JPS586822B2 - Forming method and punching die for floors etc. with uneven surfaces - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for forming an uneven pattern on the surface of a hydraulic construction base such as a mortar or concrete floor integrally with the base, and a punching die used in this method.

Among the conventionally known methods for creating an uneven or patterned surface on the surface of a floor, etc., those that can be installed on site include those that embed or adhere separate materials such as tiles to the floor base, methods that involve surface painting, and methods that use sand, etc. These methods include spreading coarse aggregate onto the surface of the base, or exposing the aggregate in the base by applying a trowel to the base while it is not yet cured. If the unevenness is formed using a separate material that is not integrated with the main material of the base, as in the case of I can't do it,
Furthermore, it is not possible to create a three-dimensional pattern by painting, and three-dimensional creation by using separate materials such as tiles requires skill and is not very easy to work with, and Ike's method cannot form the desired tangible pattern. etc., all have their disadvantages.

In order to provide a novel method free from such defects, the present invention uses a sheet-like punching die in which an arbitrary pattern is formed by the through-holes and the die surface, and the punching die is used for flooring, etc. While the substrate is still uncured, a protrusion is formed that touches the surface of the substrate and is integrated with the substrate in the perforated portion, so that when the substrate is fully cured, the substrate and the protrusion are completely integrated into one body. This is to obtain an uneven surface that looks like this.

The present invention will be described in detail below with reference to figures showing several examples.

FIGS. 1 and 2 show a punching die 1 according to the present invention. The punching die 1 has a through hole 2 and is made of a flexible water-resistant material with resilience and peelability, such as ethylene vinyl acetate or polyethylene. In combination with the mold surface 3, it becomes a sheet-like body of any size with an arbitrary pattern formed thereon, and the peripheral edge of this mold surface 3 forms an appropriate rising edge 4.

The mold surface 3 may be a flat surface, a textured surface, or the like.

The punching die can be formed by punching, vacuum-pressure forming and cutting, or any other arbitrary method.

The method according to the invention is carried out using a cutting die 1 having a shape.

3 to 5 schematically illustrate different embodiments of the floor construction method according to the invention.

Of these, FIG. 3 shows the simplest and basic method among the methods of the present invention.

In this method, first, a concrete floor (including a decorative mortar layer) formed by an appropriate method is used as a base 5, and a punching die 1 is placed on the surface while the base 5 is still uncured, and then a metal trowel 6 is used. The punching die 1 is pushed into the surface of the base 5 by pressing it down, and at the same time, the concrete is raised in the through hole 2 to form a convex part 7 (b), and the whole is leveled with a trowel.

Since the punching die 1 has flexibility, it can be installed flat with a metal trowel, and it blends into the base, so the punching die 1
without creating any voids between the concrete and the 5 surfaces,
By having the rising edge 4, it is possible to ensure an appropriate protrusion, and also to prevent the convex part from collapsing due to the sliding of the metal trowel and causing the concrete to flow and fill the punching mold part, and to make it easy to cut with the trowel. The part of the punching die that touches the trowel has a raised edge, which allows the trowel to slide easily, thereby eliminating the possibility of the die turning over.

In this way, the concrete is left for a while to semi-cure or harden to the extent that it does not crumble, and then (c) the punching mold 1 is peeled off.

Since the punching die 1 has restorability, the rising edge 4 is slightly raised compared to when it is installed, and at least the upper end of the rising edge 4 has separated from the upper end of the convex part 7. Since it is made of a material with good properties, it can be easily peeled off, and at the same time, the protruding portion 7 is formed with an inclined surface 8 that expands slightly downward, or has a soft upper corner portion 9. (d) It's going to happen.

In this way, it is possible to form a floor with an uneven surface of the desired pattern between the concrete surface and the contact area of the metal trowel is limited to a small area on the upper surface of the protrusion, and the surface of the pond is the mold surface of the punching die. Since the two are joined together, the trowel is hardly visible, and there are no sharp-angled parts that are likely to get caught in the protrusion.

Next, FIG. 4 shows an example of forming a concrete floor having colored convex portions.

In this method, the punching die 1 is placed while the concrete subfloor 5 is still uncured, as described above.

In this way, colored hydraulic powder 10 made mainly of cement, which is the main material of concrete, is sprinkled (b) into the through-hole part 2 of the punching die and filled, and this powder 10 is filled with water contained in the uncured base material or excess moisture. After absorption and mixing, the surface is pressed down with a trowel 6 and the whole is leveled (c), and the convex portions 7' formed by the powder 10 and the base 5 are waited for to be semi-hardened or hardened.

After that, just peel off the punching die in the same manner as described above (d). In this way, the concrete floor base 5 and the raised portions 7' are integrated to form a single concrete body, and a floor with an uneven pattern formed on the surface and colored only on the raised portions can be formed.

It goes without saying that all of the protrusions may be formed in the same color, or may be formed in a combination of different colors for each pattern unit.

Hydraulic powder must be manufactured by blending the same main material as the base material so that it is integrated with the base.An example of a powder component that can be used for the concrete base is: Cement 45 %, hard aggregate (emery or carborundum) 4
5%, pigment 8%, dispersant/water reducer, etc. 2%.

FIG. 5 shows an example of forming a concrete floor in which the base and the raised portions are each colored in a different color.

This method involves spraying a thin layer of hydraulic powder 11 in a predetermined color over the entire surface of the concrete floor base 5 while it is still uncured.
This powder 11 absorbs and absorbs excess moisture contained in the uncured base.
After mixing (a), a punching mold 1 is placed (b), and hydraulic powder 10" of a different color from the above is sprinkled and filled into the through hole 2 of this punching mold, and moisture is added in the same manner. absorb and mix (c).

After that, the entire surface is leveled in the same manner as described above, and finally the punching die 1 is removed (a).

In this way, it is possible to form a single concrete floor with different colored protrusions 7'' formed on the colored surface without showing the concrete color.

In addition to the above example, if the condition shown in Fig. 5b is pressed with a trowel, it is possible to form a concave-convex pattern floor with the entire surface colored in the same color, and other applications that can be deduced from the above example are also possible. The present invention encompasses.

As described above, the present invention uses a predetermined sheet-shaped punching die, spreads the die on the base surface and presses it with a trowel, or in addition, sprinkles hydraulic powder of the same base material as the base material. This creates an uneven surface that can be colored freely, and the uneven surface is completely integrated with the base, making the work simple, efficient, and stable, and making it possible to carry out on-site construction. This is an extremely efficient construction method.

In this way, it is possible to form an uneven surface with no fear of the protrusions peeling off or collapsing, and this uneven surface allows very accurate finishing, and the uneven pattern not only serves as a decoration but also serves as an anti-slip function in the case of floors.

The present invention can also be effectively applied not only to on-site construction but also to factory-manufactured products and standardized products.

In this case, the present invention can be used for all kinds of floors such as entrances, toilets, poolsides, passageways, and ponds, and can also be used for walls and pond construction sites.

The punching die is easy to form and can be provided at low cost, and since it is lightweight and in the form of a thin sheet, it is very easy and convenient to store and handle.

[Brief explanation of the drawing]

Fig. 1 is a partial plan view of an example of the punching die of the present invention, Fig. 2 is an enlarged cross-sectional view taken along the line ■-■, Fig. 3 is a schematic cross-sectional view illustrating an example of the method of the present invention, Figs. 4 and 5. 2A and 2B are schematic cross-sectional views each illustrating another example of the method of the present invention. 1 is a punching die, 2 is a through-hole part, 3 is a die surface, 4 is a rising edge, 5 is a base, 6 is a trowel, 7, 7', ? “is a convex portion, 10,
10" and 11 are hydraulic powders.

Claims (1)

[Scope of Claims] 1. A flexible water-resistant sheet-like punching mold in which an arbitrary pattern is formed by the perforations and the mold surface is applied to the surface of the hydraulic mortar and concrete layer forming the floor surface while they are not yet hardened. Then, use a trowel to press this punching mold down and level it all over to form a convex part of the hydraulic material that is integrated with the floor etc. in the through hole of the punching mold. A method for forming a floor, etc., having an uneven surface, in which a punching die is peeled off after waiting for the floor, etc., including the starting part, to be semi-hardened or hardened to the extent that it does not collapse, thereby forming an uneven pattern. 2. A flexible, water-resistant sheet-shaped punching mold with an arbitrary pattern formed by the perforations and the mold surface is integrated with the mortar or concrete base by sprinkling colored hydraulic powder mainly composed of cement on the surface of the base. The layer forming the floor surface made of material is placed on the surface while it is still uncured, and then the punching mold is pressed with a trowel, and the whole is leveled and integrated with the floor etc. into the through hole of the punching mold. This forms a convex part of the colored hydraulic material, and after waiting for the floor etc. to be semi-hardened or hardened to the extent that the floor etc., including this convex part, will not crumble, the punching mold is removed and a concave-convex pattern is formed. A method for forming a floor, etc. with an uneven surface. 3. A flexible, water-resistant sheet-like punching mold with an arbitrary pattern formed by the perforations and the mold surface is placed on the surface of the hydraulic mortar and concrete layer forming the floor surface while they are still unhardened, and then this Hydraulic powder made of the same main material as the main material of the above-mentioned floor, etc. was scattered and filled into the perforated part of the punching die, and then pressed evenly from above with a trowel, so that the filled part became integrated with the above-mentioned floor, etc. Wait until the floor, etc., including the protrusions, is semi-hardened or hardened to the extent that it does not collapse, and then peel off the punching mold [
A method for forming a floor or the like having an uneven surface by forming an uneven pattern. 4. The method for forming a floor or the like having an uneven surface according to item 3, wherein the hydraulic powder is colored. 5 Consists of a flexible, water-resistant, sheet-like punching mold with an arbitrary pattern formed by the perforations and mold surface, which is integrated by sprinkling colored hydraulic powder mainly composed of cement on the surface of the mortar or concrete base. The layer forming the floor surface is placed on the uncured surface, and then a hydraulic powder made of the same main material as the main material of the above-mentioned floor etc. is sprinkled and filled into the through holes of this punching die, and then Level it from above with a hand so that the filling part becomes a convex part that is integrated with the floor etc., and in this way, the floor etc., including this convex part, will be semi-hardened or hardened to the extent that it will not collapse. A method for forming a floor or the like having an uneven surface by waiting and peeling off a punching die to form an uneven pattern. 6. The method for forming a floor or the like having an uneven surface according to item 5, wherein the hydraulic powder is colored. 7 A sheet-like body of any size in which an arbitrary pattern is formed by a combination of a mold surface made of a flexible water-resistant material such as polyethylene with moderate resilience and peelability and through-holes, and the periphery of the mold surface is A punching die for forming floors, etc. that has an uneven surface that forms a moderately rising edge.