JPH0742179B2 - Pseudolite manufacturing method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a pseudo rock used for landscape of a leisure facility in a theme park or for decoration of an event venue.

[0002]

2. Description of the Related Art When natural rocks are used as they are when they are needed for scenery of leisure facilities or for decoration of event venues, it is inconvenient in terms of weight.
Moreover, since it is difficult to collect rocks having an intended shape and size, artificial rocks that are artificial rocks that imitate natural rocks are generally used. As this pseudo rock, conventionally,
Those made of FRP (glass fiber reinforced plastic) and those made of GRC (glass fiber mixed concrete) are known.

The FRP pseudo rock is made into a shaping mold based on a female mold that is copied from the surface of natural rock, glass fibers and synthetic resin are alternately coated on the back side of the molding mold, and after waiting for hardening, it is removed. By shaping, a plurality of panels imitating the shape of the original rock are formed, and the panels are attached one by one to a frame such as an iron frame, caulking a joint, and coloring the surface to manufacture.

Since this FRP pseudo rock uses a shape copied from a natural rock, the surface pattern has a good appearance and is suitable for appreciation or decoration. However, since all the panels are attached by hand, in the case of forming a large pseudo rock that requires a large number of panels, the labor cost is increased and the construction period is extended accordingly. Further, in such a case, since the same pattern of the panel makes the pattern monotonous and unnatural, it is necessary to prepare many kinds of patterns, which increases the manufacturing cost. Further, it has a problem that it has a high surface hardness and is not suitable for a place where it comes into direct contact with the human body, and it is weak against fire and cannot be used in a place where fireproof performance is required.

On the other hand, the above-mentioned GRC pseudo-rock is made by applying cement mortar mixed with glass fibers to solidify it and shaping it like rock, and is manufactured as follows. First, attach a metal lath to the frame made of steel frame,
Cement mortar mixed with glass fibers is applied onto the metal laths twice and three times and cured to form a substrate. Next, after the base material has completely hardened, using a mortar spray machine,
While spraying cement mortar mixed with glass fiber and other decorative mixture, if necessary, use a trowel or other tool to shape and create the final shape.
It may be completed in this state, but it may be finished with a color spray or other top coat.

[0006] This pseudo-rock made of GRC is not suitable for appreciation or decoration because it is less attractive than that made of FRP, but the manufacturing cost is relatively low, so that it is large in caves and rock mountains at theme parks. It is excellent in that it is easy to form pseudo rocks, its shape can be changed relatively freely, and because it is made of non-combustible material, it is suitable for places where fire is used and places where fire prevention performance is required. However, because of the large number of work steps, the construction period is relatively long, the workmanship of the workers directly affects the product results, and the rough surface results in poor waterproofness, and the surface coating costs too much. This is a problem in that it cannot be used in a place where it will be splashed with water unless it is applied, and because it has a high surface hardness, it cannot be used in a place that is directly touched by the human body.

[0007]

DISCLOSURE OF THE INVENTION The present invention is intended to solve the above-mentioned problems of the prior art, and its purpose is to make the construction easy and to reduce the manufacturing cost, and the special skill of the operator. It is possible to realize the appearance of a pseudo-rock that is natural and rich in variation without depending on, and it is excellent in self-extinguishing property itself, and can easily add performances such as waterproofness and noncombustibility. An object of the present invention is to provide a method of manufacturing pseudo rocks that has a wide range of use and is not dangerous even if it is installed in a contact place.

[0008]

In order to achieve the above-mentioned object, a method for producing a pseudo rock according to the present invention is to form a frame member by assembling a rebar at a place where the pseudo rock is intended to be installed, and forming an outer surface of the frame member. Is coated with a metal lath, lath mortar is placed on the mesh of the metal lath to form a substrate, and two liquids of isocyanate and polyol are mixed and injected toward the outer surface of the substrate, and the polyurethane material is foamed and cured on the outer surface. A hard polyurethane foam layer is formed, and a surface layer covering at least a part of the hard polyurethane foam layer is formed by mixing and spraying two liquids of polyurethane and aromatic amine on the surface of the hard polyurethane polyurethane layer. It is characterized by forming.

Further, in another method for producing pseudo rock according to the present invention, a plurality of corrugated pipes are arranged at the location where the pseudo rock is intended to be installed on the inner wall surface of a facility that utilizes the internal space such as a tunnel or a cave. A base material is formed, and two liquids of isocyanate and polyol are mixed and jetted toward the surface of the base material,
The rigid polyurethane foam layer is formed by foaming and curing a polyurethane material on the surface of the base material, and at the same time, two liquids of polyurethane and aromatic amine are mixed and sprayed on the surface of the rigid foam polyurethane layer to form the rigid foam polyurethane layer. Was formed to form a surface layer covering at least a part of the surface of the.

Further, according to another method of manufacturing a pseudo rock according to the present invention, a plurality of arch-shaped members are installed at predetermined intervals at locations where the pseudo-rock is intended to be installed, and each arch-shaped member is provided with a plurality of reinforcing materials. A frame member is formed by connecting them, the outer surface and the inner surface of the frame member are covered with a metal lath, and lath mortar is placed on at least one mesh of both metal laths to form a base material, and isocyanate is directed toward the outer surface and the inner surface of the base material. And two liquids of polyol and polyol are mixed and sprayed to form a hard polyurethane foam layer by foaming and curing the polyurethane material on the outer surface and the inner surface of the base material, and polyurethane and aromatic amine are formed on at least one surface of both hard foam polyurethane layers. By mixing and injecting the two liquids described above, a surface layer that covers at least a part of the surface of the rigid polyurethane foam layer is formed. .

[0011]

According to the above-described method for producing pseudo rock, the free foaming / hardening action of the polyurethane material on the surface of the base material provided at the place where the pseudo rock is intended to be installed is not restricted by the formwork or the like. Since the appearance of the pseudo-rock is determined, it is possible to obtain a natural and surprising strange appearance very easily by on-site construction, without depending on the special skill (design ability) of the worker.

The hard polyurethane foam layer itself is lightweight, and since it has elasticity, it can exhibit shock absorbing properties and also has excellent self-extinguishing property. In addition, since the hard urethane foam layer is formed of closed cells, it is difficult to absorb water even when immersed in water, and therefore, it can be used even when it is always under the water surface. By mixing and spraying two liquids of polyurethane and aromatic amine on the surface of this hard polyurethane foam layer to form a surface layer, the pseudo rock is given about 6 times the wear resistance of iron and more excellent waterproofness. can do.

[0013]

EXAMPLES A method for producing pseudo rock according to the present invention will be described below with reference to the illustrated examples. FIG. 1 is a transverse sectional view showing a first pseudo rock 2 according to the first embodiment, and FIG. 2 is a longitudinal sectional view thereof. The first pseudo rock 2 is embedded in the frame member 8 formed by assembling the arch-shaped reinforcing bar 4 and the linear reinforcing bar 6, the lath mortar layer 10 covering the frame member 8 and the lath mortar layer 10. A first metal lath 12, a hard polyurethane foam layer 14 that covers the surface of the lath mortar layer 10, and a waterproof and abrasion-resistant surface layer 16 that covers the hard polyurethane foam layer 14 are provided. Become. The first pseudo rock 2 is formed on the left and right ends 1 of the arch-shaped reinforcing bar 4.
8 and 18 are fixedly installed by embedding them in the ground or floor surface 20 of the construction site (the site where pseudo rock is intended to be installed). A cavity 22 is formed inside the first pseudo rock 2.

Next, a method of manufacturing the first pseudo rock 2 will be described with reference to FIGS. First, the frame member 8 is formed by assembling the arch-shaped reinforcing bars 4 and the linear reinforcing bars 6 according to the shape and size of the pseudo rock required and the situation of the construction site (FIG. 3). At this time, it is desirable to connect the arch-shaped reinforcing bar 4 and the linear reinforcing bar 6 by welding.

A first metal lath 12 is provided on the frame member 8.
And the frame member 8 and the first metal lath 12 are tightly bound together with a wire or the like (FIG. 4). At this time, appropriate irregularities are formed on the first metal lath 12 to roughly define the outer shape of the pseudo rock.

Lath mortar (cement mortar mixed with glass fibers) 24 is placed on the first metal lath 12 so as to be entangled with the mesh of the first metal lath 12 to form the lath mortar layer 10 (FIG. 5). . As a result, a pseudo rock matrix is formed. At this point, the degree of lath mortar 24 is appropriately adjusted, and the lath mortar 24 is shaped to some extent so that it looks like natural rock.

On the surface of the lath mortar layer 10, an isocyanate (Isoc) as a raw material for rigid polyurethane foam is
The two liquids of yanate) and polyol (Polyol) are mixed and sprayed by the spray gun 26 to form the rigid polyurethane foam layer 14 (FIG. 6).
At this stage, the final contour of the pseudo rock is determined.
The hard polyurethane foam layer 14 is formed to have a thickness of about 2 cm.

Finally, the rigid polyurethane foam layer 14
Uniroyal Chemical Company (Uniroy
al Chemical Co. , INC. ), Which is a patented product of Vibra Spray C-80, is spray coated to form a surface layer 16 having a thickness of about 2 to 3 mm (FIG. 7). Specifically, the spray coating with the Vibra spray C-80 is to spray and spray polyurethane (Polyurethane) and aromatic amine (Aromatic Amine) through the spray 28, and the surface layer 16 formed as a result is In particular, it is called Unicoat (registered trademark).

The surface layer 16 by vibraspray C-80, that is, the unicoat, has excellent waterproofness and extremely high abrasion resistance of about 6 times that of iron.
The rigid foamed polyurethane has a high foaming ratio, is relatively fragile, and has a surface that is vulnerable to local impact. By applying the surface layer 16, the surface strength can be increased and local destruction can be prevented. However, this Vibraspray C-80
Since the formation of the surface layer 16 by
Depending on the purpose of use, other general paints (for example, a two-component urethane paint composed of isocyanite and polyol) may be used together.

If necessary, the surface layer 16 is colored. For this coloring, there are a method of applying a predetermined colorant on the surface layer 16 and a method of mixing an appropriate pigment in the material of the surface layer 16. Alternatively, there is also a method in which a pigment is mixed into the material of the surface layer 16 to carry out primary coloring, and then another coloring agent is further applied to carry out secondary coloring to enhance the coloring effect. The most suitable coloring method may be selected from the above depending on the place and purpose of use of the pseudo rock. The material of the vibraspray C-80 itself has a light greenish ocher color, and it is difficult to finish it in a desired color simply by mixing a predetermined pigment therein. Therefore, a predetermined pigment is mixed and sprayed on the material of the vibraspray C-80 to form the surface layer 16 in a color close to a desired color in advance, and the surface layer 16 is finished with a silicone or acrylic paint. It is desirable to color.

The hard polyurethane foam itself has self-extinguishing properties, but by applying a suitable noncombustible agent such as a cement-based spraying agent on the surface layer 16, the first pseudo rock 2
The fire protection performance of may be further improved. As described above, the first pseudo rock 2 according to the first embodiment is completed.

Since the shape of the rigid foamed polyurethane layer 14 is subject to natural foaming action, it is not necessary to prepare a mold or the like, and no special skill for designing is required. However, the hard foamed urethane layer 14 is desired by appropriately cutting and polishing the hard foamed urethane that has been foamed and hardened to a size slightly larger than the final shape of the intended product using a tool such as a knife or a sander. You may finish in a shape.

The above-mentioned hard polyurethane foam has a good work efficiency because the foam hardening is completed within a few minutes after the injection and the next work can be started promptly, and furthermore, the cutting and polishing are easy and the workability is excellent. Even if there is a processing error, it is possible to easily correct it by re-injecting the material only to that portion. Further, since the hard urethane foam is formed of closed cells, it does not absorb water even when immersed in water. Further, the rigid urethane foam has excellent shock absorbing properties.

In order to facilitate the construction and save the material, the first pseudo rock 2 has an opening 30 in the drawing, but the opening 30 is not necessarily provided, and the installation place or purpose of use is not limited. According to the above, the opening 30 may be closed.

The first pseudo rock 2 is used, for example, for decorating a room, a garden, or the like. In addition, because it is lightweight, it is easy to install and move, and if it is damaged, it is easy to repair,
It is suitable for theater sets, movie / TV sets, etc. Or, because its dismantling and removal is relatively easy,
It is also suitable for decoration of event venues such as exhibitions and expositions. When the shock absorbing property is used for a children's game, the player's body is not damaged and safety is improved. In any case, regardless of its shape and size, it can be manufactured in any size in one piece and only by on-site work, so its range of use is extremely wide, and it can be used to produce a landscape of leisure facilities. Are suitable.

Next, a method of manufacturing the second pseudo rock 32 according to the second embodiment will be described with reference to FIG. Second pseudo rock 3
2 decorates the inner wall surface 38 of a place (facility) that uses the internal space 36 thereof, such as a tunnel 35 formed under the ground 34 or a cave. That is, by arranging the semicircular corrugated pipes 40 on the inner wall surface 38 of the tunnel 35 at appropriate intervals, a pseudo rock matrix is formed.
Next, toward the surface of the corrugated pipe 40, as in the case of the first embodiment, an isocyanate (Isocya) is used.
Nate) and a polyol (Polyol) are mixed and jetted by a spray gun to form the hard foam polyurethane layer 14 on the surface of the corrugated pipe 40.
The maximum thickness is 5 to 6 cm and the minimum thickness is 2 to 3 cm. The surface layer 16 (unicoat) is formed on the surface of the hard polyurethane foam layer 14 by spraying the vibra spray C-80 in the same manner as above to improve the waterproof property and the abrasion resistance.

A third embodiment, which is a modification of the second embodiment, will be described with reference to FIG. The third pseudo rock 42 according to the third embodiment is for producing a limestone cave.
That is, in the third pseudo rock 42, a deformed rebar 44 having an arbitrary size is welded substantially vertically to an appropriate place on the surface of the corrugated pipe 40 as a base material, and the deformed rebar 44 is secondly welded to the deformed rebar 44.
The metal lath 46 is wound into an inverted conical shape, the hard foamed polyurethane layer 14 is formed on the surfaces of the corrugated pipe 40 and the second metal lath 46, and then the surface layer 16 is formed on the surface of the hard foamed polyurethane layer 14. As a result, the stalactite-shaped protrusion 4 is welded to the welded deformed rebar 44.
8 is formed.

A fourth embodiment, which is an application of the first to third embodiments, will be described with reference to FIGS. 10 and 11. The fourth pseudo rock 50 according to the fourth embodiment is formed in a rock shape on both the inner space 36 side and the outer side thereof. That is, the T-bar 52 having a T-shaped cross section is used as a ridge, and the upper ends of the pair of quarter-circular members 56, 56 are welded to the left and right sides of the T-bar 52 through the connecting fittings 54, 54. Four
A plurality of angle members 58 having an L-shaped cross section are welded to the outside of the quarter-circular members 56, 56, and the quarter-circular member 5
A plurality of C channels 60 having a C-shaped cross section are welded to the inside of 6, 56 at positions corresponding to the welding positions of the angle member 58 to form the frame member 8 (FIG. 11). This frame member 8 is
As is apparent from FIGS. 10 and 11, a plurality of arch-shaped members formed by joining a pair of quarter-circular members 56, 56 are installed at a predetermined interval, and each arch-shaped member is T-shaped. The bar 52, the angle member 58, and the C channel 60 are connected by a reinforcing member. Then, the lower ends of the quarter-circular members 56, 56 are fixed to the base parts 64, 64 by anchor bolts 62, 62 to be installed.

Next, the first metal lath 12 is connected to the angle member 58, and the C-channel 60 is also connected to the first metal lath 12.
Connect the metal lath 12 of. Angle member 58 side first
Lath mortar is laid on the metal lath 12 to form a lath mortar layer 10, and a hard foamed polyurethane layer 14 is formed on the surface thereof. On the other hand, the hard foam polyurethane layer 14 is directly formed on the surface of the first metal lath 12 on the C channel 60 side without forming the lath mortar layer. Thus, on the outer side of the frame member 8, a pseudo rock matrix is formed by the frame member 8, the metal lath 12 and the lath mortar layer 10, and on the inner space 36 side of the frame member 8, the frame member 8 and the metal lath 12 are formed.
A pseudo-rock foundation is formed by.

The deformed rebars 44 are welded to appropriate places inside the quarter-circular members 56, 56, and the second metal laths 46 are wound around the deformed rebars 44 in an inverted conical shape to form a stalactite-shaped projection 48. May be formed. On the surface of the hard polyurethane foam layer 14 on the outer side, the above-mentioned Vibraspray C-8
A surface layer 16 (unicoat) is formed by spray coating of 0, and coloring or the like is applied on the surface layer 16. Further, the surface of the hard foam polyurethane layer 14 on the side of the internal space 36 is also painted with a predetermined color.

[0031]

According to the method for producing pseudo rock according to the present invention,
As mentioned above, the appearance of pseudo rock is determined by the free foaming / hardening action of the polyurethane material, which is not regulated by the formwork etc. on the surface of the base material that is intended to be installed. , It is possible to obtain a natural and surprising and unusual appearance very easily by on-site construction without depending on the special skill and design ability of the worker.

The above-mentioned rigid polyurethane foam layer is light in weight, has excellent workability and repairability, and is not only non-water-absorbing and shock-absorbing but also has excellent self-extinguishing property. Furthermore, by mixing and spraying two liquids of polyurethane and aromatic amine on the surface of this hard polyurethane foam layer to form a surface layer, about 6 times as much wear resistance as iron and even more excellent waterproofness are obtained. Can be given to. The pseudo rock according to the present invention makes use of the characteristics described above, and is used for landscape of leisure facilities, for decoration of events, for safety of children's game facilities, for interior of department stores, for decoration of walls and ceilings that also function as soundproof, etc. It can be used for a wide range of purposes regardless of the area.

[Brief description of drawings]

FIG. 1 is a transverse sectional view showing a first pseudo rock according to a first embodiment of the present invention.

FIG. 2 is a vertical sectional view showing a first pseudo rock according to the first embodiment of the present invention.

FIG. 3 is a schematic perspective view showing a manufacturing process of a first pseudo rock.

FIG. 4 is a schematic perspective view showing a manufacturing process of a first pseudo rock.

FIG. 5 is a schematic perspective view showing a manufacturing process of a first pseudo rock.

FIG. 6 is a schematic perspective view showing a manufacturing process of a first pseudo rock.

FIG. 7 is a schematic perspective view showing a manufacturing process of a first pseudo rock.

FIG. 8 is a cross-sectional view showing a second pseudo rock according to the second embodiment of the present invention.

FIG. 9 is a cross-sectional view showing a third pseudo rock according to the third embodiment of the present invention.

FIG. 10 is a transverse cross-sectional view showing a fourth pseudo rock according to the fourth embodiment of the present invention.

FIG. 11 is a schematic side view showing a fourth pseudo rock frame member.

[Explanation of symbols]

 2 1st pseudo rock 4 Arch-shaped reinforcing bar 6 Straight reinforcing bar 8 Frame member 10 Las mortar layer 12 First metal lath 14 Hard foam polyurethane layer 16 Surface layer 24 Las mortar 32 Second pseudo rock 35 Tunnel 36 Internal space 38 Inner wall surface 40 Corrugated pipe 42 Third pseudo rock 50 Fourth pseudo rock 52 T bar 54 Connecting metal fitting 56 Quarter circular member 58 Angle material 60 C channel

Claims (3)

[Claims] [Claim 1] Reinforcing bars are installed at locations where pseudo rocks are intended to be installed.
To form a frame member and cover the outer surface of the frame member with a metal lath
And add lath mortar to the mesh of the metal lath
It is attached to form a base material, and isocyanate is turned toward the outer surface of the base material
And 2 polyols are mixed and sprayed, and the poly
Form the rigid polyurethane foam layer by foaming and curing the polyurethane resin.
And the surface of the polyurethane foam layer is
Spray two liquids of urethane and aromatic amine
Of the surface of the rigid polyurethane foam layer by
Characterized by forming a surface layer covering at least a part
And a method for producing pseudo rock. [Claim 2] Utilizing the internal space such as a tunnel or a cave
In the place where the pseudo rock is installed on the inner wall of the facility,
A plurality of corrugated pipes are arranged to form a substrate, and the substrate is
Mix two liquids of isocyanate and polyol toward the surface of the
Combined injection, foaming and curing polyurethane material on the surface of the above-mentioned substrate
To form a rigid polyurethane foam layer,
The surface of the polyurethane foam layer has polyurethane and aroma.
By mixing and injecting two liquids of tick amine,
Cover at least part of the surface of the rigid polyurethane foam layer.
Pseudolite manufacturing method characterized by forming an overlying surface layer
Law. 3. A plurality of arcs are installed at the place where the pseudo rock is intended to be installed.
The arch-shaped members are installed at a predetermined interval.
To form a frame member by connecting a plurality of reinforcing members,
The outer and inner surfaces are covered with a metal lath,
Las mortar on one side of the net
And an isocyanate to the outer and inner surfaces of the base material.
The two liquids of the polyol are mixed and injected to form the outer surface and the inner surface of the base material.
The polyurethane material is foamed and hardened at the
The ton layer is formed, and
On at least one surface, polyurethane and aromatic
By mixing and spraying two liquids of quamin,
Cover at least a part of the surface of the polyurethane foam layer
A method for producing a pseudo rock, which comprises forming a surface layer.