JPH0229482B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a method for laminated forming of composite concrete products by immediate demolding.

<Conventional technology> When obtaining an integrated product by sequentially supplying a plurality of different types of concrete to the same formwork and performing different layer molding, the bottom opening of the formwork is closed with a product receiving pallet and the inside of the formwork is poured from the top opening. Concrete is poured into the space, and the next layer of concrete is leveled using a press or vibration in the middle of the layer so that the layers can be evenly stacked, and then the next concrete is poured and finished with a press vibration finish. Then, lamination molding was performed.

<Problems to be solved by the invention> In the conventional layering method using layered charging, the lowermost layer has a larger difference from the top opening of the formwork, so depending on the specific gravity of the material being charged, the material may be biased to one side of the formwork. It is difficult to maintain an even thickness because the material separates due to vibration or vibration, so before layering the next layer, it is necessary to flatten it by pressing or vibrating and correct it before applying the next laminated material. It is filled by dropping.

However, in the case of non-fluid materials that can be immediately demolded, it is often not possible to uniformly correct the problem by pressing and vibration alone, and since it is inevitable that materials will mix between each layer, the thickness of each layer is increased. Because it was solidified, it was not possible to mold thin products.

In recent years, in order to reduce the weight and improve the strength of products, by laminating composite concrete and non-concrete materials mixed with various expensive fibers and resins, it has become possible to obtain products with high surface decoration, thickness, and strength. However, the conventional layered method requires a certain amount of thickness between the layers, which often results in the use of more expensive materials than designed, which has the disadvantage of increasing the cost of the product.

<Means for Solving the Problems> In order to minimize the thickness of the material stacked between each layer, the present invention uses a movable hopper at the lower end when charging the material into the space formed in the formwork. A product receiving pallet can be placed on standby near the opening to create a loading space for the materials to be loaded in advance.
By lowering the product receiving pallet in synchronization with the falling speed of the material to form a space within the formwork, the forming space is minimized to reduce the movement of the input material, or By making the charging width extremely small, the material is evenly dropped into the formwork, allowing the material to be filled in an even layer of thickness, thereby reducing movement and separation during charging even with materials of light specific gravity.

This makes it possible to layer concrete with uniform density, even with dry concrete with no fluidity, or with highly viscous materials.

It also made it possible to thinly coat the top and bottom surfaces with expensive materials, make it easier to decorate the surface without using concrete, and enable layered molding of thin, high-value-added products with immediate demolding.

<Function> By minimizing the feeding distance between the material to be fed into the movable hopper and the product receiving pallet, the hopper is placed on standby on the top of the formwork in advance to reduce deviation due to falling when the hopper concrete is fed. The product receiving pallet is lowered and a space corresponding to the thickness of the layer to be introduced is formed between the lower end opening of the hopper and the upper part of the formwork and the product receiving pallet or layer surface. The material falls evenly and the top surface of each layer is layered without waste, making leveling by pressing or vibration easier.As a result, the space between each layer can be made thinner, making it possible to layer many different types of materials. It is also relatively thin and can be laminated and molded as an integral product.

<Example> Figures 3 to 7 show an example of the forming process of the present invention, in which 1 is a stationary hopper, and 2, 3, and 4 are movable hoppers that charge different types of concrete into the formwork. , 5 is a formwork.

Reference numeral 13 denotes a product receiving pallet 13 that is lowered through a demolding rod inside the mold during or after material is being loaded.
It is.

Conventionally, as shown in Fig. 13, the lower layer of concrete is poured onto the top surface of a plain pallet 25 placed at the bottom opening of the formwork, and then the concrete is vibrated and finished to level the surface of the next layer. The process of adding and filling the next layer of material was repeated to form an integrated product.

Now, embodiments of the lamination molding method of the present invention will be described. The molding machine shown in FIG. 1 is equipped with three stationary hoppers, and each movable hopper is equipped with a weighing container 10 capable of weighing. Then, the load cell 7 weighs the concrete that has fallen into the weighing container 10 from the weighing hole 9 of the fixed hopper 1 in accordance with the volume of the first layer, and the shutter 8 closes and the amount of concrete dropped into the weighing container 10 is equal to one dose. only is supplied.

Next, the cylinder 11 of the measuring container 10 is moved differentially to supply concrete to the movable hopper 2, and in order to level the supplied concrete in the movable hopper, the tips of the vibrator 14 and scraper 15 of the movable hopper are extended to make it even. Evenly.

When the moving hopper 2 is moved horizontally to the mold opening 5' as shown in FIG. When the movable hopper 2 reaches directly above the formwork opening 5', the formwork vibrator 6 is started and the product receiving pallet 13 is lowered in synchronization with the falling speed of the concrete. As the pallet descends, the weighed concrete is moved into the formwork and filled into the formwork to a substantially uniform thickness.

When the hopper retreats, the entire weight of the weighed concrete in the movable hopper is filled below the top of the formwork, so the hopper does not pull back or scrape the concrete on the top of the formwork. The poured concrete can maintain approximately the same thickness and density.

In this way, since the distance between the lower end opening of the hopper and the product receiving pallet is short, there is little separation of the material due to shifting or movement during vibration, and the formation boundary surface is kept relatively horizontal. In this way, when laminating many thin layers in the formwork, there is no need to perform press pressure vibration molding to improve adhesion each time, and a powerful press with vibration is used at the end of lamination. Then, each layer is integrally laminated and molded.

In addition, when stacking layers with thick layers or when stacking materials with extremely different specific gravity or materials, the fixed hopper 1 in which each different material is stored is metered and supplied in the amount to be stacked to the dedicated mobile hopper 3. After the material is fed into the space formed in the mold, the second layer is pressed and vibrated.

Next, the movable hopper 4, which has been supplied with material for the third layer from the stationary hopper, feeds the material into the space formed as the pallet descends, and then moves to the seventh layer.
As shown in the figure, the press cylinder 18 is lowered, the upper surface is finished with press vibration, and the laminated molded product is removed.
Demould the product from within.

In this way, the laminated molding method of the present invention forms a space on the top surface of the formwork by lowering the product receiving pallet according to the amount to be filled into the top surface of the formwork, so it can be used even with thin layers of concrete made of different materials with extremely different specific gravity. It is possible to perform laminated molding while maintaining uniform thickness.
Note that whether press vibration molding is performed during or at the end of lamination is determined by the material, thickness, and product shape.

Figure 8 shows an example in which the input width of the moving hopper is extremely small.Since the input port 22 is small, the product receiving pallet is lowered at the same time as the hopper moves forward, and the concrete supplied into the moving hopper is transferred to the formwork by the time the hopper moves forward. It falls evenly within the container.

Therefore, by freely selecting the forward and backward speed of the moving hopper depending on the type of material to be input and the shape of the product, it is easy to stack a thin layer of concrete.

Figure 9 shows that seed stones 23 of decorative fine aggregate are scattered and placed on the upper surface of the product receiving pallet in order to form an exposed surface with natural airflow, and then a base layer of concrete is layered on top of the seed stones 23 for integral molding. In this embodiment, after separation from the product receiving pallet, the surface can be washed with water to remove unhardened cement or mortar, or after hardening, it is possible to further enhance the design of the surface by sandblasting or shotblasting. Alternatively, a product receiving pallet with seed stones placed thereon may be inserted in advance to form several layers of joint mortar, base concrete, etc.

FIG. 10 is a perspective view of a product that facilitates creating a texture resembling a natural pattern of unevenness by breaking the sandwiched decorative material at an intermediate position after curing and hardening.

Figure 11 is a perspective view of a product that has been integrally laminated with non-concrete materials.When laminating this product, first of all, the surface of the first layer at the bottom is formed using decorative colored mortar M. After evenly feeding the mortar, a combination of press and vibration is used to smooth the upper surface of the mortar and to improve adhesion to the Styrofoam H. 26 with an affinity adhesive, the product receiving pallet is lowered to form a space for the Styrofoam H to enter into the formwork, and then the movable hopper containing the Styrofoam H is advanced and inserted into the formwork. Styrofoam is dropped onto the first layer, and the adhesive is sprayed onto the top surface of the Styrofoam H again.

Next, the pallet is lowered, and the moving hopper of ordinary concrete C for the foundation is advanced and poured onto the top surface of the non-concrete foamed polystyrene H. After filling, the press plate 12 is lowered while applying vibration to finish the top surface. The adhesive sprayed on the interface with the Styrofoam acts, allowing the upper and lower layers of ordinary concrete C and decorative mortar M to adhere to the Styrofoam and solidify as one piece.

In this case, if the moisture content of the decorative mortar and ordinary concrete is low, adhesion will be facilitated by sprinkling water in addition to the adhesive to give fluidity to the bonding surface.

Although the embodiments of the present invention have been described above, the term "concrete" here includes composite concrete whose strength is improved by adding small amounts of materials such as mortar, various fibers, and resins.

This manufacturing method can be used to produce foam materials with extremely light specific gravity, various synthetic resin plates formed to an appropriate thickness, monolithic refractories such as synthetic fiber mats and tiles, as well as powdered materials such as rubber chips and glass beads. Regardless, it is possible to form layers of materials with different specific gravity between concrete and non-concrete using cement or resin as a binder, and there is no need to weigh all of the concrete and non-concrete to be laminated. It is only necessary to supply the capacity according to the forming layer in combination with the above-mentioned method. By layer forming various types of materials including non-concrete materials, the instant demolding method for composite concrete products with high strength and added value will be significantly improved. was completed.

<Effects of the Invention> In this invention, a space corresponding to the thickness of the layer is formed in the upper part of the mold each time the material is poured, and therefore it becomes easy to make relatively thin layers for each layer.

This eliminates the need to create partially thick and thin layers within the formwork, making it possible to create an integrated product using high-strength composite concrete or non-concrete materials mixed with various expensive resins and fibers in a relatively thin state. It can be laminated to provide cosmetic and insulation properties,
Composite concrete products with excellent sound insulation properties and various strengths can be easily laminated and formed, and the economic effects thereof are extremely high.

[Brief explanation of drawings]

Fig. 1 is a partially longitudinal front view for explaining the molding method of the present invention, Fig. 2 is a plan view, Figs. 3 to 7 are explanatory diagrams showing examples of the lamination molding method, and Fig. 8 Figure 9 is an example of a case where the input port is made smaller, Figure 9 is an example of a decorative gravel surface, Figures 10 and 12 are perspective views of other products, and Figure 11 is an example of a case where non-concrete materials are laminated. FIG. 13, which is a perspective view of the product, shows a conventional molding method. C... Ordinary concrete, M... Decorative mortar, H... Styrofoam, 1... Stationary hopper, 7... Load cell, 21... Hopper lower end opening, 23... Seed stone, 24... Decorative material, 26...
...boundary surface.

Claims (1)

[Scope of Claims] 1. A molding machine is equipped with stationary hoppers that respectively store a plurality of different types of concrete, and each material is supplied from the storage section of each stationary hopper into a movable hopper, and the movable hoppers are placed on the same formwork. This is a manufacturing method in which the concrete is layered in a formwork and removed immediately or after curing to obtain an integrated product. The movable hopper that feeds concrete into the formwork is supplied with concrete weighed in advance to form the desired shape from at least one stationary hopper that stores the material to be layered. When feeding the above-mentioned concrete, a movable hopper that reciprocates on the upper surface of the formwork supplies and fills the space formed by lowering the product receiving pallet in the formwork, and then from the position where it is stopped in the formwork. Laminated molding of composite concrete products characterized by lowering the product receiving pallet again to create a space above the formwork and sequentially feeding different types of concrete, and performing pressure vibration molding in the middle or at the end of the layer to form an integral mold. Law. 2. The composite concrete product according to claim 1, characterized in that the lower end opening of the movable hopper has a width greater than or equal to the width of the formwork opening, and a vertical length that is sufficiently shorter than the vertical length of the formwork opening. Laminated molding method. 3.Put two or more types of materials, including a plurality of different types of concrete and non-concrete, into their respective storage sections, supply them from each storage section to a movable hopper, and bring the movable hopper onto the same formwork to form layers within the formwork. It is a manufacturing method to obtain an integrated product by demolding immediately or after curing, and concrete and non-concrete materials are supplied by lowering the product receiving pallet in the formwork, filling the space in the formwork with the material, and then removing the material from the mold. The product receiving pallet is lowered again from the position where it was stopped in the frame to create a space above the formwork, and the laminated materials are sequentially fed thereto, and the product is integrally molded by press pressure vibration molding in the middle or at the end of the layer. A lamination molding method for composite concrete products featuring the following. 4. The lamination molding method for composite concrete products according to claim 3, characterized in that an adhesive with affinity is sprayed or applied to the interface between the non-concrete material and each layer.