JPH0342206A - Method for molding solid product - Google Patents

Abstract

PURPOSE:To simply mold a solid product whose decorative layer not abraded by the friction with a tire or shoes is exposed by sprinkling a liquid curing material on a decorative layer filled with a dry particulate material different in kind from that of a surface layer and integrating the surface layer and the decorative layer to solidify both layers. CONSTITUTION:A retaining mold 1 is placed on a bottom plate 2 and a die 4 having the shape corresponding to decoration is placed thereon. A molding hole 3 is filled with a dry particulate material D1 to be formed into a surface layer 5 and a proper amount of a liquid curing material is sprinkled thereon to bond the particulate material D1 and, after the die 4 is removed, the formed hole is filled with a dry particulate material D2 to be formed into a decorative layer 6. The liquid curing material is composed of a flowable material such as cement milk, an acrylic emulsion or an SBR emulsion and, as the particulate material, sand, pearlite, a crushed synthetic resin material or sawdust are designated. After the surface layer 5 and the decorative layer 6 is the molding hole are sufficiently solidified, a product is taken out by demolding.

Description

[Detailed Description of the Invention] <Industrial Application Field> This invention is applicable to paving blocks, construction blocks, large-sized concrete panels, tiles, nameplates, RC structures, etc. with exposed candy-type decorative layers on the surface. This invention relates to a molding method for molding solid products.

<Prior Art> The present applicant proposed a method for forming such a solid product using concrete in Japanese Patent Application No. 165069/1983.

This prior proposal covers the bottom plate placed under a formwork with open holes at the top and bottom with a water-absorbent mat, places the formwork on top of this mat, and places the formwork inside the formwork's holes. Decorative materials such as gravel, tiles, stones, etc. are scattered on the mat, and then one or more types of dry concrete, dry mortar, or cement are filled into the mold hole to the required thickness to form the surface layer, and then the surface layer is humidified. Either by solidifying it, or by filling the surface layer with wet concrete that will serve as a supporting layer to a required layer thickness and solidifying it together with the surface layer, the product is made by demolding.

<Problems to be Solved by the Invention> The solid product of the previous proposal has a pattern formed by a decorative material bonded to the surface of the surface layer by solidification of the surface layer. If they are laid out face up on the pavement, over a long period of time the decorative material that makes up the pattern will peel off from the surface due to friction from the tires of cars passing over it and the shoes of passersby.

<Means for Solving the Problems> Therefore, the present invention overcomes the above-mentioned prior proposal by expressing decorations such as patterns and letters exposed on the surface of the surface layer with a decorative layer that is solidified integrally with the surface layer. The problem has been solved, and the molding method according to claim 1 is performed by placing a cutting mold on a bottom plate placed under a mold having vertically open mold holes; Spread the required amount of liquid hardening material on the mold, fill the mold hole of the mold with one or more types of dry powder to the required layer thickness to form a surface layer, and spread the required amount of liquid hardening material on top of the surface layer. to caking the powder and granular material on the surface layer, then remove the cutting die and fill the remains of the cutting die with one or more types of dry powder and granular material different from the surface layer to form a decorative layer, If necessary, a liquid curing material is sprinkled on the decorative layer to solidify the surface layer and the decorative layer as one body.

In addition, the molding method according to claim 2 includes placing a cutting die on a bottom plate placed under a mold having vertically open mold holes, or placing a required amount of liquid hardening on the bottom plate. Spread the material, fill the mold hole of the mold with one or more types of dry granular material to the required layer thickness to form the surface layer, and sprinkle the required amount of liquid hardening material on top of the surface layer to form the surface layer. The powder and granules are caked, the cutting die is removed, and the remains of the cutting die are filled with dry powder and granules of a different type from the surface layer to form a decorative layer, and if necessary, a liquid hardening material is added to the decorative layer. Then, fill the mold cavity with dry powder for the support layer to the required layer thickness and then spray the required amount of liquid curing material, or dry or wet water curable material to the required layer thickness. It is characterized in that it is filled with a layer thickness, humidified if necessary to form a support layer, and the surface layer, decorative layer, and support layer are solidified as one body.

<Embodiment> In the illustrated embodiment, reference numeral 1 indicates a mold having a mold hole that is open at the top and bottom, and 2 represents a bottom plate placed under the mold and closing the lower surface of the mold hole 3. The formwork is made of a suitable material such as a wooden plate, a metal plate, or plastic, and in this embodiment, in order to mold a plurality of blocks at the same time, it includes an outer frame 1a that constitutes a surrounding wall, and the outer frame 1a.
It consists of a partition frame tb that divides the interior surrounded by a plurality of mold holes 3 into a plurality of mold holes 3. The bottom plate 2 is made of a wooden plate, a metal plate, a concrete plate, a plastic plate, etc., and is the same size as or slightly larger than the external size of the outer frame 1a.

To perform molding, place the mold l on the bottom plate 2 and fill the mold hole 3.
One or more cutting dies 4 having a cross-sectional shape corresponding to the decoration to be expressed, such as pattern letters, figures, symbols, etc., are placed in a predetermined arrangement on the bottom plate 2 that closes the lower surface.This cutting die 4 is also made of wood or metal. It may be made of any suitable material such as plastic. Then, the inside of the mold cavity 3 is filled with dry powder to form the surface layer 5 (
(Fig. 2), the layer thickness of this powder and granule material is then
In consideration of removing the material, the thickness should be the same as the thickness of the cutting die 4 or slightly thinner, about 5 to 50 mm.

After filling the dry powder material to form the surface layer 5, an appropriate amount of liquid hardening material is sprinkled on top of the dry powder material, which causes the filled powder material to caking, and the cutting die 4 is removed and punched out. When the mold marks 4' do not collapse, the cutting mold is removed, and the marks are filled with dry powder D8, which is to be the decorative layer 6 and is of a different type from the surface layer 5 (Fig. 3). If necessary, pressure may be applied from above after filling the powder D8.

The liquid hardening materials used are fluid materials that harden over time, such as cement milk, acrylic emulsion, and SBR (styrene butadiene rubber) emulsion.The powder and granules used for the surface layer and decorative layer are sand, In addition to gravel,
Any material can be used as long as it can be hardened with the liquid curing material, such as perlite, vermiculite, pulverized products of various synthetic resin products, and sawdust.

The dry granular material to be used as the decorative layer 6 is different from the granular material D1 in the surface layer 5 because it contains a different pigment than the surface layer 5, or sparkling slag powder or grains, etc. The dry granular material D2 filled in the remains of this cutting die absorbs and solidifies the liquid hardening material contained in the surrounding surface layer of the granular material D2, but this is insufficient. If so, sprinkle a liquid curing material separately to promote solidification.

In this way, when the surface layer 5 and the decorative layer 6 are sufficiently solidified inside the mold cavity and the shape does not collapse even when the mold is removed, the mold is removed to obtain the product A shown in FIG.

In this product A, the decoration by the decorative layer 6 is exposed on both the front and back sides of the surface layer 5. Therefore, a monotonous concrete surface can be decorated by arranging or placing them with either side facing up on the fresh concrete pouring surface.

Alternatively, the cutting die 4 can be made into a small size with the name of the member joining the group and used as a nameplate.

In addition, the powder D for the decorative layer 6 is placed at the mark 4 after removing the cutting die.
2, the surface layer 5 and the decorative layer 6 are filled with dry powder D3 to a required layer thickness, and a required amount of liquid hardening material is sprayed, or dry or wet water hardening material is filled. The dry granular material for this supporting layer may be the same as the powder material for the surface layer 5, and the dry powder material for this supporting layer may be the same as the powder material for the surface layer 5. The hardening material may be dry concrete or dry mortar, and the wet water hardening material may be fresh concrete or mortar fluid. Then, when filling dry powder or granules, liquid hardening material is sprayed, and when filling dry water-curing material, water is sprayed to humidify to promote solidification. After filling, pressure may be applied from above.

In addition, the dry powder D2 for the decorative layer 6 is cut out from the die mark 4'.
When filling the dry powder for support N7 and scattering the liquid hardening material, the dry powder for the decorative layer should be replaced with the liquid hardening material sprinkled on the support layer powder. Since it is impregnated and solidified, there is no need to sprinkle the liquid curing material on the powder D2 for the decorative layer.

In this way, the surface layer 5, decorative layer 6, and support layer 7 are solidified and integrated, and when the shape does not collapse even when removed from the mold, the product is removed from the mold to obtain product B shown in FIG. Since the support layer 7 of this product B is integrally bonded, the decoration is exposed on the surface of the surface layer 5.

In the molding method according to the present invention, if the upper surface of the bottom plate 4 that closes the lower surface of the mold cavity 3 is placed on an uneven and rough surface, the caking surface layer may slip when the mold is removed, causing deformation, or the support layer This prevents the surface layer and decorative layer from slipping and deforming when filling or pressurizing the core layer from above.

In addition, unevenness opposite to the rough surface is formed on the lower surfaces of the decorative layer 6 and the surface layer 4, which makes the surface of the surface layer 5 and the surface of the decorative layer 6 exposed there three-dimensional, further improving the decorative effect. do.

In addition, by covering the upper surface of the bottom plate 2 in advance with a water-permeable material 8 such as a water-permeable plastic net, and placing the form l on top of it, water seeps out from the surface layer, decorative layer, and support layer filled in the mold hole 3. Excess liquid curing material and moisture can be drained out from around the top surface of the bottom plate through the net.

Furthermore, the upper surface of the bottom plate 2 is covered with a water-absorbing material 9 such as non-woven fabric, open-celled sponge, pulp, paper, cotton, glass wool, etc., and the formwork 1 is placed on top of the water-absorbing material 9.
This water-absorbing material can absorb excess liquid hardening material and water that seeps out from the surface layer, decorative layer, and support layer filled inside, and also allows dry powder for the surface layer to be used before filling the mold cavity. It is also possible to disperse a liquid hardening material to be included in the water-absorbing material, and to use the liquid hardening material exuded from the water-absorbing material to start solidifying the dry powder for the surface layer or decorative layer. The most preferable water-absorbing material is an inexpensive non-woven fabric made of synthetic fibers such as polypropylene, or fabric.By using this material, when removing products A and B from the mold holes of the mold, the product Mold release can be done smoothly.

Note that the water-permeable material 8 and the water-absorbing material 9 may be layered to cover the top surface of the bottom plate. In this case, the water-absorbing material 9 is placed on top as shown in FIG. It is preferable to do this properly and to drain excess liquid hardening material and moisture contained in the water-absorbing material from around the bottom plate through the water-permeable material 8.

Further, when the support layer 7 is composed of a dry or wet hydraulic material, the cement may be resin or other material in addition to ordinary cement, and this may include carbon fiber, glass fiber, metal fiber, synthetic fiber, etc. Furthermore, the surface layer 5, decorative layer 6, and support layer 7 may be made water permeable.

If a magnetic material such as iron is used for the cutting die 4, after the surface layer has caked, part or all of the cutting die can be removed at once by magnetic force.
Productivity improves during mass production. In addition, if the cutting die is small, fix it to the bottom of the mesh, place the entire mesh on the bottom plate, fill the dry water-curable material for the surface layer through the mesh, and after it has hardened, pull it out with the mesh and fill it with the remaining material. By filling the decorative layer with a hydraulic material, it is possible to express detailed decorations. In this case, the cutting die can be made of a light-sensitive material by photolithography or the like, thereby making it possible to create more complex decorations.

Furthermore, another small cutting die smaller than the cutting die is placed in the place where the cutting die was removed, and a dry hydraulic material for the decoration layer is filled between the above mark and the small cutting die, and after it hardens, the small cutting die is placed. The die can be removed and the remaining area filled with another dry, hydraulic material of a different color, for example, and this process can be repeated if necessary to create more complex decorations.

In addition, in the illustrated example, a formwork with multiple partitioned mold holes was used in order to mold multiple products at the same time, but when molding a large product such as a large concrete panel, a formwork with open holes at the top and bottom is used. A mold having one large mold hole may be used.

<Effects of the Invention> As is clear from the above, according to the present invention, it is possible to easily mold a solid product in which a decorative layer is exposed on the surface of the surface layer, and which does not have a support layer or has a support layer integrally bonded. I can do it.

The surface layer 5 and the decorative layer 6 are filled with dry powder D.
Since the liquid hardening material is added to + and D- and solidified, the strength can be improved by adjusting the water content of the liquid hardening material added.

In addition, since the decorative layer 6 is exposed on the surface of the surface layer 5 and forms a decorative pattern, it will not wear out even if it is scraped by friction with automobile tires, passersby's shoes, etc.

Furthermore, if the support layer 7 is made of leftover concrete produced at the site of concrete work, the trouble of disposing of the leftover soil without causing pollution can be saved, resulting in the effect of killing two birds with a stone.

[Brief explanation of drawings]

Since the drawings show one embodiment of the present invention, FIG. 1 shows the formwork,
Figure 2 is a cross-sectional view showing the relationship between the bottom plate and the cutting die, Figure 2 is a cross-sectional view of the surface layer formed, Figure 3 is a cross-sectional view of the decorative layer formed after the cutting die has been removed, and Figure 4 is a cross-sectional view of the surface layer formed. FIG. 5 is a perspective view of a product comprising a surface layer and a decorative layer, FIG. 5 is a cross-sectional view of a state in which a support layer is configured, and FIG. 6 is a perspective view of a product provided with a support layer. In the figure, l is the mold, 2 is the bottom plate, 3 is the mold hole, 4 is the cutting die, 5 is the surface layer, Dl is the dry powder, 6 is the decorative layer,
D2 is the dry powder, 7 is the support layer, D is the material for the support layer, 8 is the breathable material, 9 is the water-absorbing material, and A and B are the products.

Claims (5)

[Claims] (1) Place the cutting die on the bottom plate to be laid under the formwork with open mold holes at the top and bottom, and either leave it as is or sprinkle the required amount of liquid hardening material on the bottom plate and place it on the bottom plate of the above formwork. Fill the mold cavity with one or more types of dry powder or granules to a required thickness to form a surface layer, sprinkle a required amount of liquid curing material on top of the surface layer to caking the powder or granules in the surface layer, and then The cutting die is removed and the remains of the cutting die are filled with one or more types of dry powder different from the surface layer to form a decorative layer, and if necessary, a liquid curing material is sprinkled on the decorative layer to form the surface layer. A method for forming a solid product, which is characterized by solidifying a decorative layer and a decorative layer as one body. (2) Place the cutting die on the bottom plate that is placed under the formwork with open mold holes at the top and bottom, and either leave it as it is or sprinkle the required amount of liquid hardening material on the bottom plate and place it on the bottom plate of the above formwork. Fill the mold cavity with one or more types of dry powder or granules to a required thickness to form a surface layer, sprinkle a required amount of liquid curing material on top of the surface layer to caking the powder or granules in the surface layer, and then The cutting die is removed and the remains of the cutting die are filled with one or more types of dry powder different from the surface layer to form a decorative layer. If necessary, a liquid hardening material is sprinkled on the decorative layer, and then the die is removed. Fill the holes with dry powder for the support layer to the required layer thickness and spray the required amount of liquid hardening material, or fill the holes with dry or wet hydraulic material to the required layer thickness, A method for molding a solid product, characterized in that the surface layer, decorative layer, and support layer are solidified as a single unit by humidifying the surface layer as a support layer if necessary. (3) The method for molding a solid product according to claim 1 or 2, characterized in that the upper surface of the bottom plate on which the mold is placed is roughened. Method. (4) The method for molding a solid product according to any one of claims 1 and 2, characterized in that the upper surface of the bottom plate on which the mold is placed is covered with a water-permeable material. Method of forming solid products. (5) The method for molding a solid product according to any one of claims 1 and 2, characterized in that the upper surface of the bottom plate on which the mold is placed is covered with a water-absorbing material. Method of forming solid products.