JPS582042B2 - Manufacturing method and manufacturing equipment for composite concrete products - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a manufacturing method and manufacturing device for composite concrete products, and its main method is to layer a plurality of different types of concrete and non-concrete materials in order from the bottom in a formwork and solidify them as an integrated product. Features.

Cement-based concrete is rigid, durable,
Due to its ease of use and relatively low cost, its production continues to increase year by year.

In recent years, the disadvantages of concrete such as weight, water permeability, tensile strength, aesthetics, and initial strength have been improved, and its insulation properties and
Composite concrete with improved sound insulation properties is attracting attention as a means of expanding its uses and increasing added value.

This composite concrete is generally made by adding resin, glass fiber, steel wool, etc. during mixing of ordinary concrete.
When this is put into a mold and molded, the additives are evenly distributed throughout.

As mentioned above, this invention is not a composite concrete in which additives are added during concrete mixing, but various types of concrete including mortar mixed separately or non-concrete materials are layered and solidified within the same formwork. .

There are two conventional methods for producing products composed of adjacent dissimilar concrete layers.

One method is to divide the hopper inlets, which have the same area as the formwork opening, into multiple rows, and simultaneously drop different types of concrete from each of the dividers.

The second method is to fill the formwork with hardened concrete and then turn the face pallet containing decorative mortar upside down, which is often used in concrete block forming equipment for civil engineering.

The former method of simultaneous injection has the following disadvantages: the layered form of the product is unstable and quality control is difficult, it is difficult to use input materials with large differences in specific gravity, the loading mechanism is complicated, and pressing from above is required after loading. There are disadvantages such as pressure is not useful for bonding each layer and changing the thickness of each layer is troublesome.

Furthermore, the latter surface pallet type is limited to cases in which a thin layer of mortar or the like is added to the surface of the product, and is difficult to be used as a manufacturing method for general layered composite concrete products.

Therefore, at present, in order to form the above-mentioned layered type, ready-made disparate products are often combined on-site.

This invention eliminates the need for such on-site joining work, and Figures 3 to 5 show three examples of composite concrete products made according to this invention.

The structure shown in Fig. 1 has a layer of decorative colored mortar 1, a normal concrete layer 2, a foamed resin layer 3, and a normal concrete layer 2.

The one in FIG. 4 is composed of a colored mortar layer 1, a normal concrete layer 2, a heat insulating resin board 4, a normal concrete layer 2, and a colored mortar layer 1.

The product shown in Figure 5 is a concrete block for retaining walls. First, in order to create a mortar layer 1 that will become the surface of the block, mortar is dropped from the opening 10a of the formwork 10 drawn by the chain line, and the vibration causes the mortar to form on the bottom of the formwork. Spread evenly.

Subsequently, concrete is dropped and is sufficiently penetrated around the surface concave portion forming core 10b by vibration.

Then, a small amount of the ventilation/water permeable material 5 is dropped onto the substantially flat upper surface of the concrete layer 2a, in this case, on one side 9, and is caused to reach one side by vibration.

Finally, the concrete 2b layer was created.

This is so that when the concave part of the block surface formed by the core 10b is filled with soil and flowers are planted, the soil can absorb nutrients from the soil at the rear of the retaining wall through the aeration and water permeable material 5.

As the breathable and water permeable material 5, in addition to concrete with a reduced proportion of fine aggregate or coarse aggregate itself, any suitable non-concrete material may be used, as long as it is designed so that the resulting reduction in the strength of the block will not be a problem. good.

The product shown in Fig. 6 is a water conduit pipe that integrates a road gutter and a lid, and has water permeability in the lid part.First, ordinary concrete is poured and the lower side of the core 10b is filled by vibration to form the lower layer 2.

Next, a second layer 6 is created by adding water-permeable concrete.

Then, after the reinforcing bars 7 are dropped flat on top of this, the top layer 6 of water-permeable concrete is created.

In this way, according to the present invention, in which different materials are successively introduced into the same formwork, a wide variety of composite concrete products can be developed.

Now, FIGS. 1 and 2 show an embodiment of the manufacturing apparatus of the present invention for manufacturing such products.

In this case, the main parts are the four input material storage sections 11a, 1lb, 11c, and 11d that are centrally installed in one place, and the respective flow streams that receive the respective contents from these storage sections and cause them to fall from the lower end opening. Hopper 12a, 12b12c, 12
d.Sequentially open the lower end of each of these hoppers into the same formwork 1
The drive and guide mechanism for relative movement to above 0, in this case, the fluid pressure cylinder 13, turret plate 14, horizontal receiving plate 15, etc., and each hopper 12a, 12b...
A closing mechanism that allows the contents to fall only when ... comes onto the formwork 10, in this case a horizontal receiving plate 15 which is also a hopper guide mechanism.
etc.

Mixers 16a and 16 dedicated to each storage section shown only in FIG.
After kneading b, 16c, 16d like resin mortar,
The kneaded material can be used even if it hardens within several tens of minutes, and the kneaded material is put into the corresponding storage sections 11a, 11b, etc. as shown by the arrows using a skip hoist or the like, and is used immediately.

Mixer 1 6a, 1 6b... and storage section 11a
, 11b... may be partially unused or replaced depending on the target product.

For example, the product shown in Figure 3 requires three types of input materials: mortar, concrete, and foam resin particles or pieces, so mixer 1
6a and 16b make mortar and concrete, mixer 16c is used to apply adhesive to the surface of resin particles, small pieces, etc., and mixer 16d is left to rest, but if necessary, an injection device is attached to bond it to the boundary surface of each layer. A mortar layer can also be created by spraying.

In addition, the mixer required to make the product shown in Figure 4 is mortar,
For concrete only, one of the mixers will be moved to a standby position for the heat insulating resin plate 4, and its storage section and feeding means will also be replaced.

In order to manufacture the product shown in FIG. 5, in addition to mortar and concrete, a mixer or a simple feeding means for the breathable and water permeable material 5 is required, and there are no changes to the storage sections 11a, 1lb, . . . .

Use the rest storage area for upper concrete 2b,
The hoppers 12a, 12b, . . . may all be sequentially dropped once to fill the formwork 10.

The embodiment shown in FIG. 6 requires reinforcing bars 7 in addition to normal concrete and permeable concrete, but the feeding mechanism is the same as in the case of the resin plate 4 described above.

In this embodiment, the lower end of each storage section 11a, 11b, . . . occupies a quarter of the opening area of each hopper 12a, 12b, . When the hopper reaches the position, the gate 17 of the storage section is opened and the contents are dropped.

The figure shows a situation where the gate 17 of the storage section 11a is opened for the required time and the required amount of concrete 2 is dropped into the hopper 12a.

The turret plate 14, which rotates horizontally and is evenly distributed around each hopper 12a, 12b... The supporting leg rollers 19 are configured to roll on the horizontal receiving plate 15.

The turret plate 14 receives the reciprocating rotational drive of the fluid pressure cylinder 13 via a chain 20 and a chain wheel 21.

Of course, the driving source may be a motor.

The hoppers 12a, 12b, and 1.2c are bottomless frames and have the same shape, but only the hoppers 1 and 2d have a lower end opening 22 narrowed to a short rectangular shape as shown in Fig. 1 in order to drop the mortar in a thin layer. As shown in Figure 7, the mortar is dropped uniformly while moving.

If necessary, an impeller is attached just above the opening 22 and rotated as the hopper moves to keep the mortar falling speed constant.

The impeller may be of a known type, and its drive mechanism may be a known technique such as rotating with a chain linked to movement of the hopper 12d.

At the same time, impellers are attached to the lower end supply ports of the storage sections 11a, 1lb... to keep the flow rate of the contents constant, and by controlling the opening time of the gate 17, each hopper 1
It is also desirable to limit the amount of supply to 2a, 1, 2b, . . . to the required amount, but since this is also a well-known technique, detailed explanation will be omitted.

The same goes for attaching a vibrator to the storage section or hopper to promote flow.

Generally, each hopper 12a, 12b... is provided with a closing mechanism, but in this embodiment, the storage section 11
Each hopper places the contents on the horizontal receiving plate 15 from the time when the contents are received from a, 11b, . . . until the contents reach the formwork 10.

The contents are scraped from one input port 23 of the horizontal receiving plate 15 into the formwork 10 below.

This method is similar to the mobile hover that is often used in instant demolding molding machines for manufacturing concrete blocks for civil engineering.
In short, the hopper of the present invention may be of any type as long as it can accept various concrete or non-concrete materials including mortar and move its lower end opening onto the formwork.

If the lower end opening is provided at the tip of the flexible tube, it is literally possible to move only the opening onto the mold and return it.

When the opening reaches the top of the formwork, the opening closing mechanism may be opened for a certain period of time in response to a command from the detection device to achieve a dropping amount that corresponds to the thickness of the layer.

These, as well as the driving and guiding mechanisms of the aperture, are left to the well-known skill of the designer.

In this case, the formwork 10 has one side wall connected to the hydraulic cylinder 2.
4 to release the product, and the rear cylinder 25 to roll the product.
This is a type of extrusion onto a conveyor 28.

In order to layer the poured concrete evenly, the formwork 10 is vibrated by a vibrator (not shown), so the vibration isolating rubber 26
This is attached to the machine frame 18a via.

Once the formwork 10 is filled, the well-known presses 27, 27a
After compressing the layered material in the mold from above and below, the mold is removed.

Of course, the mold may not be removed immediately, but may be sent to a curing facility while being placed in the mold 10.

The lower press 27a presses the bottom surface of the mold 10, but the upper press 27 needs to enter the opening surface of the mold 10.

Since the mortar hopper 12d has a narrow bottom, it is moved from above the formwork 10, the hopper 12c with a wide open bottom is moved onto the formwork 10, and the press 27 is operated.

This ensures that the laminated materials are joined together.

Note that press pressure can also be used in the middle of the formation to smooth out the gaps between the layers.

Even if the opening area of the formwork 10 is small, as in the product shown in Figure 5, by applying pressure to the upper surface of the material, the bonding of the internal laminated materials can be strengthened, and the intervening material layers with weak bonding strength can be strengthened. ,
This makes it possible to provide a composite product that is less likely to peel off from the boundary between different materials.

The configuration of the present invention has been explained above mainly with reference to one embodiment. However, as mentioned during the explanation, each component was designed to be suitable for the intended product, factory equipment, etc. through the well-known techniques and ingenuity of designers and on-site engineers. It is natural that changes and applications will be made as appropriate.

For example, the hoppers 12a, 12b, etc. are arranged adjacent to each other in series, and the hoppers are advanced onto the formwork 10, and the contents are dropped one after another and passed through, and during press pressurization and demolding (or formwork exchange). In order to supply each material to each hopper, the hopper does not move, and the formwork on the trolley is advanced beneath it, and the hopper's closing mechanism continuously supplies one material after another, so that there is no need to close the opening. A mass production method such as dropping a fixed amount of contents into a mold is also easily considered.

This invention breaks down the conventional wisdom of manufacturing concrete products, which requires one formwork, one hopper, and one material.

Mixed fresh concrete and mortar, as well as non-concrete materials as needed, are dropped into the same formwork one after another through a dynamic hopper, stacked and layered, and the disparate materials are integrated using a combination of vibration and pressure. , making it possible to mass produce composite concrete products made of different materials, which was unthinkable with conventional concrete products.

The concrete hopper is not only used to simply drop concrete into formwork, but it can also be used to drop concrete in layers one after another.
We demonstrated that the thickness of the layer can be easily changed, and that even a thin layer of mortar can be formed by vibration, dropping, and use of a press mid-way.

In addition, it is possible to insert non-concrete materials, plates, etc. between the layers, giving properties unimaginable to conventional concrete products.In the future, we will be able to develop a wide variety of composite concrete products depending on the purpose of use. It became possible to do so.

[Brief explanation of drawings]

Figures 1 and 2 are a plan view and an elevation view of an embodiment of the manufacturing apparatus of the present invention, Figures 3 to 6 are explanatory diagrams of four examples of products according to the present invention, and Figure 7 is a thin layer formed by dropping mortar. It is an explanatory view of the hopper which forms. 1 1 a, 1 1 b... Storage section, 1 2 a
, 1 2b...Hopper, 13...Driving fluid pressure cylinder, 15...Horizontal receiving plate serving as a guide and closing mechanism.

Claims (1)

[Scope of Claims] 1. A plurality of concretes and mortars are put into each storage section from a dedicated mixer, respectively, and put into a downstream hopper from each storage section, and the lower end opening of the downstream hopper is sequentially connected to the same formwork. A manufacturing method in which the contents are poured into the mold and layered, and the mold is removed immediately or after curing to obtain an integrated product, and the above-mentioned various types of concrete and mortar are poured into the mold and layered. A method for producing composite concrete products characterized by performing vertical pressurization during or at the end of the process while the formwork is vibrating. 2. A method for manufacturing a composite concrete product according to claim 1, wherein the various types of concrete include air-permeable concrete. 3. A composite concrete product in which the lower end opening of the downstream hopper has a width greater than or equal to the width of the formwork opening, and a height and length sufficiently shorter than the vertical length of the formwork opening, in the manufacturing method according to claim 1. manufacturing method. 4 Put two or more types of materials including various types of concrete, mortar, and non-concrete into their respective storage sections, put the materials from each storage section into the flow hoppers, and sequentially connect the lower end openings of the flow hoppers to the same formwork. It is a manufacturing method in which the contents are poured into the mold, layered, and removed from the mold immediately or after curing to obtain an integrated product. A method for manufacturing composite concrete products characterized by performing vertical pressurization at the end while the formwork is vibrating. 5 One or more types of concrete, non-concrete materials as necessary, each storage section, each hopper that receives the contents from each of these storage sections and drops it from the lower end opening, and each of the above hoppers. a drive and guide mechanism for relatively moving the lower end openings so as to sequentially bring them onto the same form;
The device is equipped with a closing mechanism that allows the contents to fall only when each hopper reaches the above-mentioned formwork, and the contents dropped from each hopper are layered so that the total just fills the formwork. The hoppers are connected by a turret-type horizontal rotation mechanism so that they can enter directly under the supply ports aligned on the same horizontal plane of each of the above-mentioned storage compartments, and the lower end openings of each hopper are placed on a common circular horizontal receiving plate and slid. A composite concrete product manufacturing facility, characterized in that the contents are allowed to fall from one input port of the receiving plate into the formwork below.