JPH09323314A - Manufacture of concrete product and decorative form used therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make it possible to improve the productivity and to obtain a concrete product of stably colored quality. SOLUTION: The method for manufacturing a concrete product comprises the steps of preparing a sheet 7 formed in an uneven shape corresponding to the uneven pattern surface 4 of a decorative mat 1 to cover the surface 4 of the mat 1 detachably engaged with the pattern of the mat 1, previously distributing and holding a colored particular material 6 via an adhesive layer 5 having sticking force reduced by the moisture in a concrete material 15 on one side surface of the sheet 7, covering the surface 4 of the mat 1 so that the sheet 7 distributed and held with the material 6 is directed toward the front side, placing a concrete material 15 with the distributed and held surface as a contact surface, curing and hardening the material 15, reducing the sticking force of the layer 5 according to the moisture in the material 15, and transferring and burying the material 6 to and in the surface of the product.

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 whose surface is colored and a decorative formwork used for the method.

[0002]

2. Description of the Related Art Conventionally, the following methods have been used for coloring concrete surfaces of concrete products. That is, as shown in FIG. 9, first, as shown in FIG. 9, a makeup mat 1 in which colored particles 6 are distributed on an uneven pattern surface 4 via an adhesive layer 5 whose adhesive force is reduced by water absorption is prepared. The makeup mat 1 is a makeup mold that is repeatedly used, and examples thereof include a makeup mold for PC and a makeup mold that is repeatedly used in the on-site casting. Next, as shown in FIG. 10, the concrete material 15 is cast by using the distribution surface of the colored particles 6 of the decorative mat 1 as a contact surface. Then, the concrete material 15 is cured and hardened, and the adhesive force of the adhesive layer 5 is reduced by the water content in the concrete material 15, so that the colored granular material 6 is removed from the concrete material 15.
It is transferred and buried on the surface of. After that, as shown in FIG. 11, the decorative mat 1 is peeled off, and the colored granular material 6 is distributed and embedded in the uneven surface 8 and colored concrete product 18 is obtained.
Get. In FIG. 10, 16 and 17 are molds.

In the above conventional method, a concrete product is treated by forming an adhesive layer 5 on the uneven surface 4 of the decorative mat 1 and distributing the colored particles 6 on the surface of the adhesive layer 5 (color treatment). It is carried out at the site of placing the. This color processing is first performed in FIG.
As shown in (A), a makeup mat 1 is prepared, and the uneven surface 4 of this makeup mat 1 is cleaned.
As shown in (B), the uneven surface 4 of the decorative mat 1
The adhesive layer is formed by spraying an adhesive agent on. Next, as shown in FIG. 12 (C), the colored particles 6 are sprayed on the surface of the adhesive layer 5 to be dispersed and held. After that, the adhesive layer 5 is dried and cured for a predetermined time. Then, using the color-treated decorative mat 1, a concrete product colored as described above is manufactured. In FIG. 12, 2 and 3 are spray nozzles.

[0004]

However, in the above-mentioned conventional method, since the color treatment of the decorative mat 1 is performed at the site where concrete is placed, it is necessary to take the time for drying and hardening the adhesive layer 5 at the site. . Therefore, there is a problem that the waiting time deteriorates the work efficiency, prolongs the construction period, and significantly lowers the productivity. Further, the processing quality of the color processing also varies due to changes in the site environment such as weather and seasonal changes, and the coloring quality of concrete products also tends to vary. Further, in order to carry out uniform color processing in response to environmental changes, considerable skill is required, which is a factor that further reduces productivity. Moreover, the color processing equipment such as the spray nozzles 2 and 3 needs to be transported to the site each time, and the transportation and the like are expensive.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a method for producing a concrete product that improves productivity and obtains a concrete product with stable coloring quality, and a decorative formwork used therefor. And

[0006]

In order to achieve the above object, a method for producing a concrete product according to the present invention is a method for producing a concrete product in which a concave-convex pattern surface of a decorative mat is used as a contact surface of a concrete material. Prepare a sheet that is formed in an uneven shape corresponding to the uneven pattern surface of the mat and that detachably fits the uneven pattern of the makeup mat to cover the uneven pattern surface of the makeup mat. The colored granules are distributed and held through the adhesive layer whose adhesive strength is reduced by the moisture in the material, and the sheet on which the colored granules are distributed and held is made up so that the distribution holding surface of the colored granules faces the front side. When placed on the uneven surface of the mat, the concrete material is cast with the distribution holding surface of the colored particles as a contact surface, and the concrete material is cured and cured. Moni, the moisture in the concrete material reduces the adhesive force of the adhesive layer is summarized in that shifting buried the colored granules in the surface of the concrete product.

Further, the makeup frame of the present invention is formed with a decorative mat having an uneven pattern surface on the surface and an uneven shape corresponding to the uneven pattern surface of this decorative mat, and is attached to and detached from the uneven pattern of the decorative mat. A sheet that freely fits and covers the uneven surface of the decorative mat is provided, and the colored particles are distributed and held on the surface of the sheet through an adhesive layer whose adhesive force is reduced by moisture in the concrete material. That is the summary.

That is, in the method for producing a concrete product of the present invention, first, an uneven shape corresponding to the uneven surface of the decorative mat is formed, and the uneven pattern of the decorative mat is detachably fitted to the uneven surface of the decorative mat. Prepare a sheet to cover the surface. Next, the colored granules are preliminarily distributed and held on one surface of the sheet through an adhesive layer whose adhesive strength is reduced by the water content in the concrete material. Next, the sheet on which the colored granules are distributed and held is placed on the uneven surface of the decorative mat so that the distribution holding surface of the colored granules faces the front side, and the distribution holding surface of the colored granules is a contact surface. Then the concrete material is poured. Then, the concrete material is cured and hardened, and the adhesive strength of the adhesive layer is reduced by the water content in the concrete material to transfer and embed the colored particles on the surface of the concrete product. As described above, in the present invention, a treatment of forming an adhesive layer and retaining the distribution of colored particles on the surface of the adhesive layer (color treatment)
Is not applied directly to the decorative mat, but is applied to the sheet covering the uneven surface of the decorative mat. For this reason, the color processing on the sheet can be performed in advance in the factory or the like, not at the site. Then, in the field, it is only necessary to perform a simple operation of placing the already color-treated sheet on the uneven surface of the decorative mat. Therefore, unlike the conventional case, there is no need to provide a waiting time for drying and curing the adhesive layer on site, the productivity can be significantly improved, the construction period can be shortened, and the manufacturing cost can be reduced. Also, since color processing can be performed in the factory, it is not affected by weather or seasonal changes,
Variations in processing quality are less likely to occur. Moreover, in the field,
Since it is only necessary to perform the simple work of attaching the sheet to the makeup mat, no skill is required for the work, and the productivity is further improved. Further, since it is not necessary to transport equipment such as a spray nozzle to the site, transportation cost can be reduced. In addition, used sheets can be reused by collecting them and subjecting them to color processing again, which is economical. Moreover, since the decorative mat is coated with the concrete in a state where the sheet is covered with the concrete, the concrete material cannot be directly hit on the decorative mat, so that the uneven surface of the decorative mat is hardly worn and damaged. For this reason, the life of the makeup mat is remarkably longer than in the past, and there is an effect that it is more economical and less expensive.

Also, with the decorative formwork of the present invention, the concrete product can be easily manufactured.

[0010]

Next, embodiments of the present invention will be described in detail.

According to the method for producing a concrete product of the present invention, an uneven shape corresponding to the uneven surface of the decorative mat is formed, and the uneven surface of the decorative mat is detachably fitted to cover the uneven surface of the decorative mat. Prepare the sheet. Then
Preliminarily, on one side of the above-mentioned sheet, the colored granules are distributed and held through an adhesive layer whose adhesive strength is reduced by the water content in the concrete material, etc. It is placed on the uneven surface of the decorative mat so that the surface faces the front side. Then, a concrete material is placed by using the distribution holding surface of the colored granular material as a contact surface, and the concrete material is cured and hardened, and the adhesive force of the adhesive layer is reduced by the moisture in the concrete material and the coloring is performed. The transfer of the particles to the surface of the concrete product is carried out.

In the manufacturing method of the present invention, first, as shown in FIG. 1, a concave-convex shape corresponding to the concave-convex pattern surface 4 of the decorative mat 1 is formed, and the concave-convex pattern of the decorative mat 1 is detachably fitted. Sheet 7 for covering uneven surface 4 of makeup mat 1
Prepare

The material of the sheet 7 is ABS resin, polyvinyl chloride, polypropylene, polyethylene,
Polyvinyl alcohol, urethane resin, polystyrene, polyvinylidene chloride, polycarbonate, cellulose acetate, saturated polyester, polyamide resin, polyimide, modified polyphenylene ether, polysulfone, polyarylate, polyethersulfone, polyetheretherketone, polyetherimide, polyphenylene sulfide , TPX polymer, polyparaxylene, polyamide imide, polyester imide, polybenzimidazole, and other resin materials are preferably used. As a method for forming the sheet 7 in a concavo-convex shape, a vacuum forming method in which the sheet is vacuum-sucked and brought into close contact with the surface of a mold having air permeability while heating the sheet, and a heating press method in which the sheet is sandwiched and pressed by the mold while heating is performed. Various methods such as a method of spraying a liquid resin into a concave-convex shape mold to form a uniform thin sheet and curing the same are not particularly limited. Although the thickness of the sheet 7 varies depending on the material used and the like, it is set to about 0.2 to 5 mm and needs to be 0.5 to 5 mm because it needs to have a concavo-convex shape and rigidity that allows repeated use.
It is more preferable that it is ˜3 mm.

As the decorative mat 1, various types such as wood are used, and although not particularly limited, those made of hard urethane foam resin are preferably used. This hard matte urethane resin decorative mat 1 is manufactured by injecting a liquid urethane foam resin into a mold and curing it, and the uneven surface 4 is formed on the surface by this mold molding.

Then, as shown in FIG. 2, an adhesive layer 5 whose adhesive force is reduced by water in concrete material is formed on one surface of the sheet 7 in advance.

Examples of the pressure-sensitive adhesive whose pressure-sensitive adhesive force is reduced by the water content in the concrete material forming the pressure-sensitive adhesive layer 5 include, for example, methyl cellulose adhesive and polyvinyl alcohol whose pressure-sensitive adhesive force is reduced or eliminated by meeting with water in the concrete material. Examples include adhesives and water glass. Another example is a two-pack type acrylic adhesive that reduces or disappears the adhesive force when it meets the alkaline component in the concrete material.
As for the viscosity of the above-mentioned pressure-sensitive adhesive, it is necessary to form the pressure-sensitive adhesive layer 5 with a certain thickness and hold the colored particles 6 on the pressure-sensitive adhesive layer 5, and the pressure-sensitive adhesive layer applied to the vertical portion of the uneven shape causes sagging. 2000 to 20000 mPa from the viewpoint that there is no
・ S of s is used and 7,000 to 13,000 mPa ・
More preferably, it is s.

As a method for forming the adhesive layer 5 on the surface of the sheet, various methods such as a spraying method using a spray, a coating method using a brush, a pouring method and the like are performed, and are not particularly limited. At this time, the thickness of the adhesive layer 5 is preferably about 0.1 to 3 mm, and more preferably 0.2 to 1 mm, from the viewpoint of appropriately reducing the adhesive force due to water in the concrete material.

Then, as shown in FIG.
The colored particles 6 are distributed and held on the surface of the.

As the colored particles 6, crushed natural stone particles, ceramic particles, glass particles and the like are used. These colored particles 6 can be used alone or in combination of a plurality of types as required. From the viewpoint that the particle size of the colored particles 6 needs to be held by the adhesive force of the adhesive layer 5, and that a large amount of colored particles are dispersed in order to express the color. , About 0.01 to 6 mm is preferably used,
It is more preferably 0.1 to 3 mm.

As a method of keeping the colored particles 6 distributed on the surface of the pressure-sensitive adhesive layer 5, the colored particles 6 are sprayed onto the pressure-sensitive adhesive layer 5 together with compressed air and sprayed, and the spraying force causes the pressure-sensitive adhesive layer 5 to be colored. The particulate matter 6 is attached or partially embedded. Further, a large number of colored particles 6 may be sprinkled on the adhesive layer 5 and held by utilizing the adhesive force of the adhesive. Further, the colored particles 6 may be sprinkled on the adhesive layer 5 and then pressed from the surface to partially or completely embed the colored particles 6 in the adhesive layer 5. At this time, the distribution amount of the colored particulate matter 6 is 200 to 20 from the viewpoint that the concrete surface needs to be colored evenly and that the spray amount needs to be increased or decreased in order to express the shade of the colored state.
00g / m ² is preferable and 500 to 1000g / m
² is more preferable.

As a method of keeping the colored particles 6 distributed on the surface of the sheet 7 through the pressure-sensitive adhesive layer 5, the colored particles 6 are mixed in advance in the pressure-sensitive adhesive and the mixed solution is prepared. The adhesive layer 5 in which the colored particulate matter 6 is distributed and held may be formed by coating the surface of the sheet 7 or the like.

The above-mentioned treatment for forming the adhesive layer 5 and the adhesive layer 5
The processing (color processing) for maintaining the distribution of the colored particles 6 on the surface of the is mainly performed in the factory.

Next, as shown in FIGS. 4 and 5, the sheet 7 on which the colored particles 6 are distributed and held is provided with an uneven pattern on the makeup mat 1 so that the distribution holding surface of the colored particles 6 faces the front side. It is placed on the surface 4.

The method of applying the sheet 7 to the uneven surface 4 of the decorative mat 1 is not particularly limited as long as the used sheet 7 can be separated from the decorative mat 1. For example, in addition to a method of sticking with a double-sided adhesive tape or an adhesive, a method of fastening with a fastener, a method of sandwiching with an adherend, and the like are performed.

After that, as shown in FIG. 6, a decorative mat 1 provided with a sheet 7 in which colored particles 6 are distributed and held.
Then, the concrete material 15 is placed by using the distribution holding surface of the colored granular material 6 as a contact surface. Then, the concrete material 15 is cured and hardened, and the adhesive force of the adhesive layer 5 is reduced by the water content in the concrete material 15 and the colored granular material 6 held in the adhesive layer 5 is being hardened. It moves into the surface layer of concrete products and is partially or entirely buried. In the figure, 16, 17
Is a formwork.

Then, after the concrete material 15 is cured and hardened, the molds 16 and 17 are removed, and the sheet 7 is peeled from the concrete product 18 to be produced, as shown in FIG. At this time, in order to hold the colored granules 6 on the sheet 7, an adhesive whose adhesive force is reduced by the water content in the concrete material 15 is used. The sheet 7 can be easily peeled off, and damage to the sheet 7 is reduced.

The concrete material 15 is not particularly limited, and a conventionally known material obtained by mixing cement powder with water and an aggregate such as sand is used. The cement powder is not particularly limited, and various types of cement powder may be used, for example, hydraulic cement such as alumina cement.

After that, as shown in FIG. 8, the used sheet 7 is peeled off from the decorative mat 1. The used sheet 7 is collected, color-processed again at the factory, and repeatedly used. The makeup mat 1 is also used repeatedly.

Although the sheet 7 is formed in advance in an uneven shape to be fitted into the uneven pattern of the decorative mat 1, a soft and elastic soft sheet is used instead of the sheet 7. Alternatively, the flat soft sheet may be subjected to color treatment, and the soft sheet subjected to the color treatment may be used by being placed so as to cover the uneven pattern surface 4 of the decorative mat 1.

[0030]

As described above, according to the present invention, it is possible to form a pressure-sensitive adhesive layer and to carry out a treatment (color treatment) of distributing and retaining colored particles on the surface of the pressure-sensitive adhesive layer, instead of directly applying to the decorative mat. This is applied to a sheet that covers the uneven surface of the decorative mat. For this reason, the color processing on the sheet can be performed in advance in the factory or the like, not at the site. Then, in the field, it is only necessary to perform a simple operation of placing the already color-treated sheet on the uneven surface of the decorative mat. Therefore, unlike the conventional case, there is no need to provide a waiting time for drying and curing the adhesive layer on site, productivity can be greatly improved, and the manufacturing period can be shortened and the manufacturing cost can be reduced. Further, since color processing can be performed in the factory, variations in processing quality are less likely to occur without being affected by weather or seasonal changes. In addition, since it is only necessary to perform a simple work of attaching the sheet to the makeup mat on site, it is possible to further improve productivity without requiring skill. further,
Since it is not necessary to transport equipment such as spray nozzles to the site, transportation costs can be reduced. In addition, used sheets can be reused by collecting them and subjecting them to color processing again, which is economical. Moreover, since the decorative mat is coated with the concrete in a state where the sheet is covered with the sheet, the concrete material cannot be directly hit on the decorative mat, so that the uneven surface of the decorative mat is hardly worn and damaged. For this reason, the life of the makeup mat is remarkably longer than in the past, and there is an effect that it is more economical and less expensive.

Further, with the decorative formwork of the present invention, the concrete product can be easily manufactured.

Next, examples will be described together with comparative examples.

[0033]

Example A concrete product was produced under the following conditions by the method for producing a concrete product of the present invention. Concrete material: Ready mixed concrete Decorative mat: Material Hard urethane foam resin sheet: Material ABS resin Thickness 1.0 mm Adhesive layer: Polyvinyl alcohol adhesive (viscosity 12000 mPa · s) (Spraying at a pressure of 5-7 kg / m ₂ ) Thickness 0.3 mm Colored granules: Material Colored ceramics Particle size 0.5 mm, 1.0 mm, 2.0 mm (each sprayed by color with a dedicated spraying machine) Distribution amount 1100 g / m ²

[0034]

Comparative Example 1 Further, as a comparative example, a concrete product was manufactured by a conventional manufacturing method under the following conditions. Concrete material: Ready mixed concrete Decorative mat: Material Hard urethane foam resin Adhesive layer: Polyvinyl alcohol adhesive (viscosity 9000 mPa · s) (Spraying at a pressure of 5-7 kg / m ₂ ) Thickness 0.5 mm Colored granules: Material Crushed natural stone, colored ceramics Particle size 0.5 mm, 1.0 mm, 2.0 mm (spraying by color with a dedicated spraying machine) Distribution amount 1500 g / m ² Dry hardening: 20 ° C. natural hardening 2 hours

[0035]

[Comparative Example 2] A concrete product was produced in the same manner as in Comparative Example 1 except that the dry curing was carried out by heat curing at 35 ° C for 30 minutes.

In the above Examples and Comparative Examples 1 and 2,
The time required for each process is shown in Table 1 below.

[0037]

[Table 1]

As can be seen from the results in Table 1 above, it can be seen that the working example can be carried out in a much shorter time than the comparative examples 1 and 2.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a decorative mat and a sheet used in the present invention.

FIG. 2 is an explanatory view showing a state in which an adhesive layer is formed on the sheet.

FIG. 3 is an explanatory diagram showing a state in which colored particles are distributed and held on the surface of the adhesive layer.

FIG. 4 is an explanatory diagram showing a state in which the sheet is attached to a decorative mat.

FIG. 5 is an explanatory view showing a makeup mat to which a sheet is attached.

FIG. 6 is an explanatory diagram showing a state in which a concrete material is cast on a decorative mat to which a sheet is attached.

FIG. 7 is an explanatory diagram showing a state in which a decorative mat with a sheet attached is peeled off from a concrete product.

FIG. 8 is an explanatory diagram showing a state in which the sheet is peeled off from the makeup mat.

FIG. 9 is an explanatory diagram showing a conventional manufacturing process.

FIG. 10 is an explanatory view showing the conventional manufacturing process.

FIG. 11 is an explanatory view showing the conventional manufacturing process.

FIG. 12 is an explanatory diagram showing a conventional color processing step.

[Explanation of symbols]

 1 Decorative mat 4 Uneven pattern surface 5 Adhesive layer 6 Colored granular material 7 Sheet 15 Concrete material

Claims (2)

[Claims] 1. A method for producing a concrete product, wherein the textured surface of a decorative mat is used as a contact surface of a concrete material, and the textured surface is formed into a textured shape corresponding to the textured surface of the decorative mat. Prepare a sheet that detachably fits and covers the uneven surface of the decorative mat, and distribute the colored particles on one side of the above-mentioned sheet in advance through an adhesive layer whose adhesive strength decreases due to moisture in the concrete material. The sheet on which the colored particles are distributed and held is placed on the uneven pattern surface of the decorative mat so that the distribution holding surface of the colored particles faces the front side, and the distribution holding surface of the colored particles is a contact surface. And placing concrete material, and curing and hardening the concrete material,
A method for producing a concrete product, comprising the step of reducing the adhesive force of the adhesive layer due to water in the concrete material and migrating and embedding the colored particles on the surface of the concrete product. 2. A makeup mat having an uneven pattern surface formed on a surface thereof, and a makeup mat formed into an uneven shape corresponding to the uneven pattern surface of the makeup mat and detachably fitted to the uneven pattern of the makeup mat. And a sheet for covering the uneven surface of the above-mentioned sheet, wherein the colored particles are distributed and held on the surface of the sheet through an adhesive layer whose adhesive force is reduced by moisture in concrete material. Formwork.