JP6605193B2 - Concrete block and manufacturing method thereof - Google Patents

Description

  The present invention relates to a concrete block to which, for example, artificial turf using pile yarn is attached and a method for manufacturing the same.

  Conventionally, various methods for applying concrete blocks have been proposed. For example, in Patent Document 1, artificial turf is prepared in which a pile yarn is entangled in a fabric formed by knitting warp and weft, and the prepared artificial lawn is hardened before the concrete is hardened. A technology in which artificial turf is in close contact with the surface of a concrete molded product by placing the turf fabric directly on the surface of the concrete, and the concrete enters the gaps between the unevenness of the fabric and the warp and weft threads and hardens. It is disclosed. Thereby, the concrete molded product to which the artificial turf adhered firmly can be obtained.

JP 7-251409 A

  However, in the case of the above-described conventional concrete molded product, it is difficult to control the amount of concrete entering the gaps in the artificial turf fabric, and the fabric may fall below the concrete more than necessary. is there. In that case, there arises a problem that the pile yarn protruding from the surface of the concrete does not have a desired height. For example, when it is necessary to cut a concrete molded product at the time of installation or the like, the artificial grass is not provided on the cut surface, so that the concrete is exposed. For this reason, there is a problem that the installation location is restricted.

  This invention is made | formed in view of this situation, and provides the concrete block which can solve the subject mentioned above, and its manufacturing method by adhering artificial grass with respect to the manufactured concrete molded article. For the purpose.

In order to solve the above-described problem, a method for producing a concrete block according to one aspect of the present invention includes a first lamination step of laminating a mortar layer before curing on a surface of a water-permeable concrete block main body, and the mortar layer. A second laminating step of laminating a base fabric on which pile yarn is tufted on the surface, and a portion of the mortar layer is allowed to penetrate into the base fabric and ooze out to the surface side of the base fabric, by curing the mortar present inside and surface side and back side of the base fabric, possess a fixation step of fixing the said base fabric and said concrete block body, in said first laminating step, said concrete block body After a plurality of mortar layer formation preventing members having a height larger than the thickness of the mortar layer before curing are disposed on the surface of the mortar layer, the mortar layer before curing is laminated. Therefore, part of the surface of the Concrete block body so that exposed without being covered with mortar, laminating the mortar layer.

  The said aspect WHEREIN: It is preferable that the said base fabric is comprised with the nonwoven fabric.

  According to the present invention, it is possible to accurately control the height of pile yarn protruding from the surface of concrete.

Sectional drawing which shows the structure of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view which shows the structure of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 1 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention. The partial expanded sectional view for demonstrating the main processes in the manufacturing method of the concrete block which concerns on Embodiment 2 of this invention.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
1 is a cross-sectional view showing a configuration of a concrete block according to Embodiment 1 of the present invention. As shown in FIG. 1, the concrete block 1 includes a rectangular parallelepiped concrete block main body 10 and an artificial turf 2 laminated on the surface of the concrete block main body 10. The artificial turf 2 includes a plate-like base fabric, which will be described later, and a plurality of pile yarns 20, 20,... And an adhesive layer 21 for fixing to the concrete block body 10.

  FIG. 2 is a partially enlarged cross-sectional view showing the configuration of the concrete block according to Embodiment 1 of the present invention. As shown in FIG. 2, the adhesive layer 21 has a base fabric 211 on which pile yarns 20, 20,... Are tufted, and mortar layers 212 and 212 laminated on the front and back surfaces, respectively. In the manufacturing process of the concrete block 1, the mortar layers 212 and 212 are configured such that after the mortar is supplied onto the concrete block main body 10, the base cloth 211 is placed thereon and the mortar penetrates into the base cloth 211. Then, the mortar is formed by curing. Details of this manufacturing process will be described later.

  The base fabric 211 is composed of a non-woven fabric, and is manufactured, for example, by a needle punch manufacturing method. That is, for example, a base fabric 211 is manufactured by forming a web by a known method using, for example, polyester fibers, and repeatedly piercing the web with a needle to entangle the fibers in the web. In the case of the present embodiment, it is preferable that the thickness of the base fabric 211 is considerable in order to enhance the fixing performance of the adhesive layer 21. Therefore, it is preferable to manufacture the base fabric 211 by bonding fibers after using a bulky web or by laminating a considerable number of webs. In addition to polyester, it is possible to use fibers of various materials such as vinylon, and fibers of different materials may be combined.

  For the purpose of increasing the strength of the base fabric 211, for example, a base fabric made of polyester is prepared, and the base fabric 211 can be formed by punching cotton with a needle on the base fabric. It is.

  The pile yarn 20 is composed of polypropylene multifilaments colored green or the like to imitate the lawn. In the example illustrated in FIG. 2, the pile of the pile yarn 20 is a cut pile, but the loop pile may be left as it is. Further, the pile yarn 20 may be constituted by a filament yarn of another material such as nylon instead of the polypropylene multifilament yarn.

  As described above, in the concrete block 1 according to the present embodiment, the base fabric 211 and the pile yarn 20 are fixed to the concrete block body 10 by hardening the mortar in the manufacturing process. The details of the manufacturing method will be described below with reference to the drawings.

  3A to 3D are partially enlarged cross-sectional views for explaining main processes in the concrete block manufacturing method of the present embodiment. Prior to the following manufacturing process, it is assumed that a tufting process in which the pile yarn 20 is passed through the back surface of the base fabric 211 to perform tufting is performed.

  As shown in FIG. 3A, a rectangular parallelepiped concrete block body 10 is prepared and placed on a predetermined plane. In addition, although the rectangular parallelepiped shape is mentioned here as an example, the concrete block main body 10 may have any shape as long as it has a region to which artificial grass is attached.

  Next, as shown in FIG. 3B, a predetermined amount of mortar is supplied onto the surface of the concrete block body 10 to form a mortar layer 212. After that, as shown in FIG. 3C, before the mortar is cured, the artificial turf obtained by the tufting process is placed so that the back surface of the base fabric 211 faces down. Thereby, the back stitch part of pile yarn 20, 20, ... will be in the state which faces the concrete block main body 10 side.

  Since the base fabric 211 is composed of a nonwoven fabric, a large number of voids are provided therein. Therefore, the mortar in the mortar layer 212 penetrates into the base cloth 211 and oozes out to the surface side of the base cloth 211. As a result, as shown in FIG. 3D, mortar layers 212 and 212 are formed on both sides of the front and back surfaces of the base fabric 211, respectively. Thereafter, the mortar layers 212 and 212 are cured, whereby the base fabric 211 and the pile yarns 20, 20,... Are fixed to the concrete block body 10. Thereby, the concrete block to which the artificial turf is attached with sufficient strength can be obtained.

  In the above step, the mortar penetrates not only into the base fabric 211 but also into the pile yarn 20. When the mortar in the pile yarn 20 and the mortar filled in the gap in the base fabric 211 are cured, the base fabric 211 and the pile yarn 20 are fixed. As a result, the pulling strength can be increased and the entire pile yarn 20 can be effectively prevented from coming off. Further, the mortar in the pile yarn 20 is cured, so that the filament yarn constituting the pile yarn 20 can be prevented from falling off.

  As described above, in the case of the present embodiment, when the base cloth 211 is affixed to the concrete block body 10, the concrete block body 10 is already manufactured, so that the base cloth 211 is in the concrete block body 10. There is no such thing as falling down. Therefore, the height of the pile yarn protruding from the surface of the concrete block body 10 can be easily controlled by adjusting the amount of mortar supplied thereafter.

  As described above, after the concrete block main body is manufactured and the artificial turf is fixed to the surface of the main body, when the concrete is placed as in the prior art, the artificial turf is fixed and manufactured integrally. On the other hand, it is possible to take measures such as attaching artificial turf to the necessary surface of the concrete block body at the construction site. Moreover, after cutting a concrete block main body into a desired size, it becomes possible to affix artificial grass to the cut surface.

  In the case of this embodiment, when the artificial turf is deteriorated by use, the artificial turf can be peeled off by peeling off the mortar layer 212. In that case, the concrete block 1 can also be newly obtained by sticking a new artificial turf to the concrete block body 10 in the same manner as described above. In addition, since the adhesion strength of the artificial turf to the concrete block main body 10 can be controlled by changing the blending of the mortar, if the artificial turf is assumed to be peeled off in the future as described above, the fixation It is also possible to adjust the composition of the mortar so as to lower the strength relatively.

(Embodiment 2)
The concrete block according to Embodiment 2 has water permeability. Hereinafter, the manufacturing method will be described.

  4A to 4F are partially enlarged cross-sectional views for explaining main processes in the concrete block manufacturing method of the present embodiment. As in the case of the first embodiment, it is assumed that a tufting step of tufting a pile yarn through the back surface of the base fabric is performed prior to the following manufacturing process.

  As shown in FIG. 4A, a rectangular parallelepiped concrete block body 30 is prepared and placed on a predetermined plane. The concrete block body 30 is made of porous concrete and has water permeability. The point that the shape does not have to be a rectangular parallelepiped is the same as in the first embodiment.

  Next, as shown in FIG. 4B, a plurality of rod-shaped members 51, 51, having a height of about twice or more compared to the thickness of the base fabric 411 at appropriate locations on the surface of the concrete block body 30. ... are arranged. Thereafter, as shown in FIG. 4C, a predetermined amount of mortar is supplied onto the surface of the concrete block body 30 to form a mortar layer 412. At this time, the thickness of the mortar layer 412 is made not to exceed the height of the rod-shaped members 51, 51,.

  Next, before the mortar of the mortar layer 412 is cured, as shown in FIG. 4D, the artificial turf obtained by the tufting process is placed so that the back surface of the base cloth 411 faces down. Thereby, it will be in the state where the back stitch part of pile yarn 20, 20, ... faces the concrete block main body 30 side. In the base cloth 411, holes corresponding to the positions where the rod-shaped members 51, 51,... Are disposed are formed with holes penetrating between the front and back surfaces, and the rod-shaped members 51, 51,. The base cloth 411 is placed on the mortar layer 412 so as to be inserted.

  As in Embodiment 1, the mortar in the mortar layer 412 penetrates into the base fabric 411 and oozes out to the surface side of the base fabric 411. As a result, as shown in FIG. 4E, mortar layers 412 and 412 are formed on both sides of the front and back surfaces of the base fabric 411, respectively. Here, the region where the rod-like members 51, 51,... Are arranged is not filled with mortar. Therefore, after the mortar is cured, the rod-shaped members 51, 51,... Are extracted, and as shown in FIG. 4F, the laminate composed of the two mortar layers 412 and 412 and the base cloth 411 interposed therebetween. Holes 52, 52,... Penetrating between the front and back of the structure are formed.

  Also in the case of the present embodiment, as in the case of the first embodiment, the base fabric 411 and the pile yarns 20, 20,... 20 can be prevented, and the filament yarn constituting the pile yarn 20 can be prevented from falling off. In the case of the present embodiment, the concrete block main body 30 has water permeability, and the holes are formed in the base cloth 411 and the mortar layers 412 and 412. Is supplied, the water flows downward through the holes of the base cloth 412 and the mortar layers 412 and 412 and further flows through the concrete block body 30 and is discharged downward. Therefore, even when a concrete block is installed outdoors exposed to rain, advantages such as the need for special drainage treatment can be obtained.

  In the present embodiment, as described above, the holes are formed at appropriate plural positions of the base cloth 412, but these holes 50, 50,... May not be formed. Even in that case, since a large number of voids are provided in the base fabric 412 which is a non-woven fabric, it can be pierced through the rod-shaped members 51, 51,... And can be permeable to water. . Therefore, a water-permeable concrete block can be obtained as in the case of the present embodiment.

  In the present embodiment, rod-shaped members 51, 51,... Are used, but members having other shapes may be used. Moreover, you may make it form a hole in a mortar layer by supplying mortar only to a part rather than the whole surface of a base fabric.

(Other embodiments)
In each embodiment mentioned above, although the base fabric is comprised with the nonwoven fabric, you may be comprised with other fabrics, such as a textile fabric and a knitted fabric. However, it is desirable that the cloth can efficiently infiltrate mortar.

  The concrete block and the manufacturing method thereof according to the present invention are useful, for example, as a concrete block to which artificial grass laid on a walking path or the like is attached, a manufacturing method thereof, and the like.

DESCRIPTION OF SYMBOLS 1 Concrete block 2 Artificial turf 10,30 Concrete block main body 20 Pile thread 21 Adhesive layer 51 Bar-shaped member 52 Hole part 211,411 Base cloth 212,412 Mortar layer

Claims (2)

A first lamination step of laminating a mortar layer before curing on the surface of a concrete block body having water permeability ;
A second laminating step of laminating a base fabric tufted with pile yarn on the surface of the mortar layer;
After allowing a part of the mortar layer to penetrate into the base fabric and ooze out on the surface side of the base fabric, by curing the mortar present in the base fabric and on the front and back sides, possess a fixation step of fixing the said base fabric and concrete block body,
In the first laminating step, a plurality of mortar layer formation preventing members having a height larger than the thickness of the mortar layer before curing are disposed on the surface of the concrete block main body, and then the mortar layer before curing is laminated. By this , the manufacturing method of the concrete block which laminates | stacks the said mortar layer so that a part of surface of the said concrete block main body may be exposed without being covered with mortar . The base fabric is made of non-woven fabric,
The manufacturing method of the concrete block of Claim 1.

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