JPH07205131A - Female mold for molding concrete product with stereoscopic decorative surface and manufacture thereof - Google Patents

Abstract

PURPOSE:To uniformly accelerate a curing speed of a decorative surface in a female mold for molding a stereoscopic decorative surface of a concrete product even if an uneven difference of the surface of the product is large. CONSTITUTION:A female mold comprises a solidified layer 11 fluid capable of solidifying such as resin, rubber molded by covering a concrete product with a decorative surface of a male mold having the same decorative surface as a stereoscopic decorative surface to be expressed in a predetermined thickness, and a rear mold 21 of FRP or FRG covering the layer in a predetermined thickness.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a female mold for molding a concrete product such as a concrete plate with a three-dimensional decorative surface for decorating a building (house, building), a wall surface of a retaining wall, a floor material, etc., and a method for producing the same. Regarding

[0002]

2. Description of the Related Art The applicant of the present invention has proposed a method for producing a female mold for molding a concrete product as described above in Japanese Patent Publication No. 5-29523 (Japanese Patent Laid-Open No. 3-82503). This conventional example, a male mold having the same decorative surface as the three-dimensional decorative surface to be expressed in the concrete product, and a peripheral frame that is fixed around this male mold and surrounds the periphery of the decorative surface constitutes a mold frame,
Place the above mold with the male decorative surface facing upward or sideways, close the open surface of the peripheral frame with the support plate, and with the male decorative surface, the inner peripheral surface of the peripheral frame, and the lower surface of the support plate. The formed space is filled with a coagulable fluid such as resin or rubber, and after coagulation, the coagulation layer, which is released from the mold together with the support plate, is made into a female mold. Therefore, the support plate 51 integral with the female die 50 is arranged in the forming frame 52, and the forming frame is placed so that the female die is directed sideways or upward as shown in FIG. 8 (when the female die is directed sideways). Closes the open surface of the forming frame with a panel), pour ready-mixed concrete 53 into the space inside the forming frame to fill the space, vibrate to consolidate the concrete, and then perform curing by humidification and heating to cure the concrete. Concrete products are manufactured by accelerating the hardening and shortening the time required for demolding after filling.

[0003]

In this case, the support plate 51 is used.
Since the female mold 50 attached to the plate surface of the female mold 50 has a large heat insulating property, it is heated by steam from the supporting plate side and comes into contact with the decorative surface of the female mold 50 to give a three-dimensional decorative surface. Even if an attempt is made to accelerate the hardening of the surface of the concrete product, the temperature transmitted to the surface portion in contact with the thick portion 50A of the female mold is
The temperature is much lower than the temperature transmitted to the surface portion in contact with the thin portion 50B. That is, the hardening speed of the surface of the concrete product is different between the part in contact with the thick part of the female mold and the part in contact with the thin part. For this reason, even if the surface part in contact with the thin part is sufficiently cured, if the product is removed from the mold when the surface part in contact with the thick part is not yet sufficiently cured, the solid part of the uncured part The unevenness of the pattern will fall off or be lost, resulting in a defective product. Also, if the surface part that is in contact with the thick part is demolded after being sufficiently cured, the manufacturing cycle will take a long time, and
It consumes a lot of energy to obtain steam for heating,
The running cost is very high.

[0004]

Therefore, according to the present invention, the other side of the female die having the same decorative surface as the three-dimensional decorative surface to be expressed on the concrete product is made into the opposite concavo-convex surface to obtain the thickness of the female die. The female mold of claim 1 is a resin molded by covering the male decorative surface having the same decorative surface as the three-dimensional decorative surface to be expressed in the concrete product with a constant thickness. It is characterized in that it serves as a solidified layer of a solidifying fluid of rubber or rubber and a back mold made of FRP or FRG with a constant thickness covering the solidified layer. Further, the female mold of claim 2 is a male mold having the same decorative surface as a three-dimensional decorative surface to be expressed in a concrete product, and is covered with a constant thickness to solidify a resin or rubber solidifying fluid. Layer and a back mold made of FRP or FRG with a certain thickness that covers the solidified layer. A solid mesh material is attached to the surface of the back mold that contacts the solidified layer, and the solidified layer is a mesh of the solid mesh material. And is integrally connected to the back mold through the three-dimensional mesh material. The method for producing a female mold of the present invention is a female mold having the same decorative surface as the three-dimensional decorative surface to be expressed on the concrete product, and the other surface of the female mold is made into an opposite concavo-convex surface, and a female mold having a substantially uniform thickness is formed. The method for producing a female mold according to claim 3, wherein the male mold has the same decorative surface as the three-dimensional decorative surface to be expressed in the concrete product,
A mold is constructed with a peripheral frame that is fixed around the male mold and surrounds the decorative surface, and the mold is placed with the male decorative surface facing upward or sideways, and the male decorative surface Is coated with a plastic material such as clay or gypsum to a substantially constant thickness to form a female prototype, and then FRP or FRG is laminated on the female prototype and the inner peripheral surface of the peripheral frame with a substantially constant thickness. To form a back mold, and then the back mold and the female mold are demolded from the mold, and the demolded back mold is fitted into the mold again to form the female mold between the male mold and the decorative surface. The same space as the thickness of the mold is maintained, and the internal space formed between the male mold and the back mold is filled with a resin or rubber coagulating fluid, and after the coagulation, the coagulation layer and the back mold are formed. The mold is removed from the mold, and the solidified layer and the back mold are made into a female mold. or,
The method for producing a female mold according to claim 4, wherein a male mold having the same decorative surface as the three-dimensional decorative surface to be expressed in the concrete product, and a peripheral frame fixed around the male mold and surrounding the decorative surface. Form a mold, place the above mold with the male decorative surface facing upward or sideways, and cover the male decorative surface with a plastic material such as clay or gypsum to a substantially constant thickness. After forming the back mold, FRP or FRG is laminated on the female mold and the inner peripheral surface of the peripheral frame with a substantially constant thickness to form a back mold, and then a back mold.
The female prototype is removed from the mold, and the three-dimensional mesh material is fixed to the surface of the demolded back mold that was in contact with the female mold, and the back mold is fitted back into the mold to give a male decorative surface. The same space as the thickness of the female mold is maintained between the mold and the mold, and the internal space formed between the male mold and the back mold is filled with a coagulable fluid of resin or rubber, and after solidification, solidification Remove the mold from the mold as a layer and back mold,
It is characterized by being a female type. Further, in the method for producing a female mold according to any one of claims 3 and 4, when the male decorative surface is covered with a plastic material having a substantially constant thickness to form a female prototype, the male mold is formed on the open surface of the peripheral frame. A plurality of reaching projections are integrally projected on the female prototype, and then, when FRP or FRG is laminated to form a back mold, an integral cylinder portion surrounding the projections of the female prototype is projected, and a male mold is formed. When the coagulating fluid is filled in the internal space formed between the back mold and the back mold, it is preferable that the cylindrical portion serves as an inlet for the coagulating fluid and an air escape port from the internal space. Also, in the method for manufacturing a female mold according to any one of claims 3 to 5, when a back mold is formed by stacking FRP or FRG on the female mold and the inner peripheral surface of the peripheral frame with a substantially constant thickness. In addition, it is preferable that a wall-shaped or columnar reinforcing portion reaching the open surface of the peripheral frame be integrally provided on the back mold.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a sectional view of the female die of claim 1, FIG. 2 is a sectional view of the female die of claim 2, and FIG. 3 is a perspective view of the female die of FIGS. Is. Each of the female molds 10 has a certain thickness, for example, 10 to 3 on the decorative surface of the male mold 1 having the same decorative surface as the uneven three-dimensional decorative surface to be expressed in the concrete product.
A solidifying layer 11 of, for example, a silicone resin, a two-component urethane resin, a two-component synthetic rubber, an epoxy resin, a polyester resin or the like coated with a solidifying fluid having a thickness of about 0 mm, and a mold having a constant thickness of the solidifying layer 11. FR backed by wall 22 for reinforcement
The back mold 21 is made of P (fiber reinforced resin) or FRG (fiber reinforced rubber) and has a constant thickness. F, the raw material for the back mold
RP is a fiber such as glass fiber reinforced polyester resin, carbon fiber reinforced polyester resin, nylon Kepler, and araside, or a composite curable material composed of a fiber mesh and a curable resin, and FRG is the above fiber or a fiber mesh. A composite material made of urethane rubber, synthetic rubber, etc.

A surrounding wall 23 of a constant height projects from around the mold wall 22 of the back mold 21, and the inside surrounded by the surrounding wall is divided into a surrounding wall and a partition wall 24 connected to the mold wall. . The height of this partition wall 24 is also the same as that of the surrounding wall. These surrounding walls and partition walls have not only reinforcement of the back mold, but also functions and effects described later.

FIG. 4 is a sectional view of a concrete product being molded using the female mold 10 of FIG. 1, and FIG. 5 is a sectional view of a concrete product being molded using the female mold of FIG. It is a figure. The female mold 10 is turned upside down and housed in the product molding mold 30 having the steam flow port 32 below, and the surrounding wall 23 and the partition wall 24 of the back mold are brought into contact with the bottom plate 31 of the molding mold from above to form the female mold 10. Is separated from the bottom plate 31. In addition, the surrounding wall 2 in advance
3 is provided with a communication hole 23 'that communicates with the steam flow port 32, and the partition wall 24 is provided with a hole 24'. In this way, the ready-mixed concrete 33 is placed in the product molding form, and the steam flow port 32,
When steam is passed under the female mold 10 through the communication holes 23 ′ and the holes 24 ′, the solidification layer 11 forming the female mold and the mold wall 2 of the back mold 21.
Since 2 has a substantially constant thickness, the uneven decorative surface of the product cures at a uniform speed even if the unevenness is large.

In addition to reinforcing the back mold, the surrounding wall 22 and the partition wall 23 separate the female mold 10 from the bottom plate 31 of the product molding frame to keep a heating space 34 with steam under the female mold. , Serves as a reversing bar that supports the part of the female mold that is upwardly separated from the bottom plate 31 from below, and effectively prevents the female mold from being deformed by placing the ready-mixed concrete 33.

FIG. 6 is a sectional view showing the manufacturing process of the female die of claim 3, and FIG. 7 is a sectional view showing the manufacturing process of the female die of claim 4. In either manufacturing method, a male mold 1 having the same decorative surface as the three-dimensional decorative surface of the unevenness to be expressed in the concrete product.
And fixed around the male mold on the surface plate 2 which fixed the male mold,
A peripheral frame 3 surrounding the male decorative surface constitutes a female mold 4 for molding. In order to manufacture a female mold 10 having the same three-dimensional decorative surface as the decorative surface by using this mold 4, the decorative surface of the male mold 1 is turned sideways or faced upward as shown in FIGS. 6 and 7. Four
And a mold release agent is attached to the decorative surface, and then the entire decorative surface is covered with a plastic material such as clay or gypsum to a substantially constant thickness, for example, a thickness of about 10 to 30 mm, and the female master 20 make. In addition to clay and plaster, the plastic materials that make the female prototype 20 are
Paraffin, wax, resin clay, sodium silicate, or agar may be used, but if you use a soft clay plate molded into a plate with a certain thickness, for example, you can attach it to the entire male type decorative surface. You can make a female prototype with good sex.

In this way, the entire male decorative surface is covered with the plastic material, and when the female prototype 20 is formed, the surface of the female prototype and the inner peripheral surface of the peripheral frame 4 are sprayed with a mold release agent, and the like. The above-mentioned FRP or FRG is adhered and laminated thereon by a constant thickness, for example, 3 to 10 mm by a hand-pasting method or a mechanical spraying method to form a back mold 21 having a uniform thickness (upper part of FIGS. 6 and 7). ). Then, when the laminated back mold 21 is cured, this is molded into the female mold 20.
Remove from mold and repair if necessary. This back mold 21 comes into contact with the surface of the female mold 20 and comes into contact with the mold wall 22 of a certain thickness whose irregularities are opposite to those of the female mold, and the inner peripheral surface of the peripheral frame 3, and from around the mold wall 22. And a surrounding wall 23 protruding rearward. After demolding the back mold 21, the female mold 20 is peeled from the decorative surface of the male mold 1 and demolded from the mold 4. The steps up to this point are the same as those of claim 3 and claim 4, and the difference is from this point onward.

According to the method of manufacturing a female mold of claim 3, the female prototype 2
After demolding 0, by spraying or applying a mold release agent on the decorative surface of the male mold 1, the inner peripheral surface of the peripheral frame 3 of the mold, and the front surface of the mold wall 22 of the demolded back mold 21. After the attachment, the back mold is fitted into the mold again, and the space between the front surface of the mold wall 22 of the back mold and the decorative surface of the male mold is maintained at the same level as the thickness of the female mold 20. By enclosing the back mold inside the mold, the surrounding wall 2 of the back mold
Since 3 again comes into sliding contact with the inner peripheral surface of the peripheral frame 3 of the mold,
The back mold is held in the mold (lower part of Fig. 6). The internal space 5 formed between the male decorative surface, the back mold wall 22 and the inner surrounding surface of the peripheral frame 3 is filled with the above-mentioned resin or rubber coagulable fluid 11 '. After the solidification, the back mold 21 and the solidified layer 11 having a uniform thickness are removed from the mold 4 and the female mold 1
Set to 0. The solidification layer 11 may be simply fitted on the front surface of the back mold wall 22, but an adhesive or a double-sided adhesive tape is used.
You may adhere.

In order to efficiently manufacture the female mold by the method of the third aspect, only the back mold 21 is mass-produced by using the solidification layer 11 covering the female mold 20 or the male mold, and then the male mold is manufactured. The solidified layer 11 may be formed by one back mold and the back mold and the solidified layer may be combined. In this case, if the solidification layer is used, the back mold can be made without using the release agent, so that it is easier to use the solidification layer.

In the method for manufacturing a female mold according to claim 4, after removing the back mold and peeling the female mold 20 from the male mold, the decorative surface of the male mold 1 and the inner peripheral surface of the peripheral frame 3 of the mold frame. The mold wall 2 of the back mold 20 that has been demolded by spraying a mold release agent on the and
7 is fixed to the front surface of 2 with bolt nuts, nails, adhesives, etc., which is a three-dimensional netting material 25 that undulates by bending such as lath, expanded metal, etc., which is the base material of the mortar wall, as shown in FIG. As shown in the lower part, the back mold having the three-dimensional mesh material attached thereto is fitted into the mold again, and the back mold is held by the surrounding wall 23 of the back mold which slidably contacts the inside of the peripheral frame 3 of the mold. , An inner space 5 is formed between the front surface of the back mold wall 22 and the male decorative surface with a space about the same as the thickness of the female mold, and the resin or rubber is solidified in the inner space. Sex fluid 1
Fill 1 '. This solidifying fluid is a solid mesh material 25.
The solidification layer 11 is integrally attached to the front surface of the back mold wall 22 in order to fill the mesh and solidify. Therefore, after the solidifying fluid is solidified, the solidified layer 11 is removed from the mold together with the back mold 21 to form a female mold.

Also in the manufacturing method of the fourth aspect, only the back mold 21 is mass-produced by using the female mold 20, and then the female mold is peeled from the male mold, and the three-dimensional mesh material 25 is provided on the front surface of the mold wall 22 of the back mold. The coagulation layer 11 is formed by mounting, the male mold and the one back mold, and the female mold in which the back mold and the coagulation layer are integrated can be efficiently manufactured.

In any of the manufacturing methods of claim 3 and claim 4, when the male decorative surface is coated with a plastic material such as clay to form the female prototype 20, as shown in FIGS. 6 and 7. , A plurality of protrusions 26 that reach the open surface 3 ′ of the peripheral frame are integrally projected on the female prototype, and when the back mold 21 is formed by stacking FRP and FRG on the female prototype 20, FRP around the part 26,
It is preferable to provide the tubular portion 27 by surrounding it with FRG. This way
By separating the back mold 21 from the female mold 20, the protrusion 26 of the female mold is removed from the tubular portion 27.
As shown in the lower part of FIG. 1, when the internal space 5 between the back mold and the male mold is filled with the coagulable fluid of resin or rubber,
One or some of the above may be used as an inlet for the fluid and the rest of the tubular portion as an escape port for the air from the internal space. The completion of filling can be known by filling the internal space and overflowing the coagulable fluid from the air escape port. Further, since the solidifying fluid fills the inside of the cylindrical portion 27 and is solidified, a protruding portion 12 of the solidifying fluid similar to the female-shaped protruding portion 26 is formed, and the protruding portion 12 is surrounded by the cylindrical portion 27. Therefore, when manufacturing a concrete product using the female mold, as shown in FIGS. 4 and 5, these protrusions and cylinders float the female mold 10 above the bottom plate 31 of the molding frame 30,
Similar to the surrounding wall 23 and the partition wall 24, the bottom plate 31 and the heating space 34 for introducing steam into the female mold 10 are formed at the same time as the female mold is supported on the bottom plate so that the female mold can be used when pouring raw concrete. Prevents deformation.

Further, when forming the back mold, as shown in FIGS. 6 and 7, it is preferable to provide a reinforcing portion such as the partition wall 24 which reaches the open surface 3'of the peripheral frame 3 by FRP and FRG. The reinforcing portion is not limited to a wall and may be columnar. The reinforcing portion supports from below the portion of the female die that is upwardly separated from the bottom plate 31 of the molding frame, and effectively prevents the female die from being deformed by placing the fresh concrete. After the female mold is manufactured, holes 23 'and 24' for passing steam or the like are formed in the back wall of the surrounding wall 23 and the wall-shaped reinforcing portion that partitions the space surrounded by the surrounding wall.

[0017]

The female molds according to the first and second aspects of the present invention include a solidified layer 11 having a constant thickness and formed by solidifying a solidifying fluid, and a solid mold wall 22 having a constant thickness. FR to
The back mold 21 is made of P and FRG. Therefore, when forming the uneven three-dimensional decorative surface of the concrete product by contacting the solidified layer 11 with the ready-mixed concrete, if the back mold side is heated with steam or the like to accelerate the hardening of the ready-mixed concrete, the difference in the unevenness is large. However, the entire decorative surface of the concrete product can be cured at a uniform rate. Further, the solidified layer 11 having a constant thickness and solidified by the solidifying fluid by the method for producing a female mold according to claims 3 and 4, and the mold wall 2 having a constant thickness of the solidified layer
It is possible to obtain a female mold having a uniform thickness as a whole, which is composed of an FRP and a back mold 21 made of FRG which are lined and reinforced with 2.

[Brief description of drawings]

FIG. 1 is a sectional view of an example of a female die according to claim 1.

FIG. 2 is a partially enlarged sectional view of the female mold of claim 2;

FIG. 3 is a perspective view of the female mold of FIGS. 1 and 2.

FIG. 4 is a cross-sectional view of a state where a concrete product is manufactured using the female mold of FIG.

FIG. 5 is a cross-sectional view of a state where a concrete product is manufactured using the female mold of FIG.

FIG. 6 is a cross-sectional view showing two steps of a process for manufacturing a female mold according to claim 3;

FIG. 7 is a cross-sectional view showing two steps of a process for manufacturing a female mold according to claim 4.

FIG. 8 is a cross-sectional view of a concrete product being manufactured using a conventional female mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Male type 2 Surface plate 3 Surrounding frame 3'Open surface of surrounding frame 4 Formwork 5 Internal space 10 Female type 11 Solidification layer 11 'Solidifying fluid 20 Female prototype 21 Back mold 22 Mold wall 23 Enclosing wall 24 Partition wall 25 Three-dimensional mesh material 30 Product molding form 31 Bottom plate 32 Steam flow port 33 Raw concrete

Claims (6)

[Claims] 1. A solidified layer of a solidifying fluid of resin or rubber, which is formed by covering a male decorative surface having the same decorative surface as a three-dimensional decorative surface to be expressed in a concrete product with a constant thickness, FRP or FRG with a certain thickness over the solidified layer
A female mold for molding concrete products with a three-dimensional decorative surface, characterized by comprising a back mold made of steel. 2. A solidified layer of a solidifying fluid of resin or rubber, which is formed by covering the decorative surface of a male mold having the same decorative surface as a three-dimensional decorative surface to be expressed in a concrete product with a constant thickness, FRP or FRG with a certain thickness over the solidified layer
The back mold is made of metal, and a three-dimensional mesh material is attached to the surface of the back mold that comes into contact with the solidification layer. The solidification layer fills the mesh of the three-dimensional mesh material and is integrally connected to the back mold through the three-dimensional mesh material. A female mold for molding concrete products with a three-dimensional decorative surface. 3. A mold is composed of a male mold having the same decorative surface as the three-dimensional decorative surface to be expressed in the concrete product, and a peripheral frame fixed around the male mold and surrounding the decorative surface, The above mold is placed with the decorative surface of the male mold facing upward or sideways, and the male decorative surface is covered with a plastic material such as clay or gypsum to a substantially constant thickness to form a female prototype. On the female prototype,
FRP or FRG is laminated on the inner peripheral surface of the peripheral frame with a substantially constant thickness to form a back mold, and then the back mold and the female prototype are demolded from the mold and the demolded back mold is formed. It is fitted in the mold again and maintains a space similar to the thickness of the female mold between the male mold and the decorative surface of the male mold, and resin or rubber is solidified in the internal space formed between the male mold and the back mold. Female for molding concrete products with a three-dimensional decorative surface, characterized in that the solidified layer and the back mold are demolded from the mold after the solid fluid is filled and the solidified layer is solidified. Mold manufacturing method. 4. A mold is composed of a male mold having the same decorative surface as the three-dimensional decorative surface to be expressed on the concrete product, and a peripheral frame fixed around the male mold and surrounding the decorative surface, The above mold is placed with the decorative surface of the male mold facing upward or sideways, and the male decorative surface is covered with a plastic material such as clay or gypsum to a substantially constant thickness to form a female prototype. On the female prototype,
FRP or FRG is laminated on the inner peripheral surface of the peripheral frame with a substantially constant thickness to form a back mold, and then the back mold and the female prototype are demolded from the mold, and the demolded back mold , The three-dimensional mesh material is fixed to the surface that was in contact with the female mold, and the back mold is fitted into the mold again to maintain the same distance as the thickness of the female mold from the decorative surface of the male mold, The internal space formed between the male mold and the back mold is filled with a solidifying fluid of resin or rubber, and after solidification,
A method for producing a female mold for molding a concrete product with a three-dimensional decorative surface, characterized in that a solidified layer and a back mold are integrally removed from a mold to obtain a female mold. 5. The method for producing a female die according to claim 2, wherein the decorative surface of the male die is coated with a plastic material having a substantially constant thickness to form a female die. , A plurality of projections reaching the open surface of the peripheral frame are integrally projected on the female mold, and then, when forming a back mold by laminating FRP or FRG, an integral cylindrical portion surrounding the female mold projections is formed. When the internal space formed between the male mold and the back mold is projected and is filled with the coagulable fluid, the tube portion serves as an inlet for the coagulable fluid and an air escape port from the internal space. A method for producing a female mold for molding a concrete product with a three-dimensional decorative surface, comprising: 6. The method for producing a female mold according to claim 3, wherein FRP or FRG is laminated on the female mold and the inner peripheral surface of the peripheral frame with a substantially constant thickness. A method for producing a female mold for molding a concrete product with a three-dimensional decorative surface, characterized in that, when forming the back mold, wall-shaped and columnar reinforcing portions reaching the open surface of the peripheral frame are integrally provided on the back mold.