JP5865020B2 - Concrete panel, manufacturing equipment and manufacturing method for the concrete panel - Google Patents

Description

  The present invention relates to a concrete panel, a manufacturing facility and a manufacturing method for the concrete panel. More specifically, the present invention relates to a concrete panel with a mesh body that requires strength and a manufacturing technique thereof.

  Among concrete panels, those that have a load on the top surface and those that are supported by support legs and installed in a lifted state require high strength in the panel itself, so rebars and other nets are placed inside. ing.

There exists patent document 1 as a conventional mesh body containing concrete panel.
In this concrete panel, a net is disposed in the middle of the thickness direction in the cross section of the panel. Most conventional products have such a structure.

  However, when the mesh body is located in the middle of the thickness direction, when a bending external force is applied, the mesh body is hardly pulled or compressed, so that it does not contribute much to the improvement of the bending strength. For this reason, it did not contribute so much to improving the strength of concrete products that are subjected to bending stress due to heavy loads or concrete products that are supported in a lifted state and are susceptible to bending stress due to loads.

On the other hand, there is a conventional technique disclosed in Patent Document 1 as a method for producing a netted concrete panel.
In this prior art, a cylinder 124 is attached to a side wall 125 of a molding mold 119, and a mesh body holding scale 123 is attached to the tip of a piston rod 126 via a coupling plate 126. When the cylinder 124 is expanded and contracted, the mesh body holding scale 123 can be projected and retracted in the mold 119.
When the net body 116 is placed on the net body holding scale 123 and the concrete is poured in a state where the net body holding scale 123 is placed in the mold 119, a concrete product with a net body is completed.

However, according to this manufacturing method, the mesh body 116 will fly off or be displaced due to impacts when pouring concrete, pressure from the pressing mold, vibration during compaction, etc. There was a problem that the concrete would become defective if the concrete hardened while being displaced.
Moreover, since the production apparatus requires the cylinder 124, there is a problem that the production equipment becomes expensive.
In addition, there is a problem that the productivity is inferior because there is a trouble that the net holding scale 123 needs to be adjusted and the net length of the net holding scale 123 must be adjusted in accordance with the net 116.

Japanese Patent Laid-Open No. 10-193329

  In view of the above circumstances, an object of the present invention is to provide a concrete panel that is resistant to bending external force. It is another object of the present invention to provide a highly productive manufacturing facility and manufacturing method.

The concrete panel according to the first aspect of the invention is a parallelepiped concrete panel , wherein a net is disposed in the immediate inner side of the back surface of the panel body, and the concrete constituting the panel body is super kneaded concrete. It is characterized by.
The concrete panel of the second invention is characterized in that, in the first invention, a surface layer is formed on the surface of the panel body .
Concrete panels of the third invention, was first or the second aspect, wherein the network element is fabricated reticulated material having a rust resistance and tensile strength properties.
The concrete panel manufacturing equipment according to the fourth aspect of the present invention includes a molding die for molding a concrete panel, a netting machine for placing a net on a bottom plate located at the bottom of the molding die, and a pre-hardening concrete inside the molding die. A pre-hardening concrete feeder for pouring in, a compacting mechanism for compacting the pre-hardening concrete poured into the mold, and a die-cutting mechanism for raising and lowering the bottom plate of the mold between the molding position and the die-cutting position It is characterized by becoming.
According to a fifth aspect of the present invention, there is provided a method for producing a concrete panel comprising: a net body placing step for placing a net body at a bottom of a mold for molding a product panel; a concrete charging step for pouring pre-hardening concrete into the mold; It is characterized by comprising a compacting step for compacting the pre-concrete and a die-cutting step for extracting the product from the mold after compacting the concrete.

According to the first invention, since there is a mesh body immediately inside the back surface of the concrete panel, when the bending action is exerted by a load from the upper surface side, the mesh body resists the tensile stress generated on the back surface side, so the bending strength A strong concrete panel. For this reason, it is highly effective in improving the strength of a concrete panel on which a heavy load acts or a load acts in a floating state. Moreover, since it can demold without waiting for hardening by using super hard kneaded concrete with little water | moisture content, production efficiency can be improved.
According to the 2nd invention, a high designability can be given by giving a pattern and a beautiful finish to a surface layer .
According to the third invention, even if the net body is partly exposed from the panel body, it has rust prevention, so it will not rust, and since it has tensile strength, the bending strength of the concrete panel can be increased. .
According to the fourth aspect of the present invention, a net charging machine for placing a net on the bottom plate of a mold, a pre-hardening concrete feeder for supplying the pre-hardening concrete into the mold, and a compacting mechanism for compacting the pre-hardening concrete. Since the die-cutting mechanism for lowering the bottom plate of the mold is provided, the concrete panel can be manufactured efficiently.
According to the fifth aspect of the present invention, when the pre-hardening concrete is supplied by placing the net body on the bottom plate of the molding die with the netting machine, and the pre-hardening concrete is compacted, the bottom plate of the molding die can be lowered and die-cut. Therefore, the concrete panel can be manufactured with high efficiency without waiting for the hardening of the concrete before hardening.

(A) is the surface side perspective view of the concrete panel which concerns on 1st Embodiment of this invention, (B) is a back surface side perspective view of the panel. (A) is sectional drawing of the concrete panel which concerns on 1st Embodiment, (B) is sectional drawing of the concrete panel which concerns on 2nd Embodiment. It is explanatory drawing of the manufacturing apparatus which concerns on this invention. It is explanatory drawing of the manufacturing method which concerns on this invention. It is explanatory drawing of the usage example of the concrete panel of this invention. It is explanatory drawing of the conventional manufacturing method.

Next, an embodiment of the present invention will be described with reference to the drawings.
(Concrete panel)
Concrete panels A and B of the present invention are parallelepiped concrete panels,
A net body is disposed on the inner side of the back surface of the panel body. Although various embodiments exist in the present invention, the concrete panel A of the first embodiment and the concrete panel B of the second embodiment will be described below.

The concrete panel A of 1st Embodiment is comprised by the main body panel 1 and the net | network body 3, as shown to FIG. 1 and FIG. 2 (A).
As shown in the rear perspective view of FIG. 1B, the mesh body 3 partially protrudes from the surface of the mesh body 3, but the other part is embedded in the main body panel 1. In addition, the net body 3 in which most or all of the net body 3 is embedded in the main body panel 1 is also included in the present invention. The embedded position is immediately inside the back surface of the main body panel.

  In addition to the structure of the first embodiment, the concrete panel B of the second embodiment has a surface layer 2 formed on the upper surface of the main body panel 1 as shown in FIG.

The panel body 1 is basically a member serving as a base layer for maintaining strength. At the same time, various functions can be provided.
The surface layer 2 is basically a member that imparts design properties by applying a pattern or performing various surface treatments, but can also improve functionality at the same time.

  The surface treatment of the upper surface of the base layer or the upper surface of the surface layer can be applied by any method. For example, patterning with a stamping die, polishing, washing out, blasting and the like can be exemplified.

The net body 3 is a member that imparts bending strength, and is a net-like member made of a member having tensile strength. Moreover, since a part of net | network body 3 is exposed to an outer surface, it is necessary to use a rust prevention material.
Therefore, specifically, stainless steel, steel bars with zinc plating or zinc aluminum alloy plating, steel bars coated with synthetic resin such as epoxy resin, carbon fiber, aramid fiber, glass fiber and other reinforcing FRP, etc. Material is used.

  A net made of the above material is suitable for the net 3 of the present invention. There are no particular restrictions on the shape of the mesh, and examples of the shape having vertical and horizontal bars as shown in FIG. The overall shape is a quadrangle matched to the panel to be manufactured, or its outer dimension is slightly smaller than the inner dimension of the mold 10. The reason for making it small is that a margin is required when it is put into the mold 10. A resin cap may be placed at the end of each vertical and horizontal bar. This cap also serves as a spacer for positioning the net 10 within the mold 10.

  Although various concrete can be used for the material of the panel main body 1, typically super hard kneaded concrete is used. Super hard-mixed concrete is a concrete with a small proportion of water. Generally, the proportion of sand: cement: water is 500: 100: 50 by weight, but it is about 500: 100: 30. Concrete with a low proportion of water.

The characteristics using super-kneaded concrete are as follows.
(1) Position of net body Super hard-mixed concrete does not have high fluidity as it is, but the net body 3 is located at the bottom of the mold 10, so it hits the pre-hardening concrete that is flowing due to pouring. However, it does not jump or cause misalignment.
(2) Advantages in the molding method Since the cemented carbide concrete is inferior in water tightness, it has no rust prevention effect. In addition, when functions such as water retention and water permeability are added, the movement of moisture occurs inside the main body panel 1, so that a rust preventive material must be used for the net body 3. However, on the other hand, it is not necessary to put in the concrete of the panel main body, and it can be arranged in a state of being partially exposed on the back surface of the panel main body 1, so that a structure strong against bending strength can be obtained.

As described above, various functions can be imparted to the panel body 1. Examples of the functions that can be imparted include water retention, water permeability, and lightness.
In order to provide water retention, means such as mixing highly water-absorbing sand, gravel, or the like, or making the gap between the sand and gravel so fine that water accumulates can be used.
In order to provide water permeability, means such as a size that allows water to easily pass through sand or gravel gaps can be used.
In order to give lightness, means, such as mixing the material of specific gravity (0.8-1.5) smaller than the specific gravity (2.5-2.7) of the sand and gravel used normally, can be used.
When the weight is reduced, it is possible to reduce the load on the structure to be constructed or to improve the workability.

Examples of the function imparted to the surface layer include heat shielding properties, water retention properties, and water permeability.
In order to provide heat insulation, a method of mixing heat insulation pigments and / or heat insulation aggregates (for example, sand, gravel, etc.) that reflect infrared rays with cement, or coating with heat insulation on the surface It is possible to use means such as a method for
In order to provide water retention, means such as mixing highly water-absorbing sand, gravel, or the like, or making the gap between the sand and gravel so fine that water accumulates can be used.
In order to provide water permeability, means such as a size that allows water to easily pass through sand or gravel gaps can be used.
When water retention, water permeability, light weight, etc. are imparted to the panel body, the bending strength generally decreases, so that the advantage of putting the net body 3 as in the present invention is increased.

  In addition, when normal concrete is used instead of super hard concrete for the panel body concrete, it is suitable for use in a place where a large bending strength is required. Places that require such high bending strength include roads on which large vehicles pass, large product panels (usually 300 mm square, 600 mm square), and floating floors that are supported by floating legs. A panel etc. can be illustrated.

(production equipment)
As shown in FIG. 3, the manufacturing facility of the present invention includes a molding die 10 for molding a concrete panel, a netting machine 20 for placing the netting body 3 on a bottom plate 11 located at the bottom of the molding die 10, and a molding die. Before hardening concrete is poured into the interior of the machine, a compacting mechanism for compacting the unhardened concrete poured into the mold, and the bottom plate of the mold is moved up and down between the molding position and the mold release position. It consists of a die cutting mechanism. As the pre-hardening concrete feeder, the compacting mechanism, and the die-cutting mechanism, known mechanisms can be used without particular limitation.

In FIG. 3, 10 is a mold. The mold 10 is provided in a horizontal place such as a floor in a factory. The size and shape of the mold 10 are adapted to the product (concrete panel) to be manufactured.
A bottom plate 11 is provided at the bottom of the mold 10, and this bottom plate 10 is placed between a molding position where the bottom of the molding mold 10 is closed by a mold cutting mechanism (not shown) and a mold cutting position retracted downward therefrom. Go up and down.
For the die cutting mechanism, a hydraulic cylinder, a pantograph mechanism or other known lifting means is used.

On the upper surface of the mold 10, a supply material box 12 of a pre-hardening concrete feeder for feeding the pre-hardened concrete is arranged or moved to be positioned on the upper surface of the mold 10.
Further, the pressing die 13 of the compaction mechanism is arranged on the upper surface of the mold 10 or moved so as to be positioned on the upper surface of the mold 10.

Reference numeral 20 in FIG. 3A denotes a netting machine, which includes a hand 21 that holds the netting body 3 and a mechanism that causes the hand 21 to expand and contract and turn. Reference numeral S denotes a stocker of the net 3 and reference numeral D denotes a supply station.
The net charging machine 20 has a function of holding the net 3 on the supply station D, moving it to the upper surface of the mold 10, and arranging it on the bottom of the mold 10. If the net 3 is made of metal, a hand 21 using a magnet or the like can be used.
The structure of the net charging machine 20, the stocker S, and the supply station D is a known structure and can be arbitrarily configured.

(Production method)
The manufacturing method of the present invention is realized by the process shown in FIG.
(1) Before molding starts The bottom of the mold 10 is closed by the bottom plate 11 at the molding position.

(2) Arrangement of Net Body 3 The net body 3 is installed on the bottom plate 11 in the mold 10.
In this case, in order to raise the net 3 slightly above the bottom plate 11, a spacer 15 having a height of about 3 to 5 mm may be inserted. As described above, when the net body 3 is slightly raised, the pre-hardening concrete is well wound in the post-process 3 and the net body 3 can be firmly held.

(3) Pouring the pre-hardening concrete Pour the pre-hardening concrete C from the feed box 12. The pre-hardening concrete poured at this time is typically super-hard concrete. Therefore, although there is no fluidity as it is, the super-kneaded concrete begins to fall and flow as the feed box 12 moves. Since the net body 3 is located at the bottom of the mold 10, even when it hits the flowing pre-hardening concrete, it does not jump or cause a positional shift.
When the pouring of the pre-hardening concrete is finished, the supply box 12 is retracted.

(4) Compacting When a predetermined amount of the pre-hardening concrete C is poured, the pressing die 13 is lowered and pressurized. Thereby, the pattern formed on the stamping die 13 is transferred to the concrete surface before curing.
Moreover, the shaping | molding die 10 is vibrated and the concrete C before hardening is compacted. Super hard kneaded concrete flows when vibration is applied and fills the mold 10 to every corner, so that it can be molded into a desired shape.

(5) Die removal Immediately after compaction of the pre-hardening concrete, the die is removed.
That is, it does not wait for the hardening of the concrete before hardening. In addition, super hard kneaded concrete is used so that it can be immediately punched.
Die cutting is performed by lowering the bottom plate 11. The pressing die 13 is also retracted upward.
(6) Conveyance to the next process After the die cutting is completed, the concrete panel immediately after molding is placed on the bottom plate 11 and conveyed to the next process, that is, a curing process for hardening.

In the production method of the present invention, vibration is applied to the compaction of the concrete before hardening and the mold is released before hardening. In the present specification, such a feature is referred to as a vibration immediate demolding system.
According to this vibration type immediate demolding method, demolding can be performed without waiting for the curing of the pre-curing concrete, so that the manufacturing time is shortened, and the concrete panel immediately after molding is transported and the next molding is performed in the mold 10. Since it can be started, it can be mass-produced with one mold.
For this reason, production efficiency is greatly improved.

An application product of the concrete panel of the present invention will be described.
FIG. 5 shows the concrete panels A and B of the present invention applied to a floating floor panel. The floating floor panel has a water retention function, and is installed on the roof slab of the building in a state where the panel is floated via a support column. In this water retention floating floor panel, when water is sprinkled, the surface temperature of the water retention floating floor panel is reduced by the water spray effect, and the heat transmitted to the roof slab can be suppressed by the heat insulation effect of the panel lower air layer. As a result, power consumption due to cooling in the top floor room can be suppressed.

  The above floating floor panel is installed in a floating state in the air, and a bending external force is applied to the panel by the load when a person walks on it or an object moves. Since the tensile force acts by the net body, the bending strength is high, and the floating floor panel is prevented from being damaged.

  In addition to the above, the concrete panel of the present invention can be used for applications such as a pavement surface layer where a vehicle travels and bending stress is generated by the vehicle weight, but these are examples and disclosed. It can be used for various purposes.

1 Panel body 2 Surface layer 3 Net body 10 Mold

Claims (5)

A parallelepiped concrete panel,
A net is arranged on the inner side of the back of the panel body ,
A concrete panel, wherein the concrete constituting the panel body is super hard kneaded concrete . The concrete panel according to claim 1, wherein a surface layer is formed on a surface of the panel main body . Concrete panel according to claim 1 or 2, wherein said network element is fabricated reticulated material having a rust resistance and tensile strength properties. A mold for molding a concrete panel;
A net feeding machine for placing a net on a bottom plate located at the bottom of the mold;
A pre-hardening concrete feeder for pouring the pre-hardening concrete into the mold,
A compaction mechanism for compacting the pre-hardening concrete poured into the mold,
A concrete panel manufacturing facility comprising: a die cutting mechanism for raising and lowering a bottom plate of the molding die between a molding position and a die cutting position. A net arrangement process for placing a net on the bottom of a mold for forming a product panel;
Concrete injection process in which pre-hardening concrete is poured into the mold,
A compaction process for compacting the poured pre-hardening concrete;
A method for producing a concrete panel, comprising: a die-cutting step of drawing a product from a mold after the concrete is compacted.

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