JP6153333B2 - Cast body manufacturing method and block-shaped member holder - Google Patents

Description

  The present invention relates to a cast body manufacturing method and a block-shaped member holding body for manufacturing a cast body in which a front side portion of a block-shaped member such as a tile is exposed and joints exist between the block-shaped members.

  In JP-A-6-220977, the adhesive layer of the pressure-sensitive adhesive sheet is left with a joint width, and the tile is attached with the glossy surface on the pressure-sensitive adhesive side, and a plastic foam is formed in the gap between the tiles. Use a tile sheet that is thinner than the tile thickness and has a connected frame-shaped foam joint material attached. Lay the tile sheet in the form with the back side of the tile facing up, and reinforce the reinforcing bar in place. In the manufacturing method of tile-embedded concrete panel in which concrete is placed and then set and hardened, then demolded, and the adhesive sheet is peeled off, as a foam joint material, a cement setting retarder is applied to the surface portion. A method for producing a tile-embedded concrete panel using a foamed joint material for tile sheet is disclosed.

  If the glossy surface on the front side of the tile is flat, positioning the tile in a fixed posture by sticking the tile on the adhesive sheet with the front side as the adhesive side as described in JP-A-6-220977 Can be used effectively in the manufacture of concrete panels.

  However, if the shape of the front side of the tile is an indeterminate shape whose height changes depending on the position, the tile will tilt in various directions even if the front side of the tile is stuck on the adhesive sheet, and be positioned in a fixed posture. Cannot be used to manufacture concrete panels.

  Therefore, a tile is placed on each grid-like part of the formwork provided on the bottom side with a grid-like part sandwiching the width corresponding to the joint width, with the front side facing up, and a molten synthetic resin is poured onto the tile. It was proposed to use a solidified synthetic resin with the front side buried in the production of concrete panels.

  However, in this case, it is necessary to produce a mold for synthetic resin for each type of tile, and in the production of concrete panels, it is necessary to remove the synthetic resin from the tile after the concrete is cured. It took time and effort. Also, it is often difficult to completely remove the synthetic resin from the tile surface. In this case, the aesthetic appearance is impaired and there is a problem in fire prevention.

JP-A-6-220977

  The present invention has been made in view of the above problems existing in the prior art, and the object of the present invention is that the shape of the front side of the block-shaped member is changed from the back side of the block-shaped member to the front side. Even if it changes in height, in particular, even if the shape on the front side is different for each block-like member, the front-side portion of the block-like member is exposed in a desired state, and the space between the block-like members An object of the present invention is to provide a method for producing a cast body and a block-shaped member holder capable of easily and reliably producing a cast body having joints.

  The cast body manufacturing method and block-shaped member holder of the present invention can be expressed as follows.

1. A plurality of block-shaped members having a front side and a back side are embedded in the fluidized solidified material except for the front-side portion of each block-shaped member with a joint gap between the side surfaces of each block-shaped member, By solidifying the fluidized solidified material, the front side portion of each block-shaped member is exposed, and a method of producing a cast body in which joints exist between the block-shaped members,
The shape of the front side of at least one block-like member among the block-like members changes in the height from the back side to the front side of the block-like member,
The entire thickness of the front side of each block-shaped member or at least the entire outer periphery thereof is thicker than the change in the height direction of the shape of the front side of the block-shaped member, and deforms along the shape of the front side of the block-shaped member A step of forming a block-shaped composite by pasting the back side of the backing material that can be bonded in a deformed state along the shape of the front side of the block-shaped member;
Step B for shaping the deformed surface side according to the deformation on the back side of the backing material in the block-shaped composite into a predetermined shape;
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is supported at a predetermined position of a shape corresponding to the predetermined shape with a joint gap between the side surfaces of the block-shaped member. Step C for determining the position and orientation of the block-shaped member in the block-shaped composite,
A step D of closing the position between the front side and the back side of the block-shaped member among the joint gaps between the side surfaces of the block-shaped member with a joint forming material so that the joint can be formed on the back side of the position ;
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite with the joint gap between the side surfaces of the block-shaped member obtained through the above steps corresponds to the predetermined shape. The position and posture of the block-shaped member in the block-shaped composite body are determined, and the joint-side gap between the side surfaces of the block-shaped member is between the front side and the back side of the block-shaped member. For the one where the position between them is blocked by the joint forming material so that joints can be formed on the back side of the position, the part excluding the front part of each block-like member is embedded in the fluidized solidified material, and the flow by solidifying the sexual solidified material, to expose the front portion of the block-shaped member, and wherein the Rukoto produce a cast body in a state where there is a joint between the adjacent block-like member cast Of the process.

On the entire front surface of the block-shaped member in each block-shaped composite body, or at least the entire outer periphery thereof , the thickness is greater than the change width in the height direction of the shape of the front surface of the block-shaped member, and the front surface of the block-shaped member The back surface side of the backing material that can be deformed along the shape of is attached in a state of being deformed along the shape of the front side of the block-shaped member.

Therefore, the surface side portion deformed according to the deformation on the back side of the backing material in the block-shaped composite is shaped into a predetermined shape, and the surface side of the backing material shaped into the predetermined shape in the block-shaped composite corresponds to the predetermined shape Even if the shape of the front side of the block-shaped member changes in the height from the back side to the front side of the block-shaped member by supporting it at a predetermined location of the shape to be blocked, the block-shaped member in the block-shaped composite body Can be determined. It does not matter even if the shape of the front side is different for each block-like member.

Moreover, the position between the front side and the back side of the block-shaped member in the joint gap between the side surfaces of the block-shaped member is closed with a joint forming material so that the joint can be formed on the back side of the position.

  By doing in this way, even if the shape on the front side of the block-shaped member changes in the height from the back side to the front side of the block-shaped member, the shape on the front side differs particularly for each block-shaped member. Even if it is a thing, a cast body can be manufactured easily and reliably using a fluid solidification material. That is, the part on the back side of the joint-forming material of all the block-shaped members is embedded in the fluidized solidified material, and the fluidized solidified material is solidified so that the front side portion of each block-shaped member is exposed in a desired state. And the cast body of a state in which a joint exists between block-shaped members can be manufactured.

2. The back side of all block-shaped members is a shape along a plane,
Step B is shaped so that the surface side of the backing material in all block-like composites is parallel to the plane along which the back side of the block-like member in each block-like composite extends along a certain height. The above-described 1. The manufacturing method of the cast body described.

The front surface deformed according to the deformation of the back surface of the backing material in all the block composites is parallel to the plane along the back side of the block member in each block composite with a certain height. By supporting the surface side of the backing material shaped into such a predetermined shape in the block-shaped composite at a predetermined location of the shape corresponding to the predetermined shape, the shape on the front side of the block-shaped member is Even if the block-shaped member changes in height from the back side to the front side (and the block-side member has a different shape on the front side), the block-shaped member in the block-shaped composite body It is possible to easily and reliably determine the position and posture.

3. In the above-mentioned step B, a plurality of block composites are arranged on one side of the plane such that the back side of the block members is along a predetermined plane, and the backing material of those block composites 2 is a step of shaping so that the surface side of is parallel to the plane . The manufacturing method of the cast body described.

The surface side deformed according to the deformation of the back surface side of the backing material in the plurality of block-shaped composites is parallel to the plane along the back side of the block-shaped member in each block-shaped composite body with a certain height. The shaping operation can be easily performed.

4). Step C is
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is joined to the planar portion of the substrate having the planar portion, with a joint gap between the side surfaces of the block-shaped member. Is a step of determining the position and orientation of the block-like member in the block-like composite ,
Step D is
By inserting a joint forming member into the joint gap between the side surfaces of the block-like member and joining to the base material, the position between the front side and the back side of the block-like member in the joint gap is determined by the position. 2. A step of closing with a joint-forming material so that joints can be formed on the back side of the substrate. Or 3. The manufacturing method of the cast body described.

The surface side deformed according to the deformation on the back side of the backing material in the block-shaped composite is shaped so as to be parallel to the plane along the back side of the block-shaped member in each block-shaped composite with a certain height. Then, the surface side of the backing material shaped into such a predetermined shape in the block-shaped composite is supported by the planar portion of the base material having a planar portion which is a predetermined portion having a shape corresponding to the predetermined shape. Even if the shape of the front side of the block-shaped member changes in the height from the back side of the block-shaped member to the front side (even if the shape of the front side differs for each block-shaped member) ), The position and posture of the block-like member in the block-like composite can be determined easily and reliably. In addition, by joining the joint forming member to the base material, the block composite, the joint forming member, and the base material can be integrated to improve the handleability.

5. A plurality of block-like members having a front side and a back side, a backing material for each block-like member, and a base material having a planar portion,
The back side of all block-shaped members is a shape along a plane,
The shape of the front side of at least one block-like member among the block-like members changes in the height from the back side to the front side of the block-like member,
Each block member and the backing material for the block member are affixed to the entire front surface of the block member or at least the entire outer periphery thereof with the back surface of the backing material deformed along the shape of the front surface of the block member. To make up each block complex,
In each block-like composite, the backing material has a maximum thickness that is thicker than the change width in the height direction of the shape on the front side of the block-like member,
The front side deformed according to the deformation of the back side of the backing material in all block composites is shaped so as to be parallel to the plane along the back side of the block member in each block composite with a certain height. Has been
Each block composite is joined to the planar portion of the substrate having a planar portion on the surface side of the backing material with a joint gap between the side surfaces of the block-shaped member,
Among the joint gaps between the side surfaces of the block-shaped member, the position between the front side and the back side of the block-shaped member is blocked by a joint forming material so that a joint can be formed on the back side of the position. A block-shaped member holder.

This block-shaped member holding body can be easily and reliably manufactured by steps A, B , C and D in the manufacturing method of the cast body of the present invention. The front side deformed according to the deformation of the back side of the backing material in all block composites is shaped so as to be parallel to the plane along the back side of the block member in each block composite with a certain height. Has been. The maximum thickness of the backing material after shaping is thicker than the change width in the height direction of the shape on the front side of the block-shaped member. Each block-shaped composite is joined to the planar portion of the base material having a planar portion on the surface side of the backing material with a joint gap between the side surfaces of the block-shaped member. Even if the shape of the front side of the member changes in the height from the back side to the front side of the block-like member (even if the shape of the front side differs for each block-like member), the block The position and posture of the block-shaped member in the cylindrical composite are determined with respect to the plane along the back side of each block-shaped member and the planar portion of the substrate.

Moreover, the position between the front side and the back side of the block-shaped member in the joint gap between the side surfaces of the block-shaped member is closed by the joint forming material so that the joint can be formed on the back side of the position .

  Even if the shape of the front side of the block-shaped member changes in the height from the back side to the front side of the block-shaped member by using this block-shaped member holding body, in particular, for each block-shaped member, the front side Even if the shapes are different, the cast body can be easily and reliably produced using the fluidized solidifying material. That is, the part on the back side of the joint-forming material of all the block-shaped members is embedded in the fluidized solidified material, and the fluidized solidified material is solidified so that the front side portion of each block-shaped member is exposed in a desired state. And the cast body of a state in which a joint exists between block-shaped members can be manufactured.

  According to the present invention, even if the shape of the front side of the block-like member changes in the height from the back side to the front side of the block-like member, the shape of the front side differs particularly for each block-like member. Even so, by embedding the part on the back side of the joint-forming material of all the block-shaped members in the fluidized solidified material, and solidifying the fluidized solidified material, the front side part of each block-shaped member is desired. A cast body that is exposed in a state and has joints between the block-like members can be easily and reliably manufactured.

It is typical sectional drawing of a backing material, a tile, and a frame. It is typical sectional drawing of the state which mounted the tile which stuck the backing material on the grid | lattice-like part of the frame. It is a typical sectional view showing the state where the surface side of the backing material was shaped. It is typical sectional drawing which shows the state which inserted the joint formation material and joined the base material. It is a typical sectional view of a tile sheet. It is a typical sectional view in the state where concrete was laid for precast concrete panel manufacture. It is a typical sectional view of a precast concrete panel. It is typical sectional drawing which shows the state which forms a concrete wall part between concrete panels.

  [1] An embodiment of the present invention will be described with reference to the drawings.

  All the drawings relate to examples of embodiments of the present invention, among which FIGS. 1 to 5 relate to a so-called tile sheet Q (block-shaped member holder), and FIGS. FIG. 8 relates to a precast concrete panel R using the tile sheet Q, and FIG.

  (1) The tile sheet Q includes a tile T, a backing material L, a joint forming material J, and a base material S, and is manufactured using a frame body M.

  The tile T (block-shaped member) has a thick plate shape that is square in plan view. The tile T has a front side T1 and a back side T2, which are an upper side and a lower side, respectively, in FIG.

  The front side T1 of the tile T has an indefinite shape that changes in height from the back side T2 to the front side T1 (the height varies depending on the planar position on the front side).

  The back side T2 has a shape along a plane, and has three groove-like recesses T3 in parallel.

  The tiles T have substantially the same shape except for the shape of the front side T1.

  The backing material L has a thick plate mat shape made of closed-cell polyethylene foam. The backing material L has the same rectangular shape as the tile T in plan view, and the thickness is thicker than the change width in the height direction of the shape of the front side T1 of the tile T (difference between the minimum height and the maximum height). It can be deformed along the shape of the front side T1 of T.

  An adhesive layer (not shown) containing a cement setting retarder is provided on the back side L1 of the backing material L which is the lower side in FIG.

  The base material S is provided with a pressure-sensitive adhesive layer (not shown) on the back surface (lower side surface in FIG. 4) of a synthetic resin sheet.

  The frame body M has a tray shape in which a shallow concave portion having an upper opening is formed inside, and a lattice frame M1 having a grid pattern is provided on the bottom side. The bottom surfaces in all the lattice frames M1 are flat at a certain height.

  For each tile T, the back side L1 of the backing material L is attached to the front side T1 of the tile T through an adhesive layer provided on the back side L1 in a state of being deformed along the shape of the front side T1 of the tile T. Thus, the block-shaped composite X is formed. The front surface side L2 of the backing material L is deformed according to the deformation of the back surface side L1. The back surface side L1 of the backing material L substantially coincides with the entire front side T1 of the tile T.

  As shown in FIG. 2, each block composite X is placed on the bottom surface in each lattice frame M <b> 1 of the frame M in a state where the back side T <b> 2 of the tile T is supported. The tiles T are arranged so as to have a joint gap corresponding to the lattice frame M1 between T4.

  The backing material L is thicker than the change in the height direction of the shape of the front side T1 of the tile T, and the back side L1 is attached in a state of being deformed along the shape of the front side T1 of the tile T. Therefore, the surface side L2 of the backing material L is cut and shaped by a fixed surface (a surface that coincides with the upper end surface of the frame body M) parallel to the plane along which the back side T2 of the tile T is along (the bottom surface in each lattice frame M1). By doing so, as shown in FIG. 3, the surface side L2 of the backing material L forms a plane parallel to the plane along which the back side T2 of the tile T extends. The maximum thickness of the backing material L after shaping is thicker than the change width in the height direction of the shape of the front side of the tile T.

  The bottom surface of one base material S is attached to the front surface L2 of the backing material L thus shaped, the upper surface of the joint forming material J inserted into the upper side of the lattice frame M1 in FIG. The tile sheet Q (block-shaped member holding body) shown in FIG. 5 can be obtained easily and reliably by joining them through and removing the frame M.

  In the tile sheet Q, the tiles T form joints with a constant height between the side surfaces T4 and at the outer peripheral part of the entire array of tiles T, which is the part of the outer peripheral part of the tile T that is not opposed to the other tiles T. The material J is arranged, and the back side T2 is parallel to the base material S and arranged in a grid pattern.

  (2) As shown in FIG. 6, the tile sheet Q is placed on the bottom surface of the shallow box-shaped concrete mold D with the base material S facing down, and the ready-mixed concrete is poured into the concrete mold D. Thereby, the part (namely, part above the upper surface of the joint formation material J in FIG. 6) except the front side T1 part of each tile T can be embedded in ready-mixed concrete. As a reinforcing material, reinforcing steel may be provided above the tile sheet Q to form reinforced concrete.

  After the concrete C is hardened, the concrete mold D is removed and the backing material L and the joint-forming material J are removed, so that the precast concrete panels arranged with the front side T1 of the tile T exposed as shown in FIG. R can be obtained easily and reliably.

  On the front side T1 of the tile T, the back side L1 of the backing material L made of closed cell polyethylene foam is deformed and stuck along the shape of the front side T1 of the tile T, and the ready-mixed concrete is placed and cured. Since this is done, it is possible to prevent Noro from penetrating the front side T1 of the tile T. Even if Noro penetrates, the setting is delayed by the cement setting retarder in the pressure-sensitive adhesive layer on the back side L1 of the backing material L, so that it can be effectively removed from the front side T1 of the tile T.

  (3) As shown in FIG. 8, a pair of tile sheets Q are joined to the inner side surfaces of the concrete panels P erected so as to face each other, with the base material S positioned outside, and between the tile sheets Q. In a state where the reinforcing bar B is arranged, the concrete is poured between the tile sheets Q, so that a portion excluding the front side T1 portion of each tile T (that is, a portion inside the inner surface of the joint forming material J in FIG. 8) is produced. Can be embedded in concrete. After the concrete C is hardened, the concrete panel P is removed and the backing material L and the joint forming material J are removed to easily and reliably obtain reinforced concrete walls arranged on both sides with the front side T1 of the tile T exposed. It is done. In addition, the concrete panel P itself can also be used as the base material S of the tile sheet Q.

  About the penetration prevention and removal effect of Noro, it is the same as that of the case of manufacture of the precast concrete panel R.

  [2] Embodiments of the present invention will be further described, including forms other than those described above.

(1) In the method for producing a cast body of the present invention, a plurality of block-like members having a front side and a back side are removed, with the front-side portion of each block-like member being separated from each other by a joint gap between the side surfaces of each block-like member. By embedding the part in the fluidized solidified material and solidifying the fluidized solidified material, the front side part of each block-shaped member is exposed (those other than the front side part partially exposed are not excluded), and the block shape A method of manufacturing a cast body (for example, a precast concrete panel, a cast-in-place concrete wall, etc.) in which a joint exists between members, which includes Step A, Step B , Step C, and Step D.

  In step A, the back side of the backing material that is thicker than the change in the height direction of the shape of the front side of the block-like member and deformable along the shape of the front side is pasted on the front side of each block-like member. The block-shaped composite is formed by putting the backing material into a deformed state along the shape of the front side of the block-shaped member.

  In step B, the surface side of the backing material in the block composite is shaped into a predetermined shape.

In the step C, the surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite body with a joint gap between the side surfaces of the block-shaped member is formed at a predetermined position corresponding to the predetermined shape. The position and posture of the block-like member in the block-like composite are determined by supporting the block .
In step D, the position between the front side and the back side of the block-shaped member in the joint gap between the side surfaces of the block-shaped member is closed with a joint forming material so that a joint can be formed on the back side of the position. It is.

  The block-shaped member holder of the present invention includes a plurality of block-shaped members having a front side and a back side, a backing material for each block-shaped member, a joint forming material, and a base material having a planar portion.

  (2) Block-shaped member

  The shape of the block-shaped member may be, for example, a rectangular parallelepiped, a cube, a solid whose front and back sides are parallel, a solid whose front and back are parallel, and whose side faces are perpendicular to the front and back, and whose side surfaces are front A solid that is linear in a plan view from (or the back side) can be mentioned. Such a solid can be, for example, a plate shape, a thick plate shape, a block shape, or the like.

  Examples of the block member material include tiles (particularly, split skin tiles, stone surface tiles, scratch tiles, uneven surface tiles, etc.), bricks, stone materials, concrete, etc. Absent.

  The number of the block-shaped members used for the manufacturing method or block-shaped member holding body of the present invention is plural, and can be, for example, an even number or an odd number of 4, 6, 8, 10, 12, or more.

  It is preferable that all of the block-like members have substantially the same planar view shape from the front side (or back side) or substantially the same except for the front side shape, but this is not restrictive.

  The shape of the front side of all the block-like members or at least one block-like member can be changed in height from the back side to the front side (the height varies depending on the planar position on the front side). For example, when the block-shaped member is placed on the horizontal surface on the front side, the shape inclined in any direction, in particular, the inclined direction is different in each block-shaped member or is not stably supported. be able to. In this case, the inclination is based on the back side or the side surface (for example, when the back side has a shape along a plane, the inclination with respect to the plane, or when the side surface is perpendicular to a certain plane, (Tilt with respect to the plane).

  The block-like member may have a hole-like or groove-like recess, a protrusion, a straight line, a fold curve, or a curved protrusion at one or more locations on the front side.

  The back side of the block-shaped member has a shape along a plane, for example, a shape in which the block-shaped member can be stably supported on a horizontal plane on the back side, more specifically, a planar shape, and a hole shape in one or more places. Or a flat surface having a groove-like recess, a protrusion or a straight or bent curve or a curved protrusion at one or two or more places, and at the protrusion or protrusion, or with a protrusion or protrusion The other part preferably has a shape that is stably supported on a horizontal plane, but is not limited thereto.

  (3) Backing material

  The backing material is attached to the front side of the block-like member on the back side of the backing material for each block-like member in a deformed state along the shape of the front side of the block-like member. Make up the body. The surface side of the adhered backing material is deformed according to the deformation on the back surface side, but the degree of following the deformation on the back surface side varies depending on the material of the backing material.

  The backing material is thicker than the change width in the direction of the shape of the front side of the block-like member (height from the back side to the front side), and can be deformed along the shape of the front side of the block-like member. For example, a mat or thick sheet can be used. When there is a height from the back side to the front side between the target block-like members, among all the block-like members, those having the front portion of the lowest height and the front portion of the highest height It is also possible to use a backing material that is thicker than the difference between the lowest height and the highest height.

  The backing material covers the entire front side of the block-like member (preferably substantially on the entire front side of the block-like member) in order to prevent a part of the fluidized solidifying material from reaching the front side of the block-like member due to penetration or the like. It is preferable to apply the adhesives so that they match, but this is not necessarily the case. For example, it can be attached to at least the entire outer peripheral portion of the front side of the block-shaped member.

  Adhesion of the backing material to the front side of the block-like member shall be performed via, for example, an adhesive (preferably an adhesive arranged as an adhesive layer on the back side of the backing material) or other adhesive. Can do. It is possible to use an anti-caking agent (for example, to add an anti-caking agent to an adhesive, etc.) in order to prevent a part of the flowable solidifying material from solidifying in a state where it has reached the front side of the block-like member due to penetration. preferable. Examples of the solidification inhibitor when the fluidizable solidifying material is ready-mixed concrete include various cement setting retarders.

  As a material for the backing material, for example, a foamed synthetic resin such as polyethylene foam or a polymer foam such as foamed elastomer is suitable, but is not limited thereto. The polymer foam is preferably a closed cell polymer foam in order to prevent a part of the fluidized solidified material such as ready-mixed concrete from penetrating into the interior, but for example, a coating or the like is made on the surface portion. It is also possible to use a material in which the bubble part is not exposed to the outside.

  (4) Base material

  The base material is a member having a planar portion, and can be, for example, a sheet shape, a flat plate shape, or other shapes, and can be made of a flexible material or a material that is rigid or difficult to bend. More specifically, for example, there can be mentioned a wooden sheet such as a synthetic resin sheet, a synthetic resin plate and a concrete panel, a mold having a lattice-like portion as a joint forming material, and the like.

  The planar part can be a part that is a plane or a part that has a shape along a plane (may have irregularities or the like). The planar portion is, for example, a predetermined location on either the front or back surface of a sheet-like or flat substrate, or a predetermined location corresponding to the bottom surface in each lattice in a mold having a lattice-like portion. be able to.

  An adhesive layer or the like can be provided on the planar portion of the base material in order to join the shaped backing material surface side.

  (5) Shaping the surface of the backing material

  The surface side of the backing material in the block composite is shaped into a predetermined shape.

  The shaping can be performed by, for example, mechanical excision or cutting, but other means such as excision with a laser or high-pressure water, thermal deformation, and thermal melting can also be employed.

  The predetermined shape to be obtained by shaping corresponds to the shape of the predetermined location for supporting the surface side portion of the backing material in the predetermined location in Step C and determining the position and posture of the block-shaped member in the block-shaped composite. Shape. By matching the predetermined shape on the surface side of the backing material with the shape of the predetermined location that supports the surface side portion of the backing material (for example, by making both flat or a shape along the plane, or for example, The position and orientation of the block-shaped member in the block-shaped composite body are determined with respect to, for example, a predetermined reference surface or other reference location by forming a fitting convex portion and forming a fitting concave portion corresponding to the other. be able to.

  More specifically, for example, the back side of all the block-like members has a shape along a plane, and the back side of the backing material in all the block-like composites is the back side of the block-like members in each block-like composite. It may be shaped so as to be parallel with a certain height with respect to the plane along. The maximum thickness of the backing material after shaping is thicker than the change width in the height direction of the shape on the front side of the block-shaped member.

  The shaping of the surface side of the backing material in the block composite can be performed individually for each block composite, for example.

  Further, the shaping of the surface side of the backing material in the plurality of block-shaped composites can be performed collectively by arranging the block-shaped composites in a predetermined state, for example. As an example in this case, a plurality of block composites are arranged on one side of the plane so that the back side of the block members is along a predetermined plane (for example, on a plane such as a predetermined horizontal plane). More specifically, for example, for example, the back side of the block-like member of each block-like composite is placed in each lattice in a frame body having a lattice-like portion, and the side surfaces of the block-like members are mutually connected. The surface side of the backing material of these block-like composites is parallel to the plane (with a certain height from the plane along which the back side of the block-like member lies). And parallel shape).

  (6) Position and posture of block-shaped member

  The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is supported at a predetermined position of a shape corresponding to the predetermined shape with a joint gap between the side surfaces of the block-shaped member. Thus, the position and posture of the block member in the block composite can be determined. The block-like members are arranged in a grid pattern of, for example, n × m (n and m are each an integer of 1 or more and n + m is 3 or more, or both are an integer of 2 or more or 3 or more). (For example, a plurality of block-like members having the same square shape in a plan view may be arranged by translating the squares in the plan view vertically and horizontally by a predetermined interval), but is not limited thereto. .

  The predetermined portion may be a sheet, a plate, a lattice, or other shapes, such as a member made of a flexible material or a member made of a material that is rigid or difficult to bend, such as a sheet body or a plate. Predetermined locations on the surface, the bottom of the lattice in the frame having a lattice-like portion, and other forms of members can be defined as predetermined locations.

  The back side of all the block-like members has a shape along the plane, and the surface side of the backing material in all the block-like composites has a certain height with respect to the plane along which the back side of the block-like member in each block-like composite extends. When shaped so as to be parallel to each other, the surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite in a state having a joint gap between the side surfaces of the block-shaped member, By joining to the planar portion of the substrate having the planar portion, the position and posture of the block-like member in the block-like composite can be determined. In order to join the surface side portion of the backing material to the planar portion of the substrate having a planar portion, an adhesive (for example, an adhesive in an adhesive layer provided on the planar portion of the substrate) or other adhesive is used. Besides these, various means can be adopted.

  More specifically, for example, the back side of the block-like member of the block-like composite is placed in each lattice in the frame body having the lattice-like portion, and the joints between the side surfaces of the block-like member are placed on a predetermined plane. A planar portion of the base material is provided on the surface side of the backing material that is parallel to the plane in a state of having a gap for use, and an adhesive (for example, an adhesive layer provided on the planar portion of the base material). The position and posture of the block-like member in those block-like composites can be determined with respect to the planar portion of the base material.

  (7) Joint forming material

The joint forming material is closer to the back side than the front side of the block-like member in the joint gap between the side surfaces of the block-like member (usually a position slightly closer to the back side than the front side of the block-like member), preferably in a block shape For closing at a certain thickness direction position from the front side or the back side of the member , that is, the position between the front side and the back side of the block-like member of the joint gap between the side surfaces of the block-like member, This is for closing with a joint forming material so that joints can be formed on the back side . Further, the joint forming material can be similarly used to form joints in a portion of the outer peripheral portion of the block-shaped member that is not opposed to another block-shaped member (for example, the outer peripheral portion of the arranged block-shaped member group). The joint forming material may have an appropriate shape such as various lattice shapes or a square cross-section rod shape for forming the lattice depending on the shape and arrangement of the block-like member.

  The joint forming material can be an independent member, or can be, for example, a part of a member such as a mold or a panel constituting a mold for solidifying the fluid solidifying material.

    The joint forming material can be of a certain height, but is not limited thereto.

  As the joint forming material, a polymer material such as a synthetic resin or an elastomer, a ceramic material, a metal material, or the like can be used.

  A release agent for separating from the solidified fluidized solidified material or a material having releasability can be used in at least a portion of the joint forming material that can come into contact with the fluidized solidified material.

  The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is joined to the planar portion of the substrate having the planar portion, with a joint gap between the side surfaces of the block-shaped member. Thus, when the position and posture of the block-shaped member in the block-shaped composite are determined, the joint-forming member is inserted into the joint gap between the side surfaces of the block-shaped member, and the joint-forming member is By joining to the material, the back side of the joint gap closer to the back side than the front side of the block-shaped member can be closed by the joint forming material.

  (8) Flowable solidification material

  The flowable solidifying material is arranged such that a portion excluding the front side portion of each block-like member is embedded in a state where a joint gap is provided between the side surfaces of the plurality of block-like members, and each block is solidified. This is for forming a cast body in a state where the front side portion of the member is exposed and a joint exists between the block members.

  As the fluidized solidifying material, various synthetic resins or other materials can be used in addition to various concretes. In the case of concrete, reinforcing bars or other reinforcing materials can be used, and in the case of synthetic resins, fibrous reinforcing materials or other reinforcing materials can be used.

B Reinforcement C Concrete C1 Joint D Concrete formwork J Joint forming material L Backing material L1 Back side L2 Front side M Frame M1 Grid frame P Concrete panel Q Tile sheet R Precast concrete panel S Base material T Tile T1 Front side T2 Back side T3 Groove Recess T4 Side X Block complex

Claims (5)

A plurality of block-shaped members having a front side and a back side are embedded in the fluidized solidified material except for the front-side portion of each block-shaped member with a joint gap between the side surfaces of each block-shaped member, By solidifying the fluidized solidified material, the front side portion of each block-shaped member is exposed, and a method of producing a cast body in which joints exist between the block-shaped members,
The shape of the front side of at least one block-like member among the block-like members changes in the height from the back side to the front side of the block-like member,
The entire thickness of the front side of each block-shaped member or at least the entire outer periphery thereof is thicker than the change in the height direction of the shape of the front side of the block-shaped member, and deforms along the shape of the front side of the block-shaped member A step of forming a block-shaped composite by pasting the back side of the backing material that can be bonded in a deformed state along the shape of the front side of the block-shaped member;
Step B for shaping the deformed surface side according to the deformation on the back side of the backing material in the block-shaped composite into a predetermined shape;
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is supported at a predetermined position of a shape corresponding to the predetermined shape with a joint gap between the side surfaces of the block-shaped member. Step C for determining the position and orientation of the block-shaped member in the block-shaped composite,
A step D of closing the position between the front side and the back side of the block-shaped member among the joint gaps between the side surfaces of the block-shaped member with a joint forming material so that the joint can be formed on the back side of the position ;
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite with the joint gap between the side surfaces of the block-shaped member obtained through the above steps corresponds to the predetermined shape. The position and posture of the block-shaped member in the block-shaped composite body are determined, and the joint-side gap between the side surfaces of the block-shaped member is between the front side and the back side of the block-shaped member. For the one where the position between them is blocked by the joint forming material so that joints can be formed on the back side of the position, the part excluding the front part of each block-like member is embedded in the fluidized solidified material, and the flow by solidifying the sexual solidified material, to expose the front portion of the block-shaped member, and wherein the Rukoto produce a cast body in a state where there is a joint between the adjacent block-like member cast Of the process. The back side of all block-shaped members is a shape along a plane,
Step B is shaped so that the surface side of the backing material in all block-like composites is parallel to the plane along which the back side of the block-like member in each block-like composite extends along a certain height. The manufacturing method of the cast body of Claim 1 which is a process to perform.   In the above-mentioned step B, a plurality of block composites are arranged on one side of the plane such that the back side of the block members is along a predetermined plane, and the backing material of those block composites The manufacturing method of the cast body of Claim 2 which is the process of shaping so that the surface side of this may become parallel to the said plane. Step C is
The surface side portion of the backing material shaped into a predetermined shape in the block-shaped composite is joined to the planar portion of the substrate having the planar portion, with a joint gap between the side surfaces of the block-shaped member. Is a step of determining the position and orientation of the block-like member in the block-like composite ,
Step D is
By inserting a joint forming member into the joint gap between the side surfaces of the block-like member and joining to the base material, the position between the front side and the back side of the block-like member in the joint gap is determined by the position. The method for producing a cast body according to claim 2 or 3, wherein the cast body is closed with a joint-forming material so that joints can be formed on the back side of the sheet. A plurality of block-like members having a front side and a back side, a backing material for each block-like member, and a base material having a planar portion,
The back side of all block-shaped members is a shape along a plane,
The shape of the front side of at least one block-like member among the block-like members changes in the height from the back side to the front side of the block-like member,
The backing material that can be deformed along the shape of each block-like member and the front side of the block-like member is the entire front surface of the block-like member with the back side of the backing material deformed along the shape of the front side of the block-like member. Or, each block composite is configured by sticking to at least the entire outer periphery thereof ,
In each block-like composite, the backing material has a maximum thickness that is thicker than the change width in the height direction of the shape on the front side of the block-like member,
The front side deformed according to the deformation of the back side of the backing material in all block composites is shaped so as to be parallel to the plane along the back side of the block member in each block composite with a certain height. Has been
Each block composite is joined to the planar portion of the substrate having a planar portion on the surface side of the backing material with a joint gap between the side surfaces of the block-shaped member,
Among the joint gaps between the side surfaces of the block-shaped member, the position between the front side and the back side of the block-shaped member is blocked by a joint forming material so that a joint can be formed on the back side of the position. A block-shaped member holder.

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