JPH04305408A - Molding method for solid product with hydraulic material - Google Patents

Abstract

PURPOSE:To mold the pavement block, structual block and other solid product in which a surface layer and the decorative layer whose prescribed thickness is exposed on the surface of the surface layer are molded of the hydraulic material such as concrete. CONSTITUTION:A bottom plate 2 is laid under the form 1 opening up and down, and a cutting die 4 is placed on the bottom plate, and then the form is filled with the dry hydraulic material 5 for a surface layer by prescribed thickness, and it is caked by feeding water. Then the cutting die 4 on the bottom plate is removed, and the recessed part made by the cutting die is filled with the dry hydraulic material 6 for the decorative layer different from said surface layer, and the hydraulic materials for the surface layer and the decorative layer are integrally solidified.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] This invention is suitable for making solid products such as paving blocks, construction blocks, large concrete panels, tiles, nameplates, and RC structures with exposed Kintaro candy-style decorative layers on the surface using hydraulic hardening materials. The present invention relates to a molding method for molding.

0002

BACKGROUND OF THE INVENTION The present applicant proposed a method for forming such a solid product using concrete in Japanese Patent Application No. 165069/1983.

[0003] This prior proposal covers a bottom plate placed under a formwork with open holes at the top and bottom with a water-absorbing mat;
The formwork is placed on this mat, and decorative materials such as gravel, tiles, stones, etc. are scattered on the mat in the holes of this formwork,
Next, fill the mold hole with one or more types of dry concrete, dry mortar, or cement to form the surface layer to the required thickness.
Then, the surface layer is humidified and solidified, or a wet concrete serving as a support layer is filled on the surface layer to a desired thickness and solidified together with the surface layer, and the product is demolded.

0004

[Problems to be Solved by the Invention] The previously proposed solid product has a pattern formed by a decorative material bonded to the surface of the surface layer by solidification of the surface layer. If you lay them out on the pavement with the
Over a long period of time, the decorative material that makes up the pattern will peel off from the surface layer due to friction from the tires of cars passing over it and the shoes of passersby.

[0005]

[Means for Solving the Problems] Therefore, the present invention solves the above-mentioned prior proposal by expressing decorations such as patterns and letters exposed on the surface of the surface layer in 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 such that a cutting die is placed on a bottom plate placed under a mold having mold holes that are open at the top and bottom, and the cutting die is placed as it is or on the bottom plate. Sprinkle the required amount of water on the mold, fill the mold hole of the formwork with one or more dry hydraulic materials to the required thickness to form a surface layer, and sprinkle the required amount of water on top of the surface layer. to caking the water-curable material on the surface layer, then remove the cutting die and fill the remains of the cutting die with one or more dry water-curable materials different in type from the surface layer to form a decorative layer. The surface layer and the decorative layer are solidified as one by humidifying the decorative layer.

[0006] Furthermore, in the molding method according to claim 2, a cutting die is placed on a bottom plate placed under a mold having mold holes that are open at the top and bottom, and the cutting die is placed as it is, or a required amount is placed on the bottom plate. , and fill the mold holes of the above-mentioned formwork with one or more dry hydraulic materials to a required thickness to form a surface layer, and then sprinkle a required amount of water over the surface layer to form a surface layer. The water-curing material is caked, the cutting die is removed, and the remains of the cutting die are filled with one or more dry water-curing materials different in type from the surface layer to form a decorative layer, and then inside the die hole. The method is characterized in that a dry or wet hydraulic material serving as a support layer is filled to a required layer thickness, the support layer is moistened if necessary, and the surface layer, decorative layer, and support layer are solidified as one body.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the illustrated embodiment, reference numeral 1 indicates a mold having a mold hole that is open at the top and bottom, and reference numeral 2 designates a bottom plate that is placed under the mold and closes 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, since a plurality of blocks are molded at the same time, an outer frame 1a that constitutes a peripheral wall,
It consists of a partition frame 1b that divides the interior surrounded by the outer frame 1a 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, the formwork 1 is placed on the bottom plate 2, and a cross-sectional shape corresponding to the decoration to be expressed, such as pattern letters, figures, symbols, etc., is cut out on the bottom plate 2, which closes the lower surface of the mold hole 3. Type 4
Place one or more of them in a predetermined arrangement. This cutting die 4 may also be made of a suitable material such as wood, metal, plastic, etc. Then, the inside of the mold cavity 3 is filled with one or more dry water-curable materials 5 for the surface layer (FIG. 2). The layer thickness of this water-curable material is the same as or slightly thinner than the thickness of the cutting die 4, taking into account the subsequent removal of the cutting die 4, and is about 5 to 50 m.
It should be about m. This dry hydraulic material is a mixture of cement powder, fine aggregate such as sand, and coarse aggregate such as gravel (dry concrete) that hardens into concrete by adding an appropriate amount of water, and It is a mixture of cement powder, sand, and other fine aggregates (dry mortar) that solidifies into mortar upon addition.

After filling the dry water-curable material for the surface layer in this way, an appropriate amount of water is sprinkled on top of the dry water-curable material so that the filled water-curable material absorbs water, and even if the cutting die 4 is removed, there will be no trace of the cutting die. When the material 4' is hardened to the extent that it does not collapse, the cutting die is removed, and the remaining space is filled with one or more dry hydraulic material 6 for the decorative layer, which is different in type from the surface layer 5 (FIG. 3). Note that, if necessary, this material 6 may be pressurized from above.

The dry water-curable material 6 for the decorative layer is different from the water-curable material 5 for the surface layer because it contains a different pigment than the surface layer, or sparkling slag powder or powder. This refers to mixing bodies etc. into dry concrete or dry mortar. The dry water-curable material 6 filled into the area left by the cutting die absorbs the moisture contained in the surrounding filling material 5, which forms the surface layer, and solidifies. to humidify and 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 removed from the mold, the product is removed from the mold to obtain the product shown in FIG.

This product has a decorative layer 6 on both the front and back sides of the surface layer 5.
The decoration is exposed. Therefore, a monotonous concrete surface can be decorated by arranging or placing them with either side facing up on the fresh concrete pouring surface. Moreover, the cutting die 4 can be made into a small size with a person's name and name, and can be used as a nameplate.

[0012] Furthermore, after filling the area 4' where the cutting die was removed with the hydraulic material 6 for the decorative layer, a dry or wet hydraulic material 7 for the supporting layer is placed on the surface layer 5 and the decorative layer 6.
(Fig. 5). The dry hydraulic material 7 for this support layer is dry concrete or dry mortar similar to the surface layer 5. Further, the wet hydraulic material 7 is fresh concrete or a mortar fluid. When the dry water-curable material is filled, water is sprayed to humidify and promote solidification. In addition, if necessary, material 7
After filling, pressure may be applied from above.

[0013] Also, when filling the wet hydraulic material 7 for the supporting layer 7 after filling the cutout mark 4' with the dry hydraulic material 6 for the decorative layer, the dry hydraulic material 6 for the decorative layer is filled. The water-curable material absorbs water contained in the wet water-curable material for the support layer and solidifies, so there is no need to humidify it.

[0014] In this way, the surface layer 5, the decorative layer 6, and the 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 the product shown in FIG. This product has support layer 7
Since they are integrally connected, the decoration is exposed on the surface of the surface layer 5.

In the molding method of 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 the mold to collapse. This prevents the surface layer and decorative layer from slipping and deforming when filling the support layer or applying pressure to the 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.

Furthermore, the upper surface of the bottom plate 2 is covered in advance with a water-permeable material 8 such as a water-permeable plastic net, and the formwork 1 is placed on top of it.
By placing the net, excess water seeping out from the surface layer, decorative layer, and support layer filled in the mold cavity 3 can be discharged 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 moisture exuding from the surface layer, decorative layer, and support layer filled inside, and water can be sprayed before filling the dry hydraulic material 5 for the surface layer into the mold cavity. It can also be included in the water-absorbing material of the lever, and the moisture exuded from the water-absorbing material can initiate the solidification of the dry water-curable material for the surface layer or decorative layer. The most preferable water-absorbing material is a non-woven fabric made of synthetic fibers such as inexpensive 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-absorbent material 9 may be layered to cover the upper surface of the bottom plate. In this case, as shown in Fig. 1, the water-absorbing material 9 is placed on top to ensure good release from the mold during demolding, and excess water contained in the water-absorbing material is released from around the bottom plate through the water-permeable material 8. It is preferable to drain the water.

Further, among the materials constituting the surface layer 5, the decorative layer 6, and the support layer 7, the cement may be resin or other materials in addition to ordinary cement, and each material may include carbon fiber, glass fiber, and metal fiber. , synthetic fibers and other fibers may be mixed. Furthermore, each of these layers 5, 6, 7 may be made water permeable.

[0020] 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, improving productivity 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 out the entire mesh and leave the trace behind. 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.

[0021]Furthermore, another small die smaller than the previous die is placed in the place where the die was removed, and a dry hydraulic material for the decoration layer is filled between the mark and the die. After solidification, the small die is removed and the remaining space is 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.

[0022]Also, in the illustrated embodiment, a formwork having a plurality of partitioned mold holes was used in order to mold a plurality of products at the same time, but when molding a large product such as a large concrete panel, A mold having one large mold hole that is open at the top and bottom may be used.

[0023]

[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. Can be done.

Since the surface layer 5 and the decorative layer 6 are solidified by adding water to the filled dry hydraulic material, it is possible to adjust the amount of water added and achieve a low-moisture water:cement ratio to improve strength. .

Furthermore, 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 residual concrete produced at the concrete work site is used as the wet material for the support layer 7,
Eliminates the hassle of disposing of leftover concrete without causing pollution,
It has the effect of killing two birds with one stone.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing the relationship between a mold, its bottom plate, and a cutting die.

FIG. 2 is a cross-sectional view of a state in which a surface layer material is filled.

FIG. 3 is a cross-sectional view of a state in which the material for the decorative layer is filled in the area left after the cutting die has been removed.

FIG. 4 is a perspective view of a product consisting of a surface layer and a decorative layer.

FIG. 5 is a cross-sectional view of the support layer filled with material.

FIG. 6 is a perspective view of a product with a support layer.

[Explanation of symbols]

1 Formwork 2 Bottom plate 3 Mold hole 4 Cutting die 5 Surface layer and its dry hydraulic material 6
Decorative layer and its dry or wet hydraulic material; 7. Supporting layer and its dry or wet hydraulic material.

Claims (5)

[Claims] Claim 1: Place a cutting die on a bottom plate that is placed under a formwork that has mold holes that are open at the top and bottom, and either leave it as it is or sprinkle the required amount of water on the bottom plate, Fill the mold cavity with one or more dry hydraulic materials to a required thickness to form a surface layer, sprinkle the required amount of water onto the surface layer to caking the surface layer hydraulic material, and then The cutting die is removed and the remains of the cutting die are filled with one or more dry water-curable materials different in type from the surface layer to form a decorative layer, the decorative layer is humidified if necessary, and the surface layer and the decorative layer are combined. A method for molding a solid product using a water-curable material, characterized by solidifying the water-curable material as one unit. [Claim 2] Place the cutting die on the bottom plate that is placed under the formwork that has mold holes that are open at the top and bottom, and either leave it as it is, or sprinkle the required amount of water on the bottom plate and place the die in the formwork. Fill the mold cavity with one or more dry hydraulic materials to a required thickness to form a surface layer, sprinkle the required amount of water onto the surface layer to caking the surface layer hydraulic material, and then The cutting die is removed and the remains of the cutting die are filled with one or more dry water-curable materials of a different type from the surface layer to form a decorative layer, the decorative layer is moistened if necessary, and then filled into the die hole. A water curing method characterized by filling a dry or wet water curing material that serves as a support layer to a required layer thickness, humidifying the support layer if necessary, and solidifying the surface layer, decorative layer, and support layer as one unit. Method of forming solid products using materials. [Claim 3] In the method for molding a solid product using a hydraulic material according to any one of claims 1 and 2, the upper surface of the bottom plate on which the mold is placed is roughened. A method for molding a solid product using a water-curable material, characterized by: 4. A method for molding a solid product using the hydraulic material according to claim 1 or 2, comprising:
A method for molding a solid product using a water-curable material, characterized in that the upper surface of a bottom plate on which a formwork is placed is covered with a water-permeable material. 5. A method for molding a solid product using the hydraulic material according to claim 1 or 2, comprising:
A method for molding a solid product using a water-curable material, characterized in that the upper surface of a bottom plate on which a formwork is placed is covered with a water-absorbing material.