JPH10180736A - Mold for producing concrete block - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve abrasion resistance to concrete cast into each void by forming a thermal-sprayed film on the inner surface of a mold. SOLUTION: Thermal-sprayed films 25, 26 are formed on the uneven-backing treated surface of each part using a high speed flame fusion coating machine with the use of thermet fine powder. The thermal-sprayed film 25 is formed on the whole surface of the rib 17c of a rib attachment 17 and the whole surface of each core 18c, 18d of a core bar assembly 18. In this way, abrasion resistance to concrete can be improved, a long life is obtained, numbers of decorative blocks can be produced without generating distortion in size and shape, and rust generation due to water in concrete can be prevented. By forming the flame-coated film 26 on the outer surface of each bar 17a of the rib attachment 17 and the both surfaces of the bar 18a of the core bar assembly 18, the abrasion of each part is prevented when concrete is cast into each void A1, A2 from a material supply box.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal block for manufacturing concrete blocks, which can harden the inner peripheral surface of the mold and the outer peripheral surface of the core by thermal spraying, improve the wear resistance to concrete, and extend the life. About the type.

[0002]

2. Description of the Related Art In general, concrete blocks such as blocks, decorative blocks, concrete blocks for paving, etc.
It is manufactured by compacting the concrete packed in a formwork with vibration. Here, a method of manufacturing a decorative block, which is an example of a conventional concrete block, will be described with reference to FIGS. First, a decorative block manufacturing apparatus B used in a conventional decorative block manufacturing method will be described. As shown, in a building (not shown), a mold C for manufacturing a decorative block, which is an example of a mold frame, is oscillably arranged on a gantry (not shown). Above the decorative block manufacturing mold C, there is provided a pressing die D for pushing out a decorative block (not shown) compacted in each of the gaps C1 and C2 of the decorative block manufacturing mold C. It is arranged to be able to move up and down. A material box E for pouring concrete into each of the gaps C1 and C2 of the decorative block manufacturing die C is movably disposed beside the decorative block manufacturing die C. ing.

[0003] Next, the mold C for producing a decorative block described above.
Is described below. As shown in the figure, a frame-shaped mold body 13 formed by assembling a pair of mounting brackets 11 and a pair of end plates 12 is provided on a gantry (not shown). A partition plate 14 is attached to each of the short side inner surfaces of the mold body 13, and two end liners 15 are attached to each of the long side inner surfaces. Further, a partition plate 16 for partitioning the inside of the mold body 13 into two parts is mounted in the center of the mold body 13 in parallel with the mounting bracket 11.

In each of the two chambers of the mold body 13, a rib attachment 17 is provided.
A core bar assembly 18 is mounted on both sides of the mounting bracket 11 and also in parallel with the mounting bracket 11. In addition, each end plate 1 of the mold body 13
2 have a plurality of triangular cutouts 1
2a are formed, and a U-shaped filler plug 19 is attached to the inside of the notch 12a on both sides. In the mold body 13, a rib attachment 17 and a core bar assembly 18, which are cores, are provided in each chamber constituted by partition plates 14 and 16, an end liner 15, a filler plug 19, and a frame (not shown). Are inserted, two gaps C1 and C2 are formed.

[0005] The above-described mold C for decorative block production is used.
A pair of bearings (not shown) are mounted on the outer surface of one of the mounting brackets 11, and a rotating shaft is rotatably mounted on the pair of bearings (FIG. 7).
reference). An electric motor, which is an example of a rotary drive source (not shown), is connected to one end of the rotary shaft, and an eccentric weight (not shown) is attached to the rotary shaft (see FIG. 7). Therefore, when the electric motor is driven to rotate the rotating shaft, the eccentric weight of the eccentric weight causes the decorative block manufacturing die C to vibrate.

The pressing die D has a plunger 20 with a shoe on a lower surface of a rectangular head plate 23.
21 is attached. Further, the material supply box E has a groove 22a in which a bar attachment 17 of the mold C for manufacturing the decorative block and the bars 17a, 18a of the core bar assembly 18 are fitted in a lower portion of the rectangular box 22.
Is formed. Each groove 2 of the box 22
A supply hole (not shown) for supplying the concrete in the box body 22 into each of the gaps C1 and C2 of the mold C for producing a decorative block is provided on the lower surface between the two boxes 2a.

Next, a conventional method of manufacturing a decorative block using the decorative block manufacturing apparatus B having the above-described configuration will be described. First, after the decorative block manufacturing die C is fixed on a stand (not shown), the material box E in which concrete is previously charged is run on the decorative block manufacturing die C in the lateral direction. Meanwhile, concrete is poured into each of the gaps C1 and C2 from a supply hole (not shown) on the lower surface of the supply box E. At this time, by vibrating the decorative block manufacturing mold C, the concrete poured into each of the gaps C1 and C2 is firmly compacted, and then the decorative block solidified in each of the gaps C1 and C2 is pressed into a die. D
Die-cut. Then, the cut decorative block is cured for a required period to complete the decorative block as a product.

[0008]

However, in the conventional mold C for producing a decorative block, when the concrete is vibrated and compacted, the components constituting the voids C1 and C2, that is, the respective partition plates 14 are formed. , 16,
End core 15c of end liner 15, rib 17c of rib attachment 17, core bar assembly 18
Wear occurs in each of the cores 18c and 18d, and the gaps C1 and
Since the size and shape of C2 changed, a desired decorative block could not be formed, and there was a problem that parts constituting each of the voids C1 and C2 had to be frequently replaced or overlaid. . Therefore, the present inventors have proposed that each void C
1. It was found that by forming a carburized and quenched layer on the surface layer of each of the components made of SCM415 constituting C2, it was possible to improve the wear resistance to concrete. Satisfactory results were not obtained, and further improvements were sought.

In addition to the above-mentioned parts, SS40
The ribs 17 made of No. 0 and the bars 17a, 18a of the core bar assembly 18 also have respective void portions C1,
When pouring concrete into C2, there is a problem that abrasion due to concrete occurs. Further, each void C
1. Since the concrete poured into C2 contains moisture, there was also a problem that each part rusted. Further, if concrete adheres and remains in the gaps C1 and C2, there is a problem that the size, shape, and the like of the decorative block to be manufactured next are affected. The above-mentioned problems are caused by the block manufacturing mold for manufacturing blocks used for houses, warehouses, block walls, etc., and the concrete paving blocks for manufacturing concrete blocks for pavement laid on sidewalks, parks, plazas, etc. This was also a common problem in manufacturing dies.

The present invention has been made in view of the above circumstances, and can improve the abrasion resistance of concrete poured into each void portion, thereby not only obtaining a long life but also the water content in the concrete. It is an object of the present invention to provide a concrete block manufacturing mold excellent in moldability, which is capable of preventing rusting caused by the concrete block and, even when the concrete blocks are continuously formed, does not change the dimensions and shapes of the concrete blocks. Aim.

[0011]

According to the present invention, there is provided a semiconductor device comprising:
In the mold for manufacturing a concrete block described above, a sprayed coating is formed on the inner peripheral surface of the mold. The mold for manufacturing a concrete block according to claim 2 is the mold for manufacturing a concrete block according to claim 1, wherein the mold for manufacturing a concrete block is a mold for manufacturing a concrete block for paving. In the mold for manufacturing a concrete block according to the third aspect, a thermal spray coating is formed on an inner peripheral surface of the mold and an outer peripheral surface of a core inserted into the mold. The concrete block manufacturing mold according to claim 4 is the concrete block manufacturing mold according to claim 3, wherein the concrete block manufacturing mold is a decorative block manufacturing mold or a block manufacturing mold. . The mold for concrete block production according to claim 5 is the mold for concrete block production according to any one of claims 1 to 4, wherein the thermal spray coating is formed on a carburized and quenched layer. The mold for manufacturing a concrete block according to claim 6 is the mold for manufacturing a concrete block according to any one of claims 1 to 5, wherein the surface on which the thermal sprayed coating is formed is subjected to an uneven base treatment, and The surface roughness Rz is 50 to 1
It is in the range of 50 μm. The mold for manufacturing a concrete block according to claim 7 is the mold for manufacturing a concrete block according to any one of claims 1 to 6, wherein the thickness of the sprayed coating is 0.1 to 2 mm. . Claim 8
The concrete block manufacturing mold described in claim 1
8. In the mold for manufacturing a concrete block according to any one of items 7, the sprayed coating is a dispersion-strengthened sprayed coating having a surface hardness of Hv700 or more by high-speed flame spraying of cermet fine powder. Here, high-speed flame spraying refers to thermal spraying in which the speed of a flame (flame) is three times or more (specifically, 2000 to 2700 m / sec) as compared with normal spraying.

According to a ninth aspect of the present invention, in the mold for producing a concrete block according to the eighth aspect, the spraying temperature of the high-speed flame spraying is set to a melting point of a metal content contained in the fine cermet powder. The above temperature and the temperature below the melting point of the ceramic contained in the cermet fine powder. The concrete block manufacturing mold according to claim 10 is the concrete block manufacturing mold according to claim 8 or 9, wherein the cermet fine powder includes a cermet fine powder having a metal content less than a fixed amount and a deficient metal component. And sprayed simultaneously by independent high-speed flame sprayers to form the sprayed coating. The mold for manufacturing a concrete block according to claim 11 is the mold according to claims 8 to 10.
In the mold for manufacturing a concrete block according to any one of the above, the cermet fine powder is WC, CrC,
It is composed of at least one selected from the group consisting of TiC and SiC and at least one selected from the group consisting of Ni, Cr, Co and alloys thereof. , A carbide cermet containing 90 to 10% by weight of a metal matrix such as Cr, Co or an alloy thereof, an oxide of 10 to 90% by weight, Ni, Cr,
A metal matrix such as Co or an alloy thereof is 90-1.
Oxide-based cermet containing 0% by weight, nitride 10-90
%, A nitride cermet containing 90 to 10% by weight of a metal matrix such as Ni, Cr, Co or an alloy thereof, or 10 to 90% by weight of boride, Ni, Cr, C
o or a metal matrix such as an alloy thereof
It is composed of any one of boride-based cermets containing by weight.

According to a twelfth aspect of the present invention, in the mold for manufacturing a concrete block according to any one of the eighth to eleventh aspects, the spray flame speed of the high-speed flame spraying is 2000 to 2700 m /. Seconds, and the flame temperature is 2400-2700 ° C. The mold for concrete block production according to claim 13 is the mold for concrete block production according to any one of claims 8 to 12, wherein the sprayed coating is inclined and blended.
Ceramics increased on the surface side. In the concrete block manufacturing mold of the present invention, when the particle size of the fine powder to be sprayed is less than 10 μm, the production price rises, and the momentum becomes small, and the momentum becomes easy to flow into the air flow. Since the thermal spray coating becomes coarse and the substantial strength is reduced, it is preferable to select the thickness in the range of 10 to 50 μm. In the mold for manufacturing a concrete block of the present invention, the method of forming a carburized and quenched layer on the peripheral surface layer of the void portion was performed by any one of solid carburizing method, gas carburizing method, and liquid carburizing method. Then, a method of quenching and tempering may be used. Further, the concrete in the present invention includes not only a mixture of cement, sand, gravel, and water but also a mixture of cement, sand, and water. The surface on which the thermal spray coating is formed in the present invention refers to the inner peripheral surface of the mold and the outer peripheral surface of the core.

Therefore, in the mold for manufacturing concrete blocks according to the first, second, and fifth to thirteenth aspects, and the mold for manufacturing concrete blocks according to the third to thirteenth aspects, the inner peripheral surface of the die and the outer peripheral surface of the core are provided. Since the thermal spray coating is formed on the surface, the part can be hardened, and the wear resistance to concrete can be improved, so that the inner peripheral surface of the mold and the outer peripheral surface of the core wear out in a short period of time. However, it is possible to prevent the dimensions and the shape of the gap from being changed so that the gap cannot be used. Also, by forming a thermal spray coating on the inner peripheral surface of the mold and the outer peripheral surface of the core, the corrosion resistance of the portion can be improved, and rusting due to moisture in the concrete can be prevented. Furthermore, although it depends on the surface roughness of the thermal spray coating, the releasability of the concrete block can be improved particularly when the thermal spray coating is dense and has a smooth surface. In particular, in the mold for manufacturing concrete blocks according to claims 2 and 4, in the mold for manufacturing concrete blocks for paving, the mold for manufacturing decorative blocks, or the mold for manufacturing blocks, the inner peripheral surface and the middle of the mold are preferably used. It is possible to prevent the outer peripheral surface of the child from being worn out in a short period of time, or from being unusable due to a change in the size or shape of the gap. In the concrete block manufacturing die according to the fifth aspect, since the thermal spray coating is formed on the carburized and quenched layer, the hardness of the portion is increased, and as a result, in combination with the thermal spray coating, the peripheral surface of the void portion is reduced. Hardness can be increased, and wear resistance can be improved. In addition, for example, in the state of carburizing and quenching, not only the appearance is dirty due to oil seizure,
Although the oil adhering to the peripheral surface of the gap may adhere to the concrete block and contaminate the product, the yield may be reduced. However, by forming a thermal spray coating on the carburized and quenched layer, the peripheral surface of the cavity is reduced. The appearance can be improved, and the generation of oil stains on the concrete block surface can be prevented, so that the yield can be improved.

In the mold for producing concrete blocks according to the present invention, the surface roughness Rz of the inner peripheral surface of the mold and the outer peripheral surface of the core is in the range of 50 to 150 μm. It has good adhesion of the coating and can form a strong thermal spray coating. Here, the surface roughness Rz is 50
If it is less than μm, the surface is too smooth and the adhesion of the thermal sprayed coating becomes as small as 10 kg / cm ² or less, and the surface roughness Rz
If it exceeds 150 μm, there arises a disadvantage that the surface roughness of the thermal sprayed coating increases and the releasability deteriorates. Claim 7
In the concrete block manufacturing mold described above, since the thickness of the thermal spray coating is 0.1 to 2 mm, the life of the thermal spray coating can be prevented from being shortened and peeling, and long-term durability can be obtained. . Here, the thickness of the thermal spray coating is set to 0.
When the thickness is less than 1 mm, the thickness of the sprayed coating is too thin and the service life is shortened. When the thickness of the sprayed coating exceeds 2 mm, there is a disadvantage that the sprayed coating tends to peel off. In the mold for producing a concrete block according to the eighth aspect, the cermet fine powder is sprayed at a high speed flame onto the inner peripheral surface and the outer peripheral surface of the core to form a dispersion strengthened type thermal spray coating having a surface hardness of Hv 700 or more. Therefore, the thermal spray coating formed on the peripheral surface of the gap can be made dense. That is, the frame speed in the high-speed flame spraying, for example, as described above, for example,
2000 to 2700 m / sec, a normal flame spraying (about 30
0 m / sec) and plasma spraying (about 800 m / sec), so that a hard and dense spray coating can be formed as described above. Of course, on the peripheral surface of the void,
Since the appropriate undercoating treatment is performed, the adhesion of the sprayed coating is good, and as a result, a mold for manufacturing a concrete block in which the sprayed coating hardly falls off can be obtained. Here, if the hardness of the thermal spray coating is less than Hv700, the thermal spray coating formed on the inner peripheral surface of the mold or the outer peripheral surface of the core is easily worn, and the dimensions and shape of the void portion are changed so that it cannot be used early. Disadvantages arise.

In the mold for manufacturing a concrete block according to the ninth aspect, the spraying temperature of the high-speed flame spraying is a temperature higher than the melting point of the metal contained in the cermet fine powder and the ceramic contained in the cermet fine powder. , The metal component of the cermet fine powder is dissolved, but the ceramics is not melted to form a thermal spray coating. Therefore, the ceramics become a sprayed coating that becomes an aggregate, and because it is sprayed at a higher speed, it becomes a sprayed coating that has a higher density and strength than conventional flame spraying and plasma spraying, and has abrasion resistance. The performance is improved. In the mold for manufacturing a concrete block according to claim 10, the cermet fine powder is composed of a cermet fine powder having a metal content less than a fixed amount and a self-fluxing alloy powder containing a deficient metal content, each of which is an independent high-speed flame. Since the thermal spray coating is formed by simultaneous thermal spraying with a thermal spraying machine, it is easy to form a thermal spray coating having the most appropriate blending ratio without changing the blend to be supplied. In addition, here, a fixed quantity means 100 weight%. In the mold for manufacturing a concrete block according to claim 11, since the cermet fine powder for forming the thermal spray coating has the above-described structure and high-speed flame spraying of these materials, the unmelted ceramic aggregate therein is used. Is formed, resulting in a sprayed coating having high hardness. Here, the reason why the content of one component is set to 10 to 90% by weight with respect to the other component is that if the self-fluxing alloy is less than 10% by weight, the joining property of ceramics is deteriorated and 90% by weight. %, The aggregate in the self-fluxing alloy becomes insufficient, resulting in a disadvantage that sufficient strength cannot be obtained.

[0017] In the mold for manufacturing a concrete block according to the twelfth aspect, the metal component of the cermet fine powder heated by the flame of 2400 to 2700 ° C is dissolved, but the sprayed coating is formed before the entire ceramic is melted. It is formed. Therefore, the ceramics become a sprayed coating that becomes an aggregate, and because it is sprayed at a higher speed, it becomes a sprayed coating that has a higher density and strength than conventional flame spraying and plasma spraying, and has abrasion resistance. The performance is improved. When the thermal spray flame temperature is lower than 2400 ° C., the thermal spraying material forming the thermal spray coating is poorly melted, and it is difficult to form a thermal spray coating in which semi-molten and molten are mixed. Is inhibited. On the other hand, when the spray flame temperature is 2
If the temperature exceeds 700 ° C., the thermal sprayed material is excessively melted and does not become a hardly peelable film that can withstand the stress generated by cooling, and furthermore, the uniformity of the formed film is hindered. On the other hand, if the spraying flame speed is less than 2000 m / sec, the momentum given to the material is insufficient, so that a dense sprayed coating cannot be formed. It is not possible to form a thermal spray coating in which the melt is mixed appropriately. Therefore, by setting the spraying flame speed and the spraying flame temperature in the optimum ranges as described above, it is possible to form a strong and hardly peelable sprayed coating made of a mixed material of semi-molten and molten. In the concrete block manufacturing mold according to the thirteenth aspect, the spray amount of the spray material sprayed from each high-speed flame spraying machine can be independently changed to form a sprayed coating having a gradient composition. It is possible to increase the amount of ceramics having high abrasion resistance on the surface side, and to increase the proportion of a self-fluxing alloy which is familiar with metal on the joining side of the inner peripheral surface of the mold and the outer peripheral surface of the core.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described with reference to the accompanying drawings to provide an understanding of the present invention. Note that the same components as those in the conventional example are denoted by the same reference numerals, and description thereof will be omitted. (First Embodiment) First, a mold A for decorative block production, which is an example of a mold for concrete block production, according to a first embodiment of the present invention will be described with reference to FIGS. . The difference between the decorative block manufacturing mold A according to the present embodiment and the conventional decorative block manufacturing mold C is as follows.
The inner surface of the partition plate 14 made of SCM415, the inner surface of the plate 15a of the end liner 15 and the inner surface of the end core 15c, the surface of the partition plate 16, the entire surface of the rib 17c of the rib attachment 17, the cores 18c of the core bar assembly 18, 18
As shown in FIG. 3 (a), a carburized and quenched layer 24 having a thickness of 1.5 to 2 mm and a surface hardness of HRC = 58 to 62 is formed on the surface layer of FIG. FIG. 3 shows that a dispersion-strengthened thermal sprayed coating 25 having a surface hardness of Hv 700 or more and a thickness of 0.1 to 2 mm was formed, the outer surface of each bar 17a of the rib attachment 17 made of SS400, and both surfaces of the bar 18a of the core bar assembly 18.
As shown in (b), each has a thickness of 0.1 to 2 mm and a surface hardness of Hv700 or more (Hv1300 in this embodiment).
This is the point that the thermal spray coating 26 of the dispersion strengthening type was formed.

Next, a method of manufacturing the decorative block manufacturing die A having the above-described structure will be described with reference to FIG. First, a method of forming the carburized and quenched layer 24 on the surface layer of the partition plate 14 or the like will be described. First, each part is placed in a carburizing box, and a carburizing material such as charcoal is packed around the box. Then, after covering the carburizing box, it is sealed with clay or the like, and then heated in a furnace to 850 to 900 ° C. for several hours. Then, after the required time has elapsed, the parts are allowed to cool, and each part is taken out of the carburizing box, and then quenched and tempered to form the carburized and quenched layer 24. At this time, a coating material in which water glass is mixed with clay is applied in advance to places where the carburized and quenched layer 24 does not need to be formed, and is removed after quenching and tempering.

Next, a method of forming the thermal spray coatings 25 and 26 on the carburized and quenched layer 24 and the bar 17a of the rib attachment 17 will be described. First, each component is degreased using an organic solvent, and an uneven base treatment is performed by blasting. At this time, the surface roughness Rz of each component is set to about 70 to 80 μm, and the surface roughness Rz can be selected in a range of 50 to 150 μm. In this case, as the blast material (grid), there are alumina, steel, sand and the like, and among them, alumina is the best. This is because the effect of anchoring the sprayed coating can be increased. Next, as shown in FIG. 4A, a thermal spray coating 25 (26) of cermet fine powder is formed on the surface of each component subjected to the uneven base treatment using a high-speed flame spraying machine 27. At this time, as the cermet fine powder, for example, W having a particle size of 10 to 50 μm (preferably 15 to 44 μm) is used.
Although it is preferable to use a composite powder of C-12Co, other carbide cermets (for example, CrC, TiC, S
A composite powder of any one or more of iC and a self-fluxing alloy composed of Ni, Cr, Co, or an alloy thereof), oxide cermet, nitride cermet, boride cermet, and the like can also be used. In this case, it is assumed that the hardness of the thermal spray coating 25 (26) is Hv700 or more. Also,
If a longer service life is required, the thermal spray coating 25 (2
The strength of 6) is preferably Hv1100 or more,
In this case, WC-12 uniformly mixed as a thermal spray material
This can be easily achieved by using a composite powder of Co.

In the high-speed flame spraying, kerosene (kerosene) is used as a fuel, and is combined with oxygen to form 2400-2.
At a high temperature of 700 ° C., a high-speed gas jet of 2,500 to 2700 m / sec is made, a cermet fine powder is put thereon to melt, and a spray material is sprayed at a high speed (for example, about 750 m / sec) on the surface of each part. It shall be solidified and joined. At this time, as shown in FIG. 4A, one high-speed flame spraying machine 27 may be used, but as shown in FIG. 4B, two high-speed flame spraying machines 28, 29 are used. It is preferable to perform high-speed flame spraying. That is, one high-speed flame spraying machine 2
If the cermet fine powder (or ceramics only) is supplied to 8 and the self-fluxing alloy is supplied to the other high-speed flame spraying machine 29 and they are mixed evenly to form a thermal sprayed coating, the more efficient and stronger The thermal spray coating 25 (26) can be formed. That is, the spraying conditions are different between the cermet fine powder (or ceramics) and the self-fluxing alloy, and the optimum conditions, for example, the spraying distances L ₀ , L ₁ , L ₂ , by selecting the high-speed flame sprayers 28 and 29 independently. Spray angles θ ₀ , θ ₁ ,
The spraying can be performed by changing θ ₂ arbitrarily, and the ratio of the spraying material of the two high-speed flame sprayers 28 and 29 can be changed arbitrarily to obtain a spray coating having an optimal composition. This is because a functionally graded material can be obtained by compounding with a gradient. In this case, the spray angles θ ₁ , θ
₂ is preferably an angle close to 90 ° at which the torches do not interfere with each other, and is substantially in the range of 70 to 80 °.

The above-mentioned mold A for making decorative blocks
The method of manufacturing a decorative block using the same method is the same as that of the conventional example, and the description is omitted. As described above, according to the decorative block manufacturing die A according to the present embodiment, FIGS.
As shown in the figure, the inner peripheral surface of the mold, that is, the inner surface of the partition plate 14 constituting the gaps A1, A2, the inner surfaces of the plate 15a of the end liner 15 and the end core 15c,
Both sides of the partition plate 16, the outer peripheral surface of the core,
That is, since the thermal spray coating 25 is formed on the entire surface of the rib 17c of the rib attachment 17 and the entire surface of each of the cores 18c and 18d of the core bar assembly 18, wear resistance to concrete can be improved, and a long life can be obtained. Even if a large number of decorative blocks are manufactured, their dimensions and shapes do not change, and rusting due to moisture in concrete can be prevented. Further, since the thermal spray coating 26 is formed on the outer surface of each bar 17a of the rib attachment 17 and on both surfaces of the bar 18a of the core bar assembly 18, when the concrete is poured into each of the gaps A1 and A2 from the supply box. In addition, it is possible to prevent abrasion of each component, and it is also possible to prevent rusting due to moisture contained in the concrete, thereby extending the life. Further, since the hard and dense thermal spray coatings 25 and 26 are formed on the above-described components by high-speed flame spraying, the life can be further extended. Further, since the carburized and quenched layer 24 is formed on the surface layer of each of the components constituting the gaps A1 and A2, the inner peripheral surface of the mold and the outer peripheral surface of the core are further hardened in combination with the thermal spray coating 25 formed on the surface. In addition, the wear resistance can be improved.

(Second Embodiment) Subsequently, FIGS.
With reference to, a concrete block manufacturing mold G for paving as an example of a concrete block manufacturing mold according to the second embodiment of the present invention will be described. As shown in the figure, the mold G for manufacturing a concrete block for paving according to the present embodiment has a plurality of gaps G1 formed so as to penetrate from the upper surface to the lower surface of the mold body 30 made of SCM415.
And a carburized and quenched layer 31 having a thickness of 1.5 to 2 mm and a surface hardness of HRC = 58 to 62, respectively, and a thickness of 0.1 to 2 m on the carburized and quenched layer 31.
m, surface hardness Hv700 or more (Hv1 in this embodiment)
300 to 1500) dispersion-enhanced thermal spray coating 32
Are formed.

Next, a method of manufacturing the mold G for manufacturing a concrete block for pavement according to the present embodiment will be described. First, similarly to the first embodiment of the present invention, the mold body 30 is placed in a carburizing box, and a carburizing material such as charcoal is filled in the gap G1. Next, after covering the carburizing box, it is sealed with clay or the like, and then heated in a furnace to 850 to 900 ° C. for several hours. Then, after the required time has elapsed, the mold body 30 is taken out of the carburizing box after being left to cool, and then quenched and tempered to form the carburized and quenched layer 31. Next, as in the first embodiment of the present invention, the mold body 3 is formed using an organic solvent.
After performing the degreasing of 0, the surface roughness Rz of the inner peripheral surface of the mold, that is, the peripheral surface of the void portion G1 is reduced to about 70 to 80 μm by performing an uneven base treatment by a blast treatment. Then, as shown in FIGS. 4 (a) and 4 (b), the fine cermet powder is sprayed on the inner peripheral surface of the mold having been subjected to the uneven surface treatment by a high-speed flame spraying machine 27 (2).
8, 29) to form a thermal spray coating 32. In this case, the above-described spray angle θ ₀ (θ ₁ , θ ₂ ) may be ensured by bending the nozzle, depending on the size of the gap G1. At this time, the frame speed and the like are also taken into consideration.

The method for manufacturing a concrete block for paving using the mold G for manufacturing concrete block for paving described above is the same as that for the mold A for manufacturing decorative block according to the first embodiment of the present invention. Therefore, the description is omitted.
According to the mold G for manufacturing a concrete block for paving according to the present embodiment as described above, the same effect as that of the mold A for manufacturing a decorative block according to the first embodiment of the present invention can be obtained. Can be.

[0026]

Next, the results of a confirmation test of the mold A for producing a decorative block according to the first embodiment of the present invention will be described. First, a high-speed flame spraying machine 2 as shown in FIG.
Tables 1 to 7 show the properties of the thermal spray coating 26 of Examples 1 to 4 when thermal spraying was performed on the bar 17a of the rib attachment 17 of the mold A for decorative block production by changing the thermal spraying conditions. In Example 1, a high-speed flame spraying machine 27 having a spray nozzle of 8 inches was used, and WC-12C having a particle size of 10 to 50 μm (the same applies to the following examples) as a spray material.
The composite powder of o was sprayed. At this time, the spraying distance L ₀ is 250
mm and the spraying angle θ ₀ were 90 °. In the second embodiment, a high-speed flame sprayer 28 having a 4-inch spray nozzle and a high-speed flame sprayer 29 having an 8-inch spray nozzle are used. Was sprayed with WC-12Co at a ratio of 3 to 7. In this case, the spraying distance L ₁ of the high-speed flame spraying machine 28 3
50 mm, the spray distance L ₂ of the high-speed flame sprayer 29 is 250
mm and the spray angles θ ₁ and θ ₂ were 70 to 80 °, respectively.

In the third embodiment, the spray nozzle 4
The high-speed flame sprayer 28 and the 8-inch high-speed flame sprayer 29 are used. The high-speed flame sprayer 28 uses a self-fluxing alloy, and the high-speed flame sprayer 29 uses a SiC-40.
Co was sprayed at a ratio of 2 to 8. In addition, spraying distance L ₁ of the high-speed flame spraying machine 28 is 350mm, high-speed flame spraying machine 29
The thermal spraying distance L ₂ 250 mm, spraying angle theta _1, theta ₂ is
Each was set to 70 to 80 °. Further, in Example 4, the materials to be supplied were subjected to a gradient blending under the conditions of Example 2,
First, a self-fluxing alloy sprayed from a high-speed flame sprayer 28 having a 4-inch spray nozzle and a WC- sprayed from a high-speed flame sprayer 29 having an 8-inch spray nozzle are applied to a layer in contact with the outer surface of the bar 17a of the rib attachment 17. After spraying 12Co at a ratio of 9: 1, five layers are sprayed at gradually changing ratios. On the surface layer, a self-fluxing alloy sprayed from the high-speed flame sprayer 28 and a high-speed flame sprayer 29 are used. W sprayed
The ratio with C-12Co was 1: 9. Also in this case, spraying distance L ₁ of the high-speed flame spraying apparatus 28 is 350 mm,
HVOF spraying machine spraying distance L ₂ of 29 250 mm, spraying angle theta _1, theta ₂ was respectively 70 to 80 °.

[0028]

[Table 1]

As is clear from Table 1, Examples 1-4
Rib Attachment 17 for Mold A for Making Decorative Block
In the bar 17a, it can be understood that the thermal spray coating 26 having a sufficient hardness can be formed without performing the cermet melting treatment after the thermal spraying. Therefore, as compared with the conventional mold C for producing decorative blocks, the mold has a long life and the service life is significantly increased. Further, under the same conditions as the thermal spraying of Examples 1 to 4, the thermal spray coating 26 was 0.8 mm and 1.2 m thick.
m and 1.6 mm, the durability could be further improved. However, when the thickness was more than 2 mm, the thermal spray coating was liable to peel off.

Further, the self-flux sprayed from the high-speed flame sprayer 28 using a high-speed flame sprayer 28 having a 4-inch spray nozzle and a high-speed flame sprayer 29 having an 8-inch spray nozzle as shown in FIG. Table 2 shows properties when the alloy and the metal sprayed from the high-speed flame spraying machine 29 are variously changed and sprayed onto the bar 17a of the rib attachment 17 of the mold A for decorative block production. Also in this case, spraying distance L ₂ of the spraying distance L ₁ is 350 mm, HVOF thermal spray gun 29 of the high-speed flame spraying apparatus 28 is 250 mm, spraying angle theta _1,
θ ₂ was set at 70~80 °. As a comparative example, Ni
Table 2 also shows the results when the -Cr self-fluxing alloy was sprayed under the conditions described above. In the items of Table 2, “extension degree of life” indicates the extension degree when the life of the thermal spray coating of the Ni—Cr-based self-fluxing alloy of Comparative Example 1 is set to 1.

[0031]

[Table 2]

As is clear from Table 2, the bar 17a of the rib attachment 17 of the mold for manufacturing a decorative block (the mold for manufacturing a concrete block) A of the present invention is compared with the bar of the rib attachment of the comparative example. As a result, it can be seen that they have sufficient abrasion resistance and peel strength.

The embodiment of the present invention has been described above.
The present invention is not limited to the above-described embodiment, and all changes in conditions that do not depart from the gist are within the scope of the present invention. For example, in the first embodiment of the present invention,
Parts constituting the gaps A1 and A2 of the mold A for producing a decorative block, that is, the partition plates 14 and 16, the plate 15a of the end liner 15, and the end core 15.
c, the rib 17c of the rib attachment 17 and the cores 18c and 18d of the core bar assembly 18 are provided with SCM41.
Although 5 was used, other steel materials may be used. Further, although SS400 is used for each bar 17a of the rib attachment 17 and the bar 18a of the core bar assembly 18, other steel materials may be used.

In the first embodiment of the present invention, the carburizing and quenching layer 24 is provided on the surface layer of the components forming the voids A1 and A2 of the mold A for producing a decorative block. Although the thermal spray coating 25 was provided, the voids A1, A2
Without carburizing and quenching layer 24 on the surface layer of each component constituting
The thermal spray coating 25 may be provided directly on the peripheral surfaces of the gaps A1 and A2, that is, on the inner peripheral surface of the mold and the outer peripheral surface of the core. Further, in the first embodiment of the present invention, the rib attachment 17 is used.
And each bar 17a, 18 of the core bar assembly 18
a, the thermal spray coating 26 was provided directly on the surface of
A carburized and quenched layer may be provided on the surface layers of 7a and 18a, and the thermal spray coating 26 may be provided on the carburized and quenched layer. Further, in the first embodiment of the present invention, the thermal spray coating is not provided on the stand (not shown), the filler plug 19, the shoe 20c of the plunger 20, and the shoe 21c of the plunger 21 (see FIG. 9). A sprayed coating may be provided directly on the part,
Further, a carburized and quenched layer may be provided on the surface layer of each component, and a thermal spray coating may be provided on the surface of the carburized and quenched layer.

In the second embodiment of the present invention, the carburizing and quenching layer 3 is formed on the inner peripheral wall surface of the cavity G1 of the mold body 30.
1 was provided, and the thermal spray coating 32 was provided on the carburized and quenched layer 31. However, the carburized and quenched layer 31 was not provided on the inner peripheral surface of the gap G1. May be directly provided with the thermal spray coating 32. Further, in the first and second embodiments of the present invention, the mold A for making decorative blocks and the mold G for making concrete blocks for paving have been described, respectively. For example, concrete blocks as shown in FIG. Block manufacturing mold F which is an example of the manufacturing mold
It may be. In the drawing, reference numeral 33 denotes a pair of bearings attached to the outer surface of one mounting bracket of the block manufacturing die F, and reference numeral 34 denotes a pair of bearings that are rotatably mounted on the pair of bearings 33, and one end thereof. A rotating shaft to which an electric motor, which is an example of a rotating drive source not shown, is connected,
Reference numeral 35 denotes an eccentric weight attached to the rotating shaft 34. The block manufacturing die F is driven by an eccentric load of the eccentric weight 35 by driving an electric motor (not shown) to rotate the rotating shaft 34. It is designed to vibrate.

[0036]

As is apparent from the above description, the dies for manufacturing concrete blocks according to claims 1, 2 and 5 to 13 and the dies for manufacturing concrete blocks according to claims 3 to 13 have the following features. A thermal spray coating is formed on the inner peripheral surface of the mold and the outer peripheral surface of the core, so that the wear resistance to concrete can be improved, which not only provides a long life but also reduces the size and shape of each concrete block. It is possible to provide a mold for manufacturing a concrete block, which is free from disorder and can prevent rusting due to moisture in concrete. In particular, in the mold for manufacturing concrete blocks according to claims 2 and 4, it is possible to improve the wear resistance of the mold for manufacturing concrete blocks for paving, the mold for manufacturing decorative blocks, or the mold for manufacturing blocks. it can. In the mold for manufacturing a concrete block according to the fifth aspect, since the thermal spray coating is formed on the carburized and quenched layer, the wear resistance can be further improved. In the mold for concrete block production according to claims 6 and 7, a strong thermal spray coating can be formed on the peripheral surface of the void portion, and the long life and long-term durability of the thermal spray coating can be prevented by preventing the thermal spray coating from becoming short-lived and peeling. be able to. In the concrete block manufacturing die according to claim 8, since a hard and dense sprayed coating is formed on the inner peripheral surface and the outer peripheral surface of the core by high-speed flame spraying, the concrete block manufacturing die is surely formed. The lifespan is extended. In the concrete block manufacturing die according to the ninth aspect of the present invention, it is possible to form a high-hardness thermal spray coating in which ceramics are used as an aggregate, and to spray at a high speed. It is possible to form a thermal spray coating having a higher density and a higher strength as compared with thermal spraying and plasma spraying, thereby improving wear resistance.

According to the tenth aspect of the present invention, there is an advantage that the mixing ratio of the thermal spraying material to be supplied to the high-speed flame spraying machine can be set arbitrarily, and a thermal spray coating having a proper mixing can be formed at low cost. . In the mold for manufacturing a concrete block according to the eleventh aspect, a thermal spray coating containing an unmelted ceramic aggregate is formed inside, and a thermal spray coating having high hardness can be formed. Claim 1
In the mold for manufacturing concrete blocks described in 2,
It can form a sprayed coating with ceramics as aggregate, and because it is sprayed at high speed, it forms a sprayed coating with higher density and strength compared to conventional flame spraying and plasma spraying. And the abrasion resistance is improved. In the mold for producing a concrete block according to the thirteenth aspect, the thermal spray coating is inclinedly compounded to increase the amount of ceramic on the surface side, so that the surface hardness can be further improved and the peripheral portion of the void portion can be improved. By increasing the amount of self-fluxing alloy on the surface side, it is possible to strengthen the bondability.

[Brief description of the drawings]

FIG. 1 is a perspective view of a concrete block manufacturing mold according to a first embodiment of the present invention.

FIGS. 2 (a) to 2 (e) are exploded perspective views of a main part of the mold for manufacturing a concrete block.

FIGS. 3 (a) and 3 (b) are cross-sectional views of main parts of the mold for manufacturing a concrete block.

FIG. 4 (a) is an explanatory view of a spraying situation when one high-speed flame spraying machine is used. (B) is an explanatory view of a spraying situation when two high-speed flame spraying machines are used.

FIG. 5 is a perspective view of a concrete block manufacturing mold according to a second embodiment of the present invention.

FIG. 6 is a sectional view of a main part of the mold for manufacturing a concrete block.

FIG. 7 is an explanatory diagram of a modified example of the concrete block manufacturing mold according to the first embodiment of the present invention.

FIG. 8 is a perspective view of a conventional decorative block manufacturing apparatus.

FIG. 9 is a partially exploded perspective view of the decorative block manufacturing apparatus.

[Explanation of symbols]

A Mold for making decorative block (Mold for manufacturing concrete block) A1 Void A2 Void F Mold for manufacturing block (Mold for manufacturing concrete block) G Mold for manufacturing concrete block for paving (Mold for manufacturing concrete block) type) G1 gap portion L ₀ spraying distance L ₁ spraying distance L ₂ spraying distance theta ₀ spray angle theta ₁ spray angle theta ₂ spray angle 14 partition plate 15 end liner 15a plates 15c Endokoa 16 partition plate 17 rib attachment 17a bars 17c rib 18 Core Bar Assembly 18a Bar 18c Core 18d Core 19 Filler Plug 20 Plunger 20c Shoe 21 Plunger 21c Shoe 24 Carburizing Quenching Layer 25 Thermal Spray Coating 26 Thermal Spray Coating 27 High Speed Flame Sprayer 28 High Speed Flame Spray Machine 29 High-speed flame spraying machine 30 Mold main body 31 Carburizing and quenching layer 32 Thermal spray coating 33 Bearing part 34 Rotating shaft 35 Eccentric weight

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Hiroki Iwai 5-1 Nisone, Kokura Minami-ku, Kitakyushu-shi, Fukuoka Prefecture Inside the Machine Works Division of Mishima Kosan Co., Ltd. (72) Inventor Yasunori Kishikawa Kokura, Kitakyushu-shi, Fukuoka 5-1 Nisone, Minami-ku, Mishima Kosan Co., Ltd.

Claims (13)

[Claims] 1. A mold for manufacturing a concrete block, wherein a sprayed coating is formed on an inner peripheral surface of the mold. 2. The concrete block manufacturing die according to claim 1, wherein the concrete block manufacturing die is a pavement concrete block manufacturing die. 3. A mold for manufacturing a concrete block, wherein a sprayed coating is formed on an inner peripheral surface of a mold and an outer peripheral surface of a core inserted into the mold. 4. The concrete block manufacturing mold according to claim 3, wherein the concrete block manufacturing mold is a decorative block manufacturing mold or a block manufacturing mold. 5. The concrete block manufacturing die according to claim 1, wherein the thermal spray coating is formed on a carburized and quenched layer. 6. The surface on which the thermal sprayed film is formed is subjected to an uneven base treatment, and has a surface roughness Rz of 50 to 150 μm.
The mold for manufacturing a concrete block according to any one of claims 1 to 5, which is in a range of m. 7. The mold for producing a concrete block according to claim 1, wherein the thickness of the thermal spray coating is 0.1 to 2 mm. 8. The concrete block production according to claim 1, wherein the sprayed coating is a dispersion strengthened sprayed coating having a surface hardness of Hv700 or more by high-speed flame spraying of cermet fine powder. Mold. 9. The spraying temperature of the high-speed flame spraying is a temperature equal to or higher than a melting point of metal contained in the cermet fine powder, and is equal to or lower than a melting point of ceramics included in the cermet fine powder. Item 7. A mold for producing a concrete block according to item 8. 10. The cermet fine powder is composed of a cermet fine powder having a metal content less than a fixed amount and a self-fluxing alloy powder containing a deficient metal content, and is simultaneously sprayed by independent high-speed flame spraying machines. The mold for manufacturing a concrete block according to claim 8, wherein the thermal spray coating is formed. 11. The cermet fine powder comprises WC, Cr
At least one selected from the group consisting of C, TiC and SiC, and at least one selected from the group consisting of Ni, Cr, Co and alloys thereof, and further comprising 10 to 90% by weight of carbide. Cermet containing 90 to 10% by weight of a metal matrix such as Ni, Cr, Co or an alloy thereof, 10 to 90% by weight of an oxide, Ni, C
a metal matrix such as r, Co or an alloy thereof
Oxide cermets and nitrides containing 10 to 10% by weight
90% by weight, a nitride cermet containing 90 to 10% by weight of a metal matrix such as Ni, Cr, Co or an alloy thereof, or 10 to 90% by weight of boride, Ni, Cr,
A metal matrix such as Co or an alloy thereof is 90-1.
The concrete block manufacturing die according to any one of claims 8 to 10, comprising any one of boride-based cermets containing 0% by weight. 12. The flame speed of the high-speed flame spraying is 2
000-2700 m / sec, and the flame temperature is 240
The mold for manufacturing a concrete block according to any one of claims 8 to 11, wherein the temperature is 0 to 2700 ° C. 13. The concrete block manufacturing die according to claim 8, wherein the thermal spray coating is compounded in an inclined manner so that ceramics is increased on the surface side.