JPH0839527A - Method for forming pattern on surface of concrete - Google Patents

Abstract

PURPOSE:To provide a method wherein a natural stone pattern can be expressed on a surface of concrete with a random size product consisting of a ceramic material without using a joint filling material. CONSTITUTION:A plurality of clay board materials 4 wherein an irregular pattern is formed on its surface are arranged by keeping space between them. The spaces between a plurality of clay board materials 4 are filled with a number of beads 5. Then, surfaces of a plurality of clay board materials 4 are covered with a plastic sheet 7. By attracting by evacuating from rear surfaces of a plurality of clay board materials 4 under such a state, a vacuum packaged body wherein a plurality of clay board materials 4 are integrated is formed on a plastic sheet 7. Then, concrete material is placed by using a rear surface of the vacuum packaged body as a contact surface to a surface of the concrete thereafter. The plastic sheet 7 is peeled off from the surface of the concrete after hardening by curing, and a plurality of clay board materials 4 are transferred to the surface of the concrete to be buried therein.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a pattern forming method for a concrete surface.

[0002]

2. Description of the Related Art Conventionally, the following method has been used to express a natural stone tone pattern on the surface of concrete. That is, first, as shown in FIG. 13, random size stones (natural stones) 31 are laid on the bottom of the mold 32 in an appropriate pattern, and then set in a gap between the random size stones 31 ( The joint material 33 is filled up to a certain height (less than or equal to the thickness of the random size stone 31). Next, as shown in FIG. 14, the concrete material 34 is cast from the upper end opening of the form 32, and after curing and hardening the concrete material 34, the above-mentioned hardening retarder 3
The concrete material 34, which has been delayed in hardening in No. 3, is washed off with water or the like to form a sink mark at the joint portion, and a concrete product having a swelling stone pattern as shown in FIGS. 15 and 16 is produced. To do.

[0003]

However, this method has a problem that the hardening retarder 33 must be filled in the gaps between the random size stones 31. In addition, there is also a problem that after the curing and hardening of the cast concrete material 34, the hardening delay agent 33 delays the hardening, and the concrete material 34 in the joint-corresponding portion must be washed away.

Therefore, as a method of making it possible to express a pattern on the concrete surface without using a joint material such as a curing retarder, there is a method disclosed in Japanese Patent Laid-Open No. 6-117092. This method uses a plastic sheet as a packaging material and uses a tile unit in which a plurality of tiles of the same shape are integrated in an aligned state, and the plurality of tiles are attached to the concrete surface in an aligned state. That is,
As shown in FIG. 17, tiles 43 of the same shape are arranged in an increasingly square pattern on the breathable tile alignment plate 42 in the suction box 41,
Next, a joint depth adjusting member 44 is arranged between the tiles 43, and then a plastic sheet 45 having a size that covers all the tiles 43 is covered from above, and suction is performed from the back side of the tile alignment plate 42. Reference numeral 42a is a ventilation hole formed in the tile alignment plate 42. This allows the plastic sheet 4
5 in close contact with the surface of each tile 43 and in the gap between the tiles 43,
A tile unit in which is encapsulated with a plastic sheet 45 is obtained. Next, with the plastic sheet 45 on the lower side, the tile units are placed in a formwork (not shown) that is divided at equal intervals by joints, and the gaps between the tiles 43 are set in the formwork. Engage with joints and pour concrete. Then, after the concrete is hardened, it is released from the mold and the plastic sheet 45 is peeled off to obtain a tile plate in which a plurality of tiles 43 are attached to the concrete surface.

However, this method has a problem in that it is only possible to form a pattern of aligned tiles, and it is not possible to express a natural stone-like irregular stone pattern. Further, in order to adjust the joint height, the joint depth adjusting member 4 of various heights is used.
4 must be prepared, the number of parts increases, and since the joint depth adjusting member 44 is formed in a fixed shape (in a gradual shape), when using an irregular stone material (broken stone) There is also a problem that it cannot be used for.

The present invention has been made in view of the above circumstances, and provides a method capable of expressing a natural stone pattern on a target concrete product without using a jointing material such as a set retarder. Is its purpose.

[0007]

In order to achieve the above-mentioned object, a pattern forming method for a concrete surface of the present invention is to form a plurality of irregular shaped plate materials made of a ceramic material having an uneven pattern formed on the surface thereof. By arranging them in parallel, filling a plurality of beads in these gaps, then covering the surfaces of the plurality of irregularly shaped plate materials with a plastic sheet, and applying at least one of the following (A) and (B) in that state, A packaging body is formed by integrating a plurality of irregularly shaped plate materials with the plastic sheet, and the concrete material is placed by using the back surface of the packaging body as a contact surface with the concrete surface, and the plastic sheet is peeled from the concrete surface after curing and curing. Then, the plurality of irregular shaped plate materials are transferred and embedded in the concrete surface. (A) A vacuum is drawn from the back surface side of a plurality of irregularly shaped plate materials covered with a plastic sheet. (B) Pressurizing with compressed gas from the surface side of a plurality of irregularly shaped plate materials covered with a plastic sheet.

[0008]

That is, the pattern forming method for the concrete surface of the present invention uses a plurality of irregular shaped plate materials made of a ceramic material having an uneven pattern formed on the surface. Open and line up. Next, a plurality of beads are filled in the gaps between the plurality of irregular shaped plate materials. Next, the surfaces of the plurality of irregularly shaped plate materials are covered with a plastic sheet, and in that state (A)
At least one of and (B) is applied. Thus, the plastic sheet forms a package in which a plurality of irregularly shaped plate materials are integrated. After that, the back surface of the package is used as a contact surface for the concrete surface, a concrete material is poured, the plastic sheet is peeled off from the concrete surface after curing, and the plurality of irregular shaped plate materials are transferred and embedded on the concrete surface. . On the surface of the concrete product obtained in this way, a natural stone-like disordered stone pattern is expressed by the plurality of irregularly shaped plate materials. As described above, according to the present invention, it is possible to form a natural stone pattern on the surface of a concrete product with a plurality of irregular shaped plate materials made of a ceramic material. Moreover, unlike the conventional example, it is not necessary to use a jointing material such as a set retarder, and the work of manually laying out the natural stones in the formwork and the work of washing the surface of the concrete material with water after curing and curing are unnecessary. Become.

Next, the present invention will be described in detail.

Examples of the ceramic material used in the present invention include natural raw materials such as clay, porcelain stone, silica stone and feldspar, and synthetic raw materials such as alumina, zirconia, silicon carbide and silicon nitride, and preferably clay. Used. A color close to that of natural stone may be forcibly expressed by partially mixing different pigments into such a ceramic material. It is also conceivable to add a foam material.

The beads used in the present invention are spherical,
Examples include glass beads, sand, metal powder, etc. formed into a tubular shape. Such beads are filled in the gaps between a plurality of irregularly shaped plate materials, and the joint height can be adjusted by the number of filled beads, and the gaps formed between the beads can provide air permeability. it can.

The material of the plastic sheet used in the present invention is thermoplastic such as polyethylene (PE), polypropylene (PP), acrylonitrile-butadiene-styrene copolymer resin (ABS), polyvinyl chloride (PVC), polystyrene (PS). Resin is an example. Also,
The thickness of the plastic sheet is 1.0 to 5.0 mm
The strength is set in the range of 250 to 750 kg /
It is set in the range of cm ² (tensile strength). By setting the strength in such a range, the plastic sheet can be used as a contact surface for the concrete surface.

Further, in the present invention, in order to integrate a plurality of irregular shaped plate materials with the above-mentioned plastic sheet, vacuuming is performed from the back side of the plurality of irregular shaped plate materials and compression is performed from the front side of the plurality of irregular shaped plate materials. At least one of pressurizing with a gas is performed. A known vacuum forming apparatus or the like is used as such a vacuuming means, and a known pneumatic forming apparatus is used as a pressurizing means with a compressed gas.

Next, an embodiment will be described.

FIG. 1 shows a vacuum forming apparatus used in an embodiment of the present invention. This vacuum forming apparatus includes a mold 1 having an open upper surface, a communication pipe 2 extending from a suction port formed in a bottom wall 1a of the mold 1, and a vacuum pump (not shown) communicating with the communication pipe 2. ) And a perforated plate 3 with perforations 3a placed on the stepped portion of the inner peripheral surface of the mold 1, and as shown in FIG. A plurality of clay plate materials 4 on which patterns are formed are placed with a gap therebetween in a state of facing upward, and then a large number of beads 5 are filled between the clay plate materials 4 as shown in FIG. Adjust to Next, as shown in FIG. 4, the plastic sheet 7 is attached to the upper end of the mold 1 by using the attachment frame 6, and the heater 8 is arranged above the plastic sheet 7. After that, the plastic sheet 7 is softened by the heater 8 and the inside of the mold 1 is evacuated through the communication tube 2 as shown in FIG. Thereby, as shown in FIG. 6, the plastic sheet 7 is integrated with the surface of the clay plate material 4. In this way, the plastic sheet 7 integrated with the clay plate 4 is set in the molding frame 9 with its back surface facing upward (FIG. 7).
reference). At this time, as shown in FIG. 8, before the setting, the height adjusting rubber 10 is disposed at a predetermined position on the bottom surface of the molding frame 9 (for example, a portion where the gaps between the clay plate members 4 intersect). After the above setting, a urethane foam 11 is filled around the height adjusting rubber 10 with a syringe or the like, and this portion (the plastic sheet 7 does not lower due to the weight of the concrete material described below) Make sure to have the required load-bearing strength. After that, as shown in FIG. 9, the concrete material 12 is filled from the upper end opening of the molding frame 9, and after curing and curing, the plastic sheet 7 is peeled off as shown in FIG. As a result, a concrete product as shown in FIG. 11 is obtained. The concrete product obtained in this manner includes a plurality of irregularly shaped clay plates 4
A natural stone pattern is expressed by.

As described above, in the above-described embodiment, since the joint material such as the set retarder is not used, the work of manually laying the natural stones on the formwork 9 is unnecessary, and the concrete material 12 after curing and hardening is not required. It eliminates the need to wash away.

FIG. 12 shows another embodiment of the present invention. In this embodiment, the plastic sheet 7 is integrated with the surface of the clay plate 4 by pressurizing the surface side of the plastic sheet 7 with compressed gas. Therefore, using the mold 15 in which the suction port is not formed in the bottom wall 15a as in the above embodiment, a plurality of clay plate materials 4 are directly placed on the bottom wall 15a of the mold 15, and then, Similar to the above embodiment, a large number of beads 5 are filled between the clay plates 4, and then a plastic sheet 7 is attached to the upper end of the mold 15 using the attachment frame 6 and a heater (not shown).
Then, the pressing plate 17 is mounted on the mounting frame 6 to seal the internal space, and in this state, the pressing plate 1
The compressed air is sent to the internal space from each branch pipe 16a of the manifold 16 attached to the No. 7 manifold. The other parts are the same as those in the above embodiment, and the same parts are denoted by the same reference numerals.

In both of the above-mentioned embodiments, when the plastic sheet 7 with the clay plate material 4 integrated is set in the molding frame 9, the height adjusting rubber 10 is arranged at a predetermined position, and after the setting, Although urethane foam 11 is filled around the height adjusting rubber 10, the invention is not limited to this, and the strength of the plastic sheet 7 itself is set to a strength that can withstand the weight of the concrete material 12. Accordingly, the use of the height adjusting rubber 10 and the urethane foam 11 may be omitted.

Further, the clay sheet material 4 is attached to the plastic sheet 7.
As a method of integrating the above, both a method of drawing a vacuum from the back surface side of the plastic sheet 7 and a method of pressurizing with a compressed gas from the front surface side of the plastic sheet 7 may be used together.

[0020]

As described above, according to the method for forming a pattern on the surface of concrete according to the present invention, it is possible to form a natural stone pattern on the surface of the concrete product with a plurality of irregular shaped plate materials made of ceramic materials. . Moreover, unlike the conventional example, it is not necessary to use a joint material such as a curing retarder,
The work of manually laying out natural stones on the formwork and the work of washing the surface of the concrete material with water after curing and curing become unnecessary.

[Brief description of drawings]

FIG. 1 is an explanatory diagram of a vacuum forming apparatus used in an embodiment of the present invention.

FIG. 2 is an explanatory diagram showing a state in which a clay plate material is placed on a perforated plate.

FIG. 3 is an explanatory diagram showing a state in which beads are filled in a gap between clay plate materials.

FIG. 4 is an explanatory view showing a state in which a plastic sheet is attached to the mold.

FIG. 5 is an explanatory diagram showing a state in which a vacuum is drawn.

FIG. 6 is an explanatory view showing a state where a clay plate material is integrated with a plastic sheet.

FIG. 7 is an explanatory diagram showing a mold.

FIG. 8 is an enlarged explanatory view showing a main part of the mold.

FIG. 9 is an explanatory view showing a state where concrete is poured into the formwork.

FIG. 10 is an explanatory diagram showing a state in which a plastic sheet is peeled off.

FIG. 11 is an explanatory diagram of a concrete product.

FIG. 12 is an explanatory view showing another embodiment of the present invention.

FIG. 13 is an explanatory view showing a mold of a conventional example.

FIG. 14 is an explanatory view showing a state in which concrete is cast on the mold of the conventional example.

FIG. 15 is a sectional view of a concrete board obtained by the conventional example.

FIG. 16 is an explanatory diagram of a stone pattern of a concrete board obtained by the conventional example.

FIG. 17 is an explanatory diagram showing another conventional example.

[Explanation of symbols]

 4 Clay board 5 Beads 7 Plastic sheet 12 Concrete material

Claims (1)

[Claims] 1. A plurality of irregular shaped plate materials made of a ceramic material having an uneven pattern formed on the surface thereof are arranged with a gap therebetween, a plurality of beads are filled in these gaps, and then the plurality of irregular shaped plate materials The surface is covered with a plastic sheet, and at least one of the following (A) and (B) is applied in that state to form a package in which a plurality of irregular-shaped plate materials are integrated by the plastic sheet. For the concrete surface characterized by placing the concrete material with the back surface in contact with the concrete surface, peeling off the plastic sheet from the concrete surface after curing and curing, and embedding the plurality of irregular shaped plate materials on the concrete surface. Pattern formation method. (A) A vacuum is drawn from the back surface side of a plurality of irregularly shaped plate materials covered with a plastic sheet. (B) Pressurizing with compressed gas from the surface side of a plurality of irregularly shaped plate materials covered with a plastic sheet.