JPH03177374A - Concrete secondary product with decorative surface and its production - Google Patents

Abstract

PURPOSE:To obtain a product resistant to abrasion without any color shading, discoloring and fading by applying a granular material in a specific mode to the front of a concrete press formed product body and removing the excess granular material other than that applied in the form of a thin skin in the front part. CONSTITUTION:A concrete material 5 is charged to a frame mold 4 and pressurized with a press plate 1 to press form a product body 7. A decorative powdery granular material 3 is then charged to the frame mold 4 so as to coat the front part (7a) of the product body 7 and the powdery granular material 3 at the minimum is applied to a paste in the front part (7a). A face pallet 6 is filled onto the granular material layer and the frame mold 4 is turned over in the aforementioned state of the face pallet 6. The product body 7 is then demolded from the frame mold 4. After hardening the product body 7, the face pallet 6 is removed to remove the excess decorative powdery granular material 3 other than that applied in the form of a thin skin to the front part (7a).

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a concrete secondary product such as a building block in which the front side of the product body is formed as a decorative surface, and a method for manufacturing the secondary product by press molding. It is something.

[Prior art] The conventional stacking blow block is a smooth block with a smooth finish, and the bland and monotonous concrete surface is exposed at the front, making it difficult to adapt to the natural environment. It is. In order to solve this monotony, the surface layer of the stacked blocks is made of decorative mortar, but it is inherently undesirable to attach mortar of a different type to the surface of the concrete body.

The JIS Standards Establishment Committee is also moving toward eliminating the use of mortar, but even if mortar is removed, there are no products that can replace it, so the current situation is that they have no choice but to acquiesce.

Disadvantages of this surface layer mortar include: It is difficult to develop strength: It is weak against abrasion: It is easy to cause a cracking phenomenon: It is uneven in color; It is easy to change color; It causes shrinkage cracks after curing; It is easy to peel off from the concrete of the main body; Bulges appear at the edges: Bubbles appear on the mortar surface: The addition of a mortar plant and plating line complicates the equipment and requires one worker.

As an alternative to this smooth block using decorative mortar, we molded a base block made by joining two block products facing each other with machi stone cut from natural rough stone and joined together, as shown in Fig. 23. As shown, after curing and hardening, the base block is split at the center to form a concavo-convex pattern on the front faces 7a, 7a of the two blocks 7.7; a split block with a mold surface for forming the concave-convex pattern; After the product body is press-formed, a surface pallet filled with mortar is placed over the product body and pressurized. As shown in FIG.
Rough surface block of the surface pallet method with 6 formed: A press plate provided with a mold surface for forming an uneven pattern is used, and when the product body is press-formed with the press plate, the uneven pattern is directly formed on the concrete surface by the mold surface. A press plate type rough surface block has been proposed.

However, Amahatoma Chiseki is the best in terms of compatibility with the surrounding environment, but it has disadvantages such as: 1 stone mason disappears and 1 ha; mass production is not possible; raw stone is scarce due to development regulations; and it is expensive. There is.

Split blocks are currently the closest to natural stone and are used in large quantities, but they require a large investment in machinery and equipment; it is desirable that the irregularities appear almost evenly on both sides of the product when the base block is split, but in reality The unevenness often appears unevenly, and if one side breaks into a large convex shape, the other side becomes a large concave shape with low commercial value. Although the difference becomes smaller and the incidence of defective products decreases, the disadvantage is that the surface becomes clay-like and does not have the feel of stone.

The surface pallet type rough surface block does not require expensive mechanical equipment, but it is unavoidable that mortar gets stuck to the surface of the pattern forming mold, and the surface pallet and pallet blocks must be removed from the block product and reused the next day. However, it requires a great deal of effort and effort to remove and clean the hardened mortar; it has the disadvantage of requiring the use of mortar, which is currently the least preferred type of mortar.

The press plate method of rough surface blowing does not require expensive machinery and equipment and simplifies the cleaning of the surface pallets. Because the pattern is only transferred, the appearance of the front part of the product is still bland and cannot resemble natural stone; do not spray a large amount of water on the surface to be pressed beforehand. If the chamfered portions 7b on the four sides contact the surface pallet 6 as shown in FIG.
The central part 7d of the front part 7a containing plenty of water is the second
As shown in Figure 8, it collapses and creates a missing part 7e,
Cracks occur and cause freezing and thawing: As shown in FIG. As shown in FIG. 30, the chamfered portion 7b of the circumferential surface becomes dirty, and a rice cracker-shaped smooth surface 7f appears on the convex portion of the uneven pattern that contacted the surface pallet: After inversion,
Applying press vibration with an elevator results in a smooth block with a pockmarked surface, which loses its commercial value due to air bubbles and junk (a phenomenon in which coarse aggregate is exposed on the surface): Since reverse vibration cannot be applied, the product cannot be demolded. The problem is that sometimes the core gets caught, causing cracks or damage to the product.

In any case, there are too many contradictions when trying to make the surrounding chamfers neat.

[Problems to be Solved by the Invention] Accordingly, an object of the present invention is to have the advantages of the press board method, while also being able to decorate realistically to look like natural stone, and to avoid color unevenness, discoloration, and
To provide a secondary concrete product in which a decorative surface that does not fade and is resistant to abrasion is formed on the front part.

Furthermore, the object of the present invention is to prevent the appearance of collapsed parts on the decorative surface of the front part, the appearance of pockmarked surfaces, and the prevention of 7F damage to the decorative surface. To provide a manufacturing method capable of accurately manufacturing a secondary concrete product with a decorative surface at a low cost and having sufficiently high commercial value without producing a mochi-like smooth surface part or causing the peripheral chamfered part to sag or get dirty. That's true.

[Means for Solving the Problems] Hereinafter, using the reference numerals in the attached drawings, it will be explained that the concrete secondary product with a decorative surface of the present invention has a thin layer of decorative powder and granular material 3 on the front part 7a of the product body 7. It is solidified into a shape.

In addition, in the method for manufacturing a secondary concrete product with a decorative surface of the present invention, concrete material 5 is put into the formwork 4, and the concrete material 5 is pressurized by the press plate 1 to press-form the product body 7, and then, The cosmetic powder and granule material 3 is put into the formwork 4 so as to cover the front part 7a of the product body 7,
After attaching a minimum amount of the granular material 3 to the paste on the front part 7a and inverting the formwork 4 with the surface pallet 6 loaded on the granular material layer, the product body 7 is removed from the formwork 4. After removing the mold and curing the product body 7, the surface pallet 6 is removed and the front part 7a is removed.
The excess cosmetic powder and granule material 3 other than those adhered to the skin in the form of a thin skin is removed.

The cosmetic powder and granules referred to in the present invention include not only natural fine aggregate such as sand, which has a different color and material from concrete, but also raw stones such as ``a cast stone'', serpentine stone, and ironstone, etc., which are pulverized and crushed. Also includes artificial fine aggregate. As the material for this artificial fine aggregate, not only a single raw stone but also a mixture of multiple raw stones can be used. Moreover, a mixture of natural fine aggregate and artificial fine aggregate can also be used.

[Embodiment] In the embodiment shown in FIGS. 1 to 4, concrete material 5 is charged into the formwork 4 from the movable hopper 9 that has been advanced to the L-side frontage of the formwork 4. Concrete material 5 is densely filled into formwork 4 by applying appropriate vibrations using a vibrator 11 at the same time or after the injection.

After moving the movable hopper 9 to the retracted position, the hydraulically driven press plate 1 is moved downward to remove the concrete material 5.
is pressurized in the formwork 4 to press-form the product body 7, and at the same time, the mold surface part 2 forms an uneven pattern imitating the surface of natural stone on the front part 7a of the product body 7.

It is desirable to continue applying vibrations when pressurizing the press plate l, and with this pressure and vibration, a sufficient amount of paste can be applied to the press surface! It comes out in the period.

Pre-treatments that are effective for making the paste stand out well on the press surface include spraying water or a suitable liquid onto the surface of the concrete material 5 placed in the formwork 4, or spraying the concrete material with a mist. Examples include keeping the kneading in step 5 soft, but the vibration time and pressing force in step 31
You can also make the paste stand out with the knots.

After moving the press plate l upward to the retracted position, move the moving hopper 1
2 is advanced to the -E side opening of the formwork 4, the natural stone is pulverized, and a large amount of cosmetic powder and granule material 3 made of the powder is thrown from the movable hopper 12 onto the front part 7a of the product body 7.

After moving the mobile hopper 12 to the retreat position.

A suction cup 1 is attached to the tip of an arm that rotates around a horizontal axis 10.
A one-sided pallet 6 is placed on the cosmetic powder and granular material layer using a known one-sided pallet loading device 14 provided with a single-sided pallet 4a.

A well-known surface valley/torque restraint device 15 consisting of a hydraulic cylinder in which the tip of a rod 15a protrudes and retracts from the through hole 4a at the upper corner of the formwork 4 to engage and disengage from the edge of the surface pallet 6 is used. , restrains and holds the surface pallet 6 in a predetermined position.

The formwork 4 whose upper opening is closed by the surface pallet 6 is turned upside down around the Taihei rotating shaft 13, and the hydraulically driven elevator 8 is turned over. tlI, the surface pallet 6 is pressurized by the elevator 8 while applying vibration or without applying vibration.

After pressurizing the surface pallet 60, the surface pallet restraint device 15 is operated to loosen the contents of the surface pallet 6 against the formwork 4, and the side wall plate with recesses is rotated outward to remove uncured or semi-hardened material from the formwork 4. The cured product main body 7 is demolded while being placed in an elevator 8.

The product body 7 supported by the surface pallets 6-1 is transported to a curing yard, and after curing and hardening, the surface pallets 6 are removed from the product body 7 and shipped.

The cosmetic powder material 3 that adheres to the paste on the front part 7a of the product body 7 and is tightly integrated with the uneven pattern of the front part 7a by hardening of the product body 7 does not fall off from the front part 7a, but other surplus The cosmetic powder material 3 falls into the surface valley 7 and is collected and reused in the next molding process.

5 to 10 show specific examples of concrete secondary products with decorative surfaces produced by the method of the present invention.

The stacking blocks shown in FIGS. 5 and 6 have a front part 7a of a product main body 7 that is flat as a whole, use crushed granite as the cosmetic powder and granule material 3, and use four parts of the front part 7a.
The edges are not chamfered.

The stacking blow 2 shown in Figures 7 and 8 is the product body 7.
The front part 7a is formed flat as a whole, crushed granite is used as the decorative powder material 3, and chamfered slopes 7b are formed on the four sides of the front part 7a.

The stacking blocks shown in Fig. 9 and Fig. 1O are the product main body 7.
A deep uneven pattern as if cut from natural raw stone is formed on the entire front part 7a, and crushed @kagestone is used as the cosmetic powder material 3, and four sides of the front part 7a are chamfered. It is something that has not been done yet.

The stacked blocks shown in Figures 11 and 12 are.

A deep uneven pattern as if cut from natural raw stone is formed on the entire front part 7a of the product body 7, crushed granite is used as the cosmetic powder material 3, and chamfered slopes are formed on the four sides of the front part 7a. 7b is formed.

The stacked blocks shown in FIGS. 13 and 14 form an uneven pattern similar to iron flats on the entire front part 7a of the product body 7,
A crushed iron flat stone is used as the cosmetic powder material 3, and the four sides of the front part 7a are not chamfered.

The stacked blocks shown in FIGS. 15 and 16 form an uneven pattern similar to iron flats on the entire front part 7a of the product body 7,
A crushed iron flat stone is used as the cosmetic powder material 3, and chamfered slopes 7b are formed on the four sides of the front part 7a.

The stacked blocks shown in FIGS. 17 and 18 form an uneven pattern similar to Oya stone on the entire front part 7a of the product body 7,
A crushed Oya stone is used as the cosmetic powder material 3, and the four sides of the front portion 7a are not chamfered.

The stacked blocks shown in FIGS. 19 and 20 form an uneven pattern similar to Oya stone on the entire front part 7a of the product body 7,
A crushed Oya stone is used as the cosmetic powder material 3, and a chamfered stepped surface 7C is formed on the four sides of the front part 7a.

In the stacking block shown in FIG. 24, a deep uneven pattern is formed on the entire front part 7a of the product body 7, and the powder and granular material for cosmetics 3
A mixture of crushed granite, serpentine, Teppei stone, and Oya stone is used as the material.

In addition to the rough surface block with a natural stone-like uneven pattern on the surface, the present invention is applicable to the smooth block with a completely flat type as shown in Fig. 25 and the concave flat type as shown in Fig. 26. It can also be applied to face blocks, and there are no restrictions on the types of secondary concrete products.

In Example L, after the formwork 4 is reversed, the surface pallet 6 is pressurized again by the elevator 8, but the surface pallet 6 is not particularly pressurized by the machine elevator 8, and the elevator 8 is used for removing the product from the mold. It can also be used only as a receiving table.

Further, the drive mechanism for the press plate 1 and the elevator 8, and the loading and restraining mechanism for the surface pallet 6 are not limited to those shown in the drawings.The pattern forming die surface portion 2 may be integrally molded with the press plate 1, but may be formed as a separate member. Manufactured and bolted and glued to the press plate l,
It can also be fixed using magnetic adsorption.

In the above embodiment, the powder and granule material 3 for cosmetics is charged using one type of second moving hopper, but the powder and granule material 3 is placed on the surface pallet 6 in advance, and the surface pallet 6 is placed in the mold P1-4. The powder and granule material 3 can also be charged into the mold frame 4 during inversion loading, and the method of introducing the cosmetic powder and granule material 3 is not particularly limited.

In addition, the cosmetic powder and granule materials 3 are not limited to crushed natural stones, sand, and crushed stones, but can also be natural or artificial materials as long as they change the hue or surface texture of the concrete surface. It doesn't matter if it is.

[Effects of the Invention] As described above, in the concrete secondary product with a decorative surface of the present invention, the cosmetic powder and granule material 3 is consolidated in a thin skin shape on the front part 7a of the product body 7, so that the cosmetic powder and granule material 3 can be used in a small amount, and even if expensive crushed natural stone or sand is used as the cosmetic powder/granule material 3, the manufacturing cost can be kept relatively low.

Moreover, in the concrete secondary product with a decorative surface of the present invention,
The thin skin-like decorative surface is formed by solidifying the cosmetic powder material 3 made of natural sand, crushed natural stone, etc. on the front part 7a with paste from the product body 7 itself, so conventional mortar attachment is not possible. Unlike other products, there are no problems with shrinkage cracks, peeling, or falling off after curing, and it is also highly abrasion resistant and resistant to discoloration and fading, so it can be used stably over a long period of time without the risk of deteriorating its aesthetic value. I can do it.

Next, in the manufacturing method of the present invention, after pressurizing the concrete material 5 in the formwork 4 with a press plate 1, the decorative powder and granule material 3 is applied to the formwork 4 so as to cover the front part 7a of the product body 7. After the mold 4 is turned over with the pallet 6 loaded onto the powder layer j-, Since the mold has been removed from the formwork 4, if natural sand or crushed natural stone is used as the decorative granular material 3, the front part 7a of the product body 7 press-molded with the concrete material 5 will look like natural stone. The aesthetic value of the secondary concrete product increases dramatically as it is covered with a realistically decorated decorative surface.

In addition, in the manufacturing method of the present invention, the paste is absorbed and consumed by the solidification of the cosmetic powder and granule material 3, and in the entire process from inverting the mold 4 to demolding and curing the product body 7,
The decorative surface formed in a thin skin shape on the front part 7a of the product body 7 is held down and supported by the layer of excess cosmetic powder and granule material 3 located between the front part 7a and the surface pallet 6, so that the formwork 4
The product body 7 is cured without the decorative surface collapsing, pockmarked surfaces or smooth surfaces like fi-mochi occurring, and the surrounding chamfers not becoming sagging or getting dirty during the reversing operation or curing of the product body 7. When the surface pallet 6 is removed later, a decorative surface with a predetermined uneven pattern or a flat pattern is accurately formed and preserved on the front portion 7a.

Furthermore, in the manufacturing method of the present invention, when the surface pallet 6 is removed from the cured product body 7, the remaining cosmetic powder material 3 interposed between the front part 7a and the surface pallet 6 acts as a buffer layer. Even when the surface pallet 6 is hit, the decorative surface does not fall off, and a beautiful thin skin-like decorative surface without any damaged parts can be formed.

In the manufacturing method according to claim (3), when the surface pallet 6 is removed from the product body 7 and the excess cosmetic powder/granular material 3 other than that attached to the front part 7a is removed, the excess powder/granular material 3 is removed from the product body 7. Since the powder is collected and reused in the next molding process, the powder and granule material 3, which is used both as a decorative material for forming a thin skin-like decorative surface and as a shape-retaining material for maintaining the shape of the decorative surface, ends up being mostly Everything will be used without wastage, so even if expensive crushed natural stone or sand is used as the decorative powder/granule material 3, it is possible to accurately produce a secondary concrete product with a decorative surface at a relatively low manufacturing cost. can be manufactured.

In the g1 manufacturing method described in claim (0), the press plate l is provided with a surface portion 2 for forming a concavo-convex pattern, and the mold surface il!B2 is provided with a concave [!
'Since the cosmetic powder and granule material 3 is attached to the front part 7a of the product body 7 on which the J pattern is formed, a secondary product with a decorative surface that closely resembles the cut surface of natural stone and has a very rich shading can be created. It can be easily manufactured without producing a-products or with an extremely low incidence of defective products.

In the manufacturing method according to claim (5), the product body 7 is press-molded by pressurizing the concrete material with the press plate 1 while applying vibration, so that floating cracks of the paste on the front part 7a during the press-forming process are avoided. The cosmetic powder and granular material 3 is properly attached to the front surface 7a through the presence of the paste, and the thin skin-like decorative surface is more closely bonded to the product body 7, and the concrete secondary There is no possibility that the decorative surface will fall off due to vibrational impact during use of the product.

[Brief explanation of drawings]

FIG. 1 is a schematic vertical cross-sectional view of a press-shaped apparatus for stack blowing used in carrying out the method of the present invention, and shows a state in which concrete material is poured into a formwork. FIG. 2 is a longitudinal sectional view showing a state in which a surface pallet is loaded after press forming of concrete material. FIG. 3 is a longitudinal cross-sectional view of the surface pallet being pressurized by an elevator after the formwork has been inverted. FIG. 4 is a longitudinal cross-sectional view when the surface barrette 2 is removed after the product body has hardened. FIG. 5 is a right side view of the front end portion of a stacking block manufactured by the method of the present invention, and FIG. 6 is a front view of the stacking blow 2. Fig. 7 is a right side view of the front end portion of another stacking block 2 manufactured by the method of the present invention, and Fig. 8 is a front view of the stacking block. FIG. 10 is a right side view of the front end portion of yet another stacked block, and FIG. 10 is a front view of the stacked block. FIG. 11 is a right side view of the front end portion of another stacked block manufactured by the method of the present invention, and FIG. 12 is a front view of the stacked block. FIG. 13 is a right side view of the front end portion of yet another stacking block manufactured by the method of the present invention, and FIG. 14 is a front view of the stacking block. FIG. 15 is a right side view of the front end portion of another stacked block manufactured by the method of the present invention, and FIG. 16 is a right side view of the stacked block,
FIG. FIG. 17 is a right side view of the front end portion of yet another stacked block manufactured by the method of the present invention, and FIG. 18 is a front view of the stacked block. FIG. 19 is a right side view of the front end portion of another stacked block manufactured by the method of the present invention, and FIG. 20 is a front view of the stacked block. FIG. 21 is a vertical cross-sectional view of the front end of a molded block with conventional mortar applied, FIG. 22 is a vertical cross-sectional view of the front end of a molded block with another conventional mortar applied, and FIG. FIG. 2 is a vertical cross-sectional view of a conventional splint molding block in a cut state. FIG. 24 shows the front end portion of the stacking block according to the present invention! f
! Fig. 25 is a horizontal sectional view of the front end portion of a full-flat double blower according to another embodiment of the present invention, and Fig. 26 is a cross-sectional view of another embodiment of the present invention. It is a horizontal sectional view of the front end portion of such a concave flat type stacked block. FIG. 27 is a horizontal sectional view showing a drawback of the conventional manufacturing method of forming an uneven pattern on the upper surface of a stacked block using a press plate, and FIG. 28 is a front view of the stacked block in which the defect appears. FIG. 29 is a horizontal sectional view showing another drawback of the conventional method, and FIG. 30 is a front view of stacked blocks showing this drawback. DESCRIPTION OF SYMBOLS 1...Press plate, 2...Mold surface part for pattern formation, 3...
・Powder material for cosmetics, 4...Formwork, 4a...Through hole, 5.
... Concrete material, 6... Surface pallet, 7...
Product, 7a... Product pressure surface part, 7b... Chamfered slope,
7c... Chamfered step surface, 8... Elevator, 9...
- Mobile hopper for charging concrete material, 10...Horizontal axis, 11...Vibrator, 12...Moving hopper for sand charging, 13...Rotary axis of formwork, 14...Surface pallet charging device , 14a...Suction cup, 15...Surface pallet restraint device, 15a...Rod patent issued by Haruo Hara, Patent attorney, 1) Mamoru No. 20, Dorosha 61, et al., Fig. 13, Fig. 1S, Rod bamboo Figure 16th 22nd concave '7a 2nd middle 1st 25th 26th r21

Claims (5)

[Claims] (1) A secondary concrete product with a decorative surface, in which the decorative powder and granule material 3 is consolidated into a thin skin shape on the front part 7a of the product body 7. (2) After putting the concrete material 5 into the formwork 4 and pressurizing the concrete material 5 with the press plate 1 to press-form the product body 7, apply a decorative material to cover the front part 7a of the product body 7. Putting the granular material 3 into the formwork 4, making the minimum amount of the granular material 3 adhere to the paste on the front part 7a,
After inverting the formwork 4 with the surface pallet 6 loaded on the powder material layer, the product body 7 is removed from the formwork 4, and after the product body 7 has hardened, the surface pallet 6 is removed and the front part 7a is removed. A method for producing a secondary concrete product with a decorative surface, which removes excess decorative powder and granule material 3 other than those adhered to the surface in a thin skin form. (3) After the product main body 7 has hardened, remove the face pallet 6, remove and collect the excess cosmetic powder and granule material 3 other than the thin film attached to the front part 7a, and collect the recovered cosmetic powder and granule material. 3. The manufacturing method according to claim 1, wherein 3 is reused in the next molding process. (4) A mold surface part 2 for forming an uneven pattern is provided on the press plate 1, and the front part 7 of the product body 7 has an uneven pattern formed on the mold surface part 2.
The manufacturing method according to claim (1), wherein the cosmetic powder material 3 is attached to a. (5) The product body 7 is press-formed by pressing the concrete material with the press plate 1 while applying vibration, and the cosmetic powder and granule material 3 is attached to the paste bulging on the front part 7a of the product body 7. The manufacturing method described in 1).