JPH09131712A - Manufacture of concrete product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a simple method for manufacturing concrete product having excellent appearance which makes it possible to form uniform and smooth joint by fixing a decorative material in arbitrary design onto the surface. SOLUTION: The method for manufacturing concrete product comprises the steps of disposing a decorative material at a desired position in a concrete form, heating to melt joint forming thermoplastic material formed by using polymer blended material containing polymer organic material and low- molecular-weight material as main ingredients so that the content ratio of the organic material is smaller than that of the low-molecular-weight material and the organic material has a three-dimensional continuous net-like skeleton structure, casting it in the depth of partly exposing the decorative material, then curing the thermoplastic material, then placing concrete in the form, curing it until the placed concrete is cured to develop the desired strength, removing it from the form after the concrete is cured, and releasing the thermoplastic material adhered to the surface.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a concrete product in which a decorative material is fixed so that a part of the decorative material is exposed on the surface of the concrete product. The present invention relates to a method for producing a concrete product, which can be fixed to a concrete and can easily form a uniform concrete joint.

[0002]

2. Description of the Related Art Conventionally, as a method of fixing a surface decorative material such as natural stone, tile, or brick to the surface of concrete, a decorative material is laid in a concrete form, and a joint forming material is provided in a gap between the decorative materials. There is widely used a method of filling, then pouring concrete, curing it to cure it, removing the cured concrete from the mold, and then removing the joint forming material.

Agar, sand, styrofoam, paraffin and the like are used as the joint forming material in these manufacturing methods. The agar described in JP-A-63-264302 and the paraffin described in JP-A-6-23720. Materials that are brought into a fluid state by heating such as, and granular materials such as sand are roughly classified.

[0004] Agar, paraffin, etc. can be uniformly filled by filling the gap between the decorative materials by heating and pouring into a mold, but (1) Agar easily cracks due to drying and the finish of joints becomes poor. (2) When heat curing is carried out when curing concrete, the joint forming material may be in a fluidized state depending on the conditions, and the joints may become uneven.
(3) In order to prevent this, if the concrete is not heat-cured, the productivity will deteriorate. (4) It is difficult to remove the joint forming material after removing the concrete from the mold.
(5) Depending on the type of decorative material, paraffin may soak in and discolor, or the adhesion between the decorative material and concrete may be reduced. (6) Reuse of joint forming material is difficult, etc. Has the drawback of. Explaining (4),
Agar has a low strength as a material itself and is difficult to be peeled off uniformly, and a part of the broken material remains on the concrete surface and is difficult to remove. Further, paraffin is hard to remove because it has no elasticity after curing and is broken when removed. Therefore, as described in JP-A-6-23720, heating,
Although it has been proposed to re-fluidize and remove it, a large amount of energy is required for removal and the workability is poor.

On the other hand, when a granular material such as sand is used, (1) sand or the like cannot adhere to the surface of the concrete joint after hardening to form a smooth joint, (2) the water content state of sand Depending on the finished product, it is difficult to provide a uniform product.

That is, in the conventional manufacturing method, it was not possible to easily obtain a concrete product in which a decorative material was fixed to the surface in a desired design and uniform and smooth joints were formed.

[0007]

DISCLOSURE OF THE INVENTION The present invention has been made in view of the above-mentioned facts, in which a decorative material is fixed to the surface with a desired design, and concrete does not adhere to the surface of the decorative material, and
It is an object of the present invention to provide a method for producing a concrete product, which can form a uniform and smooth joint, facilitate the peeling work of the joint forming material, and can recycle the joint forming material.

[0008]

The method for producing a concrete product of the present invention is a method for producing a concrete product in which a decorative material is fixed to at least a part of the surface, and (1) the decorative material is placed in a concrete form. A step of arranging at a desired position, and (2) using a polymer blend material containing a high molecular weight organic material and a low molecular weight material as a main component and a content ratio of the high molecular weight organic material being lower than that of the low molecular weight material. A thermoplastic material for forming joints, which is constituted and has a three-dimensional continuous net-like skeleton structure in which the high molecular weight organic material is heat-melted, is poured into the mold to a depth at which the decorative material is partially exposed. Process,
(3) A step of placing concrete in the mold after the joint forming thermoplastic material has been cured, and (4) a step of curing until the placed concrete is cured and exhibits a desired strength. (5) After the concrete is hardened, the concrete is demolded, and the joint-forming thermoplastic material adhered to the surface is peeled off.

The joint-forming thermoplastic material used here (hereinafter, appropriately referred to as joint-forming material) is mainly composed of a high molecular weight organic material and a low molecular weight material, and the content ratio of the high molecular weight organic material is low molecular weight. A polymer blend material having a content ratio lower than that of the material, and the polymer organic material is constituted by using a polymer blend material having a three-dimensional continuous network skeleton structure.

Further, in the method for producing a concrete product according to the present invention, the polymer blend material comprises a polymer organic material having a number average molecular weight of 20,000 or more and a number average molecular weight of 20.
The main component is a low molecular weight material of less than 000, and the difference in solubility parameter between the high molecular weight organic material and the low molecular weight material is 3.0 or less.

Further, the high molecular weight organic material is a hydrogenated product of a butadiene polymer, a hydrogenated product of a butadiene-styrene copolymer, a hydrogenated product of a styrene-butadiene-styrene block copolymer, a polybutadiene and a butadiene-polymer.
It is selected from a hydrogenated product of a block copolymer with a styrene random copolymer, a block copolymer in which crystalline ethylene is linked to one end or both ends of an ethylene / butylene copolymer, and ethylene-propylene rubber. It is preferably one or more.

The joint forming material may be one having a melting temperature of 70 to 120 ° C. by using the above-mentioned suitable high molecular weight organic material and adjusting the kind and blending amount of the low molecular weight material. it can.

Since the joint forming material used in the method for producing a concrete product of the present invention holds the low molecular weight material in a three-dimensional continuous uniform network skeleton structure made of a thermoplastic polymer organic material, it has a hydrophobic property. When a low molecular weight material is retained, the entire material becomes hydrophobic and has good mold releasability from concrete and decorative materials, and the entire material is a rubber-like elastic body retained by a polymer network skeleton structure. Since the elastic deformation is possible and the strength against the tensile stress is sufficient, the work of peeling the joint forming material from the concrete surface can be easily performed.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

In order to manufacture a concrete product in which a decorative material is fixed to at least a part of the surface of the concrete product so that a part of the decorative material is exposed to the surface of the concrete product, first, (1) in a concrete formwork Place the decorative material on the desired position. As the mold used at this time, a general-purpose concrete forming mold can be arbitrarily selected. A decorative material such as natural stone, tile, or brick is arranged on the bottom surface of the mold according to a desired design.

Here, the materials used as the decorative material include
There is no particular limitation, and natural stones such as Teppei stone, porphyry stone, pebbles, etc., tiles, bricks, glass blocks, etc. can be selected and used so as to be adapted to the use of concrete products.

In addition, the step of disposing a pre-cured thermoplastic material for forming joints in at least the lower part of the decorative material in the mold before disposing the decorative material also ensures stable disposition of the decorative material. It is preferable from the viewpoint. The joint forming material may be arranged so as to be spread in a sheet shape on the entire surface of the bottom of the mold, or may be arranged only at a predetermined fixed position of the decorative material.

Next, (2) a polymer blend material containing a high molecular weight organic material and a low molecular weight material as main components and having a content ratio of the high molecular weight organic material lower than that of the low molecular weight material is used. Further, the joint-forming thermoplastic material in which the polymer organic material has a three-dimensional continuous net-like skeleton structure is heated and melted and poured into the mold to a depth at which the decorative material is partially exposed.

At this time, since the exposed part of the decorative material is fixed in the concrete, the injection amount of the joint forming material can be determined from the viewpoint of adhesive strength and design. The suitable range of depth varies depending on the shape, material, weight, etc. of the decorative material, but in the case of commonly used irregularly shaped gemstones or roughly rectangular tiles, the depth is 1 / height of the decorative material. From the viewpoint of adhesion strength, it is preferably about 3 to 1/2.

The joint forming material used in the manufacturing method of the present invention is mainly composed of a high molecular weight organic material and a low molecular weight material. The high molecular weight organic material has a number average molecular weight of 20,0.
00 or more, especially 30,000 or more, especially 40,0
00 or more thermoplastic polymer organic materials are preferable, for example, various thermoplastic elastomers such as styrene-based (butadiene styrene-based, isoprene styrene-based), ester-based, amide-based, urethane-based, etc., and their hydrogenation, etc. Modified products, styrene-based, ABS-based, olefin-based (ethylene-based, propylene-based, ethylene-propylene-based, ethylene-styrene-based, propylene-styrene-based, etc.), vinyl chloride-based, acrylate-based (methyl acrylate-based, etc.), methacryl Acid ester type (methyl methacrylate type, etc.), carbonate type, acetal type,
Nylon type, halogenated polyether type (chlorinated polyether type, etc.), halogenated olefin type (tetrafluoroethylene type, fluorinated-ethylene chloride type, fluorinated ethylene propylene type, etc.), cellulose type (acetyl cellulose type, ethyl cellulose type) And the like), vinylidene-based, vinyl butyral-based, alkylene oxide-based (propylene oxide-based, etc.) thermoplastic resins, and rubber-modified products of these resins.

As a specific thermoplastic polymer organic material, a material having a hard block such as a crystal structure or an agglomerate structure and a soft block such as an amorphous structure together is particularly preferable. Preferably, specifically, the following are mentioned.

A block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer.

A block copolymer of polybutadiene and polystyrene, or a block copolymer of polyethylene / butylene and polystyrene obtained by hydrogenating a block copolymer of polystyrene with polybutadiene or an ethylene-butadiene random copolymer. .

A block copolymer in which crystalline ethylene is linked to one end or both ends of an ethylene / butylene copolymer.

Ethylene-propylene rubber. Of these, a block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer is particularly preferable.

These various thermoplastic polymer organic materials are mainly used alone, but two or more kinds may be blended and used.

On the other hand, as the low molecular weight material, the viscosity at 100 ° C. is not more than 5 × 10 ⁵ centipoise, especially 1 × 1.
Is preferably 0 ⁵ centipoise or less, from the viewpoint of molecular weight, number average molecular weight of the low molecular material 20,
Less than 000, in particular less than 10,000, especially 5,000
It is preferably 0 or less. As such a low molecular weight material, a liquid or liquid material at room temperature is usually preferably used. Further, both hydrophilic and hydrophobic low molecular weight materials can be used, but hydrophobic low molecular weight materials are preferable from the viewpoint of releasability from concrete.

The low molecular weight material is not particularly limited,
The following are preferably exemplified. Softeners: Mineral oil-based, vegetable oil-based, synthetic-based softeners for various rubbers or resins. Examples of mineral oil-based oils include process oils such as aromatic oils, naphthene oils, and paraffin oils. Vegetable oils include castor oil, cottonseed oil, linseed oil, rapeseed oil, soybean oil, palm oil, coconut oil,
Peanut oil, wood wax, pine oil, olive oil and the like.

Plasticizers: various ester plasticizers such as phthalic acid ester, phthalic acid mixed group ester, aliphatic dibasic acid ester, glycol ester, fatty acid ester, phosphoric acid ester, stearic acid ester, epoxy type plasticizer, etc. Plasticizers for plastics or phthalates, adipates, sebacates, phosphates,
NBR plasticizers such as polyether and polyester.

Tackifier: Various tackifiers such as coumarone resin, coumarone-indene resin, phenol terpene resin, petroleum hydrocarbon and rosin derivative (tackifier).

Oligomer: Crown ether, fluorine-containing oligomer, polyisobutylene, xylene resin, chlorinated rubber, polyethylene wax, petroleum resin, rosin ester rubber, polyalkylene glycol diacrylate,
Liquid rubber (polybutadiene, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone-based oligomers, various oligomers such as poly-α-olefins.

Lubricants: Hydrocarbon lubricants such as paraffin and wax, fatty acid lubricants such as higher fatty acids and oxyfatty acids, fatty acid amide lubricants such as fatty acid amides and alkylenebisfatty acid amides, fatty acid lower alcohol esters, fatty acid polyhydric alcohol esters. , Ester lubricants such as fatty acid polyglycol ester, fatty alcohol,
Various lubricants such as alcohol-based lubricants such as polyhydric alcohols, polyglycols and polyglycerols, metal soaps, mixed lubricants.

In addition, latex, emulsion, bituminous composition, clay, inorganic silicone oil, phosphazene and the like are also suitable as the low molecular weight material.

Further, hydrocarbon-based, halogenated hydrocarbon-based, alcohol-based, phenol-based, ether-based, acetal-based, ketone-based, fatty acid-based, ester-based, nitrogen compound-based, sulfur compound-based organic solvents, petroleum, etc. , Water, an aqueous solution, etc. can be used together for adjusting the physical properties.

These low molecular weight materials may be used alone or in combination of two or more. In the present invention, in order to obtain a polymer blend material containing a large amount of a low molecular weight material with a large amount of a low molecular weight material and a small amount of a high molecular weight organic material, each of the low molecular weight material and the high molecular weight organic material used The difference in solubility parameter value δ = (ΔE / V) ^1/2 (ΔE = molar evaporation energy, V = mol volume) is 3.0 or less,
It is preferable to select both materials so that it is preferably 2.5 or less. If this difference exceeds 3.0, it is difficult to retain a large amount of low molecular weight materials from the viewpoint of the compatibility of both materials, which is an obstacle to lowering the elasticity of the polymer blend material obtained, and also causes bleeding of the low molecular weight materials. It is not preferable because it tends to occur.

Further, this joint forming material is required to have optimum shearing, tensile strength and elongation characteristics as described later in order to prevent cracking after hardening and to facilitate peeling from a concrete product. Therefore, the polymer organic material that constitutes the polymer blend material of the joint forming material needs to form a three-dimensional continuous network skeleton structure, and the average diameter of the network skeleton is 50 μm or less, The average diameter of the cells (mesh) is preferably 30 μm or less and 500 μm.
m or less, preferably 300 μm or less, and the volume fraction of the high molecular weight organic material is defined as [volume of high molecular weight organic material / (volume of high molecular weight organic material + volume of low molecular weight material)] × 100 (%) At this time, it is desirable that the volume fraction of the high molecular weight organic material is 30% or less, particularly 25% or less.

The polymer blend material is capable of forming a predetermined amount of a high molecular weight organic material and a low molecular weight material and, if necessary, other compounding agents, to form a three-dimensional continuous network skeleton structure of the high molecular weight organic material. It can be obtained by mixing under mixing conditions, but in this case, it has a uniform three-dimensional continuous network skeleton structure made of a high molecular weight organic material, low bleeding of low molecular weight material, and high performance satisfying the above-mentioned characteristics. In order to obtain the molecular blend material, it is preferable to use a high shear type mixer as the mixer, and in particular, a high shear force and a high shear rate can be given between the fixed wall and the rotating rotor. , The distance (clearance) between the fixed wall and the rotating part (rotor) is t (m), and the rotating peripheral speed of the rotor is v
(M / sec), and the shear rate of the rotor is V,
When defined as V = v / t (sec ⁻¹ ), V ≧ 5.0 × 10 ² (sec ⁻¹ ) preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ) and more preferably V ≧ 2. It is advantageous to use a high shear type special mixer satisfying 5 × 10 ³ (sec ⁻¹ ) and more preferably V ≧ 5.0 × 10 ³ (sec ⁻¹ ).

The polymer blend material according to the present invention is not particularly limited such as ordinary bulk, gel, foam, etc., but it is in a gel state, particularly a three-dimensional continuous uniform material made of a thermoplastic polymer organic material. Those in a gel state having a network skeleton structure are particularly effective for the present invention.

As the physical properties of this joint forming material after curing, the tensile strength evaluated by the tensile test of JIS K6301 is 0.5 kg / cm ² or more, and the elongation at break is 30.
It is preferably 0% or more from the viewpoint of workability when peeling from a concrete product after curing.

As the joint forming material, a high molecular weight organic material such as those mentioned above is used, and the melting temperature is adjusted to, for example, 7 by adjusting the kind and blending amount of the low molecular weight material.
Although it is possible to prepare a material having a temperature range of 0 to 120 ° C., it is preferable to use a material having a melting temperature of 100 to 120 ° C. in consideration of the case where concrete is heated for curing.

The joint-forming material is heated to a melting temperature or higher, and the oil-like material is poured into the mold. As the heating method, for example, put in a container, open the container, a method of heating by a heater, a method of heating in a dryer, a method of heating by microwave in a microwave oven, a method of heating by steam, a sand bath, A method of heating with an oil bath and the like can be mentioned, and there is no particular limitation, but it is preferable to employ a method of heating with steam from the viewpoint of reliable temperature control and uniform heating.

Since the joint-forming material melted in an oil form has a good shape-following property, it is possible to uniformly fill the voids of the decorative material in the mold and to make close contact with the surface of the decorative material. Therefore, the workability is good, and it is possible to form a uniform and good surface condition and smooth joints, there is no gap between the decorative material and the joint forming material, and it is possible to prevent the infiltration of concrete. obtain. The injection of the joint forming material is carried out from the adhesion strength and the exposed state of the decorative material to the concrete surface as described above to a predetermined depth.

Next, (3) after the joint forming thermoplastic material is cured, concrete is poured into the mold.

This joint-forming material melts when heated and exhibits a low-viscosity oil state, but when cooled to room temperature, it becomes a solid state. Therefore, the joint forming material can be cured by leaving the mold at room temperature. In addition, in order to improve workability, it is possible to positively cool and harden the mold by putting it in a low temperature chamber.

After the joint-forming material has hardened, concrete is poured into the mold. As described above, the surface of the joint-forming material is smooth, and the joint-forming material and the decorative material are in close contact with each other. Therefore, the joints of the concrete are smooth and beautifully finished, and the concrete does not wrap around the surface of the decorative material.

As the concrete used here, any one having a composition according to the purpose of use of the concrete product can be arbitrarily used. Also, the driving method can be carried out by a conventional method. At this time, in order to improve the releasability between the concrete form and the concrete, a release agent may be applied (sprayed) in advance in the form.

Next, (4) curing is carried out until the cast concrete is hardened and the desired strength is exhibited. The curing may be normal temperature curing or high temperature curing.

From the viewpoint of workability, high temperature curing is preferable,
Since the temperature of steam curing that is usually performed is 60 to 70 ° C., even if high temperature steam curing is performed under normal conditions, it does not affect the joint forming material.

When high temperature curing other than steam curing is performed, in order to prevent the deformation of the joint forming material, the heating temperature should be set to the upper limit around the melting temperature of the joint forming material from the viewpoint of finishability. preferable.

(5) After the concrete is hardened, the concrete having the joint forming material adhered to the surface (bottom surface of the mold) is removed from the mold, and the joint forming material adhered to the surface is peeled off. This joint forming material holds a low molecular weight material in a three-dimensional continuous uniform network skeleton structure made of a thermoplastic polymer organic material, and when a hydrophobic low molecular weight material is held,
The entire material is hydrophobic and has good mold releasability from concrete and decorative materials, and the entire material is a rubber-like elastic body held by a polymer network skeleton structure, which allows elastic deformation and tensile stress. Is also sufficiently strong, and a large area can be peeled off at once. Therefore, the work of peeling the joint forming material can be easily performed.

Further, since the joint forming material peeled off from the concrete surface is heated and melted, impurities such as mixed release agent, cement, sand, water and dust are precipitated,
Impurities can be easily separated and removed by a conventional method such as filtration. Therefore, the joint forming material can be easily reused (recycled).

According to the manufacturing method of the present invention, a decorative material is fixed on the surface of a concrete plate, a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a concrete block for sidewalks, a concrete fence, etc. by any design. The concrete product can be easily manufactured.
The use of the concrete product is not particularly limited, and examples thereof include construction (decoration panels for interior and exterior of buildings, floors, etc.), civil engineering (road pavement, decoration panels for wall surfaces, etc.) and the like.

[0053]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples.

1 (A) to 1 (C) are schematic cross-sectional views sequentially showing a method for manufacturing a concrete product 10 according to the present invention.

FIG. 1A shows a state in which the joint-forming thermoplastic material 16 in a molten state is injected so that a part of the decorative material 14 arranged in the mold 12 is exposed.

FIG. 1B shows concrete 18 in a mold in which a layer of cured joint forming thermoplastic material 16 is formed.
Shows the state of placing.

In this state, the concrete which has been cured at a high temperature and hardened is released from the mold, and finally the hardened joint forming thermoplastic material 16 is removed. As a result, as shown in the schematic view of FIG. The decorative panel 10 made of concrete, to which the decorative material 14 is fixed, is completed.

2 (A) to 2 (D) are schematic cross-sectional views sequentially showing a manufacturing method of the concrete product 10 according to the present invention in which a sheet made of a thermoplastic material for forming joints is previously arranged on the bottom surface of the formwork. Is.

FIG. 2A shows a state in which the decorative material 14 is placed on the joint-forming material sheet 16A previously placed in the mold 12. Since the joint forming material is a rubber-like body having elasticity, even if the irregular or spherical decorative material 14 is arranged,
It can be placed stably without shifting or rolling.

FIG. 2B shows a state in which the joint-forming thermoplastic material 16 in a molten state is injected so that a part of the decorative material 14 is exposed in the mold 12. The joint forming material sheet 16A arranged in advance is the injected joint forming material 16
Since the joint forming material 16 is in a molten state, the joint forming material sheet 16 is formed on the boundary surface between the joint forming material sheet 16A and the injected joint forming material 16.
A is melted by the heat of the joint forming material 16 and the two are integrated.

FIG. 2C shows concrete 18 in a mold in which a layer of hardened joint forming thermoplastic material 16 is formed.
Shows the state of placing.

In this state, the concrete 18 which has been cured at a high temperature and hardened is released from the mold, and finally, the joint-forming material 16 and the integrated joint-forming material sheet 16A which are hardened are removed, so that the structure shown in FIG. As shown in the schematic diagram, a decorative panel 10 made of concrete in which the decorative material 14 is fixed to the surface of the concrete 18 is formed. Joint forming material 16
Since the joint forming material sheet 16A and the joint forming material sheet 16A are integrated with each other, they can be easily peeled off as a single sheet.

The joint forming material sheet 16A may be arranged over the entire bottom surface of the mold 12 as described above, or may be arranged only under the decorative material 14. Example 1 (1) Preparation of Joint-Forming Thermoplastic Material A As a raw material, polyethylene obtained by hydrogenating a block copolymer of polybutadiene which is a polymer organic material and a butadiene-styrene random copolymer, and polyethylene. Alkylbenzene (softening agent), which is a low molecular weight material, in 15% by volume of a block copolymer (polymer organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) (Z-300, manufactured by Nippon San Oil Co., Ltd .: molecular weight 335, SP value 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co., Ltd .: molecular weight 426, SP value 8.4). ) 42.5% by volume,
And a high-shear type special mixer (“TK Auto Homo Mixer” manufactured by Special Kika Kogyo Co., Ltd.) was used to rotate at 30 rpm.
00 rpm, shear rate 1.0 × 10 ⁴ / sec, mixing temperature 180 ° C., mixing time 40 minutes, to obtain a polymer blend material having a uniform appearance, and to mix with the thermoplastic material A for joint formation. did. In addition, when a section of this polymer blend material was cut out and confirmed by an optical microscope, a three-dimensional continuous reticulated skeleton structure (average skeleton diameter 5 μm, average cell diameter 15 μm) made of a thermoplastic polymer organic material was formed. Was confirmed. The polymer blend material has an Asker-C hardness of 10 and a tensile strength of 3 kg / cm.
² , elongation at break is 1500%, compression set (70
C., 22 hours) was 30 and the melting temperature was 120.degree. (2) Filling into mold The thermoplastic material A for forming joints is heated and melted at 170 ° C., and a depth in which about 50% of the slag is exposed in a mold in which slag having an average particle diameter of 10 cm is arranged. After pouring to the above, the material was uniformly filled in the space of the rubble stones, and then left at room temperature to cool and cure the joint forming thermoplastic material A. (3) Manufacture of concrete products Concrete is placed in this formwork by a conventional method, and about 7
Steam curing was carried out at 0 ° C. for 3 hours to cure the concrete, and then the mold was removed.

Thereafter, it was turned over and the cured joint forming thermoplastic material A was peeled off from the surface.

The joint-forming thermoplastic material A is easily and cleanly removed as a sheet from the surface of the concrete joint and the exposed portion of the gravel stone, and is cut on the way and remains on the surface of the concrete and the gravel stone. Was not observed.

In the obtained concrete product, gravel stones were securely fixed to the surface, no stones had separated, and no concrete adhesion was observed on the gravel stone surface. The surface of the formed concrete joint portion was smooth and uniform, and a concrete product having an excellent appearance could be manufactured.

Further, the joint-forming thermoplastic material peeled off from the concrete surface was heated and melted to easily remove impurities, so that the joint-forming thermoplastic material could be reused (recycled). (Example 2) (1) Preparation of joint-forming thermoplastic material B As a raw material, polyethylene obtained by hydrogenating a block copolymer of polybutadiene which is a high molecular weight organic material and a butadiene-styrene random copolymer, and polyethylene. Block copolymer (polymer organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 10% by volume of alkylbenzene (softening agent)
(Z-300, Sun San Oil Co., Ltd .: molecular weight 335, SP
Value 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co., Ltd .: molecular weight 426,
SP value 8.4) 42.5% by volume, and further higher fatty acid amide (oleic acid amide Armoslip: manufactured by Lion) 5% by volume were added, and a high shear type special mixer (“TK Auto Homo”) was added. Mixer "Special Machine Industry Co., Ltd.
Rotation speed 3000 rpm, shear rate 1.0 ×
Mixing was carried out under the mixing conditions of 10 ⁴ / sec, a mixing temperature of 180 ° C. and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance, which was used as a joint forming thermoplastic material B. In addition, when a section of this polymer blend material was cut out and confirmed by an optical microscope, a three-dimensional continuous reticulated skeleton structure (average skeleton diameter 3 μm, average cell diameter 18 μm) made of a thermoplastic polymer organic material was formed. Was confirmed. The Asker-C hardness of this polymer blend material is 1
0, tensile strength 3 kg / cm ² , elongation at break 150
The compression set was 0%, the compression set (70 ° C, 22 hours) was 30, and the melting temperature was 120 ° C. (2) Filling into a mold The joint-forming thermoplastic material B is heated and melted at 170 ° C., and the brick-like tiles having a thickness of 50 mm are converted into porcelain stones.
After pouring into a mold arranged at 10 mm intervals to a depth of 15 mm, the material was uniformly filled in the gaps between the brick-like tiles and then left at room temperature to cool and cure the joint forming thermoplastic material B. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1. The cured joint forming thermoplastic material B was easily and completely peeled off as a sheet from the surfaces of the concrete joint and the exposed portion of the brick-like tile, and the brick-like tile was completely fixed to the concrete surface. Further, no concrete adhesion was observed on the tile surface, and the joint portion had a smooth surface, and a concrete product excellent in appearance was obtained.

Further, the joint-forming thermoplastic material B peeled off from the concrete surface could be reused like the joint-forming thermoplastic material A.

(Example 3) (1) Preparation of joint-forming thermoplastic material C As a raw material, polyethylene, which is a high molecular weight organic material, is present at both ends, and a block copolymer containing ethylene-butylene in the center (high Molecular organic material) (number average molecular weight 280,000:
90 vol% of paraffin oil (softening agent) (PW-32, manufactured by Idemitsu Kosan Co., Ltd .: molecular weight 405, SP value of 7.9), which is a low molecular weight material, was added to 10 vol% of SP value of 8.0) to obtain a high shear type. Mixing conditions using a special mixer (“TK Auto Homo Mixer” manufactured by Tokushu Kika Kogyo Co., Ltd.) at a rotation speed of 3000 rpm, a shear rate of 1.0 × 10 ⁴ sec, a mixing temperature of 180 ° C. and a mixing time of 40 minutes. Was mixed to obtain a polymer blend material having a uniform appearance, which was used as a joint forming thermoplastic material C. Also, cut out a section of this polymer blend material,
It was confirmed by an optical microscope that the three-dimensional continuous reticulated skeleton structure (average diameter of the skeleton was 5μ
m, the average diameter of the cells was 15 μm). In addition, asker of this polymer blend material
The C hardness was 2, the tensile strength was 1.2 kg / cm ² , the elongation at break was 970%, the compression set (70 ° C., 22 hours) was 50, and the melting temperature was 110 ° C. (2) Filling into mold After the thermoplastic material C for forming joints is heated and melted at 170 ° C., it is poured into a mold in which rubble stones are arranged in the same manner as in Example 1, and the material is uniformly filled. , Leave it at room temperature,
It was cooled and cured. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1. The hardened joint forming thermoplastic material C was easily and completely peeled off as a sheet from the surface of the concrete joint and the exposed portion of the slag, and no adhesion of the joint forming material was observed on the surface of the concrete product. In addition, the gravel stones were completely fixed on the concrete surface, and no adhesion of concrete was observed on the mortar stone surface, and the joints formed were even and smooth, and a concrete product excellent in appearance was obtained. .

Further, the joint-forming thermoplastic material C peeled off from the concrete surface could be reused like the joint-forming thermoplastic material A.

[0071]

As described above, according to the manufacturing method of the present invention, the decorative material can be fixed to the surface with a desired design, and the concrete does not adhere to the surface of the decorative material and is uniform. The ability to form smooth joints,
It has excellent effects. Further, the joint forming material used in the method of the present invention has an excellent effect that it can be repeatedly used (recycled).

[Brief description of the drawings]

1A to 1C are schematic cross-sectional views sequentially showing a method for manufacturing a concrete product according to the present invention, in which (A) a joint forming material is injected so that a part of a decorative material arranged in a mold is exposed. The state, (B) shows a state where concrete is placed in a mold in which a layer of the joint forming material is formed, and (C) shows a concrete product obtained by removing the hardened joint forming material. .

FIG. 2 is a schematic cross-sectional view showing in sequence the method of manufacturing a concrete product according to the present invention in which a joint-forming material sheet is previously arranged on the bottom surface of a mold, and FIG. 2 (A) is a joint pre-arranged in the mold. The state where the decorative material is placed on the forming material sheet, (B) shows the state where the joint forming material is injected so that a part of the decorative material is exposed, and (C) shows the joint forming material layer. The state of placing concrete in the formed form,
(D) shows a concrete product obtained by removing the cured joint forming material.

[Explanation of symbols]

10 Concrete Product 12 Formwork 14 Decorative Material 16 Polymer Blend Material (Thermoplastic Material for Joint Formation) 16A Sheet of Thermoplastic Material for Joint Formation 18 Concrete

 ─────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Shinichi Toyosawa 1407-15 Arahata, Tokorozawa-shi, Saitama (72) Inventor Hiroaki Suzuki 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research In-house (72) Inventor Shusuke Harada 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Prefecture Central Research Laboratory, Sumitomo Osaka Cement Co., Ltd. (72) Inventor Tetsuo Kobayashi, 7-1-Minamienkajima, Taisho-ku, Osaka-shi, Osaka 55 Central Research Laboratory, Sumitomo Osaka Cement Co., Ltd.

Claims (3)

[Claims] 1. A method for producing a concrete product in which a decorative material is fixed to at least a part of the surface, which comprises (1) a step of arranging the decorative material in a desired position in a concrete formwork, and (2) a polymer. It is composed by using a polymer blend material mainly composed of an organic material and a low molecular weight material, and the content ratio of the high molecular weight organic material is lower than the content ratio of the low molecular weight material, and the high molecular weight organic material is three-dimensionally continuous. And a step of injecting the joint-forming thermoplastic material having the reticulated skeleton structure into the mold to a depth at which the decorative material is partially exposed, and (3) the joint-forming thermoplastic material is After hardening, a step of placing concrete in the formwork, (4) a step of curing the placed concrete until it has a desired strength, and (5) removing the concrete after hardening. Molding and forming joints on the surface A method for producing a concrete product, comprising: a step of peeling off a thermoplastic material for use in a concrete product. 2. The polymer blend material comprises a polymer organic material having a number average molecular weight of 20,000 or more and a number average molecular weight of 2.
2. The concrete product according to claim 1, which is composed mainly of a low molecular weight material of less than 10,000 and has a solubility parameter difference of 3.0 or less between the high molecular weight organic material and the low molecular weight material. Manufacturing method. 3. The polymer organic material is a hydrogenated product of a butadiene polymer, a hydrogenated product of a butadiene-styrene copolymer, a hydrogenated product of a styrene-butadiene-styrene block copolymer, polybutadiene and butadiene-styrene. 1 selected from hydrogenated products of block copolymers with random copolymers, block copolymers of crystalline ethylene linked to one or both ends of an ethylene / butylene copolymer, and ethylene-propylene rubber The method for producing a concrete product according to claim 1, wherein the method is at least one kind.