JP4290241B2 - Manufacturing method of external block - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a manufacturing method of a building block.
[0002]
[Prior art]
External blocks such as fences, flowerbed enclosures and gateposts are often made of concrete or mortar.
Conventionally, a method for manufacturing a building block having a pattern on the outer surface of the block is generally a method in which concrete or mortar is poured into a mold having a pattern on the inner surface. A conventional method is shown in FIG.
An admixture 2 obtained by kneading cement and water, which are representative of hydraulic materials, is poured into a mold 1 made of an organic foam material and cured. Next, the formwork 1 is removed to form the exterior block. The cement is mixed with sand, pearlite, silica sand or the like as necessary.
[0003]
[Problems to be solved by the invention]
However, since the mixture 2 must be prepared before use, there is a problem that material loss increases. For example, admixtures such as cement, water and silica sand have a short pot life of only a few hours and must be used immediately after compounding. I could not.
[0004]
Moreover, when cement hardens, pressure is applied to the mold 1 and the mold 1 is easily deformed. Therefore, the appearance formed on the inner surface of the mold 1 is different from the appearance of the obtained exterior block. There is a problem that it ends up.
[0005]
The present invention has been made to cope with such a problem, and can reduce material loss, is easy to construct, has an excellent appearance of the obtained exterior block, and can be reduced in weight. It aims at providing the manufacturing method of a block.
[0006]
[Means for Solving the Problems]
A method for manufacturing an external block according to the present invention is a method for manufacturing an external block formed using a mold made of an organic foam material, and a hydraulic substance has a thickness of 50 to 200 mm in the mold. And the step of spraying the water-based material onto the layer of the hydraulic material are alternately repeated.
[0007]
Further, the organic foam material is a polystyrene foam.
[0008]
By using an organic foam material as the mold, the mold is excellent in heat insulation, so that the curing reaction of the hydraulic substance in the mold becomes a reaction in the autoclave. For this reason, hardening reaction is accelerated | stimulated. Moreover, the external appearance of the external block obtained has a natural texture.
Furthermore, it is sufficient to use foamed polystyrene as a mold, and it is only necessary to prepare a hydraulic substance and an aqueous substance as raw materials.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
The manufacturing method of the exterior block of the present invention will be described with reference to FIG. FIG. 1A, FIG. 1B, and FIG. 1C are cross-sectional views of the process of manufacturing the exterior block.
A mold 1 made of an organic foam material is prepared. This mold has a relief pattern formed on its inner surface.
First, as shown in FIG. 1 (a), the hydraulic substance 3 is filled in the mold 1 in layers. As a filling method, the hydraulic substance 3 is weighed so as to have a predetermined thickness and filled so that the surface is horizontal. By leveling the surface, the sprayed water-based material uniformly penetrates to the surface. The thickness of the layer varies depending on the hydraulic material 3, but in the case of cement, it is preferably 50 to 200 mm. If the thickness is less than 50 mm, man-hours will be required if the height of the exterior block is high, and if it exceeds 200 mm, the hardening reaction of the cement will not be sufficient.
[0010]
Next, the aqueous material 4 is sprayed. The spray amount may be an amount that can sufficiently penetrate into the layer of the hydraulic substance 3 and harden the hydraulic substance 3. For example, when the weight of the hydraulic material 3 is 10 kg , the amount of the water-based material 4 is preferably such that the amount of water constituting the water-based material 4 is in the range of 5 to 10 kg . Within this range, the exterior block 5 having excellent strength after curing can be obtained. Further, the spraying method may be any method as long as the aqueous material 4 can penetrate into the layer of the hydraulic material 3.
[0011]
Next, as shown in FIG.1 (b), the filling process of the hydraulic substance 3 and the spraying process of the water-system substance 4 are performed again. The filling process of the hydraulic substance 3 and the spraying process of the water-based substance 4 are repeated in order until a predetermined height is reached.
[0012]
Finally, after performing the spraying step, predetermined curing is performed to obtain the exterior block 5 (FIG. 1C). Since the exterior block 5 is obtained by repeating such steps, the hydraulic substance 3 and the aqueous substance 4 may be prepared in the present invention. Therefore, the construction is extremely simple and no material loss occurs.
In addition, in the case of an exterior block used in a field where strength is particularly required, a reinforcing material such as a reinforcing bar is previously provided in the mold, and then the exterior block is formed by forming the exterior block. It can also be used as a block.
[0013]
The organic foam according to the present invention is preferably a synthetic resin foam, and is preferably a synthetic resin foam having a relief pattern on the inner surface.
The synthetic resin foam suitable for the present invention is molded using a gas generated during heating by adding a foaming agent to the synthetic resin, or molded using a gas generated during reaction of the reactive resin. Obtained by foam molding.
Types of resins such as thermoplastic resins and thermosetting resins, foaming means such as decomposable foaming agents and evaporative foaming agents, molding methods such as injection foaming and extrusion foaming, low foaming with a foaming ratio of 3 to 4 times or less The foaming ratio such as high foaming of 10 to 70 times, the cell structure such as independent or open cells, and the like can be variously selected according to the type and application of the external block. For example, in the case of an outer wall block or the like, a closed cell structure is preferable.
As the synthetic resin foam, a foamed polyolefin such as foamed polystyrene, foamed urethane, foamed polyethylene, and foamed polypropylene is preferable, and a foamed polystyrene having an expansion ratio of about 10 to 50 times is particularly suitable for reducing the strength and weight. In particular, when the strength of the formwork is required, an expansion ratio of 15 to 30 times is preferable.
[0014]
The hydraulic substance according to the present invention can be used as long as it is an inorganic compound that cures by reacting with water.
Specifically, cement, ettringite, hemihydrate gypsum which is a hemihydrate of calcium sulfate that becomes a dihydrate and hardens by adding an appropriate amount of water can be exemplified.
[0015]
Cement is a) hydraulic cement that is hardened by reacting with water to form a poorly soluble hydrate such as Portland cement and alumina cement, and b) blast furnace cement, high sulfate slag cement, lime slag cement. In the case of a combination of two or more types, such as latent hydraulic cements mainly composed of substances that require an appropriate stimulant to cause a reaction, (c) silica cement, fly ash cement, etc. Any mixed sentin that reacts and cures can be used. Among these, hydraulic cement is suitable as a cement for forming the hydraulic film according to the present invention. When it is a hydraulic cement, it can be sufficiently hardened with water supplied from an aqueous emulsion. In addition, as Portland cement, even if it is early strong Portland cement and super early strong Portland cement, it can be used.
[0016]
Ettringite (3CaO.Al ₂ O ₃ .3CaSO ₄ .32H ₂ O) is a hydraulic substance that expands and hardens as an enamel when kneaded with water. Ettringite may be naturally occurring or artificially synthesized.
[0017]
In addition, other materials can be blended with these hydraulic substances to the extent that they do not inhibit the hydraulic reaction. For example, lightweight aggregates such as obsidian perlite, pearlite perlite, calcined vermiculite, shirasu balloon, river sand, quartz sand, crushed gravel, and calcium carbonate carbonate to promote weight reduction, water glass to improve strength, and cracks In order to prevent this, one kind or two or more kinds of fibers such as alkali-resistant glass fiber and ceramic fiber can be contained.
[0018]
In the present invention, the water-based substance refers to a substance containing water as a main component capable of curing the above-described hydraulic substance. A substance containing at least 60% by weight of water. For example, water alone, water containing a surfactant or an organic solvent, or an aqueous emulsion of a polymer substance can be used. A water-based emulsion of a polymer substance can improve the binding property of a hydraulic substance, and a surfactant or an organic solvent can improve penetration into the hydraulic substance.
Water-based emulsions include acrylic resin emulsions such as pure acrylic emulsions copolymerized with acrylic acid esters and methacrylic acid esters or styrene acrylic emulsions with styrene, vinyl acetate resin emulsions, vinyl acetate / veova copolymer resin emulsions. And styrene-butadiene resin emulsions. Further, it may contain a protective colloid, a surfactant, a pigment, a pigment wetting agent, a viscosity modifier, a freeze / thaw stabilizer, an antifoaming agent, an antifungal agent and the like.
Surfactants include cationic surfactants, anionic surfactants, amphoteric surfactants, nonionic surfactants, etc., and organic solvents include hydrophilic organic solvents such as alcohols and ketones. Can be mentioned.
[0019]
Since the manufacturing method of the present invention is performed using the above-described steps and materials, it has excellent characteristics as described below.
1) Since a polystyrene foam or the like is used as a mold, and since a hydraulic substance and an aqueous substance need only be prepared as raw materials, the construction is extremely simple.
2) Since water-based substances and hydraulic substances can be individually collected, there is little material loss at the time of manufacture, and a building block can be formed at low cost.
3) Since the curing reaction proceeds in the heat-insulating formwork, the curing is fast and the exterior block can be formed quickly. For this reason, it can be constructed in a short time on site.
4) An exterior block having a natural texture appearance is obtained.
5) The external building block obtained is about 1/2 that of cement mortar and can be reduced in weight.
[0020]
The manufacturing method of the present invention can be used for manufacturing awnings, flowerbed enclosures, gate pillars, etc., because the exterior block can be formed by a simple method.
[0021]
【Example】
Example 1
The circumference of a flower bed measuring 5 m long and 2 m wide was surrounded by a building block according to the method of the present invention.
A formwork with a thickness of 100 mm, a width of 600 mm, and a height of 900 mm was provided around the flower bed using expanded polystyrene. This was filled with Portland cement to a thickness of 10 cm. Next, 10 kg of water was sprayed uniformly. After that, before Portland cement began to dry and harden, Portland cement was again filled to a thickness of 10 cm and 10 kg of water was sprayed uniformly. This operation was repeated until the height was 90 cm. Cured for 24 hours, removed the formwork, and got a flowerbed enclosure.
The appearance of the resulting enclosure had a natural stone texture.
[0022]
【The invention's effect】
Since the present invention alternately repeats the step of filling a hydraulic material in a layer form in a mold made of an organic foam material and the step of spraying a water-based material onto the layer of the hydraulic material, the construction is extremely simple, The external block can be formed at low cost with little material loss. Moreover, the external appearance block obtained has a natural texture.
[0023]
In addition, since polystyrene foam is used as the organic foaming material, heat insulation and workability are excellent, and the curing reaction proceeds in the heat insulating mold, so that the curing is fast and the exterior block can be formed quickly. For this reason, it can be constructed in a short time on site.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a process of manufacturing a building block.
FIG. 2 is a diagram showing a conventional method.
[Explanation of symbols]
1 Form 2 Admixture 3 Hydraulic substance 4 Water-based substance 5 Exterior block

Claims (2)

A method for manufacturing an exterior block molded using a mold made of an organic foam material,
An external block characterized by alternately repeating a step of filling a hydraulic substance into a layer having a thickness of 50 to 200 mm in the mold and a step of spraying a water-based substance onto the layer of the hydraulic substance. Production method.   The method for manufacturing an exterior block according to claim 1, wherein the organic foam material is a polystyrene foam.

Images