JP3171549B2 - Method of manufacturing concrete products - 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 concrete product having a decorative material fixed to at least a part of its surface, and more particularly, to a method for fixing a decorative material in an arbitrary shape and forming a uniform concrete joint. The present invention relates to a method for producing a concrete product to be obtained.

[0002]

2. Description of the Related Art Conventionally, as a method of fixing a surface decorative material such as a natural stone, a tile, a brick or the like to a concrete surface, a decorative material is laid in a concrete formwork, and a joint forming material is placed in a gap between the decorative materials. A method of filling, then pouring, curing and hardening the concrete, removing the hardened concrete, and removing the joint forming material is widely used.

[0003] In these production methods, it is difficult to uniformly fill the joint forming material and to remove the joint forming material after producing the concrete product. Kaihei 6-254820
No., a support plate that can hold the cosmetic material by allowing liquid to pass through is placed in the mold, the decorative material is placed on the support plate, and the holding material liquid is injected from below the mold to remove the cosmetic material. There is disclosed a method in which a part of the concrete is immersed in a liquid, and the holding material liquid is cured, and then concrete is poured. Here, agar is exemplified as the holding material.

According to this method, the retaining material liquid (joint forming material) can be uniformly injected. However, if agar as described above is used as the retaining material liquid, it is difficult to remove the concrete after removing the mold. It is. That is, the agar has low strength of the material itself and cannot be peeled off uniformly, and a part of the broken agar remains on the concrete surface, the support plate and the bottom of the formwork, and the portion adhered to the concrete surface is high-pressure water or A great deal of labor is required for removal, such as removing by air and removing the residue on the support plate and the bottom of the form by hand. Furthermore, agar may easily crack due to drying, and the joints may not be formed uniformly.

[0005] Japanese Patent Laid-Open Publication No.
It is conceivable to use paraffin described in No. 720, but paraffin is not elastic after curing and breaks when being removed, making it difficult to remove. For this reason, Japanese Unexamined Patent Application Publication No.
No. 0 proposes to remove by heating and re-fluidizing, but it requires a large amount of energy for the removal and has poor workability.

That is, in the conventional manufacturing method, it was not possible to easily obtain a concrete product in which a decorative material is fixed on a surface with a desired design and uniform and smooth joints are formed.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described circumstances, and has a decorative material fixed on at least a part of a surface thereof with a desired design. It is an object of the present invention to provide a method of manufacturing a concrete product which can form a uniform and smooth joint, further facilitates peeling operation of the joint forming material, and makes the joint forming material recyclable. .

[0008]

The method for producing a concrete product according to the present invention is a method for producing a concrete product in which a decorative material is fixed on at least a part of its surface. And a step of disposing the decorative material at a desired position on the mesh support in the concrete formwork on which the mesh support is arranged at a distance from the bottom; As the main component, the polymer organic material
Is composed of a polymer blend material having a volume fraction of 30% or less in the main component, and the polymer organic material forms a hard block such as a crystal structure or an aggregated structure.
Easy parts and soft blocks such as amorphous structures
A joint-forming thermoplastic material having a three-dimensional continuous network skeleton structure, which is held together, is heated and melted and injected into the mold, and the joint-forming thermoplastic material is arranged on a mesh support. A process of partially immersing the material,
(3) a step of pouring concrete into the formwork after the joint forming thermoplastic material is cured; and (4) a step of curing the poured concrete until it hardens and exhibits a desired strength. (5) removing the mold after the concrete has hardened, and peeling off the joint-forming thermoplastic material adhered to the surface.

The joint-forming thermoplastic material (hereinafter referred to as joint-forming material as appropriate) used herein comprises a high-molecular-weight organic material and a low-molecular-weight material as main components, and is provided in front of the high-molecular-weight organic material.
A polymer having a volume fraction of 30% or less in the main component
A high-molecular-weight organic material, wherein the high-molecular-weight organic material comprises
Easily forms hard blocks such as crystalline and cohesive structures
Together with a soft block such as an amorphous structure
And a polymer blend material having a three-dimensional continuous network skeleton structure.

Further, in the method for producing a concrete product according to the present invention, the polymer blend material may be a polymer organic material having a number average molecular weight of 40,000 or more and a number average molecular weight.
It is characterized by having a low molecular weight material of less than 5,000 as a main component, and a difference in solubility parameter between the high molecular weight organic material and the low molecular weight material is 3.0 or less.

[0011] The high-molecular organic material may include :
Butadiene and butadiene-styrene random copolymer;
Polyethylene obtained by hydrogenating the block copolymer of
Ethylene / butylene-styrene random copolymer
Rock copolymer, (2) polybutadiene and polystyrene
With a block copolymer, or polybutadiene or
Ethylene-butadiene random copolymer and polystyrene
Obtained by hydrogenating a block copolymer with
/ Block copolymer of butylene and polystyrene,
(3) One end or both ends of ethylene / butylene copolymer
(4) a block copolymer in which crystalline ethylene is linked to
Ethylene-propylene rubber, especially polyethylene
And ethylene / butylene-styrene random copolymer
It is preferably at least one selected from block copolymers .

This joint forming material can be prepared by using the above-mentioned suitable high-molecular organic material and adjusting the kind and amount of the low-molecular material to have a melting temperature of 70 to 120 ° C. it can.

The joint forming material used in the method for producing a concrete product of the present invention is hydrophobic because it holds a low molecular material in a three-dimensional continuous uniform network skeleton structure made of a thermoplastic high molecular organic material. When a low molecular weight material is retained, the entire material becomes hydrophobic, has good mold releasability from concrete and decorative materials, and has a rubber-like elastic body in which the whole material is retained by a polymer network skeleton structure. Since the elastic deformation is possible and the strength against the tensile stress is sufficient, the work of peeling the joint forming material from the concrete surface can be easily performed.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

In order to manufacture a concrete product having a decorative material fixed to at least a part of its surface, first,
(1) A decorative material is arranged at a desired position on a mesh support of a concrete formwork on which a mesh support is arranged parallel to the bottom and at a distance from the bottom.

The mesh support used in the method of the present invention is preferably arranged parallel to the bottom of the concrete form and at a distance of at least about 3 mm from the bottom.

Here, the net-like support means a wire mesh or the like as long as the joint-forming thermoplastic material in a fluid state can pass through the net-like gap and has a rigidity capable of holding the decorative material. The mesh may be a mesh or a perforated plate, and the material, the mesh of the mesh or the size of the pores of the perforated plate is not particularly limited, and can be selected according to the size of the cosmetic material to be used.

Examples of the mesh support include wire meshes such as iron, steel, and aluminum, filaments made of FRP, synthetic resin, carbon fiber, natural or synthetic fibers, rods, twisted yarns, and the like.
In addition to a mesh formed using a rope or the like, a punched metal, FRP, a perforated plate made of a synthetic resin, a filament similar to the above, and the like arranged in a parallel interdigital shape are also included. These may be formed in a suitable frame.

On this net-like support, a decorative material to be fixed to a concrete product is arranged according to a predetermined arbitrary design.

Here, what is used as a cosmetic material is
There is no particular limitation, and natural stones such as teppei stone, gabble stone, and gravel, tiles, bricks, glass blocks, and the like can be selected and used so as to be adapted to the use of the concrete product.

Next, (2) as a main component a polymer organic material and a low molecular material, put in the main component of the high molecular organic material
That the volume fraction is constituted by using a polymer blend material is 30% or less, and, the polymeric organic material crystal structure and coagulation
And easy to form hard block
Hold together with a soft block such as a fass structure
The joint forming thermoplastic material having a three-dimensional continuous network skeleton structure is heated and melted and injected into the formwork, and the joint forming material is partially immersed in the decorative material disposed on the mesh support. I will do it.

At this time, since the part of the decorative material which is not immersed in the joint forming material is fixed in the concrete, the injection amount of the joint forming material is adjusted from the viewpoint of adhesion strength and design. can do. The preferable range of the injection amount varies depending on the shape, material, weight, etc. of the decorative material. However, in the case of irregularly-shaped rags or generally rectangular tiles, which are usually used, 1/3 to 1/2 of the height of the decorative material is used. It is preferable to be immersed to the extent from the viewpoint of adhesion strength.

The joint forming material used in the production method of the present invention mainly comprises a high molecular weight organic material and a low molecular weight material, and the high molecular weight organic material has a number average molecular weight of 40,0.
Of more than 00 thermoplastic high molecular organic materials and their rubber
And the like.

Specific examples of the thermoplastic high molecular organic material include those having both a portion where a hard block such as a crystal structure and a cohesive structure is easily formed and a soft block such as an amorphous structure. Preferably, specifically, the following are mentioned.

A block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer.

A block copolymer of polybutadiene and polystyrene, or a block copolymer of polyethylene / butylene and polystyrene obtained by hydrogenating a block copolymer of polybutadiene or an ethylene-butadiene random copolymer and polystyrene .

A block copolymer in which crystalline ethylene is linked to one end or both ends of an ethylene / butylene copolymer.

[0028] Ethylene-propylene rubber. Of these, a block copolymer of polyethylene and an ethylene-styrene random copolymer is particularly preferred.

These various kinds of thermoplastic polymer organic materials are mainly used alone, but two or more kinds thereof may be blended and used.

On the other hand, the low-molecular material preferably has a viscosity at 100 ° C. of 1 × 10 ⁵ centipoise or less , and from the viewpoint of molecular weight, the number-average molecular weight of the low-molecular material is particularly 5,000. The following is preferred. Usually, a liquid or liquid material at room temperature is suitably used as such a low molecular material. In addition, any of hydrophilic and hydrophobic low-molecular materials can be used, but from the viewpoint of releasability from concrete, hydrophobic low-molecular materials are preferable.

The low molecular weight material is not particularly limited,
The following are preferably exemplified. Softeners: Softeners for various rubbers or resins, such as mineral oils, vegetable oils, and synthetic oils. Examples of the mineral oils include aromatic, naphthenic, and paraffinic process oils. Vegetable oils include castor oil, cottonseed oil, sweet oil, rapeseed oil, soybean oil, palm oil, palm oil,
Peanut oil, wood wax, pine oil, olive oil and the like.

Plasticizers: Various ester-based plasticizers such as phthalic acid ester, phthalic acid mixed ester, aliphatic dibasic acid ester, glycol ester, fatty acid ester, phosphate ester, stearic acid ester, epoxy-based plasticizer, etc. Plasticizers for plastics or phthalates, adipates, sebacates, phosphates,
NBR plasticizers such as polyethers and polyesters.

Tackifiers: Various tackifiers (tackifiers) such as coumarone resins, coumarone-indene resins, phenol terpene resins, petroleum hydrocarbons, and rosin derivatives.

Oligomer: crown ether, fluorine-containing oligomer, polyisobutylene, xylene resin, chlorinated rubber, polyethylene wax, petroleum resin, rosin ester rubber, polyalkylene glycol diacrylate,
Various oligomers such as liquid rubbers (polybutadiene, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone oligomers, and poly-α-olefins.

Lubricants: hydrocarbon lubricants such as paraffin and wax; fatty acid lubricants such as higher fatty acids and oxy fatty acids; fatty acid amide lubricants such as fatty acid amides and alkylene bis fatty acid amides; fatty acid lower alcohol esters; fatty acid polyhydric alcohol esters , Ester lubricants such as fatty acid polyglycol esters, fatty alcohols,
Various lubricants such as alcoholic lubricants such as polyhydric alcohol, polyglycol and polyglycerol, metal soaps, and mixed lubricants.

In addition, latex, emulsion, bituminous composition, clay, inorganic silicone oil, phosphazene and the like are also suitable as low molecular weight materials.

Further, organic solvents such as hydrocarbons, halogenated hydrocarbons, alcohols, phenols, ethers, acetals, ketones, fatty acids, esters, nitrogen compounds and sulfur compounds, and petroleums , Water, an aqueous solution and the like can be used in combination to adjust the physical properties.

These low-molecular materials may be used alone or in a combination of two or more. In the present invention, in order to obtain a polymer blend material containing a large amount of the low molecular weight material with a large amount of the low molecular weight material and a smaller amount of the high molecular weight organic material, each of the low molecular weight material and the high molecular weight organic material is used. A difference in solubility parameter value δ = (ΔE / V) ^1/2 (ΔE = molar evaporation energy, V = molar volume) of 3.0 or less;
It is preferable to select both materials so as to be preferably 2.5 or less. If this difference exceeds 3.0, it is difficult to maintain a large amount of low molecular weight material due to the compatibility of the two materials, which hinders the lowering of the elasticity of the obtained polymer blend material. It is not preferable because it easily occurs.

In addition, this joint forming material does not have cracks after hardening and must have optimal shear, tensile strength and elongation characteristics as described later in order to facilitate peeling from concrete products. Therefore, the polymer organic material constituting the polymer blend material of the joint formation material needs to form a three-dimensional continuous network skeleton structure, and the average diameter of the network skeleton is 50 μm or less, Preferably, the average diameter of the cells (mesh) is 500 μm or less.
m, preferably 300 μm or less, and the volume fraction of the high-molecular organic material was defined as [volume of high-molecular organic material / (volume of high-molecular organic material + volume of low-molecular material)] × 100 (%). At this time, it is desirable that the volume fraction of the high molecular weight organic material is 30% or less, particularly 25% or less.

The polymer blend material may contain a predetermined amount of a high molecular organic material and a low molecular material, and if necessary, other compounding agents. The high molecular organic material may form a three-dimensional continuous network skeleton structure. It can be obtained by mixing under mixing conditions. In this case, it has a uniform three-dimensional continuous network skeleton structure made of a high-molecular-weight organic material, low bleeding of a low-molecular-weight material, and a high-quality material that satisfies the aforementioned characteristics. In order to obtain a molecular blend material, it is preferable to use a high-shear mixer as the mixer, and in particular, a mixer capable of providing a high shear force and a high shear rate between a fixed wall and a rotating rotor. , The distance (clearance) between the fixed wall and the rotating part (rotor) is t (m), and the rotating peripheral speed of the rotor is v
(M / sec), the shear rate of the rotor is V, and V
= V / t (sec ^-1 ), V ≧ 5.0 × 10 ² (sec ⁻¹ ), preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ), more preferably V ≧ 2.5 × 10 ³ (sec ^-1 ) More preferably, it is advantageous to use a high-shear type special mixer satisfying V ≧ 5.0 × 10 ³ (sec ^-1 ).

The polymer blend material according to the present invention is not particularly limited, such as a normal bulk shape, a gel shape, a foam shape, etc., but is in a gel state, in particular, a three-dimensional continuous uniform material made of a thermoplastic polymer organic material. Those in a gel state having a network skeleton structure are particularly effective for the present invention.

As the physical properties of the joint forming material after curing, the tensile strength evaluated by a tensile test of JIS K6301 is 0.5 kg / cm ² or more, and the elongation at break is 30 kg / cm ^2.
It is preferable that it is 0% or more from the viewpoint of workability when peeling off from the concrete product after curing.

As the joint forming material, a high-molecular organic material such as those described above is used, and by adjusting the type and blending amount of the low-molecular material, the melting temperature becomes, for example, 7
Although it is possible to prepare a material in the range of 0 to 120 ° C, it is preferable to use a material having a melting temperature of 100 to 120 ° C in consideration of the case where the curing of concrete is performed by heating.

The joint forming material is heated to a melting temperature or higher, and the oily material is poured into the mold as described above. As a heating method, for example, put in a container, a method of heating the container with an open flame, a heater, a method of heating in a dryer, a method of heating by microwave in a microwave oven, a method of heating by steam, a sand bath, A method of heating with an oil bath and the like are mentioned, and there is no particular limitation. However, it is preferable to adopt a method of heating with steam from the viewpoint that temperature control is reliable and uniform heating can be performed.

Since the joint-forming material melted in an oily state has a good shape following property, the gap of the decorative material in the mold can be uniformly filled. In addition, in the present invention, the interior of the mold is filled by injecting the oil-like joint forming material from above into the gap portion of the decorative material so that the uniform liquid level gradually rises from the lower portion of the mesh support. The space between the cosmetic materials is uniformly filled in a planar manner, and a uniform joint can be formed by injection from one place. The pouring is performed from the state in which the decorative material is fixed to the concrete surface as described above to a predetermined depth.

By spraying an appropriate amount of water on the surface of the decorative material before injecting the oil-melted joint forming material, the releasability between the decorative material and the joint forming material is improved,
It is also possible that the joint-forming material hardened into a plate shape adheres to the surface of the concrete product and does not remove at the same time, but remains in the mold.

(3) After the joint forming thermoplastic material is cured, concrete is poured into the formwork.

The joint forming material melts when heated and exhibits a low-viscosity oily state, but becomes solid when cooled to room temperature. Therefore, the joint forming material can be cured by leaving the mold at room temperature. In addition, in order to improve workability, the mold can be positively cooled and cured by placing the mold in a low-temperature storage.

Thereafter, after the joint forming material is cured,
Concrete is poured into a formwork, but as described above, the surface of the joint forming material is smooth, and the joint forming material and the decorative material are in close contact with each other, so that the concrete joint is smooth and beautiful. Finish and concrete will not wrap around the decorative material surface.

[0050] The concrete used here can be arbitrarily used in accordance with the purpose of use of the concrete product. Also, the casting method can be performed by a conventional method. At this time, in order to improve the removability between the concrete form and the concrete, a release agent can be applied (sprayed) in the form in advance.

Next, (4) curing is performed until the cast concrete hardens and develops the desired strength. The curing may be room temperature curing or high temperature curing.

From the viewpoint of workability, high-temperature curing is preferable.
Since the temperature of steam curing that is usually performed is 60 to 70 ° C., even if high-temperature steam curing is performed under normal conditions, the joint forming material is not affected.

When performing high-temperature curing other than steam curing, the upper limit of the heating temperature should be around the melting temperature of the joint-forming material in order to prevent deformation of the joint-forming material. preferable.

(5) After the concrete has hardened, the concrete having the joint forming material adhered to the surface (bottom side of the mold) is released from the mold, and the joint forming material adhered to the surface is peeled off. This joint forming material holds the low-molecular material in a three-dimensional continuous uniform network skeleton structure made of a thermoplastic high-molecular organic material. Is hydrophobic, and has good mold release properties from concrete and decorative materials. Further, the entire material can be elastically deformed by a rubber-like elastic body held by a polymer network skeleton structure, and since a network support exists inside, a large area can be formed at a time by its reinforcing effect. It can be peeled off.

If a hook or the like is fixed to the mesh support in advance before the joint forming material is injected, workability is improved even when the joint is peeled by hand. Is also possible. A known method may be used for fixing the hooks to the mesh support. When fixing the hooks, it is preferable to fix the hooks at five locations, that is, at four corners and at the center, from the viewpoint of workability.

The joint-forming thermoplastic material peeled off from the concrete surface can be heated and melted to remove the net-like support. In addition, impurities such as mixed stripping agent, cement, sand, water, and dust are precipitated by heating and melting,
Impurities can be easily separated and removed by a conventional method such as filtration. Therefore, it is easy to use (recycle) again.

According to the production method of the present invention, in addition to a concrete flat plate, at least a part of the surface of a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, a concrete fence, or the like is decorated with an arbitrary design. Concrete products with fixed materials can be easily manufactured. The use of the concrete product is not particularly limited, and examples thereof include those for construction (decorative panels for interior and exterior of buildings, floors, etc.), for civil engineering (road pavement, decorative panels for wall surfaces, etc.), and the like.

[0058]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples.

FIGS. 1A to 1D are schematic sectional views showing a method of manufacturing a concrete product 10 according to the present invention in order.

FIG. 1A shows a state in which a decorative material 16 is arranged on a net-like support (wire net) 14 provided in a mold 12. Next, a joint forming thermoplastic material 18 in a molten state is injected through a gap of the decorative material 16 so that a part of the decorative material 16 arranged as shown in FIG.

FIG. 1C shows a state in which concrete 22 is cast in the mold 12 on which the layer of the cured joint forming thermoplastic material 18 is formed.

In this state, the concrete 22 which has been cured at a high temperature and hardened is released from the mold.
As shown in the schematic cross-sectional view of FIG. 1D, a decorative panel made of concrete (a concrete product) having a decorative material 16 fixed on its surface by peeling and removing the joint forming thermoplastic material 18 holding the joint material 4. ) 10 is possible. Example 1 (1) Preparation of Joint Forming Thermoplastic Material A As a raw material, polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, was used. Block copolymer (high molecular weight organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 15 vol%, low molecular weight alkylbenzene (softening agent) (Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight: 335, SP value: 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co., Ltd .: molecular weight: 426, SP value: 8.4) 42.5% by volume)
And a high-shear type special mixer ("TK. Auto Homomixer" manufactured by Tokushu Kika Kogyo Co., Ltd.) for 30 rpm.
The mixture was mixed under mixing conditions of 00 rpm, a shear rate of 1.0 × 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance. did. When a section of the polymer blend material was cut out and confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average diameter of skeleton of 5 μm, average diameter of cell of 15 μm) composed of a thermoplastic polymer organic material was formed. It was confirmed that. The polymer blend material has an Asker-C hardness of 10 and a tensile strength of 3 kg / cm.
² , elongation at break is 1500%, compression set (70
C., 22 hours) was 30, and the melting temperature was 120.degree. (2) Preparation of Form and Filling of Form A wire mesh (mesh support) 14 made of aluminum and having an opening of 1 mm × 1 mm was arranged at a height of 5 mm from the bottom of the form parallel to the bottom. A concrete formwork 12 was prepared. An average particle size of 10 c
m mosaic stones 16 were placed.

The joint forming thermoplastic material A18 is
The mixture was heated and melted at 0 ° C. and poured into the mold 12 from the gap between the slabs 16. Joint forming thermoplastic material A1
8 was filled from the bottom of the mold 12, passed through the wire mesh 14 in a uniform liquid state, and gradually filled the gaps between the stones 16 from the bottom. The pouring was performed to a depth at which about 50% of the grit stone 16 was immersed. After the material was uniformly filled in the voids of the grit stone 16, the material was cooled and hardened by standing at room temperature. (3) Manufacture of concrete product Concrete 22 was poured into the formwork 12 by a conventional method, steam-cured at about 70 ° C. for 3 hours, and the concrete 22 was hardened and then released from the mold.

Thereafter, the thermoplastic resin A18 for joint formation hardened was peeled off from the surface.

The joint-forming thermoplastic material A18 is easily and neatly removed as a single sheet from the surface of the concrete 22 joints and the exposed portion of the shingles 16, and is cut in the middle of the concrete 22 and the shingles 16. No residue on the surface was observed.

In the obtained concrete product 10, the rough stones 16 are securely fixed on the surface, no stones are detached, no concrete 22 is adhered to the surface of the rough stones 16, and furthermore, The surface of the concrete 22 joint portion formed between the stones 16 was smooth and uniform, and the concrete product 10 excellent in appearance could be manufactured.

The joint forming thermoplastic material peeled off from the concrete surface is heated and melted to remove the wire mesh.
By removing the mixed impurities, it can be used again. Example 2 (1) Preparation of Joint Forming Thermoplastic Material B As a raw material, polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, was used. Block copolymer (high molecular weight organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 10% by volume and alkylbenzene (softening agent)
(Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight 335, SP
Value 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co .: molecular weight 426,
SP value 8.4) 42.5% by volume, and further 5% by volume of higher fatty acid amide (oleic acid amide Armoslip: manufactured by Lion) were added, and a special high-shear mixer ("TK Auto Homo") was added. Mixer ”Tokushu Kika Kogyo Co., Ltd.
3,000 rpm, shear rate 1.0 ×
The mixture was mixed under a mixing condition of 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance, and was used as a thermoplastic material B for joint formation. When a section of this polymer blend material was cut out and confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average skeleton diameter of 3 μm, average cell diameter of 18 μm) composed of a thermoplastic high molecular organic material was formed. It was confirmed that. The Asker-C hardness of this polymer blend material is 1
0, tensile strength 3 kg / cm ² , elongation at break 150
0%, compression set (70 ° C., 22 hours) was 30, and melting temperature was 120 ° C. (2) Filling the formwork A 50 mm thick brick-like tile is placed on a wire mesh in the formwork.
mm and the joint forming thermoplastic material B
The mixture was heated and melted at 70 ° C. and poured into the gap between the brick-like tiles so that the brick-like tile was immersed to a depth of 15 mm in the same manner as in Example 1. After the joint forming material was uniformly filled in the gaps between the brick-like tiles, the mixture was allowed to stand at room temperature and cooled and cured. (3) Manufacture of concrete products Concrete is poured into this formwork by a usual method,
After steam curing at 0 ° C. for 3 hours to harden the concrete, it was released from the mold.

Thereafter, in the same manner as in Example 1, the cured thermoplastic resin B for forming joints was peeled off from the surface.

The thermoplastic material B for forming joints is completely removed from the surfaces of the concrete joints and the exposed portions of the brick-like tiles, and the brick-like tiles are completely fixed on the concrete surface, and adhesion of the concrete on the tile surface is observed. However, a concrete product excellent in appearance was obtained.

The removed joint-forming thermoplastic material B was heated and melted in the same manner as in Example 1 to remove the wire mesh, and then removed again in the molten state to remove impurities. It was possible.

Example 3 (1) Preparation of Joint-Forming Thermoplastic Material C As a raw material, a high-molecular-weight organic material, polyethylene, was present at both ends, and a block copolymer containing ethylene-butylene at the center (high Molecular organic material) (number average molecular weight 280,000:
90% by volume of paraffin oil (softening agent) (PW-32, manufactured by Idemitsu Kosan Co., Ltd .: molecular weight 405, SP value of 7.9), which is a low molecular weight material, is added to 10% by volume of SP value 8.0) and a high shearing type. Using a special mixer (“TK Auto Homomixer” manufactured by Tokushu Kika Kogyo Co., Ltd.), the number of revolutions is 3000 rpm, the shearing speed is 1.0 × 10 ⁴ sec, the mixing temperature is 180 ° C., and the mixing time is 40 minutes. To obtain a polymer blend material having a uniform appearance, which was used as a thermoplastic material C for forming joints. Also, cut out a section of this polymer blend material,
When confirmed by an optical microscope, a three-dimensional continuous network skeleton structure (average diameter of skeleton of 5 μm) made of a thermoplastic polymer organic material was confirmed.
m, the average cell diameter was 15 μm). In addition, Asker of this polymer blend material
The C hardness was 2, the tensile strength was 1.2 kg / cm ² , the elongation at break was 970%, the compression set (70 ° C., 22 hours) was 50, and the melting temperature was 110 ° C. (2) Filling into Formwork The joint forming thermoplastic material C was heated and melted at 170 ° C., and the garnet was placed on a mesh support in Example 1.
After the material was uniformly filled, the mixture was allowed to stand at room temperature and cooled and cured. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1. The hardened thermoplastic material C for forming joints was completely peeled off from the surface of the concrete joint and the exposed part of the grit stone, and the grit stone was completely fixed on the concrete surface, and adhesion of the concrete to the grit stone surface was observed. However, the joints formed in the gaps between the rags were uniform and smooth, and a concrete product having excellent appearance was obtained.

The joint-forming thermoplastic material C peeled off from the concrete surface was heated and melted to remove the wire mesh, and then the molten metal was removed in the same manner as in the joint-forming thermoplastic material A of Example 1. Can be used again by removing.

[0073]

As described above, according to the manufacturing method of the present invention, a decorative material can be fixed to a surface with a desired design by a simple method, and concrete does not adhere to the surface of the decorative material. In addition, there is an excellent effect that uniform and smooth joints can be formed. Furthermore, the joint forming material used in the method of the present invention has an excellent effect that can be used repeatedly (recycled).

[Brief description of the drawings]

FIG. 1 is a schematic sectional view sequentially showing a method for producing a concrete product according to the present invention, wherein (A) shows a decorative material arranged on a mesh-like support in a mold, and (B) shows a decorative material. This shows a state in which a joint forming thermoplastic material is injected so that a part of the material is immersed. (C) shows a state in which concrete is poured into a formwork on which a layer of a thermoplastic material for joint formation is formed. (D) shows a concrete product obtained by removing the cured joint-forming thermoplastic material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Concrete product 12 Formwork 14 Wire mesh (mesh support) 16 Cosmetic material 18 Polymer blend material (thermoplastic material for joint formation) 22 Concrete

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hiroaki Suzuki 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Tetsuo Kobayashi Minami, Taisho-ku, Osaka-shi, Osaka 7-1-55 Enkajima Central Research Institute of Sumitomo Osaka Cement Co., Ltd. (72) Inventor Masao Kusano 7-1-55 Minamienkajima Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (56) References Kaihei 7-171810 (JP, A) JP-A-3-205103 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 1/16 B28B 1/14 B28B 7/16

Claims (3)

(57) [Claims] 1. A method for producing a concrete product having a decorative material fixed to at least a part of its surface, comprising: (1) a concrete in which a mesh-like support is arranged parallel to a form bottom and at a distance from the bottom. placing a decorative material on a mesh support member in the mold to a desired position, (2) as a main component a polymer organic material and a low molecular material, the
The volume fraction of the main component of the high molecular weight organic material is 30%
It is composed of the following polymer blend material, and the polymer organic material has a hard structure such as a crystal structure or an aggregate structure.
Block-forming parts and amorphous structures
A joint-forming thermoplastic material having a three-dimensional continuous network skeleton structure having a soft block together is heated and melted and injected into the mold, and the joint-forming thermoplastic material is placed on the mesh support. A step of partially immersing the placed decorative material; (3) a step of placing concrete in the formwork after the joint forming thermoplastic material has hardened; and (4) a step of placing. And (5) removing the mold after the concrete has hardened and removing the thermoplastic material for joint formation that has adhered to the surface. Method of manufacturing concrete products. 2. The polymer blend material according to claim 1, wherein the polymer blend material has a number average molecular weight of 40,000 or more and a number average molecular weight of
2. The concrete product according to claim 1, wherein the main component is a low molecular weight material of less than 5,000 , and the difference in solubility parameter between the high molecular weight organic material and the low molecular weight material is 3.0 or less. Manufacturing method. 3. The high-molecular organic material comprises: (1) polybutadiene and butadiene-styrene random
A polystyrene obtained by hydrogenating a block copolymer with a copolymer
Ethylene and ethylene / butylene-styrene random copolymer
(2) block copolymer of polybutadiene and polystyrene
Coalesced or polybutadiene or ethylene-butadi
Block copolymerization of the ene random copolymer and polystyrene
Polyethylene / butylene and poly obtained by hydrogenating the coalesced
Block copolymer with styrene, (3) one end or both ends of ethylene / butylene copolymer
The method for producing a concrete product according to claim 1 , wherein the copolymer is at least one selected from a block copolymer in which crystalline ethylene is linked to (4) ethylene-propylene rubber .