KR100750857B1 - Manufacturing method of concrete block with fieldstone texture - Google Patents

Abstract

A method for manufacturing a concrete block with texture of the natural stone is provided to shorten the manufacturing time and to cut down the manufacturing cost by separating the block at the same time in molding the block and then curing the block and to prevent separation or damage of a natural stone texture layer during separation of the block from a mold. A method for manufacturing a concrete block(100) with texture of the natural stone comprises the steps of: forming a natural stone texture layer(110) by applying first mortar on the upside of the coating material of a natural stone treating tool formed by fixing a thin film-type coating material(74) with flexibility, on a frame(72), wherein the first mortar is produced by mixing main material selected from fine sand and fine silica, cement, and a coloring matter with the water; forming a concrete layer(120) by installing the natural stone treating tool having the natural stone texture layer formed by a first mortar process, in a mold(90) having a natural stone expressing recessed groove, and then pouring second mortar onto the upper side of the natural stone texture layer, wherein the second mortar is produced by mixing sand, pebbles, and cement with the water; molding the second mortar in a predetermined shape by equally compacting the second mortar; removing the mold to separate the completely molded block from the mold; and finishing the block having the natural stone texture layer on the outside of the concrete layer by curing the block separated from the mold.

Description

Manufacturing method of concrete block with natural stone texture {MANUFACTURING METHOD OF CONCRETE BLOCK WITH FIELDSTONE TEXTURE}

1 is a process chart showing a conventional concrete block manufacturing method,

2 is a view for explaining a conventional concrete block manufacturing method,

3 is a process chart showing a method of manufacturing a concrete block having a natural stone texture according to an embodiment of the present invention;

4 is a view for explaining the primary mortar process in the method of manufacturing a concrete block having a natural stone texture according to an embodiment of the present invention,

5 is a view for explaining a manufacturing method of a concrete block having a natural stone texture according to an embodiment of the present invention;

6 is a process chart showing a method of manufacturing a concrete block having a natural stone texture according to another embodiment of the present invention;

7 is a view for explaining a method of manufacturing a concrete block having a natural stone texture according to another embodiment of the present invention.

Explanation of symbols on the main parts of the drawings

41: 1 mortar process, 42: second mortar process,

43: molding process, 44, 54: demolding process,

45, 55: curing step, 51: concrete layer forming step,

52: natural stone mortar process, 53: assembly process,

60: stand, 70: natural stone treatment,

72: frame, 74: coating material,

90: mold, 100: block,

110: natural stone texture layer, 120: concrete layer.

The present invention relates to a method for manufacturing a concrete block having a natural stone texture, and more specifically, in the manufacture of a block to express a natural stone texture using concrete, demolding the molded block on the mold and then performing a curing process. The present invention relates to a method for manufacturing a concrete block having a natural stone texture to prevent damage to the natural stone texture layer during demolding of the block.

In order to replace the general concrete blocks, various types of concrete blocks representing natural stone images have been proposed. However, the concrete block for expressing the natural stone image as described above is simply formed so that the shape and shape of the surface is the same as the natural stone, it is provided by having a concrete texture, there is a problem that is not environmentally friendly, the appearance is not beautiful.

In order to improve this point, a concrete block having a natural stone texture has been proposed, and according to the prior art, Korean Patent Publication No. 0166990 "Manufacturing Method of Natural Stone Block" arranges natural stone on the bottom of the frame, and the natural stone Sand is formed around a predetermined height to form a sand layer, and a gypsum layer is formed by injecting gypsum in water on the sand layer, and after the gypsum layer is appropriately cured, mortar or concrete is poured on the gypsum layer to harden it. Later, a method of manufacturing natural stone blocks is proposed, in which the mold is separated and a sand layer and a plaster layer are removed. And as a technology proposed in such a form, Republic of Korea Patent Publication No. 0141428 "Manufacturing method and apparatus and a natural stone brick using natural stone", Republic of Korea Patent Publication No. 10-0439519 "Using natural stone And a manufacturing method as shown in "A boundary stone and a manufacturing method thereof" and "Natural stone permeable plate block and a manufacturing method thereof" of Patent No. 10-0500575.

However, this technique is a proposed block to improve the method of constructing the wall surface using natural stone, so that natural stone is not applied to the concrete block alone, so the natural stone block is manufactured. In order to prepare a natural stone, there is a problem that the mass production is difficult and the productivity is lowered, as well as the manufacturing cost increases and harms the natural environment.

Accordingly, a technology for expressing the texture of natural stone without using natural stone has been devised. Such a prior art is disclosed in Korean Patent Laid-Open No. 1997-0025876. As shown in "Block manufactured by", a product in which a high tension film expressing natural stone texture or color is attached to a block using an adhesive has been proposed, but the block formed as described above has a problem in that productability is degraded due to detachment of the high tension film. There is this.

And as shown in the "molding method of the decorative block" of the Republic of Korea Patent Publication No. 10-0362356, cement mortar with a rubber mold formed by using a clay in the bottom frame and the side frame to the left and right sides When the block is formed and the side frame is removed while the block is cured, the decorative block is completed. This manufacturing method increases production time because the product can be separated from the frame after the block is completely cured. There is a problem in that the productivity is lowered due to the large amount of production and there is a problem that the production cost is increased because a large amount of mold and curing room for curing is provided.

1 and 2 are views for explaining the "molding method of the decorative block" of the Republic of Korea Patent Publication No. 10-0362356 in detail. 1 and 2, the first mortar process 31 for expressing the natural stone texture in the mold 20 and the second mortar process for maintaining the overall shape after the first mortar process 31 is completed ( 32), a molding step 33 for compacting and compacting through pressing and vibration after the second mortar step 32 is completed, and a curing step for drying and hardening after the molding step 33 is finished. ), And after the curing process 34 is finished, the mold 20 is removed to form a complete block.

In the primary mortar process 35, the release oil is applied to the surface of the mold 20, and then the primary mortar 12 obtained by mixing fine sand, cement, and pigment with water is sprayed or applied with a brush. By expressing the natural stone texture, and after the first mortar process 31 is completed as described above, the secondary mortar (12) in which the general sand, gravel and cement mixed with water is filled in the mold 20, the secondary After the filling of the mortar 12 is completed, the secondary mortar 12 filled is molded by using a press to apply vibration and pressure evenly, and after the molding is completed, the mold 20 is placed in a curing chamber. After injection and curing, the mold 20 is demolded to separate the block 10 formed by the primary and secondary mortars 14 and 12.

However, in the separation process as described above, the primary mortar 14 is not naturally separated, and is attached to the mold 20 due to high viscosity. By treating the defects that the whole cannot be used, the proportion of the finished product is lowered, which causes a decrease in the overall productivity or quality.

In addition, since the mold 20 must be demolded after curing, the mold 20 must always be put together in the curing chamber because of the viscosity of the primary mortar 14 constituting the natural stone in the completed molding state. As a result of the (20) requirement, there are many problems such as unnecessary cost burden and rising production cost, which weakens external competitiveness.

Therefore, the present invention is to improve the problems of the prior art by demolding the molded block on the mold so that the natural stone texture is represented by the curing process to produce a concrete block having a natural stone texture to improve the productivity and reduce the production cost It is an object to provide a method.

Another object of the present invention is to prevent the damage of the natural stone texture layer during the demoulding process of the block molded on the mold to express the natural stone texture, thereby reducing the failure rate and manufacturing a concrete block having a natural stone texture capable of producing high quality blocks The purpose is to provide a method.

According to a feature of the present invention for achieving the above object, the present invention is a method for manufacturing a block having a natural stone texture, the film formed by fixing a thin film-like coating material having elasticity on a frame formed in a constant shape A primary mortar process of forming a natural stone texture layer by applying a primary mortar in which cement and a pigment are mixed with water to a main material selected from fine sand and fine silica sand on an upper surface of the coating material of the natural stone treatment tool; The natural stone treatment tool in which the natural stone texture layer is formed by the primary mortar process is installed in the mold in which the natural stone expression groove is formed, and the secondary mortar in which sand, gravel and cement are mixed with water is filled to the upper side of the natural stone texture layer. A secondary mortar process of forming a layer; A molding process of molding the secondary mortar injected by the secondary mortar process to have a predetermined shape by uniformly compacting the secondary mortar; A demolding step of removing the mold so that the completed block is separated from the mold by the molding step; Curing the block separated from the mold by the demolding process is characterized in that it comprises a curing process for completing the block formed with a natural stone texture layer on the outer surface of the concrete layer.

In the method of manufacturing a concrete block having a natural stone texture of the present invention, the coating material remaining on the block separated by the demolding process is removed immediately after the demolding process or selectively in the state in which the curing process is in progress or the curing is completed. Can be removed.

In such a method of manufacturing a concrete block having a natural stone texture of the present invention, the release oil may be applied to facilitate the separation process of the coating material on the inner surface of the mold in which the natural stone processing tool is installed.

According to a feature of the present invention for achieving the above object, the present invention is a method for producing a block formed with a natural stone texture layer having a natural stone texture on the outer surface of the concrete layer, sand, gravel in the mold having a certain shape And a concrete layer forming process of filling and curing mortar mixed with cement to form concrete layers. Apply mortar mixed with water and cement to the main material selected from fine sand and fine silica sand on the top surface of the natural stone treatment tool formed by fixing a thin film-like coating material having elasticity on a frame formed in a constant shape. Natural stone layer mortar process to form a natural stone texture layer; An assembly process of inserting the concrete layer formed by the concrete layer forming process into the natural stone texture layer in a state in which the natural stone processing tool in which the natural stone texture layer is formed by the natural stone layer mortar process is installed on the mold having the natural stone expressing groove. and; A demoulding step of removing the mold such that the block having the natural stone material layer attached to the outside of the concrete layer is separated from the mold by the assembling process; It characterized in that it comprises a curing step of curing the natural stone layer of the block separated from the mold by the demolding process to solidly cure on the outside of the concrete layer to complete the block.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to FIGS. 3 to 7. Meanwhile, the drawings and detailed descriptions of the construction, operations and effects thereof, which can be easily understood from the general method of manufacturing a general block and various equipment, apparatus, materials required and related technologies for the same, will be briefly or omitted, and related to the present invention. The parts are shown centered.

Figure 3 is a process chart showing a method of manufacturing a concrete block having a natural stone texture according to an embodiment of the present invention, Figure 4 is a primary in the method of manufacturing a concrete block having a natural stone texture according to an embodiment of the present invention Figure for explaining the mortar process, Figure 5 is a view for explaining a manufacturing method of a concrete block having a natural stone texture according to an embodiment of the present invention.

Method of manufacturing a concrete block having a natural stone texture according to an embodiment of the present invention is the primary mortar process 41, the secondary mortar process 42, the molding process 43, as shown in FIG. The demolding process 44 and the curing process 45 are performed sequentially so that the block 100 having the natural stone texture layer 110 having a natural stone texture on the outer surface of the concrete layer 120 is manufactured.

The primary mortar process 41 is a natural stone material layer on the upper surface of the coating material 74 of the natural stone processing sphere 70 formed by fixing the coating material 74 having elasticity on the frame 72 formed in a predetermined shape. A process of applying primary mortar to form 110, as shown in FIG. 4, first forms a frame 72 using a member having a substantially rectangular plate shape, and then wraps it on the frame 72 as a wrap. The natural stone treatment tool 70 formed by fixing the thin and elastic film-like coating material 74 is placed on the upper surface of the pedestal 60 and is fine on the top surface of the coating agent 74 of the natural stone treatment tool 70. A natural mortar layer 110 is formed by applying a primary mortar in which cement and a pigment are mixed with water to a selected material from sand and fine silica sand to a predetermined thickness. In addition, the support member 60 may have a structure in which grooves in which the frame 72 is inserted at both sides of the plate member are formed, but are not limited thereto, and may be configured in various shapes according to the shape of the natural stone treatment tool 70.

Meanwhile, in the present invention, fine sand and fine silica sand refer to sand and silica sand having a particle diameter of 0.3 mm to 1 mm. In this case, when using fine silica sand, it is possible to use a color given as needed, there is an advantage that can maintain the productability by maintaining the color of the silica sand itself even if the surface is damaged due to wear after construction of the product.

As shown in FIG. 5, the secondary mortar process 42 separates the natural stone treatment tool 70 in which the natural stone texture layer 110 is formed by the primary mortar process 41 from the pedestal 60 and then molds ( 90 is inserted so that the coating material 74 is seated on the natural stone expressing groove 92 formed in the recess 90 on the mold 90. And a natural stone texture layer applied to the coating material 74 by filling the secondary mortar mixed with water, sand, gravel and cement on the upper surface of the coating material 74 seated on the inner surface of the mold 90 ( In the process of forming the concrete layer 120 on the upper side of the 110, on the inner surface of the mold 90, the natural stone treatment tool 70 in the state in which the release oil is applied to facilitate the separation process of the coating material in a later process It will be inserted and installed.

The molding step 43 is a step of molding the secondary mortar introduced by the secondary mortar step 42 to have a predetermined shape by uniformly compacting. The primary mortar step 41 is performed by a mechanism such as a press or a vibrator. And the natural stone texture layer 110 and the concrete layer 120, which are filled through the second mortar process 42, are applied to the concrete layer 120 to be compacted to increase the density by increasing vibration and pressing force. By forming the natural stone texture layer 110 of the desired shape by being accurately inserted into the natural stone expressing groove 92 formed at this time, the coating material 74 of the natural stone processing tool 70 is torn because it is a thin material having elasticity Relaxing without being built or damaged is seated on the natural stone expression groove (92).

The demolding process 44 is a process of removing a mold such that the block 100 completed by the molding process 43 is separated from the mold 90. When the mold 90 is separated from the block 100, Since the coating material 74 will be in close contact with the inner surface of the mold 90, the natural stone material layer 110 is prevented from being dropped or damaged during the separation process, and a release oil is applied onto the inner surface of the mold 90. It is separated more smoothly.

 The curing process 45 moves the block 100 separated from the mold 90 by the demolding process 44 to the curing chamber for curing for a predetermined time, thereby forming a natural stone layer 110 on the outer surface of the concrete layer 120. ) Is completed block 100 is formed.

In addition, the coating material 74 remaining on the outer surface of the natural stone material layer 110 in the state in which the block 100 is separated from the mold 90 may be separated and removed at any time in the state in which the demolding process 44 is completed. It may be removed immediately after the demolding process 44 or selectively removed in a state in which the curing process 45 is in progress or in a state where curing is completed.

Figure 6 is a process chart showing a method of manufacturing a concrete block having a natural stone texture according to another embodiment of the present invention, Figure 7 illustrates a method of manufacturing a concrete block having a natural stone texture according to another embodiment of the present invention It is for the drawing.

According to another embodiment of the present invention, a method of manufacturing a concrete block having a natural stone texture includes a concrete layer forming process 51, a natural stone layer mortar process 52, an assembling process 53, The block 100 having the natural stone texture layer 110 having a natural stone texture is formed on the outer surface of the concrete layer 120 by sequentially performing the demolding process 54 and the curing process 55.

The concrete layer forming step 51 is a process of filling and curing the mortar mixed with water, sand, gravel and cement in a mold having a predetermined shape to form a concrete layer 120, the concrete layer thus formed A mold in which the concrete layer is formed so that the 120 is easily inserted onto the mold 90 of the assembling process 53 to be described later and integrally formed with the natural texture layer 110 is used in the assembling process 53. It is preferable that the internal shape of the mold 90 is the same or similar.

The natural stone layer mortar process 52 is a film of the natural stone processing tool 70 formed by fixing a thin film-like coating material 74 having elasticity on the frame 72 formed in a predetermined shape as shown in FIG. On the upper surface of the ash 74, a natural mortar layer 110 is formed by applying mortar mixed with cement and water to a main material selected from fine sand and fine silica sand.

As shown in FIG. 7, the assembling process 53 includes a natural stone processing tool 70 in which a natural stone texture layer 110 is formed by the natural stone layer mortar process 52. 90, the outer surface of the concrete layer 120 formed by the concrete layer forming process 51 in the state of being installed on the natural stone material layer 110 is inserted into the assembly process.

As shown in FIG. 7, the demolding process 54 separates the block 100 having the natural stone material layer 110 attached to the outside of the concrete layer 120 by the assembling process 53 from the mold 90. As a process of removing the mold, when the mold 90 is separated from the block 100, the coating material 74 is separated in a state of being in close contact with the inner surface of the mold 90, so that the natural stone texture layer 110 is separated. Since it is prevented from being dropped or damaged in the process and the release oil is applied on the inner surface of the mold 90, the separation is more smoothly performed.

 The curing process 55 moves the block 100 separated from the mold 90 to the curing chamber by the demolding process 54 so that the natural stone texture layer 110 is firmly cured outside the concrete layer 120. It is a process of completing the block 100.

In addition, when the block 100 is separated from the mold 90 in the demolding process 54, the coating material 74 remaining on the outer surface of the natural stone material layer 110 of the block 100 is separated. The separation process of ash can be removed at any time in the state where the demolding process 54 is completed, and can be removed immediately after the demolding process 54 or selectively removed in the state in which the curing process 55 is in progress or in the curing state. have.

On the other hand, the concrete layer forming process 51 is a non-sequential process is carried out before the assembling process 53 is carried out to prepare the concrete layer 120 of the block 100 in advance to quickly as necessary It is possible to manufacture a concrete block 100 having a natural stone texture, that is, the work time is shortened because the concrete layer 120 is prepared by inserting the prepared concrete layer 120 without placing mortar in the assembly process 53. In addition, the demolding process 54 may also be easily performed, while curing only the natural stone material layer 110 in the curing process 55 may significantly reduce curing time, thereby rapidly manufacturing a block.

As described above, a method of manufacturing a concrete block having a natural stone texture according to a preferred embodiment of the present invention is shown according to the above description and drawings, but this is only an example and is not limited to the scope of the present invention. It will be apparent to those skilled in the art that various changes and modifications can be made therein.

According to the method of manufacturing a concrete block having a natural stone texture according to the present invention, in the manufacture of a block in which the natural stone texture is expressed, the production time is shortened by carrying out a curing process after demolding the block at the same time as forming the block on a mold, Since the number of molds are unnecessary, the production cost is reduced and productivity is improved to secure external competitiveness.

In addition, since the natural material layer is prevented from being dropped or damaged by the coating material in the process of separating the mold from the block, the defect rate is remarkably reduced and a high quality block can be manufactured as well as the separation process is easily performed. This has the effect of being improved.

Claims (5)

In the method of manufacturing a block having a natural stone texture, The natural stone processing tool 70 in a state in which the natural stone processing tool 70 formed by fixing the thin film-like coating material 74 having elasticity on the frame 72 formed in a predetermined shape is seated on the upper surface of the pedestal 60. Primary mortar process 41 to form a natural stone texture layer 110 by applying primary mortar mixed with water and cement to a main material selected from fine sand and fine silica sand on an upper surface of the coating material 74 ; By separating the natural stone processing tool 70 formed with the natural stone texture layer 110 by the primary mortar process 41 from the pedestal 60, the natural stone expressing groove 92 is inserted into the recessed recess 90 The coating material 74 is installed so as to be seated on the natural stone expression groove 92 formed on the mold, and sand, gravel, and gravel on the upper surface of the coating material 74 seated on the inner surface of the mold 90. A secondary mortar process 42 for filling the secondary mortar in which cement is mixed with water to form a concrete layer 120 on the natural stone material layer 110 applied to the coating material 74; The natural stone material layer is made by applying vibration and a pressing force to the natural stone material layer 110 and the concrete layer 120 filled by the primary mortar process 41 and the secondary mortar process 42 by a mechanism device. A molding step 43 of forming a natural stone texture layer 110 having a predetermined shape by allowing the 110 to be inserted into the natural stone expression groove 92 formed in the mold 90; A demolding process 44 for removing the mold 90 so that the block formed by the molding process 43 is separated from the mold 90 while the coating material 74 is in close contact with the inner surface of the mold 90. And; The curing process 45 is completed by curing the block separated from the mold 90 by the demolding process 44 to complete the block 100 on which the natural stone texture layer 110 is formed on the outer surface of the concrete layer 120. under, The coating material 74 remaining on the block separated by the demolding process 44 is removed immediately after the demolding process 44 in any one of a state in which the curing process 45 is in progress and a state in which the curing is completed. Method of manufacturing a concrete block having a natural stone texture. delete delete delete delete

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