JPH0134765B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a cement product or a gypsum product provided with anti-slip, decorative or reinforcing three-dimensional patterns on both sides.

First Conventional Example This type of manufacturing method involves providing a desired three-dimensional molding pattern on both opposing sides of the mold, and opening an upper end of the mold between both sides of the mold with the three-dimensional molding pattern. By pouring cement mortar, concrete, or plaster, etc., a cement or plaster product with a three-dimensional pattern on both sides is manufactured.

However, in this manufacturing method, when the height of the formwork is high and the distance between both sides of the formwork with three-dimensional patterns for molding is short, that is, when manufacturing thin-walled products, it is difficult to Due to poor clogging of cement mortar, etc., it is not possible to obtain a desired three-dimensional pattern that matches the three-dimensional pattern for molding of the formwork.

In addition, when manufacturing thin-walled products using cement mortar, etc. or concrete mixed with various types of reinforcing fibers, when pouring the cement mortar, etc. or concrete into the formwork, the reinforcing fibers or aggregate in it may be removed. Separation does not result in a product with uniformly dispersed reinforcing fibers or aggregates.

As a result, it is not possible to manufacture thin-walled products with three-dimensional patterns on both sides.

Second Conventional Example Japanese Unexamined Patent Publication No. 52-10313 discloses a method of manufacturing a concrete product in which a three-dimensional pattern is provided on one side instead of on both sides.

In this manufacturing method, as shown in Figure 2 of the publication, an air pressure regulator is attached to the bottom of a box-shaped formwork, and a mold with an uneven pattern is attached to the top surface of the air pressure regulator with pores. Place the plate, create negative pressure inside the air pressure regulator, hold the template on the top of the air pressure regulator, attach a vibrator to the bottom outside of the formwork,
Concrete slurry is poured onto the template inside the formwork, the air pressure regulator is slid into the upper part of the formwork, and the bottom surface of the air pressure regulator with the pores is inserted into the formwork through the porous sheet. It comes into contact with the top surface of the concrete slurry.

Then, the upper air pressure regulator, which is slid into the upper part of the formwork, is pressed downward to pressurize the concrete slurry between the porous sheet on the bottom of the upper air pressure regulator and the template on the top of the lower air pressure regulator. Shape.
In addition, the vibrator is operated to vibrate the concrete molded body within the formwork, causing water in the concrete molded body to float up and ooze out onto the upper surface of the concrete molded body. Further, the inside of the upper air pressure regulator is made negative pressure, and the floating water on the upper surface of the concrete molded body is sucked and discharged by the upper air pressure regulator.

While the concrete molded body has not yet dried and hardened, the upper air pressure regulator is raised while the concrete molded body is sucked by the upper air pressure regulator, and the concrete molded body is raised together with the upper air pressure regulator. The concrete product is removed from the formwork and a concrete product with a pattern formed on the lower surface using a template is obtained.

However, with this manufacturing method, although it is possible to manufacture a concrete product with a pattern formed on one side, it is not possible to manufacture a concrete product with a pattern formed on both sides.

In this manufacturing method, in order to manufacture concrete products with patterns formed on both sides, a template was suctioned and held on the top surface of the lower air pressure regulator, and a template was placed on the bottom surface of the upper air pressure regulator. If it is sucked and held, the concrete slurry between the template held by the lower air pressure regulator and the template held by the upper air pressure regulator cannot be dehydrated, and the concrete slurry is pressurized. Cannot be molded.

In the end, it is not possible to manufacture concrete products with three-dimensional patterns on both sides.

An object of the present invention is to solve the conventional problems as described above.

Next, examples of the present invention will be described.

The formwork used in the manufacturing method of this example is a shallow rectangular box-shaped lower vacuum formwork 1, a rectangular frame-shaped side formwork 7, and a lower vacuum formwork 1 overturned, as shown in part in the drawing. It consists of a top vacuum formwork 11 like this. The lower vacuum formwork 1 consists of a shallow box body 2 with an open upper surface, which has flanges 4 around the upper ends of the outer surfaces of the side plates around the four sides, and a top plate in which a large number of small holes 6 are penetrated at equal intervals on the upper surfaces of the flanges 4 around the four sides. The top plate 5 with a large number of small holes 6 is fixed to the open upper surface of the box body 2 by polymerizing the four peripheral parts of the box body 2 through a sheet material and fixing them with screws. 3, although not shown, a discharge path connected to a vacuum pump is connected to an open path with an on-off valve that is open to the atmosphere. The side formwork 7 has flanges 9 and 10 provided around the upper and lower ends of the outer surfaces of the four frame pieces of a rectangular frame body 8 with open upper and lower surfaces, respectively. The upper vacuum formwork 11 is a bottom plate in which flanges 14 are provided around the lower ends of the outer surfaces of side plates around the four circumferences of a shallow box body 12 whose bottom surface is open, and a large number of small holes 16 are penetrated at equal intervals through the lower surfaces of the flanges 14 around the four circumferences. The bottom plate 15 with a large number of small holes 16 is fixed to the open lower surface of the box 12 by polymerizing the four peripheral parts of the box 15 with a sealant and fixing them with screws, thereby creating a decompression chamber formed inside the box 12. 13
Although not shown, a discharge passage connected to a vacuum pump is connected to the exhaust passage.

In the manufacturing method of this example, first, a wire mesh in which rectangular meshes 18 are arranged at equal intervals is placed on the upper surface of the lower vacuum formwork, which has a large number of small holes 6 that communicate with the decompression chamber 3, and is placed in the side formwork 7. Place the template 17 cut to the dimensions shown in the figure below, spread a cotton cloth 19 moistened with water over the entire upper surface of the lower vacuum formwork 1 on which the template 17 is placed, and place the side formwork 7 on top of it.
The lower flanges 10 of the four peripheries of the side formwork are closely overlapped with the four periphery parts of the top plate 5 of the lower vacuum formwork via the four periphery parts of the cloth 19,
and the lower flange 10 of the side formwork are connected with a coupling tool such as a bolt and nut, and the cement mortar 20 mixed with glass fiber is driven or blown into the side formwork 7 almost completely, and the decompression chamber of the lower vacuum formwork is filled. While closing the on-off valve of the open path (not shown) connected to 3,
A vacuum pump in a discharge path (not shown) connected to the decompression chamber 3 is operated to reduce the pressure in the decompression chamber 3. Then, the cloth 19 on which the cement mortar 20 is mounted sinks into each mesh hole 18 of the template 17 due to the weight of the cement mortar and the suction force due to the reduced pressure in the decompression chamber 3, and expands, causing each sunken surface of the cloth 19 to collapse. The center part of the cloth 19 is in contact with the upper surface of the lower vacuum formwork 1, and the cloth 19, which has been wetted with water and has increased its flexibility, is bent into a three-dimensional pattern according to the shape of the hole 18 in the template, and the cement polymerized on the cloth 19 is bent. The lower surface of the mortar 20 is formed into a three-dimensional patterned surface that matches the three-dimensional patterned curved surface of the cloth. On the other hand, side formwork 7
Water in the cement mortar 20 placed in the cement mortar 20 and air sealed in the cement mortar during pouring or blowing flow into the vacuum chamber 3 through the small holes 6 through the cloth 19 and the holes 18 in the template. The water and air flowing into the mold 3 are discharged through the discharge channel and the vacuum pump, and the cement mortar 20 in the side formwork 7 is compacted by reducing its water/cement ratio. cement mortar 20
Before the vacuum pump is sufficiently compacted, the operation of the vacuum pump is stopped, the opening/closing valve of the open passage is opened, and the decompression chamber 3 of the lower vacuum formwork is opened. Next, a cotton cloth 21 moistened with water is laid on the entire upper surface of the cement mortar 20 in the side formwork 7 and the upper surface of the upper flange 9 of the side formwork, and covered with the cloth 21 in the same way as the lower cloth 19. Place the lower template 1 on the top surface of the cement mortar 20.
Similarly to 7, a template 22 made by cutting a wire mesh having rectangular meshes 23 arranged at equal intervals to the inner dimensions of the side formwork 7 is placed, and the upper vacuum formwork 11 is placed on top of it.
The bottom plate 15 of the upper vacuum formwork is superimposed on the template 22 on the cloth 21, and the upper flanges 9 on the four circumferences of the side formwork are
Then, the four peripheral parts of the bottom plate 15 of the upper vacuum formwork with the rubber packing 24 are closely overlapped through the four peripheral parts of the cloth 21, and the upper flange 9 of the side formwork and the flange 14 of the upper vacuum formwork are connected like bolts and nuts. A vacuum pump in a discharge path (not shown) connected to the decompression chamber 13 of the upper vacuum formwork is operated to reduce the pressure. Then, due to the suction force caused by the reduced pressure in the reduced pressure chamber 13, the cement mortar 20 in the side formwork 7, together with the cloth 21 on its upper surface, is moved to the bottom plate 22 on the lower surface of the upper vacuum formwork 11.
The fabric 21 stuck to the template 22 sinks into the hole 23 of the template and stretches, and the center of each depressed surface of the fabric 21 comes into contact with the lower surface of the upper vacuum formwork 11, making the fabric 21 flexible. The tall cloth 21 is curved into a three-dimensional pattern according to the shape of the hole 23 of the template, and the upper surface of the cement mortar 20 superposed on the cloth 21 is formed into a three-dimensional pattern surface that matches the three-dimensional pattern curved surface of the cloth. . on the other hand,
When the pressure in the vacuum chamber 3 of the lower vacuum formwork is reduced, the water and air in the cement mortar 20 that remains without being discharged flows through the upper cloth 21, the holes 23 in the template, the small holes 16, the vacuum chamber 13, and the discharge path. The cement mortar 20 in the side formwork 7 is discharged through a vacuum pump and is sufficiently compacted and hardened to form a mortar molded product in the form of a thin plate with a three-dimensional pattern formed on both upper and lower surfaces. Thereafter, while the mortar molded product is still adsorbed to the lower surface of the upper vacuum formwork 11, the side formwork 7 is transferred to the lower vacuum formwork 1.
Remove the exposed lower template 17, peel off the cloth 19 stuck to the lower surface of the mortar molded product, and remove the side formwork 7 adsorbed to the upper vacuum formwork 11.
The mortar molded product inside is placed on a curing plate (not shown), the upper vacuum form 11 is removed from the side form 7 by stopping the operation of its vacuum pump, the exposed upper form plate 22 is removed, and the mortar is removed. Peel off the cloth 21 stuck to the top surface of the molded product, pull out the side formwork 7 that fits around the four circumferential sides of the mortar molded product, and cure the demolded mortar molded product so that the three-dimensional pattern appears on both the top and bottom sides. The company manufactures glass fiber-reinforced mortar products in the form of thin plate shapes.

This mortar product has a desired three-dimensional pattern on the upper and lower surfaces that corresponds to the curved surfaces of the cloths 21 and 19 stuck to the lower surface of the upper vacuum formwork 11 and the upper surface of the lower vacuum formwork 1 via templates 22 and 17. The three-dimensional patterns are anti-slip or decorative, and the glass fibers are evenly distributed inside, making it heavy and strong.

Although the manufacturing method of this example is as shown above, other examples may be constructed by modifying this as illustrated below.

(1) Instead of the wire mesh templates 17 and 22, use a flat template with a hole of a desired shape formed through it.

That is, the template may be any template as long as it has a through hole of a desired shape.

(2) Instead of using the templates 17 and 22, a lower vacuum formwork whose upper surface is formed with the desired uneven surface for molding or an upper vacuum formwork whose lower surface is formed with the desired uneven surface for molding is used.

(3) Instead of the cement mortar 20 mixed with class fibers, cement mortar mixed with various fibers other than class fibers such as steel fibers, carbon fibers, and polymer fibers, cement mortar without fibers mixed, or various types of cement mortar mixed with class fibers, etc. Fiber-reinforced mortar products other than glass fiber, simple mortar products, or fiber-reinforced concrete products using concrete mixed with fibers or unreinforced or reinforced concrete;
Or manufacture unreinforced or reinforced concrete products, that is, various cement products.

In addition, various gypsum products are manufactured using gypsum or gypsum mixed with various types of fibers.

(4) Instead of the integrally formed side formwork 7, a divisible side formwork is used to facilitate the removal of the side formwork from the molded product.

In the present invention, cement mortar etc. placed in the side formwork is sucked into a curved surface for forming a three-dimensional pattern formed on the lower side of the side formwork to form a three-dimensional pattern on the lower surface of the cement mortar etc. Next, the cement mortar, etc. in the side formwork is sucked into the curved surface for forming a three-dimensional pattern formed on the top side of the side formwork, and a three-dimensional pattern is formed on the top surface of the cement mortar, etc., so the second
Unlike conventional examples, cement products and plaster products with three-dimensional patterns on both sides can be obtained.

Further, unlike the first conventional example, a thin-walled product having a three-dimensional pattern on both sides and a thin-walled product in which reinforcing fibers or aggregates are uniformly dispersed can be obtained.

In addition, since the present invention uses a vacuum forming method, unlike the first conventional example and the second conventional example of pressure forming, the cement mortar etc. are sufficiently compacted and a heavy three-dimensional pattern with high strength is formed. You can obtain cement products etc. In addition, cement mortar etc. harden quickly, demolding is quick, the rate of use of formwork is high, and cement products etc. with three-dimensional patterns on both sides can be manufactured at low cost.

Furthermore, in the present invention, the side formwork is placed on top of the lower vacuum formwork, and the flange provided around the lower end of the side formwork is overlapped and bonded to the flange provided around the upper end of the lower vacuum formwork. In addition, the upper vacuum formwork is placed on top of the side formwork, and the flange provided around the upper end of the side formwork is joined to the flange provided around the lower end of the upper vacuum formwork by overlapping. It is easy to seal between the lower vacuum formwork and the side formwork, and between the side formwork and the upper vacuum formwork.
Air leakage from between each formwork can be sufficiently prevented. Therefore, it is possible to sufficiently reduce the pressure in the decompression chamber of the lower vacuum formwork and the decompression chamber of the upper vacuum formwork.
It is possible to obtain cement products with three-dimensional patterns that have extremely high strength.

[Brief explanation of drawings]

The drawing is a cutaway perspective view showing an intermediate step in the manufacturing method according to the embodiment of the present invention. 1: Lower vacuum formwork, 3: Decompression chamber, 4: Flange,
6: Small hole, 7: Side formwork, 9, 10: Flange, 1
1: Upper vacuum formwork, 13: Decompression chamber, 14: Flange, 16: Small hole, 17: Template, 18: Hole, 19:
Cloth, 20: Cement mortar, 21: Cloth, 2
2: template, 23: hole.

Claims (1)

[Scope of Claims] 1. A side formwork with open top and bottom surfaces is placed on top of a lower vacuum formwork which has a large number of small holes in its top face communicating with a decompression chamber. The flange installed around the lower end of the side formwork is polymerized and joined to the surrounding flange, and cement mortar, concrete, or plaster is poured into the side formwork covered with filter cloth, and the pressure in the lower vacuum formwork is reduced. The pressure in the chamber was reduced, and the filter cloth on which cement mortar, etc. was placed, was sunk into the through hole of the template interposed between the filter cloth and the upper surface of the lower vacuum formwork, or the molding surface was formed into an uneven surface. The lower vacuum formwork is curved in a three-dimensional pattern along the upper surface, and the lower surface of the cement mortar etc. is formed into a three-dimensional patterned surface that matches the three-dimensional patterned curved surface of the filter cloth. A filter cloth was laid on top of the cement mortar, etc., and an upper vacuum formwork with many small holes on the bottom side communicating with the decompression chamber was placed on top of the side formwork, and the upper vacuum formwork was placed around the upper end of the side formwork. A flange provided around the lower end of the upper vacuum formwork is polymerized and joined to the flange, the pressure is reduced in the decompression chamber of the upper vacuum formwork, and the filter cloth on top of the cement mortar, etc. is connected to the filter cloth and the upper vacuum formwork. The upper surface of cement mortar, etc. is curved in a three-dimensional pattern by sinking into the through hole of the template interposed between the lower surfaces, or along the lower surface of the upper vacuum form formed on the uneven surface for molding. A three-dimensional patterned surface that matches the three-dimensional patterned curved surface of the filter cloth above is formed, and cement mortar, etc. is compacted and hardened to form a molded product. A method for manufacturing cement and plaster products with three-dimensional patterns on both sides, which is characterized by separating from the formwork and peeling off the filter cloth from the molded product.