JPH07119229A - Form for placing concrete - Google Patents

Abstract

PURPOSE:To manufacture a permanent form having high ability of joint and integration with concrete and excellent shock absorbing property and heat insulating property by crushing the waste of a thermoplastic resin foaming body into grains, filling a forming die with them, and heating and pressurizing them so as to fuse them. CONSTITUTION:The waste of a thermoplastic resin foaming body is crushed into grains of mean diameter 5-50mm, if necessary, beads containing foaming agent are mixed with them, and a forming die is filled with them by 1.2-1.5 times of the cavity volume. The side molds 1a, 1b of a permanent form having projecting parts 2 and grooves 3 and partition members 4 to be fitted in the grooves 3 are manufactured by heating, pressing, and fusion forming utilizing a heat source such as heating steam. The partition members 4 are fitted in the grooves 3 of the side walls 1a, 1b so as to form a form for placing concrete.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a concrete pouring formwork in which waste of molded foam of thermoplastic resin is reused as a waste formwork.

[0002]

2. Description of the Related Art Various forms are used as forms for placing concrete. For example, Japanese Patent Laid-Open No. 61-4504
Japanese Patent Publication No. 2 discloses a concrete pouring formwork in which ribs are formed on the inner surface of a concrete-made formwork used as a discard formwork in order to enhance the integrity and strength with the placed concrete. However, since the formwork is made of concrete, the weight is large and the transportation and construction work becomes complicated.

On the other hand, since foamed molded articles of thermoplastic resin are lightweight, they are widely used as various molded articles in addition to containers, cushioning materials, heat insulating materials and the like. For example, Japanese Patent Laid-Open No. 2-4
Japanese Patent No. 3437 discloses a lightweight block formed of a synthetic resin foam as a block useful in constructing a concrete block wall. Also, US Pat. No. 4,884,382 and US Pat. No. 4,89
Japanese Patent No. 4,969 discloses a concrete pouring formwork composed of connectable blocks made of expanded polystyrene or the like. However, since the block formed by foam molding has a smooth surface, even if it is used as a formwork, it has low joint strength and integrity with concrete.

The used foamed molded products are usually discarded as they are or after being crushed or incinerated. However, such a method cannot effectively use resources. Further, since the foam-molded article has a low bulk density, it requires a large volume for transportation. In addition, waste treatment and incineration cause environmental pollution.

[0005]

SUMMARY OF THE INVENTION Therefore, the object of the present invention is to provide excellent jointability and integrity with concrete and the like.
It is an object of the present invention to provide a concrete casting formwork which is useful in recycling wastes of a molded foam of a thermoplastic resin as a waste formwork.

Another object of the present invention is to provide a formwork which is excellent in cushioning properties, heat insulation properties and the like and which is useful for protecting concrete structures.

[0007]

Means for Solving the Problems The inventors of the present invention crush a foam, fill the crushed product in a mold under the temperature and pressure conditions where the crushed foamed particles are fused, and heat and compress the crushed product. Due to the crushed material, irregularities are formed on the surface of the recycled foam,
The present invention has been completed by finding that a mold having a rough surface and having high joint strength and integrity with concrete can be obtained.

That is, the formwork for concrete formwork of the present invention is a waste formwork composed of a foam containing waste of a thermoplastic resin foam, and is composed of a molded body in which crushed foam particles are fused. Has been done.

In the present specification, the term "abandoned formwork" means a formwork which is integrated with concrete and is used as a part of a structural member without being disassembled. "Expanded particles"
The term "crushing" refers to particles formed by foaming particles of a thermoplastic resin that have been used for foaming, and are used for foaming. Means a means for making the details smaller.

[0010]

Embodiments of the present invention will now be described in more detail with reference to the accompanying drawings as needed.

The type of foam of the thermoplastic resin is not particularly limited, and may be, for example, an olefin polymer (for example,
Polyethylene, polypropylene, etc., styrene-based polymers (for example, polystyrene, high-impact polystyrene, styrene-acrylonitrile copolymer, styrene-butadiene copolymer, styrene-acrylonitrile-).
Examples thereof include butadiene copolymers, styrene-ethylene copolymers, styrene- (meth) acrylic acid ester copolymers and other styrene-based copolymers), and polyvinyl chloride. Crushed products of these foams may be used alone or in combination of two or more.

The cells of the foam may be open cells (air-permeable cells), but preferably include at least closed cells. Preferred thermoplastic resin foams include closed cell foams, especially styrenic polymer foams.

The styrene polymer foam is preferably composed of expanded particles obtained by expanding beads or pellets of a thermoplastic resin containing a foaming agent. A particularly preferred foam is composed of expanded particles obtained by expanding beads containing a foaming agent, and the expanded particles often have a substantially spherical shape corresponding to the shape of the beads. In addition, the foamed particles using the styrene-based polymer are composed of an aggregate of a large number of bubble chambers that independently contain a foaming gas. The partition walls forming such expanded particles are fused to each other to form the foam. Therefore, when the foam of the styrene-based polymer is crushed and reused, granular crushed materials (crushed particles) are obtained as expanded particles or aggregates thereof, and the filling efficiency in the molding die can be increased.

As the foaming agent, a conventional foaming agent, for example, a volatile foaming agent (for example, propane, i, etc.) is used depending on the kind of the thermoplastic resin, the desired expansion ratio, the foaming temperature, and the like.
-Butane, n-butane, pentane and other aliphatic hydrocarbons, freon and other halogenated hydrocarbons), decomposable foaming agents (e.g., azo compounds, azide compounds, etc.) and the like can be appropriately selected. The content of the foaming agent is, for example, 2 to
It is often 10% by weight, preferably about 3 to 8% by weight. Further, conventional additives such as foaming aids can also be used. The content of the foaming aid is, for example, about 0 to 2% by weight. Further, the thermoplastic resin includes a plasticizer, an antioxidant,
It may contain various additives such as an ultraviolet absorber, a flame retardant, and a coloring agent.

The thermoplastic resin foam often has, for example, an average expansion ratio of 5 to 100 times, preferably about 10 to 80 times, and a bulk density of about 5 to 50 g / L.

A feature of the present invention is that a crushed material composed of waste material of the thermoplastic resin foam is used. Unlike the foam before reclaiming, the surface of such a crushed material has unevenness due to the presence of open cells and the aggregation of a plurality of fused foam particles. Therefore, when filling the mold and heating and compressing to fuse the crushed material, if the heating and / or pressure is small, the surface of the regenerated molded article has uneven portions due to the crushed material. It is formed. Further, even if the heating and / or the pressure is high, a regenerated foam having an uneven portion on the surface can be obtained due to the voids existing between the mold surface and the surface of the crushed material. Therefore, by using a mold made of recycled foam, the uneven surface can enhance the integrity with concrete. In addition, since the formwork is made of recycled foam, the concrete structure can be protected by the heat insulation and cushioning properties of the foam, and the stress generated by the shrinkage / expansion of the placed concrete is generated. Can be absorbed by

The crushed material may contain at least one expanded particle, but the preferable crushed material is 2 to 100,
It preferably contains 5 to 75, and more preferably 10 to 75 expanded particles. When such a crushed product is used, the molding workability is not impaired, and the foamed particles are not destroyed even if they are fused by heating and compression. In particular, when a crushed product containing a plurality of expanded particles is used, a recycled foam excellent in cushioning property and mechanical strength while suppressing the destruction of the expanded particles and having the same bulk density as the foam before regeneration. Can be molded into

When a foam is produced using thermoplastic resin beads, it is usually 0.2 to 4 mm, especially 0.4 to 4 mm.
Beads having a diameter of about 3 mm are often used, and the diameter of the expanded particles is usually 1 to 10 mm, particularly 1 to 8.5 mm in many cases.

As the crushed product, a crushed product of a foam having an average diameter of 5 to 50 mm, preferably 10 to 25 mm, depending on the size of the foamed particles can be used. If the average diameter of the crushed product is less than 5 mm, the foamed particles are destroyed, and the uniformity and cushioning property of the regenerated foamed molded product are likely to deteriorate, and if it exceeds 50 mm, the molding work including the filling property into the molding die is performed. Often impaired. In addition,
The average diameter of the crushed product is, for example, 1.
It is about 5 to 50 times, preferably about 2 to 40 times, and more preferably about 3 to 30 times.

The scrap frame may be made of a foam containing the crushed material, or may be formed of a foam containing only the crushed material containing the foamed particles, and if necessary, the crushed material. In addition to the above, it may be formed of a foam in which beads and pellets of a fresh thermoplastic resin containing a foaming agent are used together. The content of the beads or pellets can be selected according to the effective utilization of the crushed product, the expansion ratio of the beads, etc., for example, 0 to 1 with respect to 100 parts by weight of the crushed product.
The amount is 00 parts by weight, preferably about 5 to 50 parts by weight.

In such a foam, the crushed materials are fused together to form a concrete casting formwork as a scrap formwork. The formwork usually comprises side walls facing each other.

FIG. 1 is a schematic perspective view showing an example of the mold of the present invention. In this example, the mold has side walls 1a and 1b facing each other, and a plurality of convex portions 2 formed on the inner surfaces of the side walls 1a and 1b. The convex portion 2 has a side wall 1
It extends in the vertical direction of a and 1b and is formed at predetermined intervals in the longitudinal direction.

Further, the mold is provided with a partitioning member 4 which is fitted in the groove 3 between the convex portions 2 in order to partition a proper place between the side walls 1a and 1b. The partition member 4 is also made of a foamed material containing a crushed product of the foamed molded body, like the mold.

In such a mold, the surface of the foamed molded product before regeneration is smooth, while the foamed product containing the crushed material of the thermoplastic resin foam is formed. An uneven portion is formed on the. Moreover, the side walls 1a, 1b
Since the convex portion 2 and the groove 3 are formed on the inner surface of the, the joint strength and the integrity with the cast concrete can be enhanced. Therefore, when it is used as a scrap frame, it can be integrated with a concrete structure, and when it is used as a foundation of a concrete structure, heat insulating properties, cushioning properties, etc. can be enhanced. Further, by using the partition member 4, not only can the proper positions such as both ends in the longitudinal direction of the mold be partitioned, but also the elasticity of the partition member 4 made of recycled foam can be utilized to tightly close the side wall. It is possible to partition the space between 1a and 1b, and it is possible to easily form a predetermined lightweight formwork having high integrity.

The scrap frame need not be provided with the partition member, and may be a mold having side walls formed at both ends in the longitudinal direction. Further, it is not always necessary to form the concave and convex grooves on the inner surface of the scrap frame. Further, when the uneven groove is formed, it is not limited to the uneven groove extending in one direction as described above, and may be an uneven portion which is regularly or irregularly formed or an uneven portion such as a lattice shape.

Further, since the partition member has elasticity as described above, the width of the partition member is made slightly larger than the distance between the side walls so that the side walls facing each other can be tightly fitted only by fitting them. Can be partitioned. for that reason,
The partition member can be appropriately selected according to the structure of the mounting portion of the side wall, as long as it can partition the opposing side walls, and both end surfaces of the partition member may be formed flat.

FIG. 2 is a schematic perspective view showing another example of the mold of the present invention. In this example, the formwork is composed of a plurality of blocks 11 that are adjacent to each other and can be connected to each other, and a partition member 15 that partitions between the opposing side walls of the two connected block rows.

Fitting portions for fitting adjacent blocks 11 to each other by fitting are formed on both end faces of each block 11. That is, in this example, a concave groove 12 extending in the vertical direction is formed on one end surface of the block 11, and a convex portion 13 that can be fitted into the concave groove 12 is formed on the other end surface. Therefore, the adjacent block 1
By connecting 1 using the concave groove 12 and the convex portion 13, it is possible to form the side wall of the mold configured by the block row.

Further, on the inner surface of each of the blocks 11, there is formed a recess 14 extending in the vertical direction as a fitting portion.
The recess 14 is used to partition the side walls of the two block rows by fitting the partition member 15.

Each of the blocks 11 and the partition member 15 is made of crushed thermoplastic resin foam.

In such a mold, by assembling each block 11, it is possible to form a side wall composed of two opposing block rows, and by adjusting the number of blocks 11, the length of the mold can be reduced. You can control. Moreover,
Each block 11 is formed in the same shape. Therefore, it is sufficient to mold one type of block, the molding work is easy, and various rectangular molds can be easily and quickly formed according to the size of the structure at the construction site.

Moreover, since each block 11 is composed of a crushed product of a thermoplastic resin foam, the unevenness of the side wall formed due to the crushed product and the concave portion 14 not used for partitioning make the concrete The joint strength and integrity of the can be increased. Further, the partition member 15 is 2
Since it also functions as a support member that crosses between the two block rows, the formwork can be reinforced and the integrity can be improved.

The connecting portion for connecting the adjacent blocks is not limited to the concave groove and the convex portion, but may be, for example, concave-convex fitting, dovetail groove fitting, or sliding fitting using concave grooves and convex ridges. Each block may be connected using various connecting means of. Further, each block row need not be formed of blocks having the same shape. For example, a block having convex portions formed on both end surfaces and a block having concave portions to which the convex portions can be fitted are formed on both end surfaces. By connecting them next to each other alternately,
Block rows may be formed.

In addition, it extends vertically in the inner surface of each block,
The mounting portion for mounting the partition member is not limited to the concave portion or the concave groove, but may be formed by a convex strip or the like, and the mounting portion may be formed at an appropriate place of each block, for example, a side portion of the block. Good. Further, the mounting portion may be formed on the inner surface of the block in relation to the shape of the end surface of the partition member. For example, a mounting portion that can be mounted on the uneven portion formed on the partition member,
It can also be formed as an uneven portion on the inner surface of the block.
Further, it is not necessary to form the mounting portions on all blocks, and the mounting portions may be formed on the blocks located at both ends of the block row. Each block may have a curved cross-sectional shape.

The mold may include a plurality of partition members of three or more. For example, it may be provided with two partition members for partitioning both longitudinal ends of the two block rows and at least one partition member for partitioning an appropriate portion such as an intermediate portion of the two block rows. In this case, the height of the partition member for partitioning the middle portion of the block row may be smaller than the height of the block.

Further, the partition member is not limited to the case where it is mounted on the mounting portion formed on the inner surface of the block in the vertical direction as described above to partition the block row, and it is possible to partition the block row at an appropriate position. For example, in order to reinforce the connecting portion adjacent to each block in the block row, U-shaped slits having a width corresponding to the thickness of the adjacent region are formed vertically on both sides of the partition member, and the slits of the blocks are formed in the slits. The connecting portion may be reinforced by mounting the connecting adjacent area.

Further, the formwork may be provided with a bottom wall or a bottom wall block which can be assembled with the side wall or the block.
The bottom wall and the block for the bottom wall, and the side wall and the block,
For example, the concave portion and the convex portion formed on the surfaces abutting each other can be assembled by using concave-convex fitting, dovetail fitting, slide fitting and the like.

FIG. 3 is a schematic perspective view showing still another example of the mold of the present invention. In this example, the mold is provided with a plate-shaped recycled foam having side walls 21a and 21b facing each other, and a plurality of dovetail grooves 22 formed in the inner surface of the side walls 21a and 21b in the vertical direction. . These dovetails 22
Of these, partition members 23 are fitted in the dovetail grooves 22 located on both sides of the side walls 21a and 21b in the longitudinal direction, and the side walls 21a and 21b are firmly partitioned. That is, fitting portions 24 matching the cross-sectional shape of the dovetail groove 22 are formed on both sides of the partition member 23. Therefore, when the fitting portion 24 of the partition member 23 is slid and fitted in the dovetail groove 22 in the vertical direction, the dovetail groove fitting structure causes the both side walls 21 to move.
a and 21b can be regulated from separating, and both side walls 21 of the formwork can be controlled.
It is possible to integrate a and 21b.

The side wall 21 among the plurality of dovetails 22
In the dovetail groove 22 located at a proper position in the longitudinal direction of a and 21b,
A frame-shaped reinforcing member 25 for arranging a reinforcing material such as reinforcing steel or carbon fiber is fitted. Similar to the partition member 23, fitting portions 26 having a cross-sectional shape that fits the dovetail groove 22 are formed on both sides of the frame-shaped reinforcing member 25. Also,
An opening 27 for inserting a reinforcing material is formed in the center of the frame-shaped reinforcing member 25. Notch recesses 28a for arranging the reinforcing material are also provided at the upper and lower ends of the frame-shaped reinforcing member 25,
28b is formed. The frame-shaped reinforcing member 25
Can be formed of recycled foam containing the above-mentioned crushed material, fresh foam, plastic, ceramics, metal, etc., and openings and notch recesses for inserting or arranging the reinforcing material should be provided at appropriate positions of the bar arrangement member. Can be formed.

In such a mold, the side walls 21a, 2
1b and partition member 23 dovetail fitting, said side walls 21a, 2
Due to the dovetail groove fitting between 1b and the bar arrangement member 25, the side walls 21a,
21b can form a rigidly integrated mold, and at the same time, the opening 27 of the bar arrangement member 25 and the cutout recesses 28a, 28b.
By arranging a reinforcing material on the concrete and pouring concrete, it is possible to form a scrap frame firmly bonded to the reinforced concrete structure.

In order to improve the integrity of the side wall forming the mold, a groove having a wide deep portion in a cross section is formed on one of the side wall and the partition member without using the above-mentioned dovetail groove fitting. Then, on the other side, a convex portion that can be fitted into the groove may be formed. For example, as shown in FIGS. 4 and 5,
Fitting grooves 32 and 42 having a T-shaped cross section are formed on the side walls 31 and 41, and the fitting groove 3 is formed on both sides of the partition members 33 and 43.
You may form the fitting parts 34 and 44 of a T-shaped cross section which can be fitted in 2, 42.

Such a fitting structure has the above-mentioned reinforcing member and
It can also be applied to a mold made up of blocks as shown in FIG. That is, it can also be applied to joining between a plurality of adjacent blocks, and joining the opposing side walls of two connected block blocks to a partition member.

The mold of the present invention was filled using various molding apparatuses, with a filling step of filling the crushed material into the cavity of the molding die together with fresh beads and pellets containing a foaming agent as needed. It can be produced by going through a molding step in which the crushed material is heated and compressed to be molded.

In the filling step, the filling amount of the crushed material into the mold cavity can be appropriately selected depending on the presence or absence of the beads and pellets containing the foaming agent and the amount thereof, but the volume of the cavity of the mold is larger than that of the mold cavity. In many cases, an excessive amount of crushed material is filled in the mold. The crushed product can be obtained by crushing the foam by various methods such as crushing, crushing and cutting. The shape of the crushed material may be a rectangular parallelepiped or the like, and is not particularly limited,
It is preferably granular, particularly substantially spherical.

In addition, with the crushing of the foam, an irregularly crushed material may be produced and the fluidity may be lowered. Also,
Since the crushed product has a low bulk density, the efficiency of filling the crushed product in the mold is likely to decrease. Therefore, crushed material, for example,
Treated with fluidizing agents such as silicone oil, fatty acid amides, fatty acid esters and waxes, or crushed products such as wax, polyethylene, polypropylene, polystyrene, polymethylmethacrylate, silica or other organic or inorganic powder You may add an agent. The amount of the fluidizing agent used can be selected from the range of, for example, about 0.1 to 5% by weight. When beads or pellets containing a foaming agent are used together, the beads or pellets can be used as a fluidizing agent.

The filling amount of the crushed material may be larger than the volume of the cavity within a range that does not impair the moldability, but is preferably 1.2 to 1.5 of the volume of the cavity of the molding die.
It is twice, especially about 1.3 to 1.5 times. If the filling amount of the crushed material is less than 1.2 times the volume of the cavity, the mechanical strength of the regenerated mold or block is likely to be impaired, and if it exceeds 1.5 times, the molding workability is deteriorated and the mold is also damaged. The heat insulation and cushioning properties of the blocks and blocks tend to deteriorate.

In the molding step, the filling material is heated and compressed to fuse the crushed materials to each other. In this molding process,
In order to fill the crushed material in excess of the volume of the mold cavity, it is preferable to soften the crushed material while heating the packed crushed material, and compress and fuse by mold clamping while continuing heating. . Mold clamping is often done gradually. In such a method, even if an excessive amount of crushed material is filled and heated and pressed, the surface has uneven portions, and a uniform regenerated foam is produced by forced mold clamping and compression. Also, when beads and pellets containing a foaming agent are used together, even if the amount is small, it is possible to enhance the fusion integrity with the crushed material containing the foamed particles by heating and pressurizing, and thus the regenerated foaming with high integrity Can form the body.

Incidentally, in order to fill the cavity of the molding die with an excessive amount of crushed material, the mold is often provided with a movable die which is movable inside the fixed die.

Since the crushed material has almost no foaming ability, the heating temperature is often set within a temperature range in which the thermoplastic resin is fused. For example, when the thermoplastic resin foam is made of a styrene-based polymer, the heating temperature is, for example, about 100 to 130 ° C. The heat source for heating is not particularly limited, but heated steam is often used.

Incidentally, in order to increase the bonding strength of the crushed material by heating, depending on the kind of the thermoplastic resin, the crushed material may contain a cross-linking agent such as an organic peroxide and one or more polymerizable unsaturated bonds. You may add the polymerizable monomer and polymerization initiator which have.

After the molding step, the crushed material is recycled into a mold or a mold block by cooling the molding die and / or the regenerated foam by water cooling, leaving to cool, etc., and opening the mold to release it. it can.

When the crushed material of the foamed thermoplastic resin is regenerated in this manner, since the crushed material contains the expanded particles, the thermoplastic resins around the expanded particles are fused to each other while holding the expanded particles. Therefore, the regenerated mold has high cushioning properties, heat insulating properties, and impact resistance even if it has the same specific gravity as that of the foam before recycle, and exhibits the same properties as the foam before recycle.

The concrete pouring formwork of the present invention is used as a waste formwork of a concrete structure. The formwork can be applied to an appropriate place of a concrete structure, for example, a foundation.

[0054]

EFFECTS OF THE INVENTION Since the formwork of the present invention is composed of a molded product having a crushed material containing foamed particles fused and having an uneven portion on the surface, it is excellent in jointability and integrity with concrete, Waste of molded foam of thermoplastic resin can be reused as a scrap frame. Further, the formwork composed of the crushed material,
It excels in cushioning and heat insulating properties, so it can protect concrete structures.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing an example of a mold of the present invention.

FIG. 2 is a schematic perspective view showing another example of the mold of the present invention.

FIG. 3 is a schematic perspective view showing still another example of the mold of the present invention.

FIG. 4 is a schematic perspective view of an essential part showing the joint structure of the mold of the present invention.

FIG. 5 is a schematic perspective view of an essential part showing another joining structure of the mold of the present invention.

[Explanation of symbols]

 1a, 1b, 21a, 21b, 31, 41 ... Side wall 2 ... Convex part 3 ... Groove 4,15, 23, 33, 34 ... Partition member 11 ... Block 14 ... Recess 22 ... Dovetail groove 24 ... Fitting part 32, 42 , 34, 44 ... Fitting groove

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location B29C 67/20 E 9268-4F E04B 1/16 C 7121-2E // B29K 105: 04 105: 26 B29L 31:00

Claims (4)

[Claims] 1. A concrete formwork made of a foam containing a waste material of a thermoplastic resin foam, which is made of a foam molded body in which a crushed material containing foamed particles is fused. Formwork. 2. An uneven surface is formed on the inner surface.
Formwork for concrete pouring as described. 3. The concrete pouring formwork according to claim 1, further comprising a partition member for partitioning the side walls facing each other. 4. A plurality of blocks, each of which has a formwork adjacent to each other and which can be connected to each other, a mounting portion formed on an inner wall of each block, and two blocks which can be mounted on the mounting portion and which are connected to each other. The formwork for concrete pouring according to claim 1, wherein the formwork comprises a partition member for partitioning between the side walls facing each other in the row.