5, and the adhesive layer 4 is pressed with the colored brick material 11 filled in the brick mold 8 by applying pressure. The block base 1 is arranged so as to be adhered to the rib 9 of the mold 7 (in this example, the film 10 on the surface thereof), and pressure is applied in this state. 5 are simultaneously bonded to a substrate, especially a block substrate 1, and a brick 5
The joints 6 are simultaneously formed by the adhesive layer 4 according to the interval.

The block base 1 is pressurized by, for example, a hydraulic device and placed on the forming die 7 and arranged.
From the top surface (the back surface on the side of the non-mortar adhesive layer) to the table 16 side, that is, the molding die 7 side.

In this embodiment, the substrate placement and pressurizing step is performed by applying vibration to the molding die 7 after the substrate is placed or at the time of pressurizing. The material 11 is further adapted to the brick mold 8 to prevent collapse of the shape of the brick 5, generation of voids, holes, and the like, and to more reliably form the brick 5 in the above brick forming step, and furthermore, according to the present example. Thus, it is possible to faithfully and beautifully duplicate the used brick-like molding die 7 and to perform a duplicate molding thereof.

In this example, the vibration is applied by, for example, vibrating the table 16 on which the molding die 7 is mounted and fixed before or during pressing after the above-described arrangement of the brick base 1 by a vibrator. Do.

In the demolding step after the substrate disposing and pressing step, the bricks 5 bonded via the adhesive layer 4 are simultaneously released from the mold 7, and then the colored brick material 11 and the adhesive layer 4 are cured in the curing step. In order to remove the mold, for example, the table 16 on which the mold 7 is placed and fixed is inverted, and the vacuum suction of the film 10 is released. In order to leave the block A on the mounting table 16 thus set,
This is performed by raising the mold 7 mounted and fixed on the colored brick material 11 and the adhesive layer 4 at room temperature with the film 10 attached. This can be done as follows. Even if the film 10 used in this example can be peeled off during curing, if it is peeled off early, the inorganic pigment applied or scattered on the film 10 side remains, and the desired color tone by the inorganic pigment remains on the brick 5. May not be obtained.

The production of the block A in this embodiment is as described above. However, this can be collectively shown as specific steps following the brick forming step, the substrate disposing and pressing step, the demolding step, and the curing step. , As shown in FIG. In other words, the brick forming step includes a step of arranging and sucking a film into a molding die at the point of using the thermoplastic resin film 10, a step of arranging the inorganic pigment at the point of using the inorganic pigment, and a step of using the jig 12. The jig arrangement step, the colored brick material supply step at the point where the colored brick material 11 is supplied thereafter, the colored brick material leveling step at the point where the colored brick material 11 is leveled by the leveling tool 15, and the colored brick material 11 are thereafter performed. The method includes a colored brick material pressure molding step at the point of pressurization, and the substrate placement and pressurization step includes a step of placing the substrate with an adhesive layer at the point of placing the substrate 1 by performing vibration and pressing simultaneously with or after the vibration. In the demolding step, the table inversion step is performed at the point where the table 16 is inverted, and the vacuum suction of the film 10 is performed. The suction release step in that dividing, each comprise product take steps in that retrieving the block A, also curing process, colored brick material 11
And a curing step for curing the adhesive layer 4 and a film peeling step for peeling the film 10 thereafter.

The building material having a brick on the surface, particularly the block A with a surface brick, manufactured by the above-described manufacturing method is shipped, transported to a site, and reinforced using mortar and mortar. In addition to having a used-block-like brick 5 made of a colored brick material, the construction and construction of the fences and portals having joints 6 formed by the adhesive layer 4 can be performed simply and reliably to save labor on site work. It can be made possible. At this time, since the block A of the present example has the brick 5 and the joint 6 on one surface of the surface, the block A is disposed so as to be in contact with the remaining block base 1 to form the fence or the gate, or It is also possible to finish by separately stretching a brick or painting on the base 1 side. The block A is made of a foamed resin for the block base 1 to be lightweight, easy to transport and work, and has a mortar-type and inorganic-type good-brick finish, and is particularly suitable for labor saving. Can be.

In the figure, reference numeral 3 denotes a fitting portion formed on the block base 1 for the upper and lower joints.

Although the illustrated example is as described above, the use of the film is omitted by directly charging the colored brick material directly into the molding die or supplying it as described above using, for example, a jig. That is, instead of using the above-mentioned foamed resin block base as the base, an organic base, for example, a synthetic resin block or panel, or an inorganic base, for example, a mortar block, or a metal base, is used for each purpose. When using a jig, a mortar transmission part corresponding to the brick type part should be a through hole,
Parallel line shape, etc., pressurization of the colored brick material in the brick forming process should be sufficient to avoid applying vibration, and when using a jig, after supplying the colored brick material, the jig The mortar shall be leveled and the colored mortar shall be leveled; the mold shall be turned over and removed manually without using the table, and the surface brick shall be In the practice of the present invention, including the step of forming bricks and joints of building materials having bricks on the substrate surface on both sides of the substrate, including blocks with a brick, the step of forming a brick and the step of arranging the substrate , Demolding process, curing process, molding method, colored brick material, substrate, adhesive layer, etc., each specific method, process, material, shape, structure, their relationship,
The addition to these, the specific material, shape and structure of the foam resin block base, joints, and bricks, their relationship, the addition to these, and the use as building materials were variously changed unless they violated the gist of the invention. It can be in the form.

[0027]

Since the present invention is configured as described above, the invention according to claim 1 can be applied to a block, a panel, or the like having the brick on the surface in a series of steps in addition to the molding of the brick. Having bricks on the surface of the base, for example, walls and gates can be formed immediately, interior and exterior can be formed immediately, and building materials can be produced efficiently and reliably that can save labor on site. A method of manufacturing a building material can be provided, and the invention according to claim 2 adjusts the surface color tone of the brick, assuming that the brick color has, for example, an old color feeling of a used brick or a brick burning unevenness. According to the third aspect of the present invention, it is possible to prevent a brick from being applied to the joint of the adhesive mortar, to make the boundary between the joint and the brick clear, and to improve the surface appearance. According to the fourth aspect of the invention, the colored mortar can be adapted to a brick type to prevent collapse of the shape of the brick, generation of voids, holes, and the like. The invention described in (1) can have a preferable base according to the use of the building material, and the invention described in (6) can provide a block that can be suitably used particularly for forming a fence or a gate post. .

[Brief description of the drawings]

FIG. 1 is a perspective view of a block with a surface brick.

FIG. 2 is a partially enlarged cross-sectional view thereof.

FIG. 3 is a process diagram showing a basic process of the manufacturing method.

FIG. 4 is a specific process chart of each basic process in the embodiment.

FIG. 5 is a perspective view showing a model of a relationship between a molding die and a jig.

FIG. 6 is a longitudinal sectional view showing a model of a relationship between supply of a colored brick material to a molding die and a leveling tool.

FIG. 7 is a longitudinal sectional view showing a model in a state where a colored brick material is charged and supplied to a molding die or in a pressurized state.

FIG. 8 is a perspective view showing a model of a relationship between a brick of a colored brick material and a substrate on which an adhesive layer is formed.

[Explanation of symbols]

 A Block with surface brick 1 Block base 4 Adhesive layer 5 Brick 6 Joint 7 Mold 8 Brick 11 Colored brick material 12 Jig 13 Mortar transmission part 14 Masking part 15 Leveling tool

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. ⁷ , DB name) B28B 1/00-1/54 B28B 3/00-5/12 B28B 11/00-19/00

Claims (6)

(57) [Claims] 1. A colored mortar, a kneaded mixture of an inorganic material and a binder, and a colored brick material such as a kneaded mixture of inorganic materials and a binder are supplied to each of the brick molds by using a mold having a large number of brick molds arranged at predetermined intervals. Brick molding step of molding, placing the base on a mold with the adhesive layer of mortar, resin, etc. formed on the surface as the uncured brick side, pressurizing to simultaneously bond a large number of bricks at the predetermined interval and brick interval A step of simultaneously forming a joint by the above-mentioned adhesive layer according to the above-mentioned adhesive layer, a demolding step of simultaneously releasing the brick adhered to the substrate via the adhesive layer from the mold, and a curing step of curing and curing the brick and the adhesive layer. And a method for producing a building material having a brick on the surface of a substrate. 2. The substrate surface according to claim 1, further comprising a pigment disposing step of applying or dispersing an inorganic pigment having a color tone different from that of the colored brick material on the brick mold as a pre-step of the brick forming step. For producing building materials having bricks therein. 3. The supply of the colored brick material in the brick forming step is such that the brick type portion is a mortar transmitting portion such as a through hole, a mesh, a band, and a parallel line, and the outer peripheral rib portion defining the brick type is a masking portion. 3. The method according to claim 1 or 2, wherein the jig is arranged in a molding die, and the jig is leveled by a leveling tool so that the bricks are uniformly formed on a large number of brick molds at predetermined intervals. A method for producing a building material having a brick on the surface of a substrate as described in the above. 4. The substrate surface according to claim 1, wherein the substrate placement and pressurizing step is performed by applying vibration to the mold after the substrate is placed or at the time of pressing. A method for producing a building material having a brick. 5. The substrate according to claim 1, wherein the substrate is an organic or inorganic block or panel.
Or the method for producing a building material having a brick on the surface of the substrate according to 4. 6. A block base made of foamed resin, a mortar-based or resin-based adhesive layer formed on the surface of the block base, and a partly exposed and bonded to the adhesive layer using the adhesive layer as a joint. A molding die provided with a plurality of colored mortars, a brick formed by molding a colored brick material such as a kneaded material of an inorganic material and a binder, and a brick formed by molding the colored brick material having a large number of predetermined intervals, in accordance with an arrangement position on the block base. The surface is formed by simultaneously forming the bricks in the uncured state while simultaneously bonding the bricks to the uncured adhesive layer of the block substrate. Block with brick.