JP3248370B2 - Formwork with uneven pattern and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a formwork having a concavo-convex pattern used for forming a concavo-convex pattern on a concrete wall surface and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as a mold for forming an uneven pattern on a concrete wall surface, a resin mold made of urethane resin or the like having an uneven pattern on a surface on which concrete is cast is known.

When the uneven pattern formed on the concrete wall is large, a resin mold 2 as shown in FIG.
1 is used. However, when the distance A between the peaks and the valleys of the uneven surface exceeds 100 mm, the amount of resin used increases, so that the resin mold 21 is greatly deformed due to thermal expansion, and is suitable for concrete wall surfaces. However, there is a problem that it is not possible to form an uneven pattern.

[0004]

For this purpose, a metal mold 22 as shown in FIG. 9 is prepared separately from the resin mold 21, and the resin mold 21 and the metal mold 22 are shown in FIG. As shown in FIG. 10, the resin mold 21 is prevented from being deformed by thermal expansion by bonding and integrating. However, in this method, the resin mold 21 and the metal mold 22 must be separately manufactured, and a complicated dimensional adjustment work such as cutting or overlaying is required for integration. In addition, there has been a problem that adhesion failure between the resin mold 21 and the metal mold 22 frequently occurs particularly at the end B. Further, there is a problem that the amount of resin used for the mold is large and the number of steps is large, resulting in high cost.

To solve these problems, a resin surface layer 23 having an uneven surface as shown in FIG.
And a reinforcing resin layer 24 containing glass fibers inside the surface layer 23, and a foamed resin layer 25 inside the reinforcing resin layer 24, and a punching metal 26 embedded in the foamed resin layer 25. 27 have been proposed (Japanese Patent Application No. 6
-255540).

[0006] The mold can be manufactured as follows. That is, first, a design mold 28 as shown in FIG. 12 is prepared. The design mold 28 is configured by integrating an uneven surface portion 29 on which an uneven pattern is formed and a frame portion 30. Next, as shown in FIG. 13, a resin liquid (curing time: 3 minutes) of a urethane resin for forming the surface layer 23 is coated on the uneven surface portion 29 of the design mold 28 by spraying, and before the resin liquid of the urethane resin is cured. To
On this resin liquid, a resin liquid of a urethane resin (curing time: 3 minutes) for forming the reinforcing resin layer 24 containing 30% by weight of glass fiber having an average fiber length of 1.8 mm is coated by spraying. Then, the two resin liquids are simultaneously cured by drying to form the surface layer 23 and the reinforcing resin layer 24 at the same time. At this time, the surface layer 23 and the reinforcing resin layer 24 are firmly bonded and integrated. Next, as shown in FIG. 14, an end face portion 32 of a punched metal 31 made of steel is placed on an end portion of the reinforcing resin layer 24.
A resin liquid (hardening time: 20 minutes) of a hard foamable urethane resin is injected into a space formed by the resin layer 8 and the reinforcing resin layer 24 and hardened. Thereby, the mold shown in FIG. 11 can be manufactured.

However, even in the case where the foamed resin layer and the punching metal are provided, the problem that the weight is still heavy and the problem that the cost is high still remain. In addition, in order to form the foamed resin layer, it is necessary to perform a process of injecting the resin liquid in several steps and joining and bonding the respective layers, and there is a problem that these operations are troublesome. Furthermore, since the dimensional adjustment work cannot be performed at the time of manufacturing, there is a problem that the frame body for housing the frame must be post-processed and then assembled.
There is a problem that it is difficult to remove and a dedicated formwork is required.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and is capable of forming a good uneven pattern on a concrete wall surface, and is lightweight, inexpensive, and easy to manufacture. Its purpose is to provide a method.

[0009]

In order to achieve the above object, the present invention provides a resin surface layer formed in a concavo-convex pattern, and a resin containing glass fibers laminated below the surface layer. Pattern transfer with reinforcing back layer formed by
Frame having a bottom portion and a peripheral wall portion for forming an integral layer
Formwork with uneven pattern attached to the top opening of the
Thus, the integrated layer is a predetermined layer below the reinforcing back surface layer.
By the support member provided at the position, the holding frame
The in partially uneven textured mold that is支受 a first aspect, a step of forming a surface layer by coating a resin on a design mold having a concavo-convex pattern surface for transfer, the surface layer A step of coating a resin containing glass fiber on the top to integrally form a reinforcing back layer, a step of removing the integrally formed layer from the design mold, and turning the removed integrally formed layer upside down with an uneven pattern. With the surface layer facing upward, a support member for supporting the integrally formed layer is provided at a predetermined position below the reinforcing back layer , and the bottom and the peripheral wall are disposed.
Take the above-mentioned integrated layer into the upper opening of the holding frame provided.
Paste that step in the manufacturing method of the uneven textured mold including a second aspect.

[0010]

In other words, the mold frame with the concavo-convex pattern of the present invention is different from the conventional mold frame with a concavo-convex pattern in that a foaming resin and a punching metal are not provided inside the reinforcing back layer, but the reinforcing mold is provided under the reinforcing back layer. Surface layer and reinforcement by supporting member provided on the side
The integrally formed layer consisting of the back surface layer is partially
I am going to receive it. Therefore, it is possible to reduce the weight and material cost of the entire formwork ,
Simply adjusting the supporting base member, but may be dimensioned during attachment to the holding frame body, since the post-processed need to assemble by eliminating the frame to fit it, set to the frame It becomes easy to attach . In addition, it removes easy, and becomes not only frame is also required. Furthermore , since the reinforcing back layer made of a resin containing glass fiber is provided inside the surface layer, the action of the glass fiber can prevent and reinforce deformation due to thermal expansion of the uneven surface. . Only
Also , due to the anchor effect of the glass fiber contained in the reinforcing back layer, a mold frame with a concavo-convex pattern in which the reinforcing back layer is firmly integrated with the surface layer can be obtained without performing special bonding treatment. On the other hand, according to the method of the present invention, it is possible to easily produce the above-described formwork with an uneven pattern.

Next, the present invention will be described in detail.

The formwork with a concavo-convex pattern of the present invention includes a surface layer made of resin, a reinforcing back surface layer formed of a resin containing glass fiber, and a support member.

The above-mentioned surface layer is obtained by coating a resin liquid on a previously prepared uneven surface of the design type by spraying, brushing or the like, followed by drying. As the material of the resin forming the surface layer, a hard resin is preferable from the viewpoint of the transferability of the uneven pattern to the concrete wall surface. The urethane resin is preferably about 10 seconds for the time when the resin liquid does not adhere. The thickness of the surface layer is usually set to 1 mm or more, but it is not preferable to make the thickness too large from the viewpoint of weight reduction.

The reinforcing back surface layer is obtained by coating a resin solution containing glass fibers on the surface layer by spraying, brushing or the like, followed by drying. The material of the resin forming the reinforcing back surface layer is preferably the same as the resin forming the surface layer from the viewpoint of adhesiveness, and the urethane resin having a curing time of 30 minutes or less is preferable from the viewpoint of productivity.

Further, the formation of the reinforcing backside layer is preferably performed by coating a resin liquid for forming the reinforcing backside layer before the resin liquid for forming the surface layer is cured, and curing and integrating the resin solution simultaneously with the surface layer. Preferably, from the viewpoint of adhesiveness, a resin liquid of a urethane resin for forming a surface layer is coated on the uneven surface of the design type, and contains glass fibers for forming a reinforcing back layer before the resin liquid is cured. It is more preferable that the resin layer is coated with a resin liquid of a urethane resin, or is coated by spraying a resin liquid of a glass fiber and a urethane resin, whereby the surface layer and the reinforcing back layer are simultaneously cured and integrated. The glass fiber having a fiber length of 1.0 mm or more is blended at about 2 to 30%. In the formation of the reinforcing back layer, the resin liquid for forming the surface layer may be cured, and then the resin liquid for forming the reinforcing back layer may be coated and cured.

As the support member, various members such as resin, such as urethane resin, iron, and wooden plate, block, and bar are used.

Next, an embodiment will be described.

[0018]

FIG. 1 shows an embodiment of a mold frame having a concavo-convex pattern according to the present invention. In this embodiment, a predetermined portion of the integrally formed layer 3 formed by integrally forming the surface layer 1 and the back surface layer 2 for reinforcement is supported by the reinforcing member 4 from below in the formwork. At the same time, the outer peripheral portion of the integrally formed layer 3 is placed on a receiving base 5 a provided around the upper end opening of the holding frame 5. In the figure, reference numeral 6 denotes an adhesive layer.

Such a mold frame with a concavo-convex pattern can be manufactured as follows. That is, first, a design mold 10 as shown in FIG. 2 is prepared. The design die 10 has an uneven pattern surface 10a for transfer formed on the surface thereof. Next, as shown in FIG. 3, a resin liquid of urethane resin for forming the surface layer 1 (touch drying time: 10 seconds) is coated on the uneven surface 10a of the design mold 10 by spraying. This coating amount is 1mm thick
The surface layer 1 having a thickness of 1 mm or more is formed by uniformly coating several times. Next, as shown in FIG. 4, before the resin liquid of the urethane resin for forming the surface layer 1 is cured, the average fiber length is 1.0 mm.
The glass fiber 11 cut by the roving cutter 13 and the resin liquid 12 of the urethane resin (curing time within 30 minutes) sprayed from the spray gun 14 are put on the resin liquid of the urethane resin for forming the surface layer 1 above. The mixture is sprayed (at this time, glass fiber is blended in an amount of 2 to 30% by weight), and the glass fiber 11 is coated so as to be pressed down by the spray pressure. By this coating, the reinforcing back surface layer 2 having a thickness of 1 mm or more is formed. Then, by drying, the resin solution of the urethane resin for forming the surface layer 1 and the resin solution of the urethane resin for forming the back surface layer 2 for reinforcement are hardened to form the surface layer 1 and the back surface layer 2 for reinforcement. At this time, the surface layer 1 and the reinforcing back surface layer 2 are firmly bonded and integrated to form the integrally formed layer 3. The thickness of the integrally formed layer 3 was about 2 mm, and the hardness was Hs80 (JIS A). In the figure, reference numeral 15 denotes a roving of glass fiber.

Next, the integrally formed layer 3 is removed from the design mold 10 (see FIG. 5). On the other hand, a block-shaped reinforcing member 4 is disposed at a predetermined position on the bottom of the holding frame 5 having the receiving base 5a formed at its upper end opening, and an adhesive is applied to the upper portion of the reinforcing member 4. . Then, the integrated layer 3 is turned over and the surface layer 1 is turned upward.
The integrally formed layer 3 is placed on the receiving portion 5 a of the holding frame 5. At this time, the reinforcing member 4 is bonded and fixed to the back surface of the reinforcing back layer 2 of the integrally formed layer 3 by the adhesive layer 6. In this way, a formwork with a concavo-convex pattern as shown in FIG. 1 can be obtained. The above-mentioned formwork with uneven pattern is for transferring uneven pattern
Is formed integrally with the holding frame by the reinforcing member 4.
It is configured to be partially supported in the body 5.

When a concrete product is manufactured by using the thus-formed mold with a concavo-convex pattern, as shown in FIG. 6, the concavo-convex pattern surface of the surface layer 1 is made into contact with the concrete surface. Pour the material 16,
After curing and curing, peeling is performed. In addition, 1
7 is a side frame.

The formwork with the concavo-convex pattern was light in weight, low in cost, and showed no deformation due to thermal expansion. Furthermore, a mold frame with a concavo-convex pattern firmly integrated was obtained without performing an adhesive treatment, and its production was easy. Moreover,
Assembly and removal to the reinforcing member 4 and the holding frame 5 were easy.

FIG. 7 shows another embodiment of the present invention.
In this embodiment, a reinforcing plate 18 having an I-shaped cross section is used as a support member. Other parts are the same as those of the above-described embodiment, and the same parts are denoted by the same reference numerals.

In the above embodiment, the glass fiber 11 cut by the roving cutter 13 and the resin liquid 12 of urethane resin sprayed from the spray gun 14 are mixed and blown to form the reinforcing back layer 2. However, the present invention is not limited to this, and a resin liquid of a urethane resin containing 30% by weight of glass fiber having an average fiber length of 1.8 mm is sprayed onto the resin liquid of the urethane resin for forming the surface layer 1. It may be coated on top.

[0025]

As described above, according to the formwork with a concavo-convex pattern of the present invention, the reinforcing backing layer is only partially supported from below by the supporting member. Withstand concrete casting
While maintaining sufficient strength, the overall weight and material cost can be reduced . And a support member
Simply adjusting the, are possible size adjustment during attachment to the holding frame body, since the post-processed need to assemble by eliminating the frame to fit this, assembly of the frame body volume
Becomes easier. In addition, it removes easy, and becomes not only frame is also required. Furthermore , since the reinforcing back layer made of resin containing glass fiber is provided inside the surface layer, the deformation and thermal deformation of the surface of the concavo-convex pattern due to the thermal action of the glass fiber can be prevented and reinforced. Moreover , due to the anchor effect of the glass fiber contained in the reinforcing back layer,
A mold frame with a concavo-convex pattern in which the back surface layer for reinforcement is firmly integrated with the surface layer without performing a special adhesive treatment is obtained. on the other hand,
According to the method of the present invention, it is possible to easily produce the above-described formwork having an uneven pattern.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a formwork with a concavo-convex pattern of the present invention.

FIG. 2 is a cross-sectional view of a design mold used for manufacturing the mold frame with a concavo-convex pattern.

FIG. 3 is an explanatory view showing a manufacturing process of the mold frame with a concavo-convex pattern.

FIG. 4 is an explanatory view showing a manufacturing process of the formwork with a concavo-convex pattern.

FIG. 5 is an explanatory view showing a manufacturing process of the mold frame with a concavo-convex pattern.

FIG. 6 is an explanatory diagram of a method for manufacturing a concrete product using the above-described formwork with a concavo-convex pattern.

FIG. 7 is an explanatory view showing another embodiment of the present invention.

FIG. 8 is a cross-sectional view of a mold of a conventional mold with a concavo-convex pattern.

FIG. 9 is a cross-sectional view of a metal mold used for a conventional mold with a concavo-convex pattern.

FIG. 10 is a cross-sectional view of a conventional formwork with a concavo-convex pattern.

FIG. 11 is an explanatory diagram showing another conventional example.

FIG. 12 is an explanatory view of a design type used for manufacturing the other conventional example.

FIG. 13 is an explanatory view showing a manufacturing process of another conventional example.

FIG. 14 is an explanatory view showing a manufacturing process of another conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Surface layer 2 Reinforcement back layer 3 Integrally-formed layer 4 Reinforcement member 5 Holding frame 10 Design type

Claims (3)

(57) [Claims] An uneven pattern transfer comprising a resin surface layer formed in an uneven pattern and a reinforcing back layer formed of a resin containing glass fiber laminated below the surface layer.
Frame having a bottom portion and a peripheral wall portion for forming an integral layer
Formwork with uneven pattern attached to the top opening of the
Thus, the integrated layer is a predetermined layer below the reinforcing back surface layer.
By the support member provided at the position, the holding frame
In partially uneven pattern with a mold which is characterized that you have been支受. 2. The mold frame with a concavo-convex pattern according to claim 1, wherein an end of the integral layer on the surface layer side is formed in a plane. 3. A step of forming a surface layer by coating a resin on a design mold having an irregular pattern surface for transfer, and a reinforcing back surface by coating a resin containing glass fiber on the surface layer. A step of integrally forming a layer, a step of removing the integrated layer from the design mold, and turning the removed integrated layer upside down with the surface layer having a concavo-convex pattern facing upward, and the lower side of the reinforcing back layer below In place
To, and disposed支受member支受 the integrally formed layer, the bottom
The above-mentioned integrated type
Method for producing uneven textured mold, which comprises a step of Ru attaching the stratification.