JPH0342205A - Method for molding solid product of hydraulic material - Google Patents

Abstract

PURPOSE:To simply mold a solid product whose decorative surface not abraded by the friction with a tire or shoes is exposed by filling the molding hole of a retaining mold with a hydraulic material to form a surface layer and filling the hole formed by removing a die with a different hydraulic material. CONSTITUTION:A retaining mold 1 is placed on a bottom plate 2 and a die 4 having a cross-sectional shape corresponding to decoration is placed on the bottom plate 2 closing the under surface of a molding hole 3. The molding hole 3 is filled with a dry hydraulic material D1 to be formed into a surface layer 5 so that the thickness of said material D1 is made same to or slightly thinner than that of the die 4. The hydraulic material is a mixture of fine aggregate such as a cement powder or sand and coarse aggregate such as a gravel or a mixture of fine aggregates such as the cement powder, sand or the like. After the filling with the material D1, a proper amount of water is sprinkled on the material D1 and, after the hydraulic material is solidified, the die is removed and the formed hole is filled with a dry hydraulic material D2 different from the surface layer 5 to be formed into a decorative layer 6 and, after the surface layer 5 and the decorative layer 6 are sufficiently solidified, a product is obtained by demolding.

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention is applicable to paving blocks, construction blocks, large concrete panels, tiles, nameplates, RC structures, etc. in which a decorative layer in the form of candy is exposed on the surface. This invention relates to a molding method for molding a solid product using a hydraulic material.

<Prior Art> The present applicant proposed a method for forming such a solid product using concrete in Japanese Patent Application No. 165069/1983.

This prior proposal covers the bottom plate placed under a formwork with open holes at the top and bottom with a water-absorbent mat, places the formwork on top of this mat, and places the formwork inside the formwork's holes. Decorative materials such as gravel, tiles, stones, etc. are scattered on the mat, and then one or more types of dry concrete, dry mortar, or cement are filled into the mold hole to the required thickness to form the surface layer, and then the surface layer is humidified. Either by solidifying it, or by filling the surface layer with wet concrete that will serve as a supporting layer to a required layer thickness and solidifying it together with the surface layer, the product is made by demolding.

(Problems to be Solved by the Invention) The solid product of the previous proposal has a pattern formed by a decorative material bonded to the surface of the surface layer by assimilation of the surface layer. If they are laid out face up on the pavement, over a long period of time the decorative material that makes up the pattern will peel off from the surface due to friction from the tires of cars passing over it and the shoes of passersby.

<Means for Solving the Problems> Therefore, the present invention overcomes the above-mentioned prior proposal by expressing decorations such as patterns and letters exposed on the surface of the surface layer with a decorative layer that is solidified integrally with the surface layer. The problem has been solved, and the molding method according to claim 1 is such that a cutting die is placed on a bottom plate laid under a mold having mold holes that are open at the top and bottom, and the cutting die is placed on the bottom plate as is or on the bottom plate. Sprinkle the required amount of water on the mold, fill the mold hole of the formwork with one or more dry water-curing materials to the required thickness to form a surface layer, and sprinkle the required amount of water on top of the surface layer. Then, the cutting die is removed and the remains of the cutting die are filled with one or more types of dry water-curing material different from the surface layer to form a decorative layer. The surface layer and the decorative layer are solidified as one by humidifying the decorative layer.

In addition, the molding method according to claim 2 includes placing a cutting mold on a bottom plate placed under a mold having mold holes that are open at the top and bottom, and either leaving it as it is or pouring a required amount of water on the bottom plate. Sprinkle and fill the mold holes of the formwork with one or more types of dry water-curing materials to a required layer thickness to form a surface layer, and spray the required amount of water over the surface layer to water-cure the surface layer. Caking the material, then removing the cutting die and filling the remains of the cutting die with one or more types of dry water-curing material different from the surface layer to form a decorative layer;
Next, a dry or wet hydraulic material serving as a support layer is filled into the mold cavity to a required layer thickness, the support layer is crushed if necessary, and the surface layer, decorative layer, and support layer are solidified as one body. shall be.

(Example) In the illustrated example, l indicates a formwork having a mold hole that is open at the top and bottom, 2 indicates a bottom plate placed under the formwork and closing the bottom surface of the mold hole 3, the formwork is made of wood, An outer frame 1a, which is made of a suitable material such as a metal plate or plastic, and which constitutes a peripheral wall in order to mold a plurality of blocks at the same time in this embodiment;
It consists of a partition frame 1b that divides the interior surrounded by a plurality of mold holes 3 into a plurality of mold holes 3. The bottom plate 2 is made of a wooden plate, a metal plate, a concrete plate, a plastic plate, etc., and is the same size as or slightly larger than the external size of the outer frame 1a.

To perform molding, place the mold l on the bottom plate 2 and fill the mold hole 3.
One or more cutting dies 4 having a cross-sectional shape corresponding to the decoration to be expressed, such as pattern letters, figures, symbols, etc., are placed in a predetermined arrangement on the bottom plate 2 that closes the lower surface of the holder. It may be made of a suitable material such as plastic.Then, the inside of the mold cavity 3 is filled with one or more dry water-curing materials D1 to form the surface layer 5 (Fig. 2).The layer thickness of this water-curing material is as follows: , the cutting die 4 is removed in consideration of removing the cutting die 4 after that.
The same thickness as or a little thinner than that, about 5 to 50 mr.
It should be about a. This dry water-curing material is a mixture of cement powder, fine aggregate such as sand, and coarse aggregate such as gravel (dry concrete) that hardens into concrete by adding an appropriate amount of water, and It is a mixture of cement powder, sand, and other fine aggregates (dry mortar) that solidifies into mortar upon addition.

After filling the dry water-curing material to form the surface layer 5 in this way, sprinkle an appropriate amount of water on top of it, so that the filled water-curing material absorbs water, and even if the cutting die 4 is removed, there will be no trace of the cutting die 4. Once it has solidified to the extent that it does not crumble, the cutting die is removed, and the remaining area is filled with one or more dry, water-cured materials different in type from the surface layer 5, which will form the decorative layer 6.
(FIG. 3), if necessary, this material D2 may be pressurized from above.

The dry water-cured material D2 to be used as the decorative layer 6 is applied to the surface layer 5.
"Different type from the water-cured material D1" means that a pigment different from that of the surface layer 5, or sparkling slag powder, powder, etc. is mixed into dry concrete or dry immolcle. The dry water-curing material D2 filled in the remains of this cutting die is the filling material D1 that becomes the surface layer around it.
It absorbs the moisture it contains and solidifies, but if the moisture is insufficient, water is sprinkled on it to thicken it and promote solidification.

In this way, when the surface layer 5 and the decorative layer 6 are sufficiently solidified inside the mold cavity and the shape does not collapse even when the mold is removed, the mold is removed to obtain the product A shown in FIG.

In this product A, the decoration by the decorative layer 6 is exposed on both the front and back surfaces of the first surface layer 5. Therefore, a monotonous concrete surface can be decorated by arranging or placing them with either side facing up on the fresh concrete pouring surface.

Moreover, the cutting die 4 can be made into a small size with a person's name and name, and can be used as a nameplate.

Further, after filling the area 4' where the cutting die was removed with the water-curing material D8 for the decorative layer 6, dry or wet water-curing material Ds for the support layer 7 is applied on the surface layer 5 and the decorative layer 6. The dry hydraulic material for this support layer, which is filled to the required layer thickness (FIG. 5), is dry concrete or dry mortar similar to the surface layer 5. In addition, wet water-curing materials include fresh concrete and mortar fluids. When the dry water-curing material D3 is filled, water is sprayed to humidify it to promote solidification.If necessary,
After filling the material opening, pressure may be applied from above.

Also, a dry water-curing material for the decorative layer 6.

After filling the die mark 4 with the wet water-curing material for the support layer 7, when filling the dry water-curing material for the decorative layer, use the wet water-curing material for the support layer. There is no need to humidify as the material absorbs moisture and solidifies.

In this way, the surface layer 5, the decorative layer 6, and the support layer 7 are solidified and integrated, and when the shape 6 does not collapse when removed from the mold, the product B is obtained as shown in FIG. Since the support layer 7 of this product B is integrally bonded, the decoration is exposed on the surface of the surface layer 5.

In the molding method according to the present invention, if the upper surface of the bottom plate 4 that closes the lower surface of the mold cavity 3 is placed on an uneven and rough surface, the caking surface layer may slip when the mold is removed, causing deformation, or the support layer This prevents the surface layer and decorative layer from slipping and deforming when filling the core layer or pressurizing the core layer from above. In addition, irregularities opposite to the rough surfaces are formed on the lower surfaces of the decorative layer 6 and the surface layer 4, which makes the surface of the surface layer 5 and the surface of the decorative layer 6 exposed there three-dimensional, further improving the decorative effect. do.

In addition, by covering the upper surface of the bottom plate 2 in advance with a water-permeable material 8 such as a water-permeable plastic net, and placing the form l on top of it, water seeps out from the surface layer, decorative layer, and support layer filled in the mold hole 3. Excess moisture can be drained out from around the top of the bottom plate through the net.

Furthermore, the upper surface of the bottom plate 2 is covered with a water-absorbing material 9 such as a non-woven fabric, a sponge with open cells, a valve, paper, cotton, glass wool, etc., and the formwork 1 is placed on top of the water-absorbing material 9.
This water-absorbing material can absorb excess water exuding from the surface layer, decorative layer, and support layer filled inside, and water can be sprayed before filling the mold cavity with the dry water-curing material D1 for the surface layer. It can also be included in the water-absorbing material of the lever, and the moisture exuded from the water-absorbing material can initiate solidification of the dry water-curing material for the surface layer or decorative layer. The most preferable water-absorbing material is a non-woven fabric made of synthetic fibers such as inexpensive polypropylene, or fabric.By using this material, when removing products A and B from the mold holes of the mold, the product Mold release can be done smoothly.

Note that the water-permeable material 8 and the water-absorbing material 9 may be layered to cover the top surface of the bottom plate. In this case, the water-absorbing material 9 is placed on top as shown in FIG. 1 to prevent mold release during demolding. Preferably, this is done well and any excess moisture contained in the absorbent material is drained out through the permeable material 8 and out around the bottom plate.

Further, among the materials constituting the surface layer 5, the decorative layer 6, and the support layer 7, the cement may be resin or other materials in addition to ordinary cement, and each material may include carbon fiber, glass fiber, metal fiber, synthetic fiber. Furthermore, each of these layers 5, 6.7 may be made water permeable.

If a magnetic material such as iron is used for the cutting die 4, after the surface layer has caked, part or all of the cutting die can be removed at once by magnetic force.
Productivity improves during mass production. In addition, if the cutting die is small, fix it to the bottom of the mesh, place the entire mesh on the bottom plate, fill the dry water-cured material for the surface layer through the mesh, and after it has hardened, pull it out with the mesh and leave the mark. The decorative layer is filled with water-cured material to create detailed decorations. In this case, the cutting die can be made of a light-sensitive material by photolithography or the like, which allows for more complex decorations.

Furthermore, another small cutting die smaller than the cutting die is placed in the place where the cutting die was removed, and a dry water-cured material for the decoration layer is filled between the above mark and the small cutting die, and after it hardens, the small cutting die is placed. The die can be removed and the remaining area filled with another dry, water-cured material of a different color, for example, and this process can be repeated if necessary to create more complex decorations.

In addition, in the illustrated example, a formwork with multiple partitioned mold holes was used in order to mold multiple products at the same time, but when molding a large product such as a large concrete panel, a formwork with open holes at the top and bottom is used. A mold having one large mold hole may be used.

<Effects of the Invention> As is clear from the above, according to the present invention, it is possible to easily mold a solid product in which a decorative layer is exposed on the surface of the surface layer, and which does not have a support layer or has a support layer integrally bonded. I can do it.

The surface layer 5 and decorative layer 6 are filled with dry, water-cured materials, and since water is added to D□ and solidified, it is possible to adjust the amount of water added and make the ratio of water to cement with less water to improve strength. can.

In addition, since the decorative layer 6 is exposed on the surface of the surface layer 5 and forms a decorative pattern, even if it is scraped off by friction with automobile tires, passersby's shoes, etc., it will not disturb the remaining soil generated at the site where the grinding work is being carried out. By using Con, you can save the trouble of disposing of leftover Con without causing pollution, and have the effect of killing two birds with one stone.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention, and FIG. 1 shows a formwork,
A cross-sectional view showing the relationship between the bottom plate and the cutting die, Figure 2 is a cross-sectional view of the surface layer filled with material, and Figure 3 is a cross-sectional view of the area where the cutting die is removed and the decorative layer material is filled. FIG. 4 is a perspective view of a product consisting of a surface layer and a decorative layer, FIG. 5 is a sectional view of the product filled with the material of the support layer, and FIG. 6 is a perspective view of the product provided with the support layer. In the figure, l is the formwork, 2 is its bottom plate, 3 is the mold hole, 4 is the cutting die, 5 is the surface layer, D+ is its dry water-cured material, 6 is the decorative layer, and D□ is its dry water-cured material. Last name material, 7 is support group,
D indicates the dry or wet water-curing material, 8 indicates the breathable material, 9 indicates the water-absorbing material, and A and B indicate the product.

Claims (5)

[Claims] (1) Place the cutting die on the bottom plate to be laid under the formwork with open holes at the top and bottom, and either leave it as it is or sprinkle the required amount of water on the bottom plate and cut the hole in the above formwork. Fill the inside with one or more dry hydraulic materials to the required thickness to form a surface layer,
A required amount of water is sprinkled on the surface layer to caking the water-curable material on the surface layer, and then the cutting die is removed and at least one type of dry water different from that of the surface layer is added to the die mark. A method for molding a solid product using a hydraulic material, characterized by filling a curable material to form a decorative layer, humidifying the decorative layer if necessary, and solidifying the surface layer and the decorative layer as one body. (2) Place the cutting die on the bottom plate to be laid under the formwork with open holes at the top and bottom, and either leave it as it is or sprinkle the required amount of water on the bottom plate and open the hole in the above formwork. Fill the inside with one or more dry hydraulic materials to the required thickness to form a surface layer,
A required amount of water is sprinkled on the surface layer to caking the water-curable material on the surface layer, and then the cutting die is removed and at least one type of dry water different from that of the surface layer is added to the die mark. Fill a curable material to form a decorative layer, humidify the decorative layer if necessary, then fill the mold cavity with a dry or wet water-curable material to serve as a supporting layer to the required layer thickness, and if necessary add the supporting layer. A method for molding a solid product using a water-cured material, characterized in that the surface layer, decorative layer, and support layer are solidified as one body by humidifying the water-cured material. (3) The method for molding a solid product using a hydraulic material according to claim 1 or 2, characterized in that the upper surface of the bottom plate on which the mold is placed is roughened. A method for forming solid products using water-curable materials. (4) In the method for molding a solid product using a hydraulic material according to any one of claims 1 and 2, the upper surface of the bottom plate on which the formwork is placed is covered with a water-permeable material. A method for molding a solid product using a water-curable material. (5) In the method for molding a solid product using a water-curable material according to any one of claims 1 and 2, the upper surface of the bottom plate on which the formwork is placed is covered with a water-absorbing material. A method for molding a solid product using a water-curable material.