JPH0948017A - Manufacture of mold for concrete molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable to easily manufacture a lumped concrete large-sized molding similar to a rock or the like in a form case. SOLUTION: A rubber male mold layer 13 is provided on the inner surface of an outer mold 10 having a hollow lumped or spherical state and an opening at the upper surface and capable of opening at a plurality of cracks along the longitude for an upper half part to arrive from an opening at the equator via a mold release agent layer, a temporary filling material 15 such as a foamed resin or water glass is filled in the male mold layer, a rubber upper surface layer 14 is provided on the upper surface of the filling material, and integrally connected to the open upper surface of the male mold layer. Then, the filling material is removed out from an outlet 16 provided at the rubber upper surface layer, a rubber hollow male mold 18 made of the male mold layer and the upper surface layer is released out of the outer mold, the mold 18 is introduced into a form case 19, fluid is cast in the male mold and expanded, solidifiable fluid is filled out of the male mold in the case, and when the fluid is solidified, the fluid in the male mold is discharged, the volume is reduced to be released from a solid layer 20, and the trail of the male mold generated in the solid layer is used as a molding space 21.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding for manufacturing a large block-shaped object such as concrete rock to be laid on a coast or river for wave breaking and revetment using a natural rock as a male mold. A method for manufacturing a mold. In addition to the natural rock, the male type may be a solid rock-shaped object made of wood, styrofoam, or the like, or a large rock-shaped object made of a metal plate or FRP. Also, a three-dimensional pattern may be engraved on the surface of a balloon or a balloon with an arbitrary material.

[0002]

2. Description of the Related Art The applicant of the present patent application discloses, in Japanese Patent Application No. 6-31988, a large rock-shaped male mold on a support base as a method for manufacturing a female mold for molding a large-sized block-shaped concrete molding. Fix and cover the male mold with a plastic material such as clay except for the part that contacts the support, stack FRP or FRG on the upper half of this coating layer and solidify to make a bowl-shaped back mold, FRP or FRG is laminated around the part so that it can be divided by a crack along the longitude, and it is solidified to make a plurality of split back mold pieces, and then a bowl-shaped back mold and the upper half of the coating layer on the inside, and one Remove every other split back mold piece and the repellent curved surface piece of the coating layer inside it from the male mold, attach the removed split back mold piece to the male mold in the original state, and put the solidifying fluid inside it. Inject and solidify with the split back mold piece to make a split female mold piece, then every other split back mold piece , Remove the repellent curved surface piece of the inner coating layer from the male mold, attach the removed split back mold piece to the male mold in the original state, inject the coagulable fluid into the inside, and After solidifying together to make a divided female mold piece, making all the divided female mold pieces in this way, put the removed bowl-shaped back mold on the upper half of the male mold and put the lower peripheral edge on all the divided back mold pieces. Fixed,
A coagulable fluid is injected into the inside of the bowl-shaped back mold from an injection hole provided on the top of the bowl-shaped back mold, and the bowl-shaped back mold is integrally solidified into a bowl-shaped female mold, and then a bowl-shaped female mold, and It was proposed to remove all the split female mold pieces from the male mold and the support. This manufacturing method is hereinafter referred to as method A in this document. The female mold manufactured by this method A was assembled with the demolded bowl-shaped female mold and all the divided female mold pieces in the same manner as before, and the cutting die formed around the support base was partially addressed to all the divided female mold pieces. The notches gather together to form an opening for the concrete inlet.

As a similar method for producing a female mold, the applicant of the present invention discloses in Japanese Patent Application No. 6-85296 that a large rock-shaped male mold is fixed on a supporting base, except for a portion in contact with the supporting base. The male mold is covered with an elastic material such as natural rubber or synthetic rubber, and a large number of chain rows and wire mesh bands are attached along the longitude from this top pole toward the periphery of the support on this elastic cover layer to form the female mold. Then, cut the lower half of the elastic coating layer into multiple pieces by splitting along the longitude avoiding the chain row and the wire mesh band, and providing a fastener for opening and closing the split at the split, and opening the split with fasteners. It was proposed that the female mold be removed from the male mold and the support, and that the opening for concrete injection be formed by the trace of the mold removal from the support. This manufacturing method will be referred to as method B hereinafter in this document.

[0004]

Both the female mold manufactured by the above method A and the female mold manufactured by the method B are prepared by pouring and filling the raw concrete into the interior through the opening for concrete injection. Although it is possible to manufacture a large concrete molded object of a specified shape, all of the female molds are large lumps, so the opening for injection is up from the time when the fresh concrete is filled into the inside until it is solidified. A large-scale device is required to support the robot in the air, and the work requires a great deal of labor and time.

[0005]

Therefore, the present invention has a plurality of cracks along the longitude which have openings for concrete injection on the upper surface manufactured by the method A or the method B and whose upper half portion reaches the equator from the openings. A female mold that can be opened by means of is used as an outer mold so as to obtain a molding space for molding a molded product in a mold box, and the method for manufacturing a concrete-molded molded mold according to claim 1. , Hollow or spherical,
A rubber male mold layer is provided via a release agent layer on the inner surface of the outer mold which has an opening on the upper surface and which can be opened by a plurality of cracks along the longitude where the upper half part reaches the equator from the opening. Fill the inside of the mold layer with a temporary filling material such as foamed resin or water glass, provide a rubber top layer on the upper surface of the temporary filling material, and integrally bond with the open upper surface of the rubber male mold layer, and then add the temporary filling material to the rubber. Take out from the outlet provided in the upper surface layer, demold the hollow male mold of rubber consisting of the rubber male mold layer and the rubber upper surface layer from the outer mold, and put this hollow male mold in the mold box, Inject the fluid into the hollow male mold to inflate it, fill the solidified fluid outside the hollow male mold in the form box, and discharge the fluid in the hollow male mold when the solidified fluid solidifies to reduce the volume. It is characterized in that it is made smaller and demolded from the solidified layer, and the mark of the hollow male mold generated in the solidified layer is used as the molding space. Further, the method for manufacturing a mold for concrete-molded product according to claim 2 is a hollow lump or a sphere, has an opening on the upper surface, and opens at a plurality of cracks along the longitude from the opening to the equator. On the inner surface of the outer mold that can be provided, a rubber male mold layer is provided via a release agent layer, and the inside of the rubber male mold layer is filled with a temporary filling material such as foamed resin or water glass. A rubber upper surface layer is provided and integrally joined to the open upper surface of the rubber male type layer, and then the temporary filling material is taken out through the outlet provided in the rubber upper surface layer to remove the rubber composed of the rubber male type layer and the rubber upper surface layer. Remove the hollow male mold from the outer mold,
A part of this hollow male mold is fixed to the inner surface of the closing plate that closes the open surface of the mold box, and the fluid is injected into the hollow male mold to inflate it, and the coagulable flow out of the hollow male mold inside the mold box. It is characterized in that the hollow male mold is removed from the solidification layer together with the closing plate when the body is filled and the solidifying fluid is solidified, and the mark of the hollow male mold generated in the solidification layer is used as the molding space.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION
Whichever method is used for manufacturing, first, as shown in FIG. 10, the portion corresponding to the South Pole of the male mold 51 such as a natural round rock is turned upward, and the polygonal support 52 is fixed thereto.
To do this, make a plurality of holes with a drill in the part corresponding to the male South Pole, drive the anchor nut 53 into the holes, fix it with an adhesive if necessary, and mount the support base 52 on it. From the multiple holes of the same arrangement opened on the table, bolts 54
Is tightened by screwing it into the anchor nut, fixing the support stand on the part corresponding to the south pole of the male mold, then hoisting the male mold with a crane or the like, and lowering the support base 52 downward on the surface plate 55, Separate the lower surface of the male southern hemisphere without the support fixed above the surface plate. Then, the mold release agent is attached to the male mold 51 except for the portion that comes into contact with the support base 52, and is dried or solidified.

FIG. 11 shows a female mold which is the outer mold 10 manufactured by the method A, and the female mold is a bowl-shaped female mold 111 for molding the northern hemisphere.
And a divided female mold 115 which is composed of a plurality of divided female mold pieces 116 which are divided into 6 or 7 along the longitude and are assembled and assembled to form the southern hemisphere. When the female molds 115 are assembled together and assembled, the opening 11 for concrete injection is formed at the position of the South Pole. Therefore,
Assemble the divided female molds by assembling the divided female molds, cover them with a bowl-shaped female mold and fix them, turn over the female mold so that the South Pole is on top, and open the female mold from the opening 11 in the South Pole. The product can be released from the mold by pouring, filling, and hardening the raw concrete inside, and disassembling the bowl-shaped female mold 111 and the divided female mold 115.

In order to produce a female mold, a plastic material such as clay, gypsum, paraffin, wax, oil clay, resin clay, water glass, agar, etc., around the male mold having a release agent attached, preferably 10 mm thick. About 10 to 30 mm thick by sticking a soft clay plate that does not solidify into a plate shape,
The coating layer 130 made of a plastic material is formed. The lower part of the coating layer 130 surrounds the support base 52 (FIG. 12). Then, a mold release agent is attached to the entire surface of the coating layer 130, and FRP (fiber reinforced resin) or FRG (fiber reinforced rubber) is applied to the upper half of the coating layer 130 by a manual attachment method, a mechanical spraying method, or the like. The bowl-shaped back mold 112 is made by stacking the layers to a thickness of 10 mm and hardening them. At this time, an integral brim 1 extending outward is provided at the lower end peripheral portion of the bowl-shaped back mold.
Make 13 at the same time. In addition, a repellent split back mold piece 117 having a curved surface that is divided into, for example, six at the cracks 12 along the longitude around the lower half of the coating layer 130 is similarly used for the FRP or FRG of 3 to 10 mm. Laminate to thickness and harden to make.
At this time, a flange piece 118 that extends outward from the upper edge portion of the split back mold piece and is joined to the flange of the side edge portion of the adjacent split back mold piece on both sides of the flange piece 118 that is in contact with the flange 113.
9 and 119 are also made integrally. The lower end of each divided back mold piece contacts one side of the polygon of the support base 52. FRP, which is a raw material for the back mold, is a composite curable material composed of fibers such as glass fiber reinforced polyester resin, carbon fiber reinforced polyester resin, nylon Kepler and aramid, and a fiber mesh and a curable resin. It is a composite material composed of fibers, fiber mesh and urethane rubber, synthetic rubber and the like.

When the bowl-shaped back mold and the divided back mold pieces are solidified, FIG.
As shown in FIG. 3, the bowl-shaped back mold 112 is demolded from the upper half of the coating layer 130, and the coating layer 130 is placed along the joint (the equator in the earth) of the bowl-shaped back mold and the divided back mold pieces. Cut laterally and remove the upper half 130 'of the cover layer from the male mold 51. Then, for example, an even-numbered alternate split back mold piece 117-I
I, IV, VI are peeled off from the lower half of the coating layer to form even-numbered divided back mold pieces and odd-numbered divided back mold pieces 117-I, III, V
Cut the lower half of the coating layer vertically along the crevice (longitude on earth) to the support.

Then, as shown in FIG. 14, the repellent curved surface piece of the covering layer covered with the even-numbered divided back mold pieces was removed from the male mold, and the inner surface of the even-numbered divided back mold pieces peeled off earlier. For example, a three-dimensional mesh material 121 such as lath, expanded metal, etc., which is a base material of a mortar wall, is bent and corrugated as a whole.
After fixing them with bolts, nuts, nails, adhesives, etc., the flanges 119, 119 on both side edges of each divided back mold piece are joined to the flanges of the adjacent odd-numbered divided back mold pieces with bolts and nuts, etc. Assembling each split back mold piece around the male mold as before, and then removing the inside of the split back mold piece, that is, the repellent curved surface piece of the coating layer, Coagulating fluid such as silicone resin, two-part urethane resin, two-part synthetic rubber, epoxy resin, polyester resin, etc. is injected into the space between the lower half part from above and solidified to have a curved surface. A repellent divided solidified piece 120 is formed.
This divided and solidified piece is filled with the three-dimensional mesh material 121 fixed to the inner surface of the divided back mold piece and solidified, and becomes an even numbered divided female mold piece 115 integrally with the divided back mold piece, and the lower end of the support stand is Touch every other side. Next, the odd-numbered divided back mold piece and the fan-shaped curved surface piece of the coating layer inside the odd-numbered divided mold piece are removed from the male mold, the repellent curved surface piece of each divided back mold piece is removed, and the three-dimensional mesh material 12 is applied to the inner surface.
After fixing 1, the flanges 118, 118 on both side edges are joined to the flanges of the adjacent even-numbered divided back mold pieces to assemble the odd-numbered divided back mold pieces around the male mold as before, A coagulable fluid is injected from the above to solidify to form a repellent split solidified piece 120 having a curved surface integral with the split back mold piece, and odd-numbered split female mold pieces 116 are formed. The lower end of this divided solidified piece also contacts the remaining one side of the polygon of the support base 52.

The number of divided female mold pieces 115 is 6, 8, and 10.
In the case of an even number of pieces, the required even number of divided female mold pieces can be produced by the above operation. The number of split female mold pieces is 7
Odd number such as 9 sheets, 9 sheets, 11 sheets, for example, 2 in case of 9 sheets
The even divided female mold pieces 4, 6, 8 and the odd divided female mold pieces 1, 3, 5, 7 are made, and finally the 9th divided female mold piece is made.

When injecting the coagulable fluid,
Before that, a mold release agent is attached to the exposed part of the male mold, the coating layer inside the adjacent divided back mold piece, and the side surface of the solidified piece.

In this way, when all of the divided female mold pieces are assembled around the lower half of the male mold, a mold release agent is attached to the upper surface of the divided solidified pieces of each divided female mold piece to remove the mold. After opening the injection hole 112 ′ on the top of the bowl-shaped back mold 112 and fixing the three-dimensional mesh material 121 to the inner surface, the male mold is covered from above as shown in FIG. 15, and the collar 113 at the lower end peripheral portion, The brim piece 118 at the upper edge of the split back mold piece is joined with a bolt nut or the like, whereby the inner lower end of the bowl-shaped back mold is closed with the split solidification piece inside the split back mold, and the coagulation flow from the injection hole at the top. The body is injected and solidified into a bowl-shaped solidified shell 114. This bowl-shaped solidified shell 11
4 is integrated with the bowl-shaped back die 12 to fill and solidify the mesh material 121 fixed to the inner surface of the bowl-shaped back die, and the bowl-shaped female die 111
Is configured. The injection hole 112 'is closed with a bowl-shaped solidified shell.

When the bowl-shaped solidified shell is solidified, the collar 113 and the collar piece 1
18 is removed, the bowl-shaped female die 111 is removed from the male die 51, and the flange 119 is detached from the male die 51 to separate the female die 1.
All the divided female mold pieces 116 constituting 15 are removed from the male mold 51 and the support base 52. All the divided female mold pieces are straight portions 11 formed by contacting each side of the polygon of the support base 52.
Since 6'is provided at the lower end, when the divided female molds 115 are assembled by joining the flanges 119 to each other, this straight line portion becomes the polygonal opening 11 in the center of the lower surface of the divided female molds, which is the mark of the support base.

A hollow female die can be constructed by assembling the divided female die 115, covering the bowl-shaped female die 111 on it, and joining the collar 113 and the collar piece 118 together. The female mold is turned upside down so that the opening 11 faces upward, and as shown in FIG. 16, the female mold is placed on a gantry 140 assembled by welding angle steel or the like according to the form of the female mold. The lower surface of the female-shaped brim 113 and the lower surface of the bowl-shaped female mold are supported by the above-mentioned pedestal from below to stabilize and the opening 11 of the upper divided female mold is made horizontal and Fresh concrete C such as cement concrete or resin concrete is poured into the inside of the female mold, and long legs 127 'of several hooks 127 are inserted into the female mold from around the opening 11 in the middle of the opening, and the continuous injection of fresh concrete is opened. 11
It fills until it is closed, and waits for the filled fresh concrete to solidify and become a product. Then, when solidified, the flanges 119 of the split female mold pieces on the upper side are removed from each other, and the flange piece 118 is also removed from the bowl-shaped female collar 113, and all the divided female mold pieces are released from the product. A rope from a crane or the like is hung on the hook 127 in which long legs are put in the product, the product is lifted, the bowl-shaped female mold 111 is released from the product, and the product is carried to the curing yard and lowered.

The adjacent divided female mold pieces 116 are left without removing the bolts and nuts 128 connecting the ends of the flanges 119 on the side edges close to the opening 11 when they are disassembled in order to remove them from the product. As a result, if 6 or 7 divided female mold pieces are individually assembled in a state in which they can be individually turned upward as shown in FIG. 17, all the divided female mold pieces can be turned upward. After moving it and peeling it from the product, you can lift it up with a crane etc. and remove it from the product, and lower it with a crane etc. onto the bowl-shaped female mold, open the divided female mold piece addressed to one and open the brim piece 118 into a bowl shape. It is possible to assemble the bowl-shaped female die by contacting the female collar 113 from above. As a result, it is possible to greatly reduce the number of steps and time required to remove the individual divided female mold pieces from the product or to assemble them with the bowl-shaped female mold. In this case, the diameter of the hole formed at the end portion of each flange 119 near the opening 11 for allowing the bolt 128 to pass is made larger than the shaft portion of the bolt, and the bolt loosely passes through the hole to divide the female type. It is advisable to allow the piece to rotate easily.

The joint (equator) between the bowl-shaped female die 111 and the divided female die 115 may be provided along the maximum waist circumference of the male die 51. Even if the surface of the joint is horizontal, it is inclined with respect to the horizontal. Or it may be uneven. In short, bowl-shaped female mold 111
It suffices that the mold can be easily removed from the upper half of the male mold 51 or the lower half of the product when the product is molded by turning upside down.

FIG. 18 shows a female mold which is the outer mold 10 manufactured by the method B, and the female mold is a bowl-shaped portion 211 for molding the northern hemisphere.
And a bowl-shaped part, but is divided into 6 or 8 by the cracks 12 along the longitude, and a plurality of divided pieces 212 that form the southern hemisphere except the South Pole by concentrating. When the split pieces are closed and concentrated, an opening 11 for concrete injection is formed at the position of Antarctica. Therefore, as shown in FIG. 18 (a), the divided pieces are gathered, the female mold is turned upside down so that the South Pole is on the top, and the raw concrete is injected and filled into the female hollow through the opening 11 in the South Pole. Harden, Figure 1
By opening the split pieces as shown in 8 (b), the product can be released from the hollow inside of the female mold.

In order to manufacture this female mold, natural rubber or synthetic rubber may be sprayed in multiple layers around the male mold 51 to which the release agent is attached as described above, or multiple layers may be applied and the thickness may be increased. Is 10
A laminated elastic coating layer 220 having a thickness of about 30 mm is prepared. In order to make the elastic coating layer 220, a male die having the support base 52 fixed thereon is hung up by a crane or the like, the male die is turned upside down, and the support base 52 is directed downward and is lowered onto the surface plate 55 to support it. Separate the lower surface of the male southern hemisphere with the base not fixed from the surface plate, then attach the male mold release agent, and make an elastic coating layer on it,
Alternatively, a mold release agent is attached within the range in which the support base is fixed on top, and an elastic coating layer is formed on the mold release agent, then lifted with a crane etc. to reverse the male type upside down and support The table 52 is lowered onto a surface plate 55, a mold release agent is attached to the male surface on which the elastic coating layer is not yet formed, and the elastic coating layer is formed thereon. The lower part of the elastic coating layer thus formed surrounds the support (FIG. 19).

When making the coating layer, the top pole (north pole) of the coating layer
The anchors of the anchor fasteners 231 that connect the upper ends of a large number of chain rows and wire mesh bands 230 are embedded and fixed, and the respective chain rows and wire mesh bands are arranged along the longitude that is arranged toward the periphery of the support base 52. The anchor of the anchor bolt 232 is embedded and fixed at an appropriate interval. The chain row may be a mantel chain or a link chain in which one link is formed by alternately connecting 90-degree turns of egg-shaped links. Further, the wire mesh belt is a flexible mesh formed by weaving or knitting a metal wire and freely bending in any direction of 360 °, for example, a wire mesh for a belt conveyor (Nippon Filcon Co., Ltd., trade name spiral wire mesh). NTN-1 or NTN-2) can be used, preferably the maximum width at the equator is 30 cm or 60 cm, and the boat shape as shown in FIG. 24A constitutes a spherical paper balloon narrowing toward the North Pole and the South Pole. One piece is good. As a result, when the elastic coating layer 220 is solidified, the upper end of the elastic coating layer 220 is fixed to the anchor fastener 2
The chain row or one of the wire mesh bands connected to 31 is lowered along the longitude at a predetermined interval, and the lengths of the chains are fixed to the anchor bolts 232 with nuts so that the lower ends reach around the support base. The arrangement interval of the chain rows and the adjacent intervals of the wire mesh bands may be about 5 to 10 cm around the equator of the coating layer 220.

Since the surface of the elastic coating layer 220 on which the chain rows and the wire mesh bands are arranged and fixed is almost as uneven as the surface of the male mold, the chain rows and the wire mesh bands which are arranged and fixed depend on the unevenness. It bends and its length is not uniform. In this manner, the chain of chains and the wire mesh band are bent and fixed on the elastic coating layer according to the irregularities of the elastic coating layer.
The bolts used in FIG. 25 are swingable with respect to the anchor 232 '. It should be noted that the anchor bolt for fixing the chain row for one wire may be provided for one row along the longitude of the elastic coating layer, but in the case of a wire mesh band, there is a width, so an anchor bolt per one wire mesh band A plurality of columns 232 are provided along the longitude.

It is preferable to connect adjacent chains of chains and wire mesh bands 230, 230 on the elastic coating layer with connecting members 233. This connecting tool may be a wire, a bolt nut, or the like, but since adjacent chain rows and wire mesh bands may be bent differently, the elastic material 234 such as a coil spring or rubber capable of extending the length. 27, an elastic connector 235 pulled by a coil spring 234 or the like is suitable.

Before arranging the chain row and the wire mesh band described above,
Alternatively, after the arrangement is fixed, the lower half portion of the elastic coating layer 220 is incised along the longitude different from the chain row or the wire mesh belt 230 to the position of the support table to form a plurality of, for example, eight divided pieces 212, and the split 12 thereof. A fastener 221 for opening and closing the crack is provided. The fastener 221 is a slide fastener shown in FIG. 26 (a) attached by gluing over a crack, a groove having a C-shaped cross section, and a plastic elastic member that becomes an Ω-shaped protrusion that fits into this groove. The fastener shown in FIG. 26 (b) (Tokushige Rubber Industry Co., Ltd., trade name Cisna) that deforms and engages and disengages may be used, or a groove having a C-shaped cross section formed by processing an elastic coating layer along one of the cracks. 26 and an Ω-shaped ridge that is processed along the other side of the crack to process the elastic coating layer and fits into the groove.
It may be a cis-na-shaped fastener of (c). When the number of the divided pieces 212 is eight, for example, the shape of the support base is a regular octagon, and when the shape of the support base is a regular polygon corresponding to the number of the divided pieces, the corners of the regular polygon form a crack. Since this is a guide for the position to be formed, the work of forming cracks is facilitated, which is preferable.

In this way, the elastic coating layer 220 is formed, a large number of chains and wire mesh bands 230 are attached to the outside in the longitudinal direction, and the lower half of the elastic coating layer is cut into a plurality of divided pieces 212, and the fasteners are formed at the cracks. When 221 is provided and the female mold is completed, the cracks are opened with fasteners, all the divided pieces 212 are peeled from the male mold as shown in FIG. 19, and the female mold is released from the male mold and the support table upward. When the split of the female die 100 is closed with fasteners and the divided pieces 212 are assembled, the support base 52
The opening 11 for pouring concrete is formed by the lower end of the divided piece formed in contact with the. Support 52
If is a polygon, the opening 11 is also the same polygon.

In order to manufacture a large lump shaped product (product) using this female mold, the cracks of the divided pieces are opened with fasteners 221 and a mold release agent is adhered to the entire inner surface of the female mold to fix the fasteners. A large number of telescopic connectors 241 each having one end attached to a column of a pedestal or a cross beam for connecting columns to each other are inserted into the frame 240 that closes and surrounds the female mold with the opening 11 facing upward (FIG. 20).
For example, the other end of a turnbuckle, a piston cylinder, a mechanical jack, a gas jack such as an air bag, or a liquid jack such as a liquid such as water should be slanted upward from the side around the lower half of the female mold or the split piece. Then, the female mold which cannot be self-standing is erected in a lump shape by connecting the chain row and the wire mesh band from diagonally downward, and the opening 11 is directed upward and is horizontal (FIGS. 21 and 22). The lower surface of the female mold may be supported by the floor of the gantry or a stone block placed on the floor, but the piston cylinder and jack are also mounted upward on the floor of the gantry to support the lower surface of the female mold. You may.

The appearance of the female type which is erected by the expansion and contraction connecting device 241 does not have to be the same as that of the male type. Change the stone block placed on the floor, change the position to put the stone block, and jacks that support the female mold from below, and push and pull the female mold from around and pull the elastic mold. The elastic coating layer 220 constituting the female die is elastically deformed in various ways by various changes, the chain row and the wire mesh belt 230 are flexed freely following the deformation of the coating layer, and the appearance of the female die is variously changed.

In this way, when the female mold stands up in the mount, as shown in FIG.
As shown in (a), the ready-mixed concrete C such as cement concrete or resin concrete is filled from the opening 11 into the female mold until the opening is closed, and when the filling is completed, the ready-mixed concrete in the opening portion is hooked in an inverted U-shaped hook. Insert 214 and wait for the filled raw concrete to solidify and become a product. And
Once solidified, the expansion and contraction tool or the like connected to the split piece 212 is removed from the split piece, the split piece 212 is opened with fasteners 221 and the split piece is peeled off from the product so as to peel the mandarin orange (FIG. 18B, 23), hang a rope from a crane on the hook 214 fixed to the product,
The female bowl-shaped part 211 is peeled off from the product to remove the product, and the product is transported to a curing yard and lowered to be cured.

In order to manufacture the next product, a mold release agent is attached to the entire inner surface of the female mold, the cracks are closed by the fasteners 221, and the expansion joints and the like are again connected around the divided pieces 212 to form the opening 1
Make the female mold stand again with 1 facing up. At this time, while changing the stone blocks placed on the floor and changing the position of the stone blocks,
By changing the pushing condition and pulling condition of the telescopic connector from the previous time, the female mold becomes a different figure. Therefore, a product different in appearance from the previous time can be manufactured by filling fresh concrete from the opening and following the same procedure. The adjacent chain rows and wire mesh bands are connected by an elastic member 234 such as a coil spring or rubber or an elastic connecting member 235 pulled by a coil spring. However, as shown in FIG. 21, these coil springs, elastic members 234, and connecting members 235 are connected. Depending on the location, chains may be connected to form a chain row, or the wire mesh band may be divided into a plurality of pieces in the vertical direction as shown in Fig. 24B, and the pieces adjacent to each other in the vertical direction may be coil springs, rubber, etc. The elastic member 234 or the connecting tool 235 may be used for connection. By doing so, the appearance of the female mold can be changed more greatly, and various variety of products and products having different weights can be manufactured.

Furthermore, as shown in FIGS.
On the outer surface of the lower half excluding the split pieces, a latitude chain row 236 similar to the chain row 230 is wound along the latitude at an appropriate interval from the equator to the South Pole outside the chain row or wire mesh belt. 236 may be connected to the chain row or the wire mesh belt 230 with a wire, bolts or nuts, and the connection between adjacent chains of the chain row or the wire mesh belt 230 may or may not be omitted. By inserting an elastic member 234 such as a coil spring or rubber and an elastic connecting member 235 in places in the latitude chain 236, the female mold can be deformed. This latitudinal chain can strengthen the lower half of the female mold more strongly.

In addition, adjacent chain rows and wire mesh bands 230, 3
When 0 is connected with the non-stretchable connecting tool 233, the internal volume of the female mold does not become larger than a certain amount, so that the female mold is dented with a product that has the same volume and a different shape, or an elastic connecting tool such as a jack. It is possible to manufacture a product with a different shape, which has a smaller volume than the internal volume of the female mold.

As described above, in order to mold a product by the female mold manufactured by the method A, the polygonal opening 11 for pouring and filling the ready-mixed concrete should face upward and the mount 140 should support the female mold stably. I have to. And the size of the female mold,
It is necessary to make a special mount for each female mold according to the change of form. Further, in order to mold a product by the female mold manufactured by the method B, the female mold is put in a pedestal 240 surrounding the female mold, and a turnbuckle, a piston cylinder, a mechanical jack, a gas jack such as an air bag, a water bottle, and the like. It is necessary to use a liquid jack with a liquid such as, to make the female mold that cannot stand on its own stand in a lump by pulling it around, and to direct the opening 11 for pouring and filling the ready-mixed concrete to the top, which is very troublesome. . The present invention was developed to solve the above-mentioned problems of the female molds manufactured by the A method and the B method.

Whether the hollow female die produced by the method A is used as the outer die, the opening 11 is directed upward as shown in FIG. When the hollow female die manufactured by the method B is used as the outer die, the opening 11 is directed upward and the telescopic support 141 is formed into a block in the pedestal as shown in FIG. 18 (a). It is supported in a swelled state, and in any case, a worker enters inside through the opening 11 to form a release agent layer on the entire inner surface of the outer die by a spraying method or a coating method, and after drying the release agent, The rubber male layer 13 is formed by spraying or laminating natural rubber or synthetic rubber in multiple layers on the entire inner surface of the release agent layer (FIG. 1A).

Next, in order to form the rubber upper surface layer 14 which is integrally formed with the rubber male mold layer and closes the opening 11, the worker goes out through the opening, and the foamed resin and water glass are placed inside the rubber male mold layer inside the outer mold. The upper surface of the rubber that closes the opening by spraying or stacking multiple layers of natural rubber or synthetic rubber on the temporary filling material layer exposed from the opening by the temporary filling material layer 15 A layer 14 is formed, and at the same time, the periphery of this rubber upper surface layer is joined to the rubber male mold layer 13 around the opening to be integrated with the rubber male mold layer (FIG. 1B).

The rubber upper surface layer 14 has an outlet 16 that can be opened / closed to take out the temporary filling material layer 15 and an openable / closable port for injecting a fluid into the inside after the temporary filling material layer 15 is taken out. Attach the mouthpiece 17 and inject the solvent from the outlet to dissolve the temporary filling material, or insert a rod-shaped tool from the outlet to crush the temporary filling material layer finely and turn the outer mold upside down to make the temporary filling material. Take out.

When the outer hollow female mold is made by method A,
The split female mold piece is peeled from around the upper half part of the rubber male mold layer, the lower half part of the rubber male mold layer is peeled from the bowl-shaped back mold, and the hollow male mold of rubber consisting of the rubber male mold layer and the rubber upper surface layer 18 is removed from the outer mold 10 (FIG. 1C). When the outer hollow female mold is made by the B method, the fastener 221 that closes the split 12 of the upper half part of the split piece is opened, and the split piece 212 is peeled on the mandarin orange to form the upper layer of the rubber male layer. It is peeled from around the half part, the lower half part of the rubber male mold layer is peeled from the lower half part of the outer mold, and the hollow male mold 18 of rubber composed of the rubber male mold layer and the rubber upper surface layer is released from the outer mold ( (Fig. 1 c).

The above-mentioned temporary filling material may be taken out after the hollow male mold is removed from the outer mold. It should be noted that the function of the outlet 16 ends when the temporary filling material is taken out, so that the outlet may be removed and the removed trace may be covered with rubber or the like.

According to a first aspect of the present invention, a liquid such as air or water is injected from the mouthpiece 17 into the hollow male mold of the rubber thus demolded to inflate the hollow male mold, and the release agent layer is formed on the outer surface thereof. As shown in FIG. 1D, a rubber upper surface layer 14 having a base is provided.
Is placed inside the form box 19 with the upper surface open, and a suitable support such as stone is packed between the bottom of the form box to stabilize it.
A solidifying fluid such as agar or water glass that can be easily crushed even if it solidifies is poured into the mold box. An appropriate amount of admixture material such as an accelerator for accelerating the setting speed may be added to the solidifying fluid.
The amount of the coagulable fluid poured is determined by the rubber upper surface layer 1 having the mouthpiece.
It is enough that 4 appears on the liquid surface.

When the poured coagulating fluid is solidified and the solidified layer 20 is formed outside the hollow male die, the mouthpiece 17 is opened to remove air from the hollow male die. In the case of liquid, a pump is connected to the mouthpiece. Then, the liquid is sucked out and the volume of the hollow male mold is reduced to remove the mold from the solidified layer 20 (dashed line in FIG. 1).

Then, the mark of the hollow male mold formed in the solidified layer in the mold box is used as the molding space 21 (FIG. 1E), and the green concrete C is used.
Is filled in to mold a large model, and the solidified layer 20 is crushed to demold the model (FIG. 2). If the solidified layer is the above-mentioned water glass or agar, the fragments crushed for demolding can be returned to the fluid and used again, so it is not wasted. Also, when injecting air or liquid into the hollow male mold to inflate it, changing the injection amount changes the swelling condition of the hollow male mold, so that the molding space generated in the solidified layer can be changed to various shapes. The changed shaped object can be molded with one hollow male mold.

Furthermore, since the molded product is molded by pouring the ready-mixed concrete into the molding space formed in the solidification layer in the mold box, the molding operation is easy, and the demolding work is also performed because the solidification layer is broken to remove the mold. It's easy. The hollow male mold is small by extracting the air or liquid inside and folding it, so that it can be stored in a narrow space because it can be stored, and it can be inflated and used again each time the molded object is molded.

According to the second aspect, the inner surface of the closing plate, such as the lower surface of the lid plate that detachably closes the open upper surface of the mold box 19 or the upper surface of the bottom plate that detachably closes the open lower surface, is removed as described above. A rubber top layer 14 of a hollow male mold 18 of molded rubber,
A portion of the rubber male mold layer surrounding the rubber upper surface layer is fixed by adhesion or other suitable means. For example, when molding the rubber upper surface layer, the anchor portion of the anchor bolt may be embedded in the rubber layer and attached, and the anchor bolt may be passed through the hole of the lid plate or the bottom plate and tightened with the nut. In addition, a through hole is provided in the lid plate and the bottom plate, and the base 17 for fluid on the rubber upper surface layer is formed in the through hole.
Alternatively, it is projected outside through the take-out port 16.

In FIG. 3, a part including the rubber upper surface layer 14 of the hollow male mold 18 is fixed to the lower surface of the lid plate 22 that closes the open upper surface of the mold box, and the base 17 protrudes from the upper surface of the lid plate. Air or liquid is injected into the inside of the hollow male mold, the part of the hollow male mold that is not fixed to the lower surface of the lid plate is inflated in the mold box, and agar is placed inside the mold box and outside the hollow male mold. A state in which a solidifying fluid such as water glass is being poured is shown. It is advisable to provide a release agent layer on the outer surface of the portion of the hollow male mold that swells in the mold.

In this way, the solidifying fluid solidifies and the solidifying layer 2
When it becomes 0, the hollow male mold is removed from the solidification layer together with the lid plate as shown in FIG. 4, and the mark of the hollow male mold generated in the solidification layer in the mold box is used as the molding space 21. A large shaped article is molded by filling with C and hardening (FIG. 5), and demolding. Further, the hollow male mold, which is formed by removing the mold from the solidified layer integrally with the lid plate, discharges the air or the liquid inside to the outside and stores it in a small volume.

In FIG. 6, a part including the rubber upper surface layer 14 of the hollow male mold 18 is fixed to the upper surface of the bottom plate 23 that closes the open lower surface of the mold box 19, and the hollow male is protruded from the lower surface of the bottom plate. Inject air or liquid into the mold to make a hollow male mold.
It shows a state in which a portion not fixed to the lower surface of the bottom plate is inflated in a mold box and a solidifying fluid such as agar or water glass is poured into the outside of the hollow male mold in the mold box. It is advisable to provide a release agent layer on the outer surface of the portion of the hollow male mold that swells in the mold.

In this way, the solidifying fluid solidifies and the solidifying layer 2
When it reaches 0, as shown in FIG. 7, the mold box is lifted to remove the solidified layer from the hollow male mold, and the mold box is inverted (FIG. 8) to form the hollow male in the solidified layer 20 in the box. The mark of the mold is used as the molding space 21, and a large molded object is molded by demolding by filling it with green concrete and hardening it. In addition, the hollow male mold, which has been removed from the solidified layer integrally with the bottom plate, discharges the internal air or liquid to the outside and stores it in a small volume.

A suitable amount of an admixture such as an enhancer for increasing the strength of the solidifying fluid when it solidifies and an accelerator for accelerating the solidifying speed may be added to the solidifying fluid.

When a molded product is molded by filling the molding space of the female mold manufactured in claim 2 with fresh concrete, the molded product can be demolded without crushing the solidified layer, so that the molded product having the same shape can be molded again. .

When the hollow male mold is inflated in the mold box, the degree of swelling is changed by changing the amount of air or liquid to be injected into the hollow male mold. Molded spaces having different shapes can be formed therein, and molded articles having different shapes can be molded by one hollow male mold.

The molded product is molded by pouring ready-mixed concrete into the molding space formed in the solidified layer in the mold box, so that the molding operation is easy. The hollow male mold exhausts the air and liquid inside, and as shown in FIG. 9, the storage box 24 is integrated with the lid plate and the bottom plate.
Since it can be stored on the box and protected in the box, no accident such as rubber breakage occurs during storage.

[0050]

According to the first aspect of the present invention, the molding space is formed in the solidification layer in the mold box, and the green concrete is poured into the molding space to mold the molded article. The demolding work is easy because the layers are broken and demolded. And
The hollow male mold that forms the molding space can be stored in a narrow space because it is small by extracting the air and liquid inside and folding it, and it can be inflated and used again each time the molded object is molded. Also, when injecting gas or liquid into the hollow male mold to inflate it, changing the amount of injection changes the bulging condition of the hollow male mold. Therefore, the molding space generated in the solidified layer can be changed to obtain various shapes. The changed shaped object can be molded with one hollow male mold.

According to the second aspect, the molding space is formed in the solidified layer in the mold box, and the green concrete is poured into the molding space to mold the molded article. Therefore, the molding operation is easy. And since the solidified layer can be removed from the mold without crushing, the molded article having the same shape can be molded again. Furthermore, when the hollow male mold is inflated in the mold box, the degree of swelling can be changed by changing the amount of air or liquid injected into the hollow male mold. Different molding spaces can be formed, and molded articles having different shapes can be molded with one hollow male mold.

[Brief description of drawings]

FIG. 1A is a cross-sectional view in which a male rubber layer is formed on the inner surface of an outer mold. (B) is a sectional view in which a rubber upper surface layer is formed on the temporary filling material layer in the outer mold. FIG. 3C is a cross-sectional view of a rubber hollow male die removed from the outer die. D is a cross-sectional view in which the hollow male mold is inflated and housed in a mold box, and a solidified layer is formed in the mold box. (E) is a cross-sectional view in which the hollow male mold is demolded from the solidified layer and fresh concrete is poured into the trace.

FIG. 2 is a cross-sectional view of demolding a product from a solidified layer.

FIG. 3 is a cross-sectional view in which the upper surface of the mold box is closed with a lid plate having a hollow male mold attached to the lower surface, and the solidifying fluid is poured into the box.

FIG. 4 is a cross-sectional view in which a hollow male mold is released from a solidified layer.

FIG. 5 is a cross-sectional view in which ready-mixed concrete is poured into a molding space of a solidified layer.

FIG. 6 is a cross-sectional view in which the lower surface of the mold box is closed with a bottom plate having a hollow male mold attached to the upper surface, and the solidifying fluid is poured into the box.

FIG. 7 is a cross-sectional view in which the hollow male mold is released from the solidified layer.

FIG. 8 is a cross-sectional view in which the mold box is inverted and ready-mixed concrete is poured into the molding space of the solidified layer.

FIG. 9 is a cross-sectional view of a storage state of a hollow male die attached to a lid plate or a bottom plate.

FIG. 10 is a side view, partly in section, showing a state in which a support base is attached to a male mold for an outer mold.

FIG. 11A is a plan view of the entire outer mold according to the method A in which some of the divided female mold pieces are disassembled. (B) is a cross-sectional view of a state in which ready-mixed concrete is being injected into the hollow inside of the outer mold.

FIG. 12 is a cross-sectional view of a state in which a male mold is supported on a surface plate by a support and a coating layer made of a plastic material is formed by method A, and then a bowl-shaped back mold and a split back mold are molded.

FIG. 13 is a sectional view of a part of a bowl-shaped back mold and a part of the divided back mold, which are removed from the male mold together with a coating layer inside thereof.
FIG.

FIG. 14: The even numbered split back mold is removed from the male mold, the inner coating layer is peeled off, the three-dimensional mesh material is fixed to the inner surface,
It is explanatory drawing of the A method which shows the state attached to the circumference | surroundings of a male type | mold as it was after fixing the three-dimensional mesh material.

FIG. 15 is a cross-sectional view of the method A showing a state in which a coagulable fluid is injected between the bowl-shaped back mold and the upper half of the male mold to make a bowl-shaped female mold.

FIG. 16 is a cross-sectional view of Method A in a state where hook legs are inserted into the hollow inside of a female mold (outer mold) and fresh concrete is injected.

FIG. 17: All of the split female dies are individually rotatably connected,
It is a side view of the outer mold of Method A showing a state in which one of them is peeled from the product surface and opened.

FIG. 18A is a cross-sectional view showing a state in which a fresh mold is filled in a female mold (outer mold) by method B. (B) is a cross-sectional view showing a state in which a female (outer mold) divided piece is opened with a crack for demolding the product.

FIG. 19 is a side view of method B in which an elastic coating layer is formed around a male mold, and a part of the elastic coating layer in which the divided pieces are opened is cut away.

FIG. 20 is an explanatory diagram of the B method in a state where the female die is put inside the gantry.

FIG. 21 is a side view of the method B in which a female die having a chain row attached to the outer surface is put into a gantry to stand in a state for molding a product.

FIG. 22: Insert the female mold with the wire mesh band attached to the outer surface into the frame,
It is a side view of the B method set up in the state which shape | molds a product.

FIG. 23 is a plan view of the method B in which the female-shaped divided pieces are opened at the cracks for releasing the product from the mold.

FIG. 24A is a plan view of an example of a wire mesh band according to method B. (B) is a plan view of another example of the wire mesh band according to the B method.

FIG. 25 is an enlarged cross-sectional view of method B showing a state where anchor bolts are attached to the elastic coating layer.

FIG. 26A is a cross-sectional view of a first example of a fastener that opens and closes a split in a split piece according to method B; (B) is a sectional view of a second example of a fastener that opens and closes a split of a divided piece by the B method. FIG. 3C is a cross-sectional view of a third example of a fastener that opens and closes a split piece split by the B method.

FIG. 27 is a cross-sectional view of a B-method elastic connector pulled by a coil spring.

[Explanation of symbols]

 10 Outer Mold 11 Opening 12 Cracks 13 Rubber Male Mold Layer 14 Rubber Top Layer 15 Temporary Filling Material Layer 16 Outlet 17 Clasp 18 Hollow Male Mold 19 Form Box 20 Solidifying Layer 21 Molding Space 22 Lid Plate 23 Bottom Plate 24 Storage Box

Claims (2)

[Claims] 1. An inner surface of an outer mold, which is a hollow lump or a sphere, has an opening on the upper surface, and which can be opened by a plurality of cracks along the longitude where the upper half portion reaches the equator from the opening,
A rubber male mold layer is provided via a release agent layer, a temporary filling material such as foamed resin or water glass is filled inside the rubber male mold layer, and a rubber upper layer is provided on the upper surface of the temporary filling material to form a rubber male mold. It is integrally joined to the open upper surface of the layer, and then the temporary filling material is taken out from the outlet provided in the rubber upper surface layer, and the hollow male mold of rubber composed of the rubber male mold layer and the rubber upper surface layer is placed outside the outer mold. After demolding, place this hollow male mold in the mold box, inject the fluid into the hollow male mold to inflate it, fill the outside of the hollow male mold in the mold box with a coagulable fluid, and solidify flow When the body is solidified, the fluid in the hollow male mold is discharged, the volume is reduced to release from the solidification layer, and the mark of the hollow male mold generated in the solidification layer is used as a molding space. Method for manufacturing a molding die for a product. 2. An inner surface of an outer mold, which is a hollow mass or a sphere, has an opening on the upper surface, and can be opened by a plurality of cracks along the longitude where the upper half portion reaches the equator from the opening,
A rubber male mold layer is provided via a release agent layer, a temporary filling material such as foamed resin or water glass is filled inside the rubber male mold layer, and a rubber upper layer is provided on the upper surface of the temporary filling material to form a rubber male mold. It is integrally joined to the open upper surface of the layer, and then the temporary filling material is taken out from the outlet provided in the rubber upper surface layer, and the hollow male mold of rubber composed of the rubber male mold layer and the rubber upper surface layer is placed outside the outer mold. After demolding, a part of this hollow male mold is fixed to the inner surface of the closing plate that closes the open surface of the mold box, the fluid is injected into the hollow male mold to inflate it, and the outside of the hollow male mold inside the mold box is closed. It is characterized in that the solidified fluid is filled in the mold, and when the solidified fluid is solidified, the hollow male mold is removed from the solidified layer together with the closing plate, and the mark of the hollow male mold generated in the solidified layer is used as the molding space. A method for producing a molding die for a concrete production shape.