JP3219662B2 - Method for manufacturing decorative formwork for concrete molding - 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 producing a decorative formwork for concrete molding suitable for producing a concrete product having an irregular pattern on its surface, and more particularly, to an irregular pattern having an arbitrary shape and three-dimensional appearance. The present invention relates to a method for manufacturing a decorative mold for concrete molding, which can be easily formed, easily peeled from a concrete product, and can be recycled.

[0002]

2. Description of the Related Art In recent years, there has been a general tendency to improve the aesthetics of buildings and sidewalks by giving an uneven pattern to the concrete surface. It is actively manufactured.

Conventionally, as a method of forming a concavo-convex pattern on the surface of concrete, a resin-made concrete formwork having a concavo-convex pattern previously formed on the bottom surface is generally used. This resin-made decorative form is formed of a material such as a hard resin such as styrene foam or urethane, and a fiber reinforced resin (FRP) in which these resins are filled with reinforcing fibers. When molding these hard resins, it is necessary to produce a mold having a desired uneven pattern, and furthermore, specialized equipment is required to mold the resin into a decorative mold using this mold. Such,
It has been difficult to arbitrarily form a decorative mold having a desired uneven pattern. For this reason, in most cases, a ready-made decorative form is purchased and used.

[0004] In particular, a mold using styrofoam has a low resin strength, and is damaged when the mold is removed, resulting in poor workability. In addition, it is disposable, and disposal of styrofoam waste is also a problem. In addition, urethane molds can be reused, but the mold release property of concrete is poor, cement paste adheres to the mold surface sequentially, it becomes difficult to form a sharp uneven pattern, and the number of reuses is 10 to 10. Only about 20 times.

Further, the conventional decorative formwork is made of hard resin, and in addition to (1) it is difficult to manufacture the decorative formwork having an arbitrary uneven pattern, and (2) the concrete mold form (3) Concrete can not be removed except for those with irregular shapes with a demolding slope.
There are drawbacks, such as the fact that the pattern that can be formed is limited.

That is, it is difficult to manufacture a concrete product having a desired uneven pattern formed on the surface of the conventional decorative formwork.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and it is possible to transfer a desired uneven pattern, particularly an arbitrary solid material, onto a surface and to set an arbitrary transfer depth. An object of the present invention is to provide a method for manufacturing a concrete formwork for concrete molding that can manufacture a concrete product having a selected uneven pattern formed thereon and that can be reused and recycled.

[0008]

Means for Solving the Problems The present inventors have proposed a concrete molding decorative material capable of producing a concrete product having a desired shape by combining a solid material for molding, a material for adjusting the depth of unevenness, and a thermoplastic material. The present inventors have found that a mold can be manufactured and completed the present invention.

That is, the method for producing a decorative mold for concrete molding according to the present invention comprises: (1) a step of disposing a solid material for molding at a predetermined position in a mold for producing a decorative mold; and (2) Arranging a concave-convex depth adjusting material to a predetermined position in the mold for manufacturing a decorative mold; (3) providing a high-molecular organic material and a low-molecular material in the mold for manufacturing the decorative mold; And the main component,
The volume fraction of the main component of the high molecular weight organic material is 30.
% Or less, 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 step of heating and melting a thermoplastic material for a decorative form having a three-dimensional continuous network skeleton structure having a soft block together and injecting the thermoplastic material to a predetermined position; and (4) a thermoplastic material for the decorative form. Removing the material for adjusting the depth of unevenness and the solid material for molding after the material is cured.

The thermoplastic material for a decorative mold used here (hereinafter, appropriately referred to as a mold material) is mainly composed of a high molecular weight organic material and a low molecular weight material.
Volume fraction in the component is configured using the polymer blend material is 30% or less, and, the polymeric organic material is sintered
Easy to form hard block such as crystal structure or aggregate structure
And a soft block such as an amorphous structure
It is configured using a polymer blend material having a three-dimensional continuous network skeleton structure.

Further, in the method for producing a decorative formwork for concrete molding according to the present invention, the high molecular blend material is a high molecular organic material having a number average molecular weight of 40,000 or more and a low molecular material having a number average molecular weight of less than 5,000. And the main component,
In addition, a difference in solubility parameter between the high molecular weight organic material and the low molecular weight material is 3.0 or less.

The high-molecular-weight organic material may include :
Between tadiene and butadiene-styrene random copolymer
Polyethylene and ethylene obtained by hydrogenating a block copolymer
Blow with Tylene / butylene-styrene random copolymer
(2) Polybutadiene and polystyrene
Block copolymer, or polybutadiene or ethylene
Of styrene-butadiene random copolymer and polystyrene
Polyethylene / butyl obtained by hydrogenating a block copolymer
Block copolymer of styrene and polystyrene, (3)
Crystalline end at one or both ends of the styrene / butylene copolymer
(4) Ethylene-
Propylene rubber, especially polyethylene and ethylene
/ Block copolymer with butylene-styrene random copolymer
And at least one selected from the group consisting of a polymer and water.

This mold material can be prepared from those having a melting temperature of 70 to 120 ° C. by using the above-mentioned suitable high-molecular organic material and adjusting the kind and blending amount of the low-molecular material. it can.

[0014] The mold material used for the decorative mold of the present invention includes:
Since the low-molecular material is held in a three-dimensional continuous uniform network structure made of a thermoplastic high-molecular organic material, when a low-molecular material with hydrophobic properties is held, the whole material becomes hydrophobic, It has good mold releasability from the solid material for molding, and is a rubber-like elastic body in which the whole material is held by a polymer network skeleton structure. It can be elastically deformed and has sufficient strength against tensile stress. Therefore, it is possible to easily remove the solid material for molding and the material for adjusting the depth of unevenness used in the molding of the decorative formwork, and also from the concrete surface of the decorative formwork when molding the concrete product. Can be easily performed. Therefore, concrete does not remain in the mold and the decorative mold is not damaged at the time of demolding, so that it can be used repeatedly.

[0015]

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

In the method for producing a decorative formwork for concrete molding according to the present invention, a solid material for molding is used to form a desired uneven pattern. This can be arbitrarily used as long as it is a solid material having a certain volume and shape.

Examples of the solid material for molding include a natural stone, a brick, a columnar body having an arbitrary cross-sectional shape such as a circle, an ellipse, a triangle, a quadrilateral, and a star for forming a repetitive pattern;
A three-dimensional sculpture or the like produced with an arbitrary design can be used.

First, (1) a mold for manufacturing a decorative mold (hereinafter, simply referred to as a mold as appropriate) which is sufficiently higher than a desired height of the decorative mold to be manufactured is prepared. The above-mentioned solid material for molding (hereinafter, simply referred to as a molding material as appropriate) is arranged at a predetermined position which is predetermined in order to apply a desired design to a concrete product. Since the shape of the molding material determines the shape of the convex part of the concrete product to be finally manufactured, the shape, the number of the molding materials, the arrangement position, etc. are the purpose of the concrete product. The design must be fully considered in this process.

When disposing the molding material in the mold, it is preferable to wet it with water or the like in advance from the viewpoint of improving the removability of the molding material.

Next, (2) a material for adjusting the depth of unevenness is placed in a mold for producing a decorative mold up to a predetermined position for applying a desired design. If the arrangement depth of this unevenness depth adjusting material is large, the depth of the unevenness pattern of the decorative formwork will be shallow, so the depth of the unevenness pattern formed on the concrete product is adjusted by this arrangement amount (arrangement height). can do.

The material for adjusting the depth of unevenness may be a solid material or a fluid material as long as the material does not allow the mold material to enter.

As the solid material, a material that can be arranged without gaps between the solid materials for molding in the mold, for example, a material such as clay that can be plastically deformed, or a material that hardens from a fluid state such as concrete or gypsum. A material that becomes solid is preferable.

Further, as the fluid material, since the specific gravity of the mold material in a molten state is about 0.8 to 0.9, the material is limited to a material having a specific gravity higher than this specific gravity. Non-affinity materials that do not mix with the frame material are preferred. For example, water, hot water and the like have a specific gravity of about 1.0, and the mold material is a hydrophobic material, and both are incompatible, so that they can be suitably used.

When a solid material such as clay is used as the material for adjusting the depth of unevenness in the steps (1) and (2), the material for adjusting the depth of unevenness is uniformly filled in advance in the bottom of the mold. It is also possible to insert and arrange the molding material at a desired depth later.

[0025] Then, (3) to the decorative mold mold frame for production, as a main component a polymer organic material and a low molecular material, the high
The volume fraction of the main component of the molecular organic material is 30% or less.
It is constituted using a polymer blend material below , and
The high-molecular-weight organic material has a hard structure such as a crystal structure or an aggregated structure.
Soft parts such as amorphous structure
A thermoplastic material for a decorative formwork having a three-dimensional continuous network skeleton structure having a block together is melted by heating and injected to a predetermined position. When the unevenness depth adjusting material is a flowable material, the specific gravity is larger than that of the thermoplastic material for a decorative form that has been melted and is in a flow state, and
Since the thermoplastic material is a fluid material having incompatibility with the thermoplastic material, if the decorative thermoplastic material is injected gently from the upper part of the form, these materials do not mix and the upper part becomes a fluid state according to the specific gravity. Two layers are formed, namely, a material for the formwork and a material for adjusting the depth of unevenness in the lower part. In addition, when the unevenness depth adjusting material is a solid material, the molding material and the unevenness depth adjusting material are in close contact with each other. As in the case of using the material, two layers are formed, that is, a mold material in a fluid state at the upper part and a material for adjusting the depth of the unevenness of the filled solid.

The thermoplastic material for a decorative form used here is mainly composed of a high molecular weight organic material and a low molecular weight material.
As a high molecular weight organic material, the number average molecular weight is 40,000.
The above thermoplastic high-molecular organic materials and the resins of these resins
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.

[0031] Ethylene-propylene rubber. Of these, a block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer is particularly preferred.

These various kinds of thermoplastic high-molecular organic materials are mainly used alone, but two or more kinds may be used by blending.

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 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 resin, coumarone-indene resin, phenol terpene resin, 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, petroleums , Water, an aqueous solution and the like can be used in combination to adjust the physical properties.

These low molecular weight 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.

Further, in order to prevent the mold material from being cracked after hardening and to be easily separated from a concrete product, it is necessary that the material for the formwork has optimum shearing, tensile strength and elongation characteristics as described later. Therefore, it is necessary that the high-molecular organic material constituting the high-molecular-weight blend material of the mold material should form a three-dimensional continuous network skeleton structure,
The average diameter of the reticulated skeleton is 50 μm or less, preferably 30 μm or less.
μm or less, the average diameter of the cells (mesh) is 500 μm or less,
When the volume fraction of the high-molecular-weight organic material is defined as [volume of high-molecular-weight organic material / (volume of high-molecular-weight organic material + volume of low-molecular-weight material)] × 100 (%), The volume fraction of the molecular organic material is 30% or less, especially 2
It is desirable that it is 5% 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) and the shear rate of the rotor as V,
When V = v / t (sec ^-1 ), V ≧ 5.0 × 10 ² (sec ⁻¹ ), preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ), and more preferably V ≧ 2. It is advantageous to use a special high-shear mixer that satisfies 5 × 10 ³ (sec ⁻¹ ), more preferably 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, gel, foam, 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 application to the present invention.

The mold material is made of a high-molecular organic material such as those described above, and by adjusting the type and blending amount of the low-molecular material, the melting temperature becomes, for example, 70 to 70.
Although it is possible to prepare those in the range of 120 ° C,
In consideration of the case where the curing of the concrete is performed by heating, it is preferable to use one having a melting temperature of 100 to 120 ° C.

As a heating method for melting the mold material, for example, a method in which the material is put in a container and the container is heated by an open flame, a heater, a method in a dryer, or a microwave in a microwave oven Method, a method of heating with steam, a method of heating with a sand bath, an oil bath, and the like.There is no particular limitation. It is preferable to employ it.

Since the mold material melted in an oily state has a good shape followability, it is uniformly filled into the details of the irregularities of the solid material for molding, and accurately reproduces the details of the material for molding. A finished decorative form can be created.

When a mold material is injected into the mold,
In order to reinforce the decorative formwork, a lath material serving as a core material, a lath material with ribs, a wire mesh, a mesh bar made of reinforcing steel, and the like can be arranged at a position not in contact with the material for forming in the formwork material.

(4) After the injected thermoplastic material for the decorative form is cured, the material for adjusting the depth of unevenness and the solid material for molding are removed to obtain the decorative form. Is melted when heated and exhibits a low-viscosity oily state, but becomes solid when cooled to room temperature. Therefore, the curing of the mold material can be performed 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.

The physical properties of the mold material after curing are as follows.
The tensile strength evaluated in the tensile test of JIS K6301 is 0.5 kg / cm ² or more, and the elongation at break is 300
% Or more is preferable from the viewpoint of workability when separating the molding material and when releasing the cured concrete product when used as a decorative mold.

After confirming the curing of the thermoplastic material for the decorative form, the cured material for the form is taken out of the form for manufacturing the decorative form, and the material for adjusting the depth of unevenness is removed. Usually, since the form material and the unevenness depth adjusting material are incompatible, the unevenness depth adjusting material remains in the form, and the form material holding the forming material is removed. You. When the material for adjusting the depth of unevenness is a solid material, the material for adjusting the depth of unevenness may be rarely attached to the surface of the material for the formwork. It is sufficient to remove it.

Thereafter, the hardened mold material is inverted to remove the solid material for molding. The formwork material is a rubber-like elastic body whose entire material is held by a polymer network skeleton structure, which can be deformed elastically and has sufficient strength against tensile stress. Without separating, the solid material for molding can be easily separated.

The cured product of the obtained mold material becomes a flat decorative mold. In order to obtain a concrete product having a desired thickness, this flat decorative mold is used as a concrete casting mold. Laying and using it is preferable in terms of workability.

As the concrete to be poured into the decorative formwork obtained by the production method of the present invention, a concrete having a composition according to the purpose of use of the concrete product can be arbitrarily used. Also, the casting method can be performed by a conventional method. That is, ordinary cement concrete, prestressed concrete (PC), lightweight cellular concrete, or the like can be used. In the case of manufacturing a concrete product of a fixed shape such as a flat plate or an L-shaped retaining wall, a reinforcing material is put in advance to manufacture. You can also.

The curing after the concrete is poured into the decorative formwork of the present invention may be normal 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 thermoplastic material forming the decorative form 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 decorative form material in order to prevent deformation of the decorative form. preferable.

After the poured concrete has hardened, it is released from the mold to obtain a concrete product having an uneven pattern formed on its surface. As described above, the material for the decorative formwork is made of a tertiary thermoplastic polymer organic material. A low molecular weight material is held in a uniform continuous network skeleton structure, and when a hydrophobic low molecular weight material is held, the whole material becomes hydrophobic, has good mold release from concrete, and has a decorative mold. A concrete product having a desired uneven pattern can be obtained without the concrete remaining on the frame. Therefore, pretreatment such as application of a release agent becomes unnecessary.

Moreover, since the entire mold material is a rubber-like elastic body held by a polymer network skeleton structure, it can be elastically deformed and has sufficient strength against tensile stress. The makeup frame can be easily separated, and the makeup frame can be easily separated even when an uneven pattern at an angle of 90 ° without a removal inclination is formed. Furthermore, it is possible to peel off a large area at once. Further, since there is no breakage of the decorative form when removing the concrete product, the decorative form after taking out the concrete product can be repeatedly used.

Further, in order to use the thermoplastic material constituting the decorative mold of the present invention for another pattern or shape, the thermoplastic material is melted.
It can be used again after molding. In other words, the mold material is heated and melted to precipitate the mixed release agent, cement, sand, water, dust and other impurities, and easily separated,
It can be removed and can be molded again into any shape. Therefore, it is easy to use (recycle) again.

By using the decorative formwork according to the present invention, an arbitrary uneven pattern is formed on the surface of a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, a concrete fence, etc. in addition to a concrete flat plate. And a three-dimensional concrete product that imitates a shape such as a log can be easily manufactured.

The use of the concrete product to which the decorative formwork according to the production method of the present invention can be applied is not particularly limited, and is used for construction (decorative panels for interior and exterior of buildings, floors, etc.) and civil engineering (for roads). Pavement, decorative panels for wall surfaces, etc.) and decorative objects (exterior products, objects, etc.).

[0063]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples. (Example 1) (1) Preparation of thermoplastic material A for decorative frame 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, Block copolymer (high molecular weight organic material) of ethylene and ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) to 15% by volume of 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 .: 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. And 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) Manufacture of a decorative mold A cubic molding material 14a and a triangular prism molding material 14b, which are solid molding materials 14, were arranged at predetermined positions in a mold 12 for producing a decorative mold. Before placing these molding materials 14, the surfaces were wetted by spraying with water. FIG. 1A shows a mold 12 for producing a decorative mold.
FIG. 4 is a schematic cross-sectional view showing a state in which a solid material for molding 14 (14a, 14b) is disposed therein.

Clay 16 as a material for adjusting the depth of unevenness is filled (arranged) to a predetermined position in the mold 12 for producing the decorative mold [FIG. 1 (B)].

Next, into the mold 12 for producing a decorative mold, a thermoplastic material A18 for a decorative mold which is melted at 170 ° C. to form an oil is injected to a predetermined position (FIG. 1).
(C)].

This is left at room temperature to cure the thermoplastic material A18 for a decorative formwork, and then is released. Thermoplastic material A for decorative mold holding solid materials 14a and 14b for molding
18 is removed from the mold, and the clay 16 remains in the mold 12. The clay 16 may be discarded or recycled.

FIG. 1D shows a thermoplastic material A for decorative formwork.
It is a schematic sectional drawing which shows the state in which the solid material 14 for casting was fixed to the 18 hardened body.

The cubic molding material 14a and the triangular prism molding material 14b are removed from the cured body of the decorative frame thermoplastic material A18, and the decorative molding 10 having a cubic and a triangular prism-shaped concave portion is removed. Get. (3) Manufacture of concrete product The obtained decorative form 10 is placed in a steel form 20 for casting concrete, concrete 22 is cast by a conventional method, and steam curing is performed at about 70 ° C. for 3 hours. After the concrete was hardened, it was released from the mold. FIG. 2A is a schematic cross-sectional view showing a state in which concrete 22 is cast on a decorative mold 10 arranged in a steel mold 20.

FIG. 2B is a schematic sectional view showing the obtained concrete product 24.
Has convexes in the shape of cubes and triangular prisms on the surface,
Cube molding material 1 whose concrete surface is the prototype
It was observed that the surface condition of the molding material 4b of 4a and the triangular prism was accurately reproduced, and it was possible to manufacture a concrete product 24 having an excellent appearance.

Further, the concrete 22 was cleanly removed from the surface of the thermoplastic material A18 constituting the decorative mold 10, and no concrete 22 remained on the surface of the decorative mold 10.

Accordingly, the decorative formwork 10 can be disposed as it is in the steel formwork 20 for concrete placement and used repeatedly. (Example 2) (4) Reproduction of the decorative formwork The decorative formwork obtained by the production method of Example 1 was heated and melted at 170 ° C, and the oil-like thermoplastic material A for the decorative formwork was formed again. , And contaminants were removed by precipitation.

The same as Example 1 except that the oil-like thermoplastic material A for decorative form was used and a cylindrical solid material for forming was arranged in the form for producing the decorative form. To produce a decorative formwork.

Further, a concrete product was manufactured in the same manner as in Example 1. The obtained concrete product was observed to have a columnar convex part formed on the surface, and the surface accurately reproduces the original cylindrical solid molding material, which was a prototype. Could be manufactured.

After that, concrete has been cleanly removed from the surface of the thermoplastic material A constituting the decorative formwork.
No concrete remained on the decorative formwork surface and no deterioration of the formwork was observed. (Example 3) (1) Preparation of thermoplastic material B for decorative frame Polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, as raw materials Block copolymer (high molecular weight organic material) of ethylene and 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. 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) Production of decorative formwork The thermoplastic material B for decorative formwork was heated and melted at 170 ° C, and a decorative formwork was produced in the same manner as in Example 1. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1 using this decorative formwork.

In the obtained concrete product, cubic and triangular prism-shaped projections are formed on the surface, and it is observed that the surface accurately reproduces the original pattern, so that a concrete product having excellent appearance can be manufactured. Was.

The thermoplastic material B constituting the decorative mold is
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork. Even if this makeup form is used more than 30 times,
No degradation was observed.

Example 4 (1) Preparation of Thermoplastic Material C for Decorative Formwork As a raw material, a block copolymer containing polyethylene, which is a high-molecular organic material, at both ends and containing ethylene-butylene in the center ( Polymer 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 designated as thermoplastic material C for decorative formwork. 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) Production of decorative formwork The thermoplastic material C for decorative formwork was heated and melted at 170 ° C, and a decorative formwork was produced in the same manner as in Example 1. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1 using this decorative formwork.

In the obtained concrete product, cubic and triangular prism-shaped projections are formed on the surface, and it is observed that the surface accurately reproduces the original pattern, so that a concrete product with excellent appearance can be manufactured. Was.

Further, the thermoplastic material C constituting the decorative mold is
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork. Even if this makeup form is used more than 30 times,
No degradation was observed.

[0080]

As described above, according to the method for manufacturing a decorative mold frame of the present invention, a desired uneven pattern on the surface, particularly, an uneven pattern obtained by arbitrarily selecting a transfer depth of a transferred material. A decorative form for manufacturing the formed concrete product can be easily obtained, and the decorative form has an excellent effect of being reusable and recyclable.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view showing a method for manufacturing a decorative mold of Example 1, wherein FIG. 1 (A) shows a state in which a solid material for molding is arranged in a mold for manufacturing a decorative mold; (B) shows a state in which an irregularity depth adjusting material is further disposed, (C) shows a state in which a thermoplastic material for a decorative form has been melted and injected therein, and (D) shows a state in which the thermoplastic material for a decorative form has been injected. The state where the solid material for molding is fixed to the cured body of the thermoplastic material A is shown.

FIG. 2 is a schematic cross-sectional view showing a method for manufacturing a concrete product. FIG. 2 (A) shows a state in which the decorative formwork of Example 1 is placed in a steel formwork for casting concrete, and concrete is cast. (B) shows the obtained concrete product.

[Explanation of symbols]

Reference Signs List 10 decorative formwork 12 formwork for the manufacture of decorative formwork 14 solid material for molding 16 clay (material for controlling uneven depth) 18 thermoplastic material for decorative formwork 20 steel formwork for concrete placement (concrete placement) Formwork) 22 concrete

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Shusuke Harada 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Institute (72) Inventor Kikuo Tachibana Minami-Taishoku-ku, Osaka-shi, Osaka 7-1-55 Enkajima Central Research Institute of Sumitomo Osaka Cement Co., Ltd. (72) Inventor Hiroaki Suzuki 7-1-55 Minamienkajima Taisho-ku, Osaka City, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Institute (56) References JP-A-1-249302 (JP, A) JP-A-3-205103 (JP, A) JP-A-5-147013 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B7 / 16 B28B 1/14

Claims (3)

(57) [Claims] The present invention relates to a method for manufacturing a decorative formwork for concrete molding which forms an uneven pattern on the surface of concrete, comprising: (1) placing a solid material for forming at a predetermined position in a formwork for manufacturing a decorative formwork; (2) arranging the unevenness depth adjusting material to a predetermined position in the mold for manufacturing a decorative mold; and (3) placing the material in the mold for manufacturing a decorative mold. as a main component a polymer organic material and a low molecular material, the main of the polymer organic material
Volume fraction in the component is configured using the polymer blend material is 30% or less, and, the polymeric organic material is sintered
Easy to form hard block such as crystal structure or aggregate structure
And a soft block such as an amorphous structure
The decorative mold for thermoplastic material having a three-dimensional continuous network skeleton structure are combined Chi heated and melted by a step of injecting to a predetermined position, (4) after said decorative mold for thermoplastic material has cured Removing the unevenness-depth-adjusting material and the solid-state material for molding, and a method of manufacturing a decorative mold for concrete molding. 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 molding method according to claim 1, wherein a low molecular weight material of less than 5,000 is 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. Of manufacturing decorative formwork. 3. The polymer organic material comprises: (1) polybutadiene and butadiene-styrene random copolymer;
Polyester obtained by hydrogenating a block copolymer with a polymer
Tylene and ethylene / butylene-styrene random copolymerization
(2) block copolymer of polybutadiene and polystyrene
Body or polybutadiene or ethylene-butadiene
Block copolymerization of random copolymer and polystyrene
Polyethylene / butylene and police obtained by hydrogenating the body
Block copolymers of styrene, on one or both ends of the (3) ethylene / butylene copolymer
Block copolymer crystalline ethylene are linked, (4) an ethylene - propylene rubber, of which in particular polyethylene
Tylene and ethylene / butylene-styrene random copolymerization
2. A block copolymer selected from the group consisting of clay and water, wherein the material is at least one selected from the group consisting of a block copolymer and a body.
A method for producing a decorative formwork for concrete molding according to the above.