JPH106315A - Production of composite concrete product fitted with surface protecting layer and colored resin layer having concrete surface three-dimensional shape - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a three-dimensional composite concrete product fitted with a surface protecting layer and a colored resin layer not generating peeling or fading by integrally molding cement mortar or ready-mixed concrete and a pigment-containing curing agent mixed synthetic resin having weatherabillty. SOLUTION: A curing agent mixed synthetic resin prepared by appropriately adding a viscous material, inorg. particles or pigment to a light-resistant, water-resistant, abrasion-resistant, fading resistance and chemical-resistant synthetic resin and further mixing a curing agent therewith is applied to the inner surface of a concrete female mold 2 having a three-dimensional shape as a resin layer 4 with a thickness of about 500-2000μm and fibers 7 or a nonwoven fabric 5 are bonded or arbitrarily laminated on the resin layer 4 and, further, the aformementioned curing agent mixed synthetic resin is again laminated thereon in a thickness of about 100-200μm and fibers with a thickness of 5-15 denier cut into a length of about 3-5mm are focked thereon by an electrostatic flocking machine or other spray method and, before the curing agent mixed synthetic resin is cured, cement mortar or ready-mixed concrete is cast thereon and the whole is vibrated, heated, humidified and aged and subsequently cured and demolded to obtain a composite concrete product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing a composite concrete product having a three-dimensional surface protection of a cement mortar or a concrete molding and a colored resin layer.

[0002]

2. Description of the Related Art Conventionally, when protecting and strengthening a three-dimensional surface of a cement mortar or concrete molding, an adhesive is applied to the surface of a concrete molding made of cement mortar or concrete, and then synthesized. Resin materials are laminated and bonded, or a reinforcing material or a pigment is kneaded and contained in concrete to take measures such as strengthening and protecting the surface and the concrete molding itself, coloring, and the like.

[0003] As a method of obtaining a colored concrete molded body which does not cause a feeling of strangeness to the construction site, a paint or a pigment is applied to the surface of the concrete molded body, or a color ceramic aggregate is used. A kneaded coloring material is sprayed and pressed, or a pigment is sprayed into a female mold and dried, and then concrete is poured and transferred to obtain a colored concrete product.

[Problem to solve the problem]

However, since the concrete molded body obtained by the above-mentioned conventional method can be obtained through various processes until a synthetic resin material or the like is applied, the production efficiency is extremely low, and the difference in specific gravity between the concrete and the resin layer results. The resulting uneven pressure does not allow the concrete surface to form uniformly.

[0005] Also, due to drying shrinkage due to volume change of concrete, temperature change, hydration reaction, shrinkage due to carbonation, etc.,
Cracks and the like are generated, and the durability and weather resistance of the concrete are remarkably deteriorated, the bonded synthetic resin material is peeled off, and the concrete is collapsed by repeated freezing and thawing.

Further, a concrete molded body kneaded with a reinforcing material has a problem that a desired surface shape cannot be obtained because a foreign substance is difficult to adjust to a mold frame due to a foreign substance.

In the above-mentioned coloring method, surface protection coloring painting is performed only after concrete is poured and cured, demolded, and dried, and it takes a long time to obtain colored concrete. Is very bad, and the colored portion is liable to be peeled off, discolored or discolored with the passage of time depending on the components of the paint, pigment and cement used.

Further, in order to obtain a desired colored concrete molding, a pigment of about 3 to 5% by weight of cement must be mixed. If the amount of concrete increases, the pigment must also increase. Therefore, it becomes a very expensive concrete molding.

Further, the concrete surface is liable to be whitened due to the lime content in the cement and compounds such as carbon dioxide and the like, and it is difficult to obtain a desired coloring.

Also, in a method of kneading a pigment with a water-soluble adhesive or the like and spraying the adhesive into a female mold to color the female mold, the female mold is erected and the female mold is cast by rain or the like before casting concrete. There have been various problems such as the adhesive sprayed into the mold flowing down from the female mold.

The present invention provides a synthetic resin layer adaptable to various situations in a three-dimensional surface protection and coloring method, a three-dimensional surface protection and a colored resin layer in which colored portions are not peeled off, and discoloration and fading do not occur. It is an object of the present invention to provide a composite concrete product with a cover and a method for producing the same.

[0012]

In order to achieve the above object, a concrete product having a three-dimensional shape protection and a colored resin layer according to the present invention and a method of manufacturing the same are provided by the present invention.
Light resistance, on the inner surface of a three-dimensional concrete molded female mold
To a synthetic resin containing water resistance, abrasion resistance, color resistance, chemical resistance, etc., a viscous material, an inorganic powder and a pigment are appropriately added, and a hardener is mixed with the synthetic resin. The first layer of the hardener-mixed synthetic resin is formed into a resin layer having a thickness of about 500 to 2,000 μm, a fiber, a nonwoven fabric, or the like is laminated on the resin layer.
~ 200μ again and the thickness is 5 ~ 15
The fiber cut to a denier of about 3 to 5 mm is sprayed and planted by an electrostatic flocking machine or another method, and a cement mortar or a ready-mixed concrete is poured while the hardener-mixed synthetic resin is not cured. A method for producing a composite concrete product with a three-dimensional surface protection of a concrete surface and a colored resin layer, which is obtained through hardening and demolding after processes such as heating, humidification and curing.

According to a second aspect of the present invention, there is provided a method for manufacturing a concrete product having a three-dimensionally shaped concrete surface and a colored resin layer, wherein the inner surface of the three-dimensionally shaped concrete molded female mold is provided with light resistance, water resistance, abrasion resistance and color resistance. To a synthetic resin containing properties and chemical resistance, a viscous material, an inorganic powder and a pigment are appropriately added, and a hardener mixed synthetic resin of the first layer obtained by mixing a hardener with the synthetic resin is used. After forming a resin layer of about 500 to 2000 μm, laminating a fiber or a nonwoven fabric on the resin layer, and then adding a curing agent mixed synthetic resin of the second layer to 100 μm.
~ 200μ again and at the same time, 0.5 ~ 3m
m of aggregate such as sand is applied by electrostatic adhesion or spraying, and cement mortar or ready-mixed concrete is poured while the hardening agent-mixed synthetic resin of the second layer is not cured; It is obtained through hardening and demolding after processes such as humidification and curing.

Further, in the manufacturing method according to the third aspect, after the first and second hardener-mixed synthetic resin layers are hardened, they are removed from the female mold to obtain a surface protection and coloring of the concrete. Three-dimensional pattern sheet material of resin layer.

5. The method according to claim 4, wherein the phosphorescent material is kneaded with a synthetic resin to provide a three-dimensional surface protection of the concrete surface and a composite concrete product with a colored resin layer.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a composite concrete product having a three-dimensional surface of a concrete surface and a colored resin layer according to the present invention will be described with reference to the drawings. FIGS. 1 and 2 are a state diagram before the product is released from the mold and a product diagram after the product is released, and FIGS. 3 and 4 are a state diagram before the product is released from the product and the product after the release. FIG. 5, FIG. 5, and FIG. 6 are a state diagram of the three-dimensional pattern sheet material of claim 3 before the mold release and a product diagram after the mold release. FIG.
FIG. 8 is a state diagram before the product is released from the mold and a product diagram after the mold is released, and FIGS. 9 (a) to 9 (e) show an embodiment showing the molding step of the invention.

The molding steps in FIGS. 9 (a) to 9 (e) are as follows: (a) First step (FIG. 7 (a)): A three-dimensional molded female mold 2 is set on the inner surface of The release agent layer 3 is provided on the surface of the molded female mold 2 by uniformly spraying the release agent onto the inner surface of the mold frame and the three-dimensional molded female mold 2 using a sprayer or the like. (B) Second step (FIG. 7 (b)): The surface of the release agent layer 3 contains light resistance, water resistance, abrasion resistance, color resistance, and chemical resistance corresponding to each installation location. To the synthetic resin, a hardener mixed synthetic resin obtained by appropriately adding a viscous material, an inorganic powder and a pigment, and a hardener is sprayed or poured at least about 500 to 2000 μ with a spray gun or the like, and provided by painting or the like. A first hardener-mixed synthetic resin layer 4 is formed. (C) Third step (FIG. 7 (c)): A nonwoven fabric or the like is adhered to the surface of the first hardener-mixed resin layer 4 to form a woven fabric layer 5. (D) Fourth step (FIG. 7D): On the surface of the non-woven fabric layer 5, the synthetic resin mixed with a hardener is again laminated by about 100 to 200 μm by the same procedure as above, and the mixed hardener of the second layer is synthesized. When the resin layer 6 is formed, the nonwoven fabric layer 5 is pressed from the surface of the hardener-mixed synthetic resin layer 6 by a roller, a brush, or the like, and the nonwoven fabric layer 5 penetrates from the nonwoven fabric layer 5.
The second hardener-mixed synthetic resin layer 6 may not be provided. (E) Fifth step (FIG. 7 (e)): Next, a fiber cut to a thickness of about 5 to 15 denier and about 3 to 5 mm on the surface of the second layer of the hardener-mixed resin layer 6 is statically applied. It is fixed to the hardener-mixed synthetic resin 6 of the second layer by spraying with an electric flocking machine or the like to form the fiber layer 7, and before the hardener-mixed resin layer 6 of the second layer is completely hardened, cement mortar or green It consists of the steps of casting concrete into a formwork, then applying vibration, shaking, heating and humidifying, curing, and demolding.

FIGS. 3 and 4 show an embodiment of the present invention.
A three-dimensional molded female mold 2 is installed on the inner surface of the mold, and a release agent is uniformly sprayed on the surface of the three-dimensional molded female mold 2 to the inner surface of the mold and the three-dimensional female mold 2 by a sprayer or the like. 3 is provided. Next, on the surface of the release agent layer 3, light resistance, water resistance,
A hardening agent mixed synthetic resin obtained by appropriately adding a viscous material, inorganic powder, pigment, etc. and a hardening agent to a synthetic resin containing abrasion resistance, color resistance, chemical resistance corresponding to each installation location At least about 500 to 2000 μm is sprayed using a spray gun or the like to form a first hardener-mixed synthetic resin layer 4. Next, a nonwoven fabric is adhered to the surface of the first hardener mixed resin layer 4 to form a nonwoven fabric layer 5, and a hardener mixed synthetic resin is applied to the surface of the nonwoven fabric layer 5 and the like by the same procedure as described above. The second layer of the hardener-mixed synthetic resin layer 6 is formed again by about 100 to 200 μm. Next, an aggregate such as sand particles or crushed stone of about 0.5 to 3 mm is electrostatically attached to or sprayed on the surface of the second layer of the hardener-mixed resin layer 6 to form the hardener-mixed synthetic resin 6 of the second layer. And cement aggregate mortar or ready-mixed concrete is cast in the mold before the hardening agent mixed resin layer 6 of the second layer is completely hardened, and then vibrated. Excitation,
Demolds through steps such as heating, humidification, and curing.

FIGS. 5 and 6 show a third embodiment of the present invention.
A three-dimensional molded female mold 2 is installed on the inner surface of a mold frame 1, and a release agent layer 3, a first hardener-mixed synthetic resin layer 4, a nonwoven fabric layer 5, and a second non-woven fabric layer 5 are formed on the surface of the three-dimensional molded female mold 2. A layer of a hardener-mixed synthetic resin layer 6, a fiber layer 7, or an aggregate layer 7 '
After the hardening material mixed synthetic resin is cured, it is released from the mold 1 and mass-produced, mounted in another female mold such as expanded polystyrene manufactured in another process, and cast concrete.

FIGS. 7 and 8 show an embodiment of claim 4, in which a three-dimensional molded female mold 2 is installed on the inner surface of one mold frame, and a release agent is sprayed on the surface of the three-dimensional molded female mold 2. The mold release agent layer 3 is uniformly sprayed on the inner surface of the mold frame and the three-dimensionally molded female mold 2 by the above method. Next, on the surface of the release agent layer 3, a synthetic resin containing light resistance, water resistance, abrasion resistance, color resistance, and chemical resistance corresponding to each installation location, a phosphorescent material, sand particles, powder, etc. At least about 500 to 2000 μm is sprayed or poured by a spray gun or the like, and is provided by coating or the like, and a first layer of the luminous curing agent mixed synthetic resin layer 4a is obtained. To form Next, a nonwoven fabric or the like is attached or laminated on the surface of the luminous hardener mixed resin layer 4a to form a nonwoven fabric layer 5, and a hardener mixed synthetic resin is applied to the surface of the nonwoven fabric layer 5 in the same manner as described above. A second layer of the hardener-mixed synthetic resin layer 6a is formed again by about 100 to 200 μm. Next, fibers cut to a thickness of about 5 to 15 denier and about 3 to 5 mm are sprayed on the surface of the second layer of the hardener mixed resin layer 6a by an electrostatic flocking machine or the like, and the hardener mixed resin of the second layer is blown. The cement layer is fixed to the synthetic resin layer 6a to form the fiber layer 7, and before the hardener-mixed resin layer 6a of the second layer is completely hardened, a cement mortar or ready-mixed concrete is poured into a mold, and then vibration is applied. Demolding is performed through processes such as applying, shaking, heating and humidifying, and curing.

[0021]

Since the present invention is configured as described above, the following effects can be obtained.

According to the first and second aspects, a hardener-mixed synthetic resin layer is provided in a three-dimensionally shaped female mold, and a nonwoven fabric, sand particles, silica sand, crushed stone, or the like is adhered to the upper surface of the hardener-mixed synthetic resin layer. By pouring the cement mortar and the ready-mixed concrete before hardening, the cement mortar and the ready-mixed concrete mixed with a hardening agent-containing synthetic resin are contained, and an effect of being able to be integrated with the concrete and preventing peeling or the like can be obtained.

Also, a hardening agent-mixed synthetic resin layer is provided in the three-dimensionally shaped female mold, and nonwoven fabric, sand grains, silica sand, crushed stones, etc. are adhered to the upper surface thereof, and the nonwoven fabric is pushed in with a roller or a brush to mix the hardening agent. By infiltrating into the synthetic resin layer, remove all the air layer contained in the non-woven fabric, etc., before the hardening agent mixed synthetic resin is hardened, put cement mortar and ready-mixed concrete, cure, cure, Through demolding, etc., the surface of the concrete molded body of the desired three-dimensional shape is obtained, and the three-dimensional concrete surface with significantly improved tensile strength, tear strength, peeling, chemical resistance, etc. by synthetic resin, non-woven fabric, etc. and aggregates It is effective in obtaining a composite concrete product with surface protection and a colored resin layer.

According to the third aspect, the synthetic resin mixed with the curing agent is provided in the female mold, and after the synthetic resin mixed with the curing agent is cured through the nonwoven fabric, sand grains, silica sand, crushed stone, etc., the resin is removed from the mold and cured. It is possible to improve the production efficiency in the production of concrete products by mass-producing a hardener-mixed synthetic resin sheet and temporarily attaching it to the same three-dimensionally shaped female formwork in a site construction or a concrete factory, etc. It works.

According to the fourth aspect, a luminous material or the like is kneaded in a synthetic resin containing light resistance, water resistance, abrasion resistance, color resistance, chemical resistance, etc. By doing so, it becomes an integrally formed body with cement mortar or ready-mixed concrete, and the luminous material emits light even in the dark, and has an effect of continuing the luminous action.

The cement concrete according to claims 1 to 4 is not limited to cement mortar and ready-mixed concrete, and the same effect can be obtained by using resin concrete using a binder other than cement.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a production state of a composite concrete molded product according to the first embodiment.

FIG. 2 is a cross-sectional view of a main part of the composite concrete molded product removed from the three-dimensional female mold frame in FIG. 1;

FIG. 3 is a cross-sectional view showing a manufacturing state of the composite concrete molded article according to the second embodiment.

FIG. 4 is a cross-sectional view of a main part of the composite concrete molded product removed from the three-dimensionally shaped female formwork in FIG. 3;

FIG. 5 is a cross-sectional view showing a manufacturing state of a three-dimensionally patterned sheet material having a surface protection and a colored resin layer according to claim 3;

FIG. 6 is a cross-sectional view of a three-dimensionally patterned sheet material having a surface protection and a colored resin layer in FIG.

FIG. 7 is a cross-sectional view showing a manufacturing state of the composite concrete molded product according to claim 4;

FIG. 8 is a cross-sectional view of a main part of the composite concrete molded product removed from the three-dimensionally shaped female formwork in FIG. 7;

FIG. 9 is a sectional view showing a manufacturing step of the first embodiment.

[Explanation of symbols]

REFERENCE SIGNS LIST 1 mold frame 2 three-dimensional shaped female mold 3 release agent layer 4 first hardener mixed synthetic resin layer 4 a first luminous hardener mixed synthetic resin layer 5 nonwoven fabric layer 6 second hardener mixed synthesis Resin layer 6a Second layer of luminous hardener mixed synthetic resin layer 7 Fiber layer 7 'aggregate layer 8 Cement, ready-mixed concrete or resin concrete, etc.

Claims (4)

[Claims] 1. A synthetic resin containing light resistance, water resistance, abrasion resistance, color resistance and chemical resistance, a viscous material, an inorganic powder, a pigment, etc. And a hardener-mixed synthetic resin obtained by mixing a hardener with the synthetic resin is 500
A resin layer having a thickness of about 2000 μm, a fiber, a nonwoven fabric, and the like are laminated on the resin layer, and the synthetic resin mixed with a curing agent is laminated again about 100 to 200 μm. The fiber cut to about 5 mm is sprayed and planted with an electrostatic flocking machine or another method,
Casting cement mortar or ready-mixed concrete while the hardener-mixed synthetic resin does not harden, and after curing, heating, humidifying, curing, etc., curing and demolding the concrete surface. Manufacturing method of composite concrete products with resin layer. 2. A synthetic resin containing light resistance, water resistance, abrasion resistance, color resistance and chemical resistance, a viscous material, an inorganic powder and a pigment. And a hardener-mixed synthetic resin obtained by mixing a hardener with the synthetic resin is 500
A resin layer of about 2000 μm, and after laminating a fiber or a non-woven fabric on the resin layer, the synthetic resin mixed with a curing agent is again laminated about 100 μm to 200 μm;
Aggregate such as sand of about 5 to 3 mm is adhered by electrostatic adhesion or spraying, and cement mortar or ready-mixed concrete is poured while the hardener-mixed synthetic resin is not cured, and vibration, heating, humidification, A method for producing a composite concrete product having a three-dimensional surface shape of a concrete surface and a colored resin layer obtained through curing and demolding after curing and other steps. 3. A three-dimensionally patterned sheet material for a concrete surface protection and colored resin layer obtained by removing the mold from a female mold after the curing agent-mixed synthetic resin layer is cured, according to the production method according to claim 1. 4. The method according to claim 1, wherein a phosphorescent material is kneaded with a synthetic resin to provide a three-dimensional surface protection of the concrete surface and a composite concrete product with a colored resin layer.