JPH1142652A - Base material mat for decorative form, its manufacture, and decorative form - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a light-weight base material mat for expediting curing of concrete by vapor curing by casting uncured urethane frothing material formed by using polyol and isocyanate in an upper part open type simple form formed on its inner surface with protrusion and recess pattern. SOLUTION: A liquid made of polyol and frother, B liquid containing isocyanate and compressed air are fed to a frothing mixer 10. As a simple form, form 5 formed on its surface with protrusion and recess pattern is adhered onto a support frame 4 and then its four sides are partitioned by side frames 6 for use. Uncured urethane frothing material 7 regulated by the mixer 10 is cast in its inside, cured, and then released from the form to a base material mat. Further, a sheet having a protrusion and recess pattern similar to the mat is manufactured by using polyvinyl chloride raw fabric sheet by a vacuum molding method, and adhered to a surface of the pattern of the mat to manufacture the decorative form.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative form for producing a concrete product having a textured surface. More specifically, a base material mat for a decorative formwork made of foamed polyurethane, which is lightweight, excellent in strength and capable of hardening concrete by steam curing, a method for producing the same, and a decorative material comprising the base material mat and a cover sheet For formwork.

[0002]

2. Description of the Related Art Generally, in order to manufacture a concrete product having a concavo-convex pattern formed on a concrete surface, a decorative form having a concavo-convex pattern on an inner surface is fixed on a steel support with an adhesive or the like, and the four sides are fixed. It is manufactured by placing concrete in the interior partitioned by side frames, curing and curing, and then removing the mold.

As a decorative mold, a resin mold made of urethane resin or the like has been conventionally used. In recent years, designs with large irregularities have become preferred, and the decorative molds have also had large irregularities, and accordingly the amount of mold materials used has increased. Its use as a solid entity has led to increased production costs.

[0004] Further, in the case of the decorative mold made of the solid material, there is a problem that it is difficult to judge the life when the decorative mold is repeatedly used. That is, when the concrete material is cast using the decorative formwork, the poured concrete material is violently hit against the uneven surface, and the uneven surface gradually wears due to repeated use. Since the pattern design of the obtained concrete product is different from the initial one when the uneven pattern surface is shaved, the decorative form frame worn over a certain amount cannot be used any more. However, since the above-described conventional decorative mold is a solid body, it is difficult to determine how much the surface of the decorative mold has worn out even if the uneven pattern surface is worn, and it is extremely difficult to determine the life of the decorative mold. For this reason, there has been a considerable number of accidents in which a decorative mold having a service life longer than the service life is incorrectly used and a defective product having a poor design is generated.

Therefore, the present applicant has divided the decorative mold into a base material mat and a sheet to be adhered to the base material form, and used a foam such as polystyrene or polyurethane as the base material mat material to reduce material costs and reduce weight. (Japanese Patent Application No. 8-144615).

[0006]

The foamed styrene as a base material mat is a material having excellent suitability such as being lightweight and having a required load-bearing strength. The production cost is high because a special mold is required. In addition, there is a problem in heat resistance, and the productivity is poor because steam curing usually performed at a temperature of 60 to 80 ° C. cannot be performed to improve the production efficiency of concrete products. Even if foamed polyurethane which is lightweight as foamed styrene and has temperature resistance during steam curing is used, its foaming pressure (foaming ratio: 10 to 10) is similar to foamed styrene.
(20 times).

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a base material mat for a decorative formwork which is lightweight and has heat resistance capable of accelerating the hardening of concrete by steam curing, a method for producing the same, and a decorative mold using the base material mat. To provide a frame.

[0008]

Means for Solving the Problems In order to solve the above-mentioned problems, the present inventors have made intensive studies on reducing the foaming pressure of foamed polyurethane. As a result, by using polyurethane foamed before curing as the material of the base mat, the pressure during foaming is reduced, and a mold is not required as when using conventional foamed polystyrene or foamed polyurethane. The present invention was completed by confirming that the base material mat could be formed using an open simple mold, so that a significant cost reduction could be realized.

That is, the present invention provides: 1) a method for producing a base material mat for a decorative form used by attaching a sheet, for producing a concrete product having an uneven pattern formed on a surface thereof; A gas is mixed with the first chemical solution containing the polyol (Solution A) to form a foam, and this is mixed with the second chemical solution containing the isocyanate (Solution B), or a gas is mixed with a mixture of the A solution and the B solution. Production of a base material mat for a decorative formwork, wherein the uncured urethane foam obtained by the above is cast using a simple form of an open top system having an uneven pattern formed on the inner surface. A method, 2) A base material mat for decorative formwork produced by the method described in 1 above, 3) A base material mat described in 2 above, and a sheet which is in close contact with the uneven pattern surface of the base material mat. And 4) a sheet made of polyurethane, 4. A decorative form according to the above 3, which is selected from polypropylene, polyethylene, polyvinyl chloride and ABS resin. Hereinafter, the present invention will be described in detail.

As shown in FIG. 1, a decorative mold frame 1 according to the present invention is used by being integrated with a base material mat 2 having a concave and convex pattern formed on the surface thereof and being integrally formed on the concave and convex pattern surface. And a top sheet 3. The base mat 2 is formed using an uncured urethane foam.

The uncured urethane foam to be used in the present invention is foamed by mixing a gas with a first chemical solution (solution A) containing a polyol, and is then foamed with a second chemical solution (B) containing isocyanate.
Liquid A) or by mixing a gas with a liquid mixture of the liquid A and the liquid B.

First chemical liquid (liquid A) : Liquid A is basically a chemical liquid containing a polyol, a foaming agent, a curing catalyst and water. (1) Polyol The polyol used in the present invention is not particularly limited. Specific examples of usable polyols include ethylene glycol, diethylene glycol, triethylene glycol,
Propylene glycol, dipropylene glycol, tripropylene glycol, 1,3-propanediol, 1,
Diols such as 3-butanediol, 1,4-butanediol, neopentyl glycol, and hexylene glycol; triols such as glycerin and trimethylolpropane; or ethylene oxide, propylene oxide, and ethylene / propylene copolymers And polyols such as polyethylene and polypropylene copolymerized polyols, polyethylene glycol, and polypropylene glycol. A polyol containing an amino group is also suitably used. The polyol content is preferably 10 to 90% by weight of the total amount of the liquid A. In order to obtain sufficient strength, the content is more preferably set to 40% by weight or more.

(2) Foaming agent Since a sufficient foaming property cannot be obtained with a polyol alone, in the present invention, the polyol is usually diluted with water and a foaming agent is added. The foaming agent includes various surfactants. Any of amphoteric, nonionic, cationic and anionic types may be used, but nonionic surfactants having two or more functionalities are preferred. Examples of such nonionic surfactant compounds include, for example, higher alcohol ethylene oxide adducts containing alkyl groups having 12 to 24 carbon atoms, alkylphenol ethylene oxide adducts, fatty acid ethylene oxide adducts, polyhydric alcohol ester ethylene oxide adducts Fatty acid esters of glycerol, fatty acid esters of pentaerythritol, fatty acid esters of sorbitol and sorbitan, fatty acid esters of sucrose, fatty acid esters of glycerol, higher alkylamine ethylene oxide adducts, fatty acid amide ethylene oxide adducts, etc. Nonionic surfactants such as polyhydric alcohol ethylene oxide adducts such as alkyl ethers of polyhydric alcohols; and fatty acid amides of alkanolamines.

In particular, a bifunctional or higher functional nonionic surfactant is preferred. By using the bifunctional nonionic surfactant, the foaming agent reacts with the isocyanate of the liquid B and is fixed as a solidifying component. Such a surfactant is a polyethylene glycol type nonionic surfactant containing two or more polyethylene oxide chains in one molecule, and a polyhydric alcohol type nonionic surfactant obtained by reacting with an aliphatic alcohol while leaving at least two hydroxyl groups. Alkanolamine-type nonionic surfactants containing two or more hydroxyl groups in one molecule. The foaming agent content is 1 to 40% by weight of the total amount of the liquid A.
It is preferable that If the content of the foaming agent is less than 1% by weight, sufficient foaming properties cannot be obtained.

(3) Curing Catalyst In order to smoothly proceed with the reaction with Liquid B, it is preferable to add a curing catalyst to Liquid A. Examples of curing catalysts include:
Tertiary alkylamines and cyclic amines such as dimethyloctylamine, dimethyllaurylamine, morpholine and piperazine; dibutyltin dilaurate, triethylenediamine, imidazole, monoethanolamine, diethanolamine, triethanolamine and other water-soluble amines, betaine or imidazole type And the like.

(4) Foam Retaining Agent A foam retaining agent may be added to the liquid A in order to maintain the properties of the foam after foaming until completion of injection and curing. Examples of the foam-retaining agent include an alcohol-based nonionic surfactant, an amphoteric surfactant, a cationic surfactant, and an anionic surfactant. The content of the foam retaining agent is preferably 1 to 5% by weight of the total amount of the liquid A. If the content of the foam-retaining agent is less than 1% by weight, a sufficient foam-retaining effect cannot be obtained.

Second chemical solution (Solution B) : The B solution is preferably a partial prepolymer containing a polymeric MDI and a monomeric MDI as raw materials and containing a primary emulsifying OH in water. Examples of the polyisocyanate used for producing such a prepolymer include diphenylmethane diisocyanate, 1,4-butane diisocyanate, dicyclohexylmethane diisocyanate,
6-hexane diisocyanate, cyclohexane diisocyanate, 1,5-bisisocyanate-1,3,3
Aliphatic diisocyanates such as trimethylcyclohexane, m-xylylene isocyanate, 1,3-bis- (isocyanatomethyl) benzene and methylcyclohexane diisocyanate, 2,4- or 2,6-tolylene diisocyanate, m- or p-phenylene Examples thereof include diisocyanate and 1,5-naphthylene diisocyanate. Diphenylmethane diisocyanate is particularly preferred. Diphenylmethane diisocyanate has various isomers, and any of them can be used.
These mixtures may be used.

The prepolymer is obtained by reacting the above-mentioned isocyanate with a polyalkylene glycol. As such a polyalkylene glycol, polyethylene glycol or an ethylene oxide (EO) -propylene oxide (PO) copolymer is used. The EO content in the copolymer is usually 20% by weight or more,
The average OH value as a (co) polymer is 56 or more.
The NCO% in the prepolymer (= the sum of the number of NCOs contained in the isocyanate compound x the NCO formula weight divided by the molecular weight of the isocyanate compound) is preferably in the range of 25 to 29%. If the NCO% is less than 25%, the time required for the curing reaction after mixing with the solution A tends to be too short. Conversely, if it exceeds 29%, B
The water miscibility (emulsifiability) of the liquid decreases. When the content is in the range of 25 to 29%, the time until the curing reaction after mixing with the liquid A becomes appropriate.

The foaming Foaming, A solution or in some cases carried out by mixing the gas in a mixture of liquid A and liquid B. If a mixed solution is used, the reaction of the two solutions may proceed at the same time and may be hardened during foaming. Therefore, it is preferable to mix a gas into the A solution. Usually, foaming is performed about 5 to 100 times. When the foaming is less than 5 times, the efficiency is poor, and when the foaming is more than 100 times, sufficient strength cannot be obtained. Generally, about 10 to 50 times is preferable. The gas to be mixed is not particularly limited as long as it does not react with the liquid A or the liquid B and does not adversely affect the environment, but usually air is used. The gas mixing method is not particularly limited, but is usually performed by blowing gas. It is preferable to use a foaming device described below.

Mixing of Liquid A and Liquid B Liquid A and liquid B are mixed after foaming of liquid A or before foaming in some cases. The mixing ratio depends on the composition of each liquid, but the uniaxial compressive strength after curing is 3 to 10 kgf / cm.
^A range of ² is sufficient. Usually, solution A: solution B is 1:
Mix 1: 1-1: 3. Mixing must be performed sufficiently. Generally, the liquid A foam is white and the liquid B is colored (brown), so that the mixed state can be visually confirmed.
The mixing method is not particularly limited, but it is preferable to use an apparatus described later.

Foaming Apparatus As the foaming apparatus, an apparatus whose schematic sectional view is shown in FIG. 2 or 3 can be used. Apparatus 10 shown in FIG.
A first chamber 11, a second chamber 12 for foaming a chemical solution, and a third chamber 13 in a hollow cylindrical housing 20.
Are provided in order. Between the first and second chambers and between the second and third chambers, there are perforated partition walls 14 and 15 respectively.
Partitioned by. Each of the partition walls 14 and 15 has a wire mesh 1
6 and 17 may be added. The housing and each chamber are preferably formed in a straight cylindrical shape, but may be a cylindrical body having a polygonal or elliptical cross section, and the second chamber may be formed in a curved pipe, a spiral pipe, a coil pipe, or the like. The outflow end 18 of the third chamber has a structure formed in a nozzle shape. The first chamber is a premixing section for the first chemical solution and the compressed gas, and has introduction holes 21 and 22 at its ends. Hole 21
Then, a first chemical solution (A solution) is introduced by a pump means, and a compressed gas is introduced from a hole 22 by an air compressor.

The second chamber 12 is preferably filled with a large number of fillers 19 to change the gas-liquid flow path in a complicated manner to promote uniform mixing and foaming. The shape of the filler is not particularly limited as long as it does not completely block the gas-liquid flow path. For example, a shape such as a spherical shape, a circular tube shape, and a cylindrical shape is used. Further, the material may be any material that is not affected by the first chemical solution and has considerable wear resistance. For example, glass, ceramic, plastic, stainless steel and the like are used. Usually, small balls made of glass, ceramic or plastic having a diameter of about 1 to 5 mm are filled.

A third chamber is provided immediately after the second chamber for adding the second chemical to the foamy fluid obtained in the second chamber. An introduction hole 23 for introducing the second chemical is provided in the third chamber. Preferably, the tube 24 is extended from the introduction hole to a substantially central portion of the third chamber, and a chemical solution is sprayed from a nozzle 25 provided at the tip thereof. Thus, the foamed fluid mixed with the second chemical solution is supplied to the nozzle 1
Sent from 8. Usually, the foamy fluid and the second chemical liquid flow out as a uniform mixture, but a static mixer or the like may be provided in the nozzle 18 to promote the mixing.

In the embodiment shown in FIG. 2, the second chemical is introduced directly into the third chamber from the outside of the housing, but as shown in FIG. 3, a second chemical introduction hole 33 is provided at the end of the first chamber. A pipe 34 extending from the introduction hole, preferably along the axis of the apparatus, through the first chamber and the second chamber to reach the third chamber may be provided, and a chemical solution may be ejected from a nozzle 35 at the tip thereof. Nozzle 1
8 may be provided with a static mixer or the like to promote mixing. By adopting such a configuration, the second chemical liquid is jetted uniformly to the foamy fluid, and the two are mixed smoothly.

A base material mat is formed using the uncured urethane foam obtained as described above. Since the urethane foam does not foam after injection into the mold, a simple mold having an open top can be used 13. As shown in FIG. 4, for example, as shown in FIG. 4, a simple mold having a concave / convex pattern formed on a support mold 4 is attached to the support mold 4, and four sides thereof are partitioned by side frames 6. Used, and the uncured urethane foam 7 prepared by the apparatus 10 or the like is poured into the inside thereof. After the urethane foam 7 is cured, it is released from the mold to obtain the base material mat 2 with the uneven pattern transferred to the surface. The base material mat that has been removed from the mold is subjected to surface finishing by horizontally shaving the bottom surface (the opposite side of the uneven pattern surface). Or after pouring uncured urethane foam,
The back surface is exposed by pressing the open surface with a lid-like member or by scraping off excess material.

The decorative formwork of the present invention is obtained by attaching and integrating a base material mat obtained above and a sheet member previously formed so as to conform to the shape of the uneven pattern surface of the base material mat. It is. As the sheet member, those made of various resin materials can be used, but polyurethane, polypropylene,
Polyethylene, polyvinyl chloride, ABS resin and the like are preferred.

There is no particular limitation on the method of forming the sheet member so as to conform to the shape of the uneven pattern of the base material. For example, a flat raw resin sheet is heated and vacuum-sucked onto the surface of a gas-permeable mold. Vacuum forming method to make close contact, hot press method to press and hold in a mold while heating, spraying method to spray and harden liquid resin into uniform thin sheet shape on uneven shape mold, brush liquid resin on uneven shape mold A brush coating method for curing or the like can be used.

The decorative formwork of the present invention thus obtained can be used in the same manner as in the prior art to produce a concrete product having an uneven pattern on the surface. That is, after the decorative formwork of the present invention is installed on a steel support formwork, four sides thereof are partitioned by side frame members, and a concrete material is cast inside. After the concrete is cured and cured, the concrete product is removed from the mold to transfer the concave and convex pattern of the decorative mold to the surface. Curing and curing of concrete can be carried out by steam curing which is excellent in productivity, unlike the case where foamed styrene is used, since the base material mat is made of foamed polyurethane having heat resistance.

In the decorative formwork of the method of the present invention, the base material mat, which is the main member, is made of lightweight polyurethane foam, so that the workability of concrete product production is improved.

[0030]

EXAMPLE inner diameter 4 cm, with a straight tube cylindrical length 30 cm, taken generally create a stainless steel frothing mixing apparatus similar structure as FIG. The volume ratio of the first chamber / second chamber was 1 / 2.6. The second chamber accommodates about 200,000 glass beads of 1 mm in diameter, and the partition walls between the first and second chambers and the second and third chambers are concentric circles over a plurality of rows. Stainless steel disks 14 and 15 having through holes arranged in a circle, a wire mesh 16 of 100 mesh
And 17 were used, respectively. Solution A consisting of 20 parts by weight of a polyol, 25 parts by weight of a foaming agent, 45 parts by weight of water, 7 parts by weight of a foam retaining agent, and 3 parts by weight of a curing catalyst, and a solution B containing isocyanate were added at 1 kg / min and 2 kg / min, respectively. At the rate of
Also, 5 kgf / cm ² of compressed air was sent from the compressor to the above-described foaming and mixing apparatus, and a foamy fluid was obtained from the nozzle 18.

A base material mat (600 mm in length × 900 mm in width × 3 in height) was prepared by using the above-mentioned foamed fluid and using the form shown in FIG.
5 mm). Also, using a 1 mm thick raw sheet made of polyvinyl chloride, a sheet having the same concavo-convex shape as that of the base material mat is produced by a vacuum forming method, and is adhered to the surface of the concavo-convex pattern of the base material mat, Formwork was manufactured.

Using the above-mentioned decorative mold, a concrete product having an uneven surface was manufactured in the same manner as in the prior art.
The concrete hardening step was performed by steam curing (60 ° C.) for 2 hours. The obtained concrete product was a product in which the concave and convex pattern of the decorative formwork was well transferred. When the production of the concrete product was repeated 20 times by using the above-mentioned formwork, the surface sheet was worn and the base material mat under the surface sheet was exposed. During this time, the pattern design did not deteriorate.

Comparative Example A decorative form was produced in the same manner as in the example except that a foamed styrene (expansion ratio: 20 times) was molded using a mold to obtain a base material mat, and a concrete product was produced in the same manner. The decorative frame was deformed in the inside, and the uneven pattern on the surface was not transferred well.

[0034]

The base material mat for a decorative formwork of the present invention uses an uncured urethane foam, so that there is no post-foaming, and it can be manufactured using a simple open-top formwork. It is economical because it does not require a strong mold that can withstand a large foaming pressure as used in molding styrene or urethane foam. Since the decorative formwork of the present invention is made up of a lightweight and high-strength base material mat and its surface sheet, it is lighter than the conventional formwork made as a solid body and has excellent workability in the field. In addition, the base material mat is obtained by curing the foamed body,
Uses less material. Since the foamed polyurethane withstanding the curing temperature of 60 to 80 ° C. is used, the hardening of the concrete can be promoted, and the productivity is improved. Furthermore, the life of the decorative formwork can be judged from the wear of the surface sheet layer when the decorative formwork is repeatedly used, and the base material mat can be continuously used only by replacing the inexpensive surface sheet, resulting in a significant cost reduction. .

[Brief description of the drawings]

FIG. 1 is a sectional view of an example of a decorative mold frame of the present invention.

FIG. 2 is a schematic cross-sectional view showing one example of a foam mixing apparatus used for manufacturing the base material mat of the present invention.

FIG. 3 is a schematic cross-sectional view showing another example of the foam mixing apparatus used for producing the base mat of the present invention.

FIG. 4 is a schematic cross-sectional view illustrating a method of manufacturing a base material mat.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Make-up formwork 2 Base material mat 3 Sheet 4 Support formwork 5 Formwork for make-up formwork 6 Side frame 7 Uncured urethane foam 10 Foaming mixing device 11 First room 12 Second room 13 Third room 14 , 15 Perforated partition wall 16, 17 Wire mesh 18 Nozzle 19 Foaming filler 20 Housing 21 First chemical liquid introduction hole 22 Compressed air introduction hole 23, 33 Second chemical liquid introduction hole 24, 34 Tube 25, 35 Second chemical liquid injection nozzle

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI C08G 101: 00) B29K 105: 04

Claims (4)

[Claims] 1. A method for producing a base material mat for a decorative form used by attaching a sheet, for producing a concrete product having an uneven pattern formed on a surface thereof, wherein the first chemical solution contains a polyol. (A liquid) is mixed with a gas to form a foam, and this is mixed with a second chemical solution containing an isocyanate (a B liquid) or by mixing a gas with a mixed liquid of a A liquid and a B liquid. A method for producing a base material mat for decorative formwork, comprising casting the cured urethane foam using a simple form having an open top with an uneven pattern formed on the inner surface. 2. A base material mat for decorative formwork produced by the method according to claim 1. 3. A decorative formwork comprising the base material mat according to claim 2, and a sheet closely covered with the uneven surface of the base material mat. 4. The decorative formwork according to claim 3, wherein the sheet is selected from polyurethane, polypropylene, polyethylene, polyvinyl chloride and ABS resin.