JPH0623722A - Method for integrally molding surface material and concrete backing layer by press molding - Google Patents

Abstract

PURPOSE:To integrally mold a surface material and a concrete backing layer by press molding. CONSTITUTION:A buffer mat 3 having an area smaller than that of the inner bottom of a female mold A is laid on the inner bottom of the female mold A and a surface material 4 is placed on the mat 3 and mortar for forming a concrete backing layer is further placed on the surface material 4. Thereafter, a male mold B is introduced into the female mold A under pressure to integrally mold the surface material 4 and the concrete backing layer 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for integrally molding a surface material and a concrete backing layer by press molding.

In the field of general concrete products such as pavement blocks, and in the field of fiber reinforced concrete such as sizing and OA floors, there are considerable achievements in press molding technology. However, in the field of surface materials such as tiles and natural stone lined with fiber reinforced concrete, the surface accuracy of the surface material is not sufficient according to press molding and the surface material is damaged. It is not integrally molded with a material, but a method such as pre-casting by a casting method or bonding with a surface material after molding a backing layer is adopted.

[0003]

The conventional method of separately forming a concrete backing layer and attaching it to a surface material requires labor and time, and the concrete backing layer is warped, which results in dimensional stability. It has the drawback of being bad. Therefore, an object of the present invention is to provide a technique capable of mass-producing a product having good dimensional stability by press molding.

[0004]

The present invention has been made in order to achieve the above-mentioned object. A cushioning mat smaller than the bottom area is laid in a female mold, and a surface material is placed on the cushioning mat. The problem is solved by adopting a method of placing a concrete backing layer forming mortar on top and then press-fitting a male mold into a female mold to integrally form a surface material and a concrete backing layer.

[0005]

The function of the cushioning mat prevents the surface material from being damaged during press molding. Since the cushioning mat is the size that fills the bottom of the male mold during press molding, even if the surface material is smaller than the area of the inner bottom of the female mold, the concrete inner layer does not wrap around to the front side of the surface material and dimensional stability Good product is obtained.

[0006]

EXAMPLE FIG. 1 shows a process chart in one example of the present invention. A is a female type consisting of a bottom plate 1 and a side frame 2, B is a male type, 3 is NBR (acrylonitrile butadiene diene copolymer). Buffer mat, 4 is a surface material, and 5 is a concrete mortar. First, a cushioning mat 3 slightly smaller than the area of the bottom plate 1 is laid on the bottom plate 1 as shown in FIG. In the case of the embodiment, the cushioning mat 3 has a size of 1 mm wide around the cushioning mat 3. Next, a surface material 4 having the same size as that of the buffer mat 3 is placed on the buffer mat 3 as shown in (b), and then an appropriate amount of concrete mortar 5 is placed on the surface material 4 as shown in (c). Then, the male mold B is press-fitted as shown in FIG. In this case, the cushioning mat 3 extends fully to the bottom plate, and the concrete mortar 5 does not wrap around the lower surface of the surface material. After the above-mentioned press molding, the male mold B is raised as shown in (e) and the side frame 2 is lowered to obtain a product as shown in (f). The product may be as it is, but after the portions 5a, 5a protruding in the joint shape are removed, primary curing (steam curing) and secondary curing are performed, and then the finished product is obtained. In addition,
If the size of the surface plate 4 is made the same as the size of the bottom plate 1, theoretically the above-mentioned protruding portion cannot be formed, but the peripheral edge of the surface plate 4 may be chipped during pressing or moving the side frame. The size of the surface plate 4 should be smaller than that of the bottom plate 1. Further, although the side frame 2 is lowered in this embodiment,
Conversely, the side frame 2 may be fixed, and the bottom plate 1 may be lifted to remove the product from the mold. As the surface material 4, tiles, bricks, natural stones, ceramic plates and the like are used. As the mortar 5, lightweight concrete using ultra-light aggregate or fiber reinforced concrete reinforced with glass fiber, carbon fiber, vinylon fiber, aramid fiber or the like is used. As the cement for fiber reinforced concrete, low alkaline cement, low shrinkage cement, ordinary Portland cement or other JIS specified cement is used.

[0007]

EFFECTS OF THE INVENTION At present, integral molding of a surface material such as a tile by press molding and a concrete backing layer has not been put to practical use because the surface material of the surface material is not sufficient in accuracy and the surface material is damaged during pressing. According to the present invention, a cushioning mat smaller than the inner bottom area is laid between the die and the surface material so that the pressing force does not act as a concentrated load on the surface material and is uniformly applied to the entire surface, thereby causing the surface material to crack. This enables mass production of composite products with good dimensional stability without any problems.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing each step of an embodiment of the present invention. A Female type B Male type 1 Bottom plate 2 Side frame 3 Buffer mat 4 Surface plate 5 Mortar

Claims (1)

[Claims] 1. A cushioning mat smaller than the bottom area is laid in a female mold, a surface material is placed on the cushioning mat, a mortar for forming a concrete backing layer is further placed on the surface material, and then the male mold is press-fitted into the female mold. An integral molding method for the surface material and the concrete backing layer by press molding, which comprises integrally molding the surface material and the concrete backing layer.