JPH09131713A - Manufacture of concrete product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a simple method for manufacturing concrete product which can be recycled by fixing a decorative material in an arbitrary design to the surface, forming uniform and smooth joint, and facilitating the releasing operation of joint forming material. SOLUTION: The method for manufacturing the concrete product comprises the steps of disposing a decorative material on net-like support in a concrete form in which the support is disposed at a distance from the bottom in parallel with the bottom in the 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 form, 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 producing a concrete product in which a decorative material is fixed on at least a part of the surface, and more specifically, the decorative material can be fixed in an arbitrary shape and a uniform concrete joint is formed. The present invention relates to a method for producing a concrete product to be obtained.

[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.

In these manufacturing methods, it is difficult to uniformly fill the joint forming material and remove the joint forming material after the concrete product is manufactured. Therefore, as a simple manufacturing method for solving these problems, Kaihei 6-254820
In No. 3, a support plate that allows liquid to pass therethrough and retains a decorative material is placed in the formwork, the decorative material is placed on the support plate, and the holding material liquid is injected from below the formwork to remove the decorative material. A method is disclosed in which concrete is poured after being partially immersed in a liquid, the holding material liquid is hardened. Here, agar is exemplified as the holding material.

According to this method, the holding material liquid (joint forming material) can be uniformly injected, but if agar as described as the holding material liquid is used here, it is difficult to remove the concrete after demolding. Is. That is, agar has a low strength of the material itself and cannot be evenly peeled off, and a part of the broken agar remains on the concrete surface, the supporting plate or the bottom of the formwork, and the part adhered to the concrete surface is treated with high pressure water or A great amount of labor is required for removal, such as removing by air and remaining on the support plate or the bottom of the mold. Furthermore, the agar may be easily cracked by drying, and the joints may not be formed uniformly.

As the holding material liquid, Japanese Patent Laid-Open No. 6-23
Although it is possible to use the paraffin described in No. 720, it is difficult to remove the paraffin after curing because it does not have elasticity and is broken when removed. Therefore, JP-A-6-2372
In No. 0, it is proposed to remove by heating and re-fluidizing, but a large amount of energy is required for removal and workability is also poor.

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]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described facts, in which a decorative material is fixed to at least a part of the surface with a desired design, and concrete does not adhere to the surface of the decorative material, and An object of the present invention is to provide a concrete product manufacturing method capable of forming a uniform and smooth joint, facilitating the peeling work of the joint forming material, and recycling the joint forming material. .

[0008]

The method for producing a concrete product according to the present invention is a method for producing a concrete product in which a decorative material is fixed on at least a part of the surface, and (1) is parallel to the bottom of the formwork, And, a step of arranging the decorative material at a desired position on the mesh support in the concrete formwork in which the mesh support is arranged at a distance from the bottom, and (2) the high molecular weight organic material and the low molecular weight material. Forming joints composed of a polymer blend material containing a high molecular weight organic material as a main component and a low molecular weight organic material content lower than that of a low molecular weight material, and the high molecular weight organic material having a three-dimensional continuous network skeleton structure. A thermoplastic material for heating is melted by heating and injected into the mold, and the thermoplastic material for forming joints is partially immersed in the decorative material arranged on the mesh support; After the joint-forming thermoplastic has cured A step of placing concrete in the mold, (4) a step of curing the placed concrete until it hardens to develop a desired strength, and (5) demolding after the concrete has hardened, the surface Peeling off the joint forming thermoplastic material adhered to the.

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 produce a concrete product having a decorative material immobilized on at least a part of its surface, first,
(1) A decorative material is arranged at a desired position on a net-like support of a concrete formwork in which the net-like support is arranged parallel to the bottom and at a distance from the bottom.

The net-like support used in the method of the present invention is preferably arranged in parallel with the bottom of the concrete form and at a distance of at least about 3 mm from the bottom.

Here, the reticulated support is a wire mesh or the like as long as it can pass the joint forming thermoplastic material in a fluid state through the reticulated gap and has a rigidity capable of holding the decorative material. The material may be a mesh or a perforated plate, and the material, the mesh of the mesh and the size of the holes of the perforated plate are not particularly limited, and can be selected according to the size of the decorative material to be used.

Examples of the mesh support include a wire mesh of iron, steel, aluminum or the like, FRP, synthetic resin, carbon fiber, filament made of natural or synthetic fiber, rod-shaped body, twisted yarn,
In addition to a net-like body formed by using a rope or the like, a punching metal, FRP, a perforated plate made of synthetic resin, a filament in which the same filaments as those described above are arranged in parallel in a comb shape, and the like are also included. These may be formed in an appropriate frame.

On this mesh support, a decorative material to be fixed to a concrete product is arranged according to a predetermined 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.

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 material 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, and the joint forming material is arranged on the net-like support. Make a part of the decorative material.

At this time, since the part of the decorative material not partially immersed in the joint forming material is fixed in the concrete, the injection amount of the joint forming material is adjusted from the viewpoint of adhesion strength and design. can do. The suitable range of the injection amount varies depending on the shape, material, weight, etc. of the decorative material, but in the case of commonly used irregularly shaped porphyry stones or roughly rectangular parallelepiped tiles, it is 1/3 to 1/2 of the height of the decorative material. From the viewpoint of the adhesion strength, it is preferable to immerse it to some extent.

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.

Block copolymer of polybutadiene and polystyrene, or block copolymer of polyethylene / butylene and polystyrene obtained by hydrogenating a block copolymer of polystyrene with polybutadiene or 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-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 esters, phthalic acid mixed group esters, aliphatic dibasic acid esters, glycol esters, fatty acid esters, phosphoric acid esters, stearic acid esters, epoxy plasticizers, 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 oxy fatty 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, from the viewpoint of the compatibility of both materials, it is difficult to retain a large amount of low molecular weight materials, which is an obstacle to lowering the elasticity of the obtained polymer blend material, 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 will be 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 polymer organic material and a low molecular weight material, and optionally other compounding agents, to form a three-dimensional continuous network skeleton structure of the polymer 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), the shear rate of the rotor is V, and
= V / t (sec ⁻¹ ), V ≧ 5.0 × 10 ² (sec ⁻¹ ) preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ) more preferably V ≧ 2.5 It is advantageous to use a high-shear type special mixer satisfying × 10 ³ (sec ⁻¹ ) 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 composed of a thermoplastic polymer organic material. Those in a gel state having a network skeleton structure are particularly effective for the present invention.

With respect to 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 set 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 the melting temperature or higher, and the oil-like material is poured into the mold as described above. 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 state has a good shape-following property, it is possible to uniformly fill the voids of the decorative material in the mold. Further, in the present invention, the oil-like material for forming the joint is injected into the gap portion of the decorative material from above so that the uniform liquid level is gradually increased from the lower portion of the mesh support to fill the inside of the mold. In addition, it is possible to uniformly fill the gaps between the cosmetic materials in a planar manner and form uniform joints by injection from one place. The injection is performed from the fixed state of the decorative material to the concrete surface as described above to a predetermined depth.

By spraying an appropriate amount of water on the surface of the decorative material before injecting the oil-melted material for forming the joint, the mold releasing property between the decorative material and the material for forming the joint is improved,
It is also possible that the joint-forming material hardened in the form of a plate adheres to the surface of the concrete product and is not removed from the mold at the same time, and remains in the mold.

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

The joint forming material melts when heated and exhibits a low-viscosity oil state, but becomes solid when cooled to room temperature. 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.

Then, after hardening the joint forming material,
Although concrete is placed in the mold, the surface of the joint forming material is smooth as described above, and the joint forming material and the decorative material are in close contact with each other, so the concrete joint is smooth and beautiful. Finished, concrete does not wrap around the surface of the decorative material.

As the concrete used here, any one having a composition suitable for the purpose of use of the concrete product can be 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 deformation of the joint forming material, the upper limit of the heating temperature is near the melting temperature of the joint forming material. 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 the low molecular weight material in the three-dimensional continuous uniform network skeleton structure made of the thermoplastic polymer organic material. Becomes hydrophobic and has good mold releasability from concrete and decorative materials. Furthermore, the whole material can be elastically deformed by a rubber-like elastic body held by a polymer network skeleton structure, and since the network support is present inside, a large area can be added at once due to its reinforcing effect. It can be peeled off.

If a hook or the like is fixed to the net-like support in advance before injecting the joint forming material, workability is improved even when peeling by hand, and further, peeling by a mechanical means such as a forklift. Will also be possible. A known method may be used to fix the hook to the net-like support, and when fixing the hook, it is preferable to fix the hook at five points of the four corners and the central portion from the viewpoint of workability.

The reticulated support can be removed by heating and melting the joint forming thermoplastic material peeled from the concrete surface. Also, due to heat melting, impurities such as mixed release agent, cement, sand, water, dust are precipitated,
Impurities can be easily separated and removed by a conventional method such as filtration. Therefore, it is easy to reuse (recycle).

According to the manufacturing method of the present invention, in addition to the concrete flat plate, at least a part of the surface of the concrete PC plate, the curtain wall, the concrete L-shaped retaining wall, the concrete block for the sidewalk, the concrete fence, etc. is made up with any design. It is possible to easily manufacture a concrete product formed by fixing materials. 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.

[0058]

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 (D) 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 decorative material 16 is arranged on the net-like support (wire net) 14 provided in the mold 12. Next, the joint-forming thermoplastic material 18 in a molten state is injected from the gap of the decorative material 16 so that a part of the decorative material 16 arranged as shown in FIG.

FIG. 1 (C) shows a state in which concrete 22 is placed in the mold 12 in which the layer of the cured joint forming thermoplastic material 18 is formed.

In this state, the concrete 22 that has been cured at a high temperature and hardened is released from the mold, and finally, the hardened concrete 22 is hardened and the wire mesh 1 is placed inside.
As shown in the schematic cross-sectional view of FIG. 1 (D) by peeling and removing the joint-forming thermoplastic material 18 holding 4 the decorative material made of concrete (concrete product) ) You can do 10. 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) Preparation of Formwork and Filling Formwork Forming a metal mesh (mesh support) 14 made of aluminum and having an opening size of 1 mm × 1 mm at a height of 5 mm from the bottom of the formwork was arranged parallel to the bottom. A concrete form 12 was prepared. An average particle size of 10c is provided on the mesh support 14 of the mold 12.
m grated stone 16 was placed.

17 of the joint forming thermoplastic material A18
It was heated and melted at 0 ° C., and poured from the void portion between the porcelain stones 16 in the mold 12. Joint forming thermoplastic material A1
8 was filled from the bottom of the form 12, passed through the metal net 14 in a uniform liquid state, and gradually filled the voids between the stones 16 from the bottom. The injection was performed to a depth at which about 50% of the porcelain stones 16 were immersed, and after the material was uniformly filled in the voids of the porcelain stones 16, the mixture was left at room temperature to be cooled and hardened. (3) Manufacture of Concrete Product Concrete 22 was placed in the mold 12 by a conventional method, and steam curing was performed at about 70 ° C. for 3 hours to cure the concrete 22 and then remove the mold.

Then, it was turned over and the hardened joint forming thermoplastic material A18 was peeled from the surface.

The joint forming thermoplastic material A18 is easily and cleanly removed from the surface of the concrete 22 joint and the exposed portion of the gravel stones 16 as a single sheet, and is cut along the way and the concrete 22 and the gravel stones 16 are removed. No residue was observed on the surface.

In the obtained concrete product 10, the gravel stones 16 were securely fixed to the surface, no stones had come off, and no adhesion of the concrete 22 was observed on the rugged stone 16 surface. The surface of the joint portion of the concrete 22 formed between the stones 16 was smooth and uniform, and the concrete product 10 having an excellent appearance could be manufactured.

The joint-forming thermoplastic material peeled off from the concrete surface is heated and melted to remove the wire mesh,
It can be used again by removing the mixed impurities. (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 (high molecular organic material) with ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) 10% by volume, 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 the formwork Brick-like tiles with a thickness of 50 mm are placed on the wire mesh in the formwork for 10 minutes.
1 mm of the thermoplastic material B for forming joints, which are arranged at mm intervals.
The mixture was heated and melted at 70 ° C., and was poured so that the brick-like tiles were immersed to a depth of 15 mm from the voids between the brick-like tiles as in Example 1. After the joint-forming material was uniformly filled in the gaps between the brick-like tiles, the joint-forming material was left to stand at room temperature to be cooled and cured. (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, as in Example 1, the resin was inverted and the cured joint forming thermoplastic material B was peeled from the surface.

The joint-forming thermoplastic material B was completely removed from the surface of the concrete joint and the exposed portion of the brick-like tile, the brick-like tile was completely fixed to the concrete surface, and the adhesion of concrete to the tile surface was observed. However, a concrete product having an excellent appearance was obtained.

Further, the removed joint forming thermoplastic material B is heated and melted in the same manner as in Example 1 to remove the wire mesh, and thereafter, the impurities are removed in the molten state to allow reuse. It was possible.

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 Formwork The thermoplastic material C for forming joints was heated and melted at 170 ° C., and a morrolith was placed on a reticulated support.
After pouring in the same manner as above and filling the material uniformly, the mixture was left standing at room temperature to be 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 is completely peeled off from the surface of the concrete joint and the exposed portion of the solid stone, the solid stone is completely fixed on the concrete surface, and the adhesion of concrete to the solid stone surface is observed. However, the joints formed in the gaps of the slag stone were uniform and smooth, and a concrete product having an excellent appearance was obtained.

The joint-forming thermoplastic material C peeled off from the concrete surface is heated and melted in the same manner as the joint-forming thermoplastic material A of Example 1 to remove the wire mesh, and then, the impurities are kept in the molten state. It was possible to use again by removing.

[0073]

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 by a simple method, and the adhesion of concrete to the surface of the decorative material can be prevented. Moreover, it has an excellent effect that uniform and smooth joints can be formed. Further, the joint forming material used in the method of the present invention has an excellent effect that it can be repeatedly (recycled) used.

[Brief description of the drawings]

1A to 1C are schematic cross-sectional views sequentially showing a method for producing a concrete product according to the present invention, in which (A) shows a decorative material arranged on a mesh support in a mold and (B) shows makeup. The state where the joint forming thermoplastic material is injected so that a part of the material is immersed is shown. (C) shows a state in which concrete is placed in a mold in which a layer of the joint-forming thermoplastic material is formed. (D) shows a concrete product obtained by removing the cured joint forming thermoplastic material.

[Explanation of symbols]

 10 Concrete Products 12 Formwork 14 Wire Mesh (Reticulated Support) 16 Decorative Material 18 Polymer Blend Material (Thermoplastic Material for Joint Formation) 22 Concrete

Front page continuation (72) Inventor Shinichi Toyosawa 1407-15 Arahata, Tokorozawa-shi, Saitama Prefecture (72) Hiroaki Suzuki 7-1-55 Minamienkajima, Taisho-ku, Osaka City, Osaka Prefecture Sumitomo Osaka Cement Co., Ltd. Central Research Institute (72 ) Inventor Tetsuo Kobayashi 7-55, Minami Enkajima, Taisho-ku, Osaka City, Osaka Prefecture Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Masao Kusano 7-1-55, Minamienkajima, Taisho-ku, Osaka City, Osaka Prefecture Sumitomo Osaka Central Research Institute of Cement Co., Ltd.

Claims (3)

[Claims] 1. A method for producing a concrete product in which a decorative material is fixed on at least a part of the surface, and (1) concrete in which a net-like support is arranged in parallel to the bottom of the formwork and at a distance from the bottom. A step of arranging a decorative material at a desired position on a reticulated support in a mold; and (2) a high molecular weight organic material and a low molecular weight material as main components, and a high molecular weight organic material content ratio of the low molecular weight material. A thermoplastic material for forming joints, which is composed of a polymer blend material whose content is less than the content and the polymer organic material has a three-dimensional continuous network skeleton structure, is melted by heating and injected into the mold. And a step in which the joint-forming thermoplastic material is partially immersed in the decorative material arranged on the net-like support, and (3) after the joint-forming thermoplastic material is cured, the joint material is placed in the mold. The process of placing concrete, and (4) placing A step of curing the concrete until it hardens to develop a desired strength, and (5) a step of removing the joint-forming thermoplastic material adhering to the surface after the concrete has hardened and then demolding. A method of manufacturing 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.