JPH04201410A - Resin form for manufacturing concrete formed body and manufacture of formed body thereof - Google Patents

Abstract

PURPOSE:To obtain a form for concrete formed body, which can be easily produced in shorter time, at lower cost and more simply than a metal form by a method wherein the form concerned is produced by composition made mainly of aggregate containing thermosetting resin as binder. CONSTITUTION:The resin form concerned is produced by casting composition, which is made mainly of aggregate such as silica sand or the like and at least one kind of thermosetting resin preferably selected from the group consisting of furan resin, phenolic resin, epoxy resin, urethane resin and the like, in the configuration prepared by arranging a male mold corresponding to the shape of a concrete formed body, for example, in an outer form, and, after the setting of the resin, removing the male mold. The weight ratio of the thermosetting resin to the aggregate is normally 0.005-0.1. Further, at the production of the concrete formed body, relevant layer is preferably formed on the inner face of the form. At the concrete used for the production of the formed body, no limitation present and especially resin concrete is effective for trial form, reproduction form and the like from the view point of easy local fitting of a form.

Description

Detailed Description of the Invention <Industrial Field of Application> The present invention relates to a resin form for producing a concrete molded body or a mortar molded body, and a concrete molded body or a mortar molded body (hereinafter both are collectively referred to as "concrete molded body"). The present invention relates to a method for manufacturing a molded body (abbreviated as “molded body”). In particular, because it can be easily produced in a short period of time and at low cost,
The present invention relates to a resin mold for producing a concrete molded body, which is suitable as a formwork used when pouring concrete to form a concrete molded body, and a method for manufacturing a concrete molded body using the resin mold.

<Prior Art> Members constituting the main skeletons of structures such as machine tools, measuring machines, working machines, etc., such as bases and columns, are important components that greatly affect the performance of these structures. for example,
The machine bed, which is a component of machine tools such as grinders, lathes, and milling machines, forms the base of these machine tools and affects the machining accuracy, suppression of chatter vibration, and machining efficiency of the machine tools. It is an important part that affects Traditionally, this bed was made of cast iron, but recently,
Materials made of cement concrete and resin concrete are beginning to be put into practical use.

On the other hand, cement concrete and resin concrete are used for monuments, car stops, planters, benches, reproductions of sculptures, construction materials, landscape materials, etc.

By the way, in order to manufacture the above-mentioned structure using concrete or resin concrete, conventionally, wood, iron,
The method used is to pour concrete mortar into a formwork made of metal such as aluminum, allow it to cure and harden, and form the concrete.

<Problems to be Solved by the Invention> However, the formwork made of wood or metal takes a considerable amount of time to manufacture, and is also expensive to manufacture. It was difficult to respond to the production of

Therefore, an object of the present invention is to provide a formwork for use in pouring concrete to form a concrete molded body, which can be manufactured more easily in a shorter period of time and at lower cost than conventional metal molds. The object of the present invention is to provide a resin mold for producing a concrete molded body suitable for use as a molded concrete body, and a method for manufacturing a concrete molded body using the resin mold.

Means for Solving the Problems> In order to solve the above problems, the present invention provides a resin formwork for manufacturing concrete molded bodies, which comprises aggregate as the main component and thermosetting resin as the bonding side. The present invention provides a resin mold for producing a concrete molded body, which is formed by molding and curing a composition containing the present invention in accordance with the shape of the concrete molded body.

It is preferable that the thermosetting resin is at least one resin selected from furan resins, epoxy resins, and urethane resins.

The ratio of the thermosetting resin/aggregate is 0.005 to 0.005 by weight
It is preferable that it is 0.1.

Further, the present invention provides a concrete molded product having a step of forming a release agent layer on the surface of the resin form for producing a concrete molded product that comes into contact with the concrete molded product, and then pouring concrete and curing and curing the molded product. The present invention also provides a manufacturing method.

Preferably, the concrete is resin concrete.

Preferably, the resin concrete is made of a liquid formulation for resin concrete containing a methacrylate resin composition.

EMBODIMENT OF THE INVENTION Hereinafter, the resin form|frame for manufacturing a concrete molded object of this invention and the manufacturing method of a concrete molded object using the same are demonstrated in detail.

As shown in an embodiment of the present invention shown in FIG. 1, the resin formwork for producing concrete molded bodies of the present invention is a resin formwork that is formed in accordance with the shape of the concrete molded body to be molded using the resin formwork. It basically consists of a reed casting part 1, a formwork 2, and an outer frame 3 surrounding the outside of the formwork 2.

In the present invention, the formwork is made of a composition containing as a main component at least one resin selected from thermosetting resins such as furan resin, phenol resin, epoxy resin, and urethane resin, preferably furan resin, and silica sand. The main component is aggregate, and the composition has a concrete casting part formed in accordance with the shape of the concrete molded body to be manufactured.

The outer frame is shaped to hold the formwork,
For example, it is formed in the shape of a box that surrounds the formwork, and is appropriately selected according to the shape and size of the formwork, and its material is usually made of metal, such as iron, that is normally used for this type of formwork. good.

In addition, when a mold release agent layer is provided on the inner surface of the formwork, when producing a concrete molded body, the molding obtained and the demoldability when demolding the body are improved, and the surface of the molded body obtained is It is advantageous in that it does not cause rough skin and does not require post-treatment such as surface preparation.

Examples of the mold release agent used include paraffin wax, silicone wax, silicone resin, water and/or alcohol solution of polyvinyl alcohol resin, urethane resin, rubber, epoxy resin, grease,
Examples include oils such as varafinoyl, fatty acids, fatty acid metal salts, etc., and are appropriately selected depending on the resin forming the mold.

For example, when forming resin concrete using furan resin as the resin, paraffin wax or an aqueous solution of polyvinyl alcohol may be used.

In manufacturing this resin formwork, for example, a male mold formed to correspond to the shape of the concrete molded object to be manufactured is placed at a predetermined position within the outer frame 3, and the furan resin, phenol resin, epoxy resin, etc. After pouring and curing a composition containing as main components at least a lIO thermosetting resin selected from resins, urethane resins, etc. and aggregates such as silica sand,
This can be done by removing the male mold.

In the composition used for the resin formwork for producing concrete molded bodies of the present invention, the ratio of thermosetting resin/aggregate is usually set at a weight ratio of: The range is from 0005 to 0.1, preferably from 0007 to 0.02.

In addition, a method for producing a concrete molded body using this resin formwork includes, for example, first forming a mold release agent layer on the surface of the resin form for producing a concrete molded body that comes into contact with the concrete molded body, and then Concrete is poured, and the concrete is cured and hardened. Next, this can be done by demolding the resin mold.

The concrete used in manufacturing the concrete molded body is not particularly limited, and examples thereof include cement concrete whose main component is ordinary Portland cement, resin concrete, polymer cement concrete, and the like. In particular, the present invention is useful for economic efficiency, formwork creation, and formwork production when using resin concrete to produce molded objects such as prototype beds and columns for machine tools, and reproductions of monuments manufactured in small quantities. It is effective in that partial rework is easy and the period required for formwork creation and partial rework is short.

A specific example of this resin concrete includes resin concrete that has a methacrylate resin composition as a main component and is obtained using a liquid formulation for resin concrete.

The methacrylate resin composition, which is the main component of this liquid mixture for resin concrete, has methacrylate yarn as a main component.

Examples of the methacrylate thread pick include methyl methacrylate, ethyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, t-butyl methacrylate, 2-ethylhexyl methacrylate, cyclohexyl methacrylate, and lauryl methacrylate. may be used alone or in combination of two or more. Among these, methyl methacrylate is preferred.

The methacrylate-based resin composition also includes methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-
Acrylate monomers such as ethylhexyl acrylate, cyclohexyl acrylate, lauryl acrylate; ethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, polyethylene glycol di(meth)acrylate, polypropylene glycol di(meth)acrylate, Butylene glycol di(meth)acrylate, hexylene glycol di(meth)acrylate, 2.2-bis[4-(meth)acryloyloxyphenyl]propane, 2.2-bis[4-
(meth)acryloyloxycyclohexyl]propane, 2,2-bis[3-(meth)acryloyloxy-2
- Polyfunctional (meth)acrylate monomers such as propane, trimethylolpropane tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, and dipentaerythritol hexa(meth)acrylate; dimethyl maleate , diethyl maleate, di-n-butyl maleate, di-t-butyl maleate, di-isobutyl maleate, etc.; dimethyl fumarate, diethyl fumarate, di-n-butyl fumarate, di-t- Fumaric acid ester monomers such as butyl fumarate and diisobutyl fumarate; subcomponents such as various vinyl monomers that can be copolymerized with the methacrylate monomers such as styrene and vinyltoluene. Or it may contain two or more types.

Furthermore, the methacrylate resin composition contains, as a subcomponent, a homopolymer or a copolymer of two or more of the methacrylate yarn threads: a homopolymer of the acrylate monomer, or a copolymer of two or more of the acrylate monomers: It may also contain a copolymer of the above-mentioned methacrylate monomer and/or acrylate monomer and a vinyl monomer (for example, styrene, vinyltoluene, etc.) that can be copolymerized with these monomers.

Furthermore, this methacrylate resin composition has upper ff&
In addition to the main components and subcomponents, the composition may also contain a plasticizer, an oxygen blocker, various weather stabilizers, a trace amount of a polymerization inhibitor for monomer stabilization, etc., if necessary.

Examples of the plasticizer include di-2-ethylhexyl phthalate, di-n-octyl phthalate, tricresyl phosphate, and di-2-ethylhexyl adipate. These may be used alone or in combination of two or more.

Examples of oxygen blockers include paraffin wax, etc.
Examples include oils such as liquid paraffin, mineral oil, tall oil, and castor oil.

In the method of the present invention, a liquid formulation for resin concrete containing the above methacrylate resin composition as a main component is poured into the resin form, and a polymerization initiator is added to the liquid formulation for resin concrete. In this method, a concrete molded body is obtained by molding and curing at or near room temperature in the presence of.

Examples of the polymerization initiator include redox polymerization initiators. Specific examples of this redox polymerization initiator include a combination of an organic peroxide and a polymerization accelerator consisting of an amine compound; a combination of an organic peroxide and a ferrous salt; a combination of an organic peroxide and a mercaptan; Combinations of peroxides and naphthenates and combinations of monopersulfates and sodium bisulfite may be mentioned. As organic peroxides,
Examples include organic peroxides such as dibenzoyl peroxide, dicumyl peroxide, diacetyl peroxide, cicapril peroxide, dilauroyl peroxide, distearyl peroxide, t-butyl peroxide, cumene hydroperoxide, and t-butyl hydroperoxide. Examples of amine compounds that are polymerization accelerators include aniline, N,N-dimethylaniline, N,N-dimethyl-P-toluidine, and N,N-di(
hydroxyethyl)-p-toluidine, N,N-di(hydroxyethyl)-m-f-luidine, N.

Examples include N-di(β-hydroxypropyl)-p-toluidine.

In the method of the present invention, these redox polymerization initiators may be used alone or in combination of two or more.

Among these polymerization initiators, those consisting of a combination of an organic peroxide and an amine compound are preferred.

As a specific example of the liquid mixture for resin concrete in the method for producing a concrete molded body of the present invention, commercially available liquid mixtures for resin concrete, such as those commercially available from Mitsui Seki Kassanshi Co., Ltd. under the trade name Silical. can be mentioned.

In the method of the present invention, in addition to cement or resin concrete liquid formulations, defoaming/defoaming agents, aggregates, fillers, pigments, hardening agents, stabilizers, dispersants, etc. Additives such as agents, resin emulsifiers, etc. may be included.

Examples of the aggregate include coarse aggregates such as natural gravel, crushed stone, and ceramics, and fine aggregates such as river sand, sea sand, crushed sand, and ceramics. The type and amount of this aggregate may be selected as appropriate based on the workability of the concrete, the dimensions, shape, required appearance, aesthetics, strength, etc. of the concrete molded product obtained, but resin concrete In,
The ratio of the resin component to the aggregate is usually 0.0 by weight.
It is about 5 to 0.2.

Examples of the filler include calcium carbonate, barium sulfate, aluminum oxide, aluminum hydroxide, kaolin, talc, and silica sand powder.

In the method of the present invention, when pouring concrete into a resin form, for example, a vibrator is attached to the outer frame,
When concrete is poured into a formwork without being shaken, air bubbles formed by the air accompanying the concrete, so-called beards, and unfilled areas formed by aggregates of coarse aggregate, so-called junkers, are formed. This is preferable because it can prevent formation inside the body.

<Example> Hereinafter, the present invention will be specifically explained by giving examples and comparative examples of the present invention.

(Example 1) A resin mold 2 shown in FIG. 341 was created using a mixture of furan resin used for cast iron molds and silica sand. The mold release agent layer 4 is made of molten paraffin wax (melting point: 60°C)
was applied to the inner surface of the resin formwork 2 with a brush.

On the other hand, resin concrete has the formulation shown in Table 1 below. First, coarse aggregate, fine aggregate, filler, and pigment are immersed in a forced (pan-type) mortar mixer and mixed for 60 seconds. Stirring was stopped. Next, a polymerization initiator is blended into the liquid component placed in a separate container, and the mixture is stirred for 30 seconds to disperse and dissolve the polymerization initiator to form a homogeneous solution.Then, this is poured into a forced mortar mixer, and the mixture is stirred for 30 seconds to disperse and dissolve the polymerization initiator. A resin concrete mortar was prepared by stirring for 60 seconds.

Table 1 Note *1: Gravel: specific gravity 2.58, coarse grain ratio (FM) 5.8
$2: No. 3 silica sand: specific gravity 2.58; No. 5 silica sand; specific gravity 2.56 Next, the resin concrete prepared above was cast into the resin form 2 and the form for strength testing, and - Place on top, vibrate for 60 seconds, 20±2℃, 50±
It was cured and hardened in an atmosphere of 5% RH for 120 minutes to obtain a concrete molded body.

Thereafter, the mold 2 was demolded and the surface condition of the obtained molded body was observed. As a result, a molded product with good mold releasability, few bubbles on the surface, and gloss was obtained. Partially attached paraffin wax could be easily removed by heating and melting it with hot water.

Further, the obtained concrete molded body was demolded, and the tensile strength, compressive strength, and compressive elastic modulus of the molded body after one week of age were measured according to the following methods.

In accordance with JIS A1185 (tensile test method for polyester resin concrete), a 100φ x 100 specimen made using a 100φ x 200 tin bundle concrete tester mitt in accordance with JISA1132 was tested using a universal testing machine. Tensile strength was determined by splitting test.

Compressive strength: Based on JIS A1182 (compressive strength test method for polyester resin concrete), JIS A113
A 100φ×200 specimen prepared using a 100φ×200 tin plate bundle concrete tester mitt conforming to 2 was placed on a universal testing machine to measure compressive strength.

Compressive Modulus When measuring the compressive strength above, measure the strain using a combresometer (compressive strain meter for Shimadzu universal testing machine), create a strain-stress curve, and calculate the compression from the slope of the tangent to the rising point of this curve. The elastic modulus was determined.

The above results are shown in Table 2.

Table 2 <Effects of the Invention> Since the resin formwork for producing concrete molded bodies of the present invention can be easily produced in a short period of time and at low cost,
It is suitable as a formwork used when pouring concrete mortar to form a concrete molded body.

Furthermore, the method of the present invention is a method for manufacturing a concrete molded body using this resin form, and is particularly suitable for manufacturing structures such as the bed of machine i using resin concrete.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view for conceptually explaining the resin mold and method of the present invention. Explanation of symbols 1... Concrete placement part, 2... Formwork, 3... Outer frame, 4... Mold release agent layer FIG, 1

Claims (6)

[Claims] (1) A resin formwork for manufacturing a concrete molded body, in which a composition containing aggregate as a main component and a thermosetting resin as a binder is molded and hardened in accordance with the shape of the concrete molded body. Resin formwork for producing concrete molded bodies. (2) The resin form for producing a concrete molded body according to claim 1, wherein the thermosetting resin is at least one resin selected from furan resin, epoxy resin, and urethane resin. (3) The ratio of the thermosetting resin/aggregate is 0.0 by weight
3. The resin form for producing a concrete molded body according to claim 1 or 2, wherein the resin form has a particle size of 0.05 to 0.1. (4) After forming a release agent layer on the surface of the resin mold for producing a concrete molded body according to any one of claims 1 to 3 that comes into contact with the concrete molded body, concrete is poured, and then cured and hardened. A method for producing a concrete molded body, comprising the step of: (5) The method for producing a concrete molded body according to claim 4, wherein the concrete is resin concrete. (6) The method for producing a concrete molded body according to claim 6, wherein the resin concrete is made of a liquid mixture for resin concrete containing a methacrylate resin composition.