JP3064902B2 - Manufacturing method of artificial rock block - 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 pseudo rock block having an appearance similar to natural rock.

[0002]

2. Description of the Related Art Pseudo-rock blocks matched to natural scenery have been used for structures such as stairs on hills, slopes on hills, and seawalls along rivers and coastlines. The structure using the pseudo rock block is roughly classified into a structure having an appearance using a large number of rocks and a structure having an appearance such as one large rock or a rock wall as a whole. The present invention relates to a method for manufacturing a pseudo rock block applied to the former structure.

For example, for a staircase or a retaining wall, a pseudo rock block is used in which the surface of each block represents one or more rocks. Examples of such pseudo rock blocks include those described in Japanese Utility Model Laid-Open No. 6-27944 and Japanese Patent Laid-Open No. 7-324320.

The block described in Japanese Utility Model Laid-Open Publication No. 6-27944 is a block for a retaining wall, which is made of concrete and has a trapezoidal shape in a front view, and whose surface is disguised as a plurality of cobblestones. Also, Japanese Patent Application Laid-Open No. 7-324320
The block described in Japanese Patent Laid-Open Publication No. H10-15095 discloses a method of forming a cover in which a pseudo-rock portion formed of concrete containing a coloring material is provided at a central portion of a body formed of concrete, and a hole for attaching a blind joint block is provided around a surface portion of the body. This block is a retaining wall block that combines a block and a joint-hiding block that is formed into a pseudo-rock shape with concrete containing coloring material and has vertical and horizontal reinforcements embedded inside.

[0005] By using a large number of these blocks in combination, it is possible to construct a retaining wall that looks like a natural pile of natural boulders or a pile of natural rocks.

[0006]

However, in the conventional pseudo-rock block, since the butted portion when it is combined with another block is formed in a straight line, the surface of the structure is not easily assembled when a large number of blocks are combined. A geometric straight line pattern is formed as a whole. For this reason, artificial linear patterns can be seen while natural cobblestones and rocks are piled up, and pseudo-rocky patterns such as cobblestones and rocks appear at equal intervals, which impairs the precious landscape close to nature There is.

[0007] Further, since the individual blocks have the same shape, and even if they are arranged in different orientations, they exhibit a regular appearance as a whole, so that an artificial feeling remains.

The problem to be solved by the present invention is that when a plurality of blocks are combined, no geometric line appears on the outer surface and pseudo rock patterns do not appear at equal intervals. An object of the present invention is to provide a method of manufacturing a pseudo rock block that can construct a structure closer to the combination of the above.

[0009]

A pseudo rock block according to the manufacturing method of the present invention is a pseudo rock block for constructing a structure by combining a plurality of blocks, and the outer shape of the block is an aggregate of a plurality of stones. And the boundary between adjacent blocks is formed in a shape in which a part of the outer periphery of the plurality of stones is continuous.

[0010] The pseudo rock block according to the production method of the present invention comprises:
It can be used to construct stairs and retaining walls by combining multiple blocks. Although the size of one block is not particularly limited, for example, for construction of stairs, the thickness is 150 to 300 mm, the length is 350 to 650 mm, and the width is 500.
A size of about 2000 mm is appropriate.

The shape of one pseudo-rock block according to the manufacturing method of the present invention can have an outer shape approximating an aggregate of about 5 to 10 stones having different sizes and shapes. By making each stone different in size and shape, it is possible to give the impression that natural stones are assembled. When preparing structures of multiple types as aggregates, when constructing structures,
By combining different types of blocks, a more natural feeling can be obtained.

[0012] The shape of the boundary between adjacent blocks is a shape in which a part of the outer periphery of each stone forming the aggregate is continuous, and the boundary between the blocks adjacent to each other has a shape in which they fit together. And By forming the boundary part in this way, when a plurality of blocks are combined,
The boundary line looks like a series of natural stone edges, giving a more natural feel.

In the case of a block used for constructing a step-like structure, the shape of the edge of the block on the front side of the structure is made uneven in plan view, and the center in the thickness direction is made convex. The shape can be made as follows. By forming the front surface in such a shape, when the blocks are combined and constructed in a stepped shape, a shadow is generated by natural light, and the feeling of a natural stone is further emphasized.

The pseudo rock pattern on the surface of the block is formed by using a face plate having a pseudo rock pattern formed on the inner surface. This face plate is
The model can be manufactured by placing a model of a pseudo rock block having a pseudo rock pattern on the surface in a mold for forming a face plate and pouring a resin between the mold and the model.

That is, according to the present invention, a model of a block is manufactured, the model is placed in a mold for forming a face plate, and a resin is poured between the mold and the model. A method for manufacturing a pseudo rock block in which a mold for use, a model, and a face plate of a cured resin are separated from each other, and the face plate is put into a mold for block production and concrete is poured. Characterized in that it is composed of a roughly formed body having a shape including a straight line or a plane approximating the plane shape of the above and a clay applied to the surface thereof and capable of pressing a stone.

Here, the separated model can be reused, or can be repaired and reused as a model of a block having a different shape.

[0017]

FIG. 1 is a perspective view of an example in which a pseudo rock block manufactured by the manufacturing method of the present invention is used for stair construction, and FIG. 2 is a perspective view showing a stair constructed using a plurality of pseudo rock blocks. FIG. 3 and FIG. 3 are longitudinal sectional views of the stairs of FIG.

As shown in FIG. 1, the pseudo rock block 10 comprises:
The shape of one block is changed to six virtual stones 1 of different shapes.
A part of the outer periphery of the virtual stones 1a, 1f and 1c, 1d which approximates the aggregate of a to 1f, and forms the boundary between the pseudo rock blocks 11 and 12 adjacent to the left and right at the time of building the stairs. Are formed in a continuous shape. Virtual stone 1
One size of a to 1f is about 200 to 250 m thick
m, about 200-400 m in length and about 400-700 mm in width. In addition, this pseudo rock block 10 is for stairs construction, and when it is constructed on a staircase, the shape of the block edge on the front side is a concave-convex shape in plan view, and the central portion in the thickness direction is a convex shape. The back is hidden when the stairs are constructed, so the back is straight.

By forming the pseudo rock block 10 in such a shape, the pseudo rock block 10 looks like a combination of six natural stones, and when the other pseudo rock blocks 11 and 12 are arranged side by side, The boundary between adjacent pseudo rock blocks does not become linear, and it looks like a large number of natural stones arranged side by side.

The shape of the pseudo rock block 10 in FIG. 1 is one example, and another pseudo rock block for constructing a stair may be a pseudo rock block having the same shape as the pseudo rock block 10 in FIG. A pseudo rock block having a different shape from the pseudo rock block 10 of FIG. 1 may be used. For example, artificial rocks can be eliminated by using pseudo rock blocks of about five different shapes and by randomly arranging the rocks in an up-down direction so as to have an irregular appearance.

When the adjacent pseudo-rock blocks are formed into different shapes when constructing the stairs, the shape of the boundary between the adjacent pseudo-rock blocks is made to fit each other. In the example shown in FIG.
The right side of the pseudo rock block 11 has a convex shape with respect to the concave shape on the left side of 0, and the left side of the pseudo rock block 12 has a concave shape with respect to the right convex shape of the pseudo rock block 10. With such a shape, when the pseudo-rock blocks 11 and 12 are arranged on the left and right of the pseudo-rock block 10, the boundary between the pseudo-rock blocks 10 and the pseudo-rock blocks 11 and 12 is almost in close contact with each other. Appear to be continuously arranged in the horizontal direction. That is, as long as the left and right portions of the pseudo rock block are formed into shapes that can be fitted together, the pseudo rock portion may have any shape.

The staircase shown in FIG. 2 is a staircase constructed by combining a simulated rock block with an inclined portion of the ground having a height difference. In the present embodiment, as shown in FIGS. 2 and 3, 15 pseudo rock blocks 10 to 12, 20 to 22,
30 to 32, 40 to 42, 50 to 52 in the horizontal direction
The stairs were constructed by arranging the pieces and stacking five steps in the height direction.
In addition, it is a matter of course that a large number of pseudo rock blocks can be arranged in a staggered manner or randomly. Here, reference numeral 71 in FIG. 3 denotes base concrete, 72 denotes shoulder concrete, 73 denotes leveling concrete, and 74 denotes backfill material.

As in the case of the pseudo rock block 10 of FIG. 1, each of the pseudo rock blocks approximates an aggregate of a plurality of stones having different shapes, and a boundary between the pseudo rock blocks adjacent to the left and right is defined as a boundary. Since the stone is formed in a shape in which a part of the outer circumference of the stone is continuous, when constructing the stairs as shown in FIG. 2, no artificial linear part appears at the boundary of each block, and Because the same shape does not appear regularly, the entire staircase looks as if many natural stones are lined up and stacked. In addition, the shade of natural stones when natural light shines on the irregularities of the pseudo rock pattern on the upper surface and the front surface emphasizes the feeling of natural stone, and furthermore, as shown in FIG. By arranging the formed pseudo rock blocks 61 to 63, a natural feeling can be further enhanced.

Next, a method of manufacturing a pseudo rock block according to the present invention will be described with reference to FIGS. FIG. 4 shows a synthetic resin-made rough molded body and a model of a block produced by applying clay to the surface thereof, and FIG. 5 shows a mold for producing a face plate.
FIG. 6 shows a state in which a model of the block of FIG. 4 is put in a mold for forming a face plate and resin is poured between the mold and the model.
FIG. 7 shows a cross-sectional shape of the resin face plate separated from the state of FIG. FIG. 8 shows a state in which a face plate has been put into a block manufacturing form and concrete has been poured.

First, as shown in FIGS. 4A and 4B,
A rough molded body 80 having a substantially block shape made of a synthetic resin such as styrene foam is manufactured. The outer shape of the rough molding 80 is
FIG. 4A which is a plan view and FIG. 4B which is a front view
As shown in (1), any shape may be used as long as it approximates the shape of the pseudo rock block, and may be a shape including straight lines or planes. This roughly formed body 80 is stacked in two stages, and the surface thereof is shown in FIG.
As shown in (d), the clay 81 is applied to adjust the shape as shown in FIG. 1, and a block model 82 is manufactured.

In order to make a pseudo-rock pattern appear on the clay portion of the model 82, a pseudo-rock pattern having a texture of a stone surface can be obtained by pressing a real stone against the clay surface. However, since it is difficult to press the real stone against the joints between the virtual stones, a thin resin is applied to the surface of the real stone, and the stone surface is transferred to the resin. By pressing the joint in a folded shape,
A pseudo rock pattern can be obtained.

Next, a mold 90 for forming a face plate shown in FIG.
The model 82 of FIG. 4 is put into the inside as shown in FIG. 6, and the resin is poured between the mold 90 and the model 82. As the resin to be used, a resin that is somewhat flexible after curing is preferable from the viewpoint of ease of demolding. When the poured resin is cured, a face plate 91 having a pseudo rock pattern formed on the inner surface is completed as shown in FIG. After the resin is cured, the mold 90, the model 82, and the face plate 91 are separated.

Next, as shown in FIG. 8, a face plate 91 is put in a block forming formwork 92, and concrete 93 is poured. After the concrete 93 is solidified, it is removed from the mold to obtain the pseudo rock block shown in FIG.

The model 82 after the separation is repaired to its original shape by adding the clay peeled off at the time of the separation.
Can be used repeatedly. In addition, a part of the clay can be removed or added to make a model having a shape different from the original shape, and used to manufacture a pseudo rock block having a different shape.

According to the above-described manufacturing method, the block model 82 can be used repeatedly, and a pseudo-rock block having a different shape can be easily formed at a low cost based on the shape of the rough compact 80. Can be manufactured.

[0031]

According to the method for producing a pseudo rock block of the present invention,
This is a method of manufacturing a block model by applying clay to the surface of the roughly formed body and manufacturing a pseudo rock block based on this model, so add clay to the model used once and repair the shape as before And can be used repeatedly.
In addition, a part of the clay can be removed or added to make a model having a shape different from the original shape, and used to manufacture a pseudo rock block having a different shape.

[Brief description of the drawings]

FIG. 1 is a perspective view of an example in which a pseudo rock block manufactured by the manufacturing method of the present invention is used for stair building.

FIG. 2 is a perspective view showing a stair constructed using a pseudo rock block.

FIG. 3 is a longitudinal sectional view of the stairs of FIG. 2;

4A and 4B are diagrams illustrating a process of manufacturing a model of a block in a process of manufacturing a pseudo rock block, wherein FIG. 4A is a plan view of a roughly formed body, FIG. 4B is a front view of the same, and FIG. Figure,
(D) is the same side view.

FIG. 5 is a perspective view showing a mold for forming a face plate.

FIG. 6 is a view showing a state in which a model of a block is put in a mold for forming a face plate, and a resin is poured between the mold and the model.

FIG. 7 is a diagram showing a cross-sectional shape of a face plate.

FIG. 8 is a diagram showing a state in which a face plate is put in a block manufacturing form and concrete is poured.

[Explanation of symbols]

1a-1f Virtual stone 10-12,20-22,30-32,40-42,5
0-52,61-63 Pseudo rock block 71 Basic concrete 72 Shoulder concrete 73 Leveling concrete 74 Backfill material 80 Roughly molded body 81 Clay 82 Block model 90 Face plate making form 91 Face plate 92 Block production form 93 Concrete G Inclined part

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-7-118051 (JP, A) JP-A-7-324320 (JP, A) JP-A 9-151468 (JP, A) JP-A 55- 126406 (JP, A) Japanese Utility Model Hei 6-27944 (JP, U) (58) Field surveyed (Int. Cl. ⁷ , DB name) B28B 1/14 B28B 7/16

Claims (1)

(57) [Claims] 1. A model of a block is manufactured, the model is put in a mold for forming a face plate, a resin is poured between the mold and the model, and after the poured resin is cured, the mold for forming the face plate is formed. A method for manufacturing a pseudo rock block in which the model and the hardened resin face plate are separated, and the face plate is put into a block manufacturing form and concrete is poured, wherein the model has a plan shape of a pseudo rock block to be manufactured. A method for producing a pseudo-rock block, comprising using a rough compact having a shape including an approximated straight line or plane and a clay applied to the surface thereof and capable of pressing a stone.