JP4521646B2 - Imitation brick manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to imitation bricks, and in particular, relates to imitation bricks that are easy to carry and excellent in workability, and imitation bricks excellent in aesthetics.
[0002]
[Prior art]
Bricks and blocks (hereinafter referred to as bricks and the like) are generally used for construction and civil engineering, but in recent years, they tend to be used for decoration such as interiors. However, conventional bricks and the like are heavy and require labor at the time of construction and construction, so that weight reduction is required, and various types of lightweight imitation bricks have been proposed. For example, a cemented cured product formed by mixing foamed resin, hollow ceramic particles, particulate material containing air bubbles, etc. (eg, Japanese Utility Model Publication No. 62-15539, Japanese Utility Model Publication No. 63-171521) Formed by using a lighter material than cement such as fly ash and incinerated ash (for example, Japanese Patent Laid-Open No. 2-217355, Japanese Patent Laid-Open No. 5-68959). Foamed or molded by mixing foaming agent or foaming agent into cement or resin (eg, Japanese Utility Model Laid-Open No. 5-49920, Japanese Utility Model Registration No. 3056059, Japanese Patent Laid-Open No. 10-316482) Etc.) are proposed.
[0003]
For these imitation bricks, various proposals have been made in which a cosmetic layer is formed on a part of the surface because pores and mixed particles appear on the surface, and it is difficult to use in parts that require aesthetics. Has been. For example, a glaze is applied and heat-treated to form an exterior (see JP-A-2-217355, JP-A-5-68954, etc.), a resin, paint, mortar, etc. Sho 62-132781, JP-A-5-49920, etc.), foamed resin particles exposed on the surface are melted to form irregularities (see JP-A 63-171521, etc.), foam concrete Cut in a semi-solid state to form a hardened surface layer (eg, see JP-A-10-316482, etc.), bonded surface cosmetic material layer (eg, Japanese Utility Model Laid-Open No. 58-39913, Japanese Utility Model No. 5-49920, registered utility model No. 3056059, etc.) have been proposed.
[0004]
[Problems to be solved by the invention]
However, it is difficult to say that the above-mentioned imitation bricks are sufficient for interior use in terms of weight and aesthetics. For example, a fireplace-like decoration table made by stacking bricks as an interior article is known. Since many bricks are used for this decoration stand, even if imitation bricks are reduced in weight, they become considerable heavy objects. For this reason, it is difficult to rearrange the decoration table in order to change the atmosphere of the living space, and there is a possibility that a large load is applied to the installation place and the floor surface or the like is damaged. The decorative table is expected to have a calm atmosphere similar to the case where fired bricks are used, but for the lighter imitation bricks, there are bubbles and mixed fine particles appearing on the surface. Therefore, even if a cosmetic material is applied to the surface, it is difficult to bring out the atmosphere. Moreover, about the imitation brick etc. which provided the surface decorative material layer, all are provided in the 1st or 2nd surface, and there is nothing provided in the whole surface. When it is provided on the entire surface, a seam is formed between the surface decorative material layers on each surface, which may cause an aesthetic defect.
[0005]
Therefore, as a result of earnest research on weight reduction of imitation bricks, etc., by covering the core made of a lightweight material with an outer shell made of a cement-based hardened material that hardens by mixing with water so as to be located in the center, it is more It has been found that lightweight imitation bricks can be molded. That is, with respect to the conventional imitation brick or the like, the ratio of mixing lightweight materials such as foamed resin particles is limited from the viewpoint of strength, and it is difficult to reduce the weight sufficiently. On the other hand, for those with a core, the outer shell made of cement-based hardened material is mainly responsible for compressive strength, bending strength, etc., and the core is responsible for tensile strength, and the core and outer shell are integrated. The core will reinforce the outer shell. As a result, the thickness of the outer shell can be reduced, and the amount of cement-based hardened material forming the outer shell can be made much smaller than that of the conventional imitation brick and the like, thereby reducing the weight.
[0006]
By the way, Japanese Utility Model Publication No. 55-71213 discloses a concrete block for revetment, etc., in which wastes such as metal products are hardened and covered with an outer shell made of a cement-based hardened material. Japanese Patent Application Laid-Open No. 58-500557 discloses that two cavities formed in the outer shell are filled with foamable resin, the cavity is closed with a closing member, the resin is foamed, and the foaming member is closed after foaming. An insulating block formed by removal is disclosed. The former is required to be extremely heavy because the core is made of heavy material and is used for revetment, and is not intended to be lightened at all. Further, the external shape is formed without particular consideration, and the surface has a seam or the like by a mold, and it is difficult to say that it has an excellent aesthetic appearance. The latter is lightweight because the outer shell has a cavity and is filled with foamed resin, but it is not a closed structure in which the foamed resin is wrapped in the outer shell to ensure strength. Since it is necessary to increase the thickness of the outer shell and provide a reinforcing wall, it is not necessarily light. Moreover, the outline of the cavity and the foamed resin appear on the surface, and it is difficult to say that the material has excellent aesthetics.
[0007]
The present invention has been made in view of the above-mentioned conventional situation, and its problem is to provide a dummy brick that is lightweight and excellent in carrying and workability, and further imitation brick that is excellent in aesthetics and can be applied to interiors. It is in.
[0008]
[Means for Solving the Problems]
In order to solve the above problems, in the present invention, a core made of a light material made of natural or man-made is coated with an outer shell made of a cement-based hardened material so as to be located in the center. Since the surface of the core is covered with a hard outer shell and the outer shell and the core are united, the compression strength, bending strength and tensile strength of the core and outer shell are combined, so the weight It is stronger than the image that comes from, and can secure the strength required for imitation bricks. And by using a core with the dimensions and strength required for imitation bricks, the thickness of the outer shell can be reduced, the overall weight can be reduced, and the outer shell is required as imitation brick It is possible to have a surface texture.
[0009]
  That is, the imitation brick of the present invention comprises a core made of a lightweight material disposed in the center and an outer shell made of a cemented hardened material that is integrally formed by wrapping the core.An imitation brick, which is formed by a formwork comprising a saddle-shaped formwork body formed deeper than the thickness of the imitation brick and a pressing formwork mounted in the upper part of the formwork body, A fluid cemented cured material forming a part is poured into the mold body, and a core material made of a lightweight material is placed on the cemented cured material so as to be the center position of the mold body in plan view. The core material is squeezed into the cemented hardened material until the thickness of the cemented hardened material becomes equivalent to the thickness of the outer shell, and the fluid hardened cemented material that forms the remainder of the outer shell is used as the core material. Pour into the mold body so as to cover it, smooth the cement-based cured product, and then attach and close the pressing mold in the upper part of the mold body so as to press the upper surface of the cement-based cured product. Keeping the pressed hardened cement until it hardens Ri is molded,The outer shell is a single layer and has a seamless structure over the entire surface.
[0010]
  Imitation brick of the present inventionManufacturing methodConsists of a lightweight core placed in the center and an outer shell made of cementitious hardened material that surrounds the core., The outer shell is two layers of inner shell and outer shellImitation brickManufacturing methodThus, it is composed of a bowl-shaped formwork body formed deeper than the thickness of the imitation brick and a presser formwork to be installed in the upper part of the formwork body.The material is elastic material or FRP resinIn the formworkA method for producing imitation bricks to be molded,Paste-like cement-based hardened material that forms part of the outer shellThe outside was held with rigid reinforcementApply evenly to the thickness equivalent to the thickness of the imitation brick on the inner surface of the mold body, pour a fluid cement-based cured product that forms part of the inner shell, and mold the mold on the cement-based cured product in plan view. A core material made of a lightweight material is placed so as to be the center position of the frame body, and the core material is pressed down to a position where the thickness of the fluid cement-based cured product becomes equivalent to the thickness of the inner shell. The cemented cured product is pushed into the cemented cured product, and the fluidized cementitious cured product that forms the remainder of the inner shell is poured into the mold body so as to cover the core material. Attach and close the press mold that uniformly applies the paste-like cement-based cured product that forms the remainder of the outer shell on the inner surface to press the upper surface of the cement-based cured product,Hold the upper surface of the holding mold with a rigid reinforcement.By holding down until the cement-based hardened product is solidifiedTo moldImitation brick characterized byThe imitation brick that is manufactured isThe outer outer shell has a seamless structure over the entire surface.
[0011]
  Also,The material of the mold for molding the imitation brick of the present invention is an elastic material, FRP resin, or the like, and it is preferable that the outer side of the mold body and the upper surface of the pressing mold frame are held by a rigid reinforcing material at the time of molding. The core and the core material may be made of a porous material. An adhesive layer may be formed between the core and the core material and the outer shell.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an explanatory diagram of an imitation brick according to the first embodiment, and FIG. 2 is a manufacturing process diagram thereof. The imitation brick 1 shown in FIG. 1 is formed by imitating the appearance of a known fired brick by a manufacturing method described later, and has an outer shape of a horizontally long rectangular parallelepiped and has a surface of a fired brick pattern with no joints on the entire surface. Lightweight unfired brick. This imitation brick 1 has a structure in which a rectangular parallelepiped core 2 is arranged at the center, an outer shell 3 is formed to have a constant thickness so as to surround the core 2, and a thin adhesive layer is formed between the core 2 and the outer shell 3. 4 is formed. Since the core 2 and the outer shell 3 are integrated with the adhesive layer 4, the strength of compression, bending and tension of the core 2 and the outer shell 3 are combined and compared with the image that comes from the weight. Surprisingly big.
[0013]
The core 2 is made of an integral lightweight material. Lightweight materials used include a crushed stone, which is an aggregate usually mixed in cementitious hardened materials, with a specific gravity of about 2.6 and a specific gravity of sand of about 2.5, but less than these specific gravity. For example, the following porous material may be used. Natural pumice simple substance, natural pumice particles hardened with hardened material, foamed resin simple substance, foamed resin particles hardened with hardened material, ceramic fine hollow particles hardened with hardened material, foamed cement-based hardened Products (including foamed gypsum-based cured products, calcium silicate-based cured products, etc.), porous aluminum simple substances, sawdust and fir shells, etc., hardened with a cured product.
[0014]
Each of these porous materials has the following characteristics. Some natural pumice stones have a specific gravity of 1.0 or less, are lightweight, and have excellent compression, bending and tensile strengths. A natural pumice particle hardened with a cured product has a specific gravity of about 1.2 to 1.5 and excellent compression strength. The simple substance of the foamed resin has a specific gravity of about 0.03 and is extremely light, excellent in compression, bending, and tensile strength, and is particularly suitable as a material for the core 2. A foamed resin particle hardened with a cured product has a specific gravity of about 0.3 and excellent compression strength. Examples of the foamed resin include foam styrene and urethane foam. The specific gravity is about 0.02 to 0.04 although it varies depending on the foaming ratio, and it is light and excellent in strength. The urethane foam contains CFC gas in the bubbles and is excellent in heat insulation. The ceramic fine hollow particles hardened with a hardened product have substantially the same characteristics as those obtained by hardening natural pumice particles with a hardened product. The foamed cement-based cured product varies depending on the degree of foaming, the type of aggregate, the mixing rate, and the like, but has a specific gravity of about 0.7 to 1.5 and excellent compression strength. A single porous aluminum has a specific gravity of 1.0 or less, and is lightweight and excellent in compression, bending, and tensile strength. Sawdust, fir shells, etc., hardened with a cured product, the strength varies greatly depending on the type and amount of the cured product, but is required as the core 2 by having a specific gravity of about 0.7 to 1.2. Strength can be secured.
[0015]
The outer shell 3 secures the surface hardness and surface properties required for the imitation brick 1 and is formed of a cement-based hardened material that is mixed with water and hardened. The cement-based hardened material used is composed of hardened main materials that are hardened by mixing with water such as Portland cement-based, hydraulic lime, ceramic-based, calcium silicate-based, etc. Further, reinforcing materials, pigments and the like may be mixed. At that time, the aggregate may be a lightweight material such as pearlite particles, foamed resin particles, natural pumice, artificial lightweight material, water granulated, other porous materials mentioned as the material of the core 2, etc. 3 can be reduced in weight. Moreover, the sand used normally may be sufficient and can raise an intensity | strength. As the reinforcing material, various kinds of organic and inorganic reinforcing fibers and their nets may be used. Examples of the pigment include those obtained by combining or blending known pigments such as Bengala, oxidized yellow, ultramarine blue, and pine smoke, and are set according to the color required for the outer shell 3.
[0016]
The adhesive layer 4 only needs to be capable of firmly bonding the core 2 and the outer shell 3, and may be composed of, for example, a solvent-based adhesive or an acrylic adhesive. The core 2 and the outer shell 3 are firmly and integrally joined by the adhesive layer 4, and the strengths of the core 2 and the outer shell 3 are more reliably combined. In addition, it is preferable that the uneven | corrugated | grooved part is formed in the surface of the core 2, and joining to the core 2 and the outer shell 3 becomes stronger. In addition, the adhesive layer 4 is not necessarily required, but in that case, it is preferable that an uneven portion is formed on the surface of the core 2, and a cement-based cured product that forms the outer shell 3 when the imitation brick 1 is formed. However, the concavo-convex portion, the entangled core 2 and the outer shell 3 are firmly and integrally joined.
[0017]
The manufacturing method of the imitation brick 1 shown in FIG. 1 is demonstrated based on FIG. In FIG. 2, reference numeral 5 denotes a mold, which includes a bowl-shaped mold body 6 and a flat pressing mold 7. A rigid reinforcing frame (see FIG. 2) is formed on the outer side of the mold body 6 and the upper surface of the pressing mold 7 during molding. (Not shown). In the mold 5, the surface of a normal fired brick is molded with an elastic material such as silicon rubber or urethane rubber, FRP resin, or the like, and the inner surfaces of the mold body 6 and the pressing mold 7 are formed in a fired brick pattern. . At the time of molding, as shown in FIG. 2 (a), the mold body 6 is held horizontally by a rigid reinforcing frame, and is placed horizontally to form a predetermined amount of fluid hardened cementitious material 8 that forms part of the outer shell 3. Is poured into the mold body 6 as shown in FIG. The fluid cement-based cured product 8 is obtained by mixing an aggregate, a reinforcing material, a pigment, and the like in a cured main material according to the purpose, and adding water to knead in a mortar shape. Next, the adhesive 10 is thinly and uniformly applied to the entire surface of the core material 9 made of a lightweight material, and the core material 9 is positioned at the center of the mold body 6 in plan view using a jig (not shown). Thus, it is placed on the cement-based cured product 8 and pushed down to the state shown in FIG. That is, the core material 9 is formed to a dimension that can secure the necessary thickness of the outer shell 3, and the thickness of the cement-based cured product 8 on the bottom side of the mold body 6 corresponds to the thickness of the outer shell 3. Press down until you do. As a result, a part of the cement-based cured product 8 is pushed up along the side wall of the mold body 6 to fill a part between the core material 9 and the side wall of the mold body 6 as shown in FIG. To do.
[0018]
Next, the remaining cement-based cured product 11 is poured in a state where the core material 9 is pressed and held. The cement-based cured product 11 is of the same quality as the cement-based cured product 8 and is filled between the side walls of the core material 9 and the mold body 6 as shown in FIG. An amount in which the upper surface side corresponds to the thickness of the outer shell 3 is poured. Then, as shown in FIG. 2 (e), the mold body 6 is sealed with the pressing mold 7, and a rigid reinforcing frame (not shown) is installed on the upper part of the pressing mold 7, and the rigid reinforcing frame is attached to the weight, It presses by pressing means (not shown), such as a spring device, and hold | maintains until the cement-type hardened | cured materials 8 and 11 are set and it can be demolded.
[0019]
The imitation brick 1 shown in FIG. 1 is formed as described above, but it is preferable to perform a compacting operation by applying vibrations in each manufacturing process, and the surface is excellent in accuracy and free from bubbles. Can be molded. At that time, when the aggregate is mixed in the cement-based cured products 8 and 11 forming the outer shell 3, the aggregate and the core material 9 are not separated or raised due to the specific gravity difference due to the compaction work. The compaction timing and compaction time are set according to the mixing ratio of the aggregate and the kneading hardness of the cement-based cured products 8 and 11. The kneading hardness of the cement-based cured products 8 and 11 is set in relation to the fluidity in the mold body 6 although the hardness tends to be difficult to separate even if the hardness is increased. Steps (b) to (e) in FIG. 2 are performed in a state where the cement-based cured products 8 and 11 are not yet cured, and at the time of curing, the cement-based cured products 8 and 11 shown in FIG. There is no boundary between 11 and an integral outer shell 3 is formed without a seam.
[0020]
For example, as a specific example of the imitation brick 1 shown in FIG. 1, a case will be described in which outer dimensions are 235 mm in length, 115 mm in width, 50 mm in thickness, and the outer shell 3 has a thickness of 10 mm. The manufacturing conditions are as follows. The mold 5 is made of silicon rubber obtained by molding a foreign-made fired brick having a good surface shape with silicon rubber. The mold body 6 has a saddle shape with internal dimensions of 235 mm in length, 115 mm in width, 50 mm in depth, 10 mm in extra length depth, and 10 mm in thickness. The pressing mold 7 is a rectangular flat plate having a thickness of 10 mm and has a dimension for sealing the mold main body 6. The extra length depth of the mold body 6 is provided for mounting the pressing mold 7 during use, and corresponds to the thickness dimension of the pressing mold 7. The core material 9 is a flat plate-like foamed resin, and is formed in a length of 215 mm, a width of 95 mm, and a thickness of 30 mm. The dimension of the core material 9 is set to be 20 mm shorter than the internal dimension of the mold body 6 in each direction so that the thickness of the entire surface of the outer shell 3 is uniformly 10 mm. The adhesive 10 is acrylic. The cement-based cured products 8 and 11 forming the outer shell 3 use cement as a main curing material, use foamed resin particles and pearlite particles as aggregates, mix pigments with these, and form body 6 The mortar is made by adding water and kneading just before pouring into the container.
[0021]
At the time of manufacture, a mortar-shaped cement-based hardened material 8 is poured into a mold body 6 that is held horizontally by a metal reinforcing frame and is about 13 mm thicker than the thickness 10 mm of the outer shell 3, and is about 3 seconds with an electric vibrator. Apply vibration and tighten. A core material 9 in which an acrylic adhesive 10 is thinly and uniformly applied on the entire surface of the cement-based cured product 8 is placed so as to be centered in a plan view of the mold body 6, and the core material 9 is cemented-cured. While pushing down to the position where the thickness of the object 8 becomes 10 mm, it is vibrated by an electric vibrator and hardened. At this time, the cement-based cured product 8 rises between the core material 9 and the side wall of the mold body 6. In this state, the bottom surface of the core material 9 and the cement-based cured product 8 are in close contact with each other and the core material 9. Is fixed in place. Next, the remaining cement-based hardened material 11 is poured from the upper part, and is fixed with an electric vibrator until the whole becomes uniform visually while preventing the core material 9 from being lifted with a jig. After completion of the compaction, the amount of excess or deficiency is adjusted so that the surplus is 3 mm while the upper surface of the cement-based cured product 11 is smoothly acclimatized. After smoothing the upper surface of the cement-based cured product 11, the holding mold 7 is dropped into the mold body 6 and temporarily placed, and a strong metal reinforcement frame is arranged from the upper part, and is incorporated into the metal reinforcement frame. The final compression is performed with an electric vibrator from the upper part of the metal reinforcing frame while applying a pressing force of about 50 kg with a spring. The pressing mold 7 is gradually lowered by the action of the pressing force, and is stopped at the time when the extra portion is lowered by 3 mm, that is, at a position where the size of the imitation brick 1 is fixed in the thickness direction. Hold until solidified and demoldable.
[0022]
After the cement-based hardened products 8 and 11 are hardened, the metal reinforcing frames are removed from the presser mold 7 and the mold main body 6 and the upper part of the mold main body 6 is opened to the outside to be molded with the presser mold 7. The imitation brick 1 is extruded and demolded. Since the mold body 6 was made of silicon rubber and easily elastically deformed, it could be removed easily without damaging the imitation brick 1. The imitation brick 1 thus obtained is about 0.35 kg compared to about 2.9 kg of the overseas fired brick used for the mold 5, and is about 1/8 in weight ratio. It was lightweight. In terms of specific gravity, it was extremely small, about 0.26, compared to about 2.1 for overseas-produced baked bricks. On the surface of the imitation brick 1, almost no pores or aggregates appeared, and the surface shape of the overseas-produced fired brick formed in the mold 5 over the entire surface, that is, a beautiful fired brick pattern was formed. This is a dense structure because the cemented cured products 8 and 11 are compressed by pressing the holding mold 7 with a spring. Further, since the mold 5 is made of silicon rubber and has elasticity, the presser mold 7 and the mold body 6 themselves are slightly elastically deformed, so that the cemented cured products 8 and 11 are slightly cured. Although it shrinks, it follows the shrinkage and maintains a close contact state until curing. Therefore, the fired brick pattern formed on the surfaces of the pressing mold 7 and the mold body 6 is neatly copied.
[0023]
Next, the imitation brick of 2nd Embodiment is demonstrated based on FIG.3 and FIG.4. 3 and 4, the same reference numerals as in FIGS. 1 and 2 mean the same functional members. The imitation brick 1 shown in FIG. 3 has the same structure as the imitation brick 1 shown in FIG. 1 except that the outer shell has a two-layer structure including an inner outer shell 12 and an outer outer shell 13. That is, the imitation brick 1 shown in FIG. 3 is formed with a constant thickness so that the inner outer shell 12 surrounds the core 2, and is formed with a constant thickness so that the outer outer shell 13 surrounds the inner outer shell 12. 2 is a lightweight unfired brick in which a thin adhesive layer 4 is formed between the inner shell 12 and the inner shell 12. Since the inner outer shell 12 is encased in the outer outer shell 13, the mixing ratio of the aggregate in the cement-based hardened material as the material is appropriately set without considering the surface properties and strength. For example, when particles of lightweight material are mixed as aggregate, the mixing rate can be made larger than that in FIG. 1, thereby further reducing the weight. The outer outer shell 13 has a fired brick pattern on the surface, and the mixing rate of the aggregate in the cement-based hardened material that is the material is set to a small value in consideration of surface properties and strength.
[0024]
A method for manufacturing the imitation brick 1 shown in FIG. 3 will be described with reference to FIG. The manufacturing method shown in FIG. 4 is the same as the process shown in FIG. 3 except that the same mold 5 as shown in FIG. 3 is used and the outer shell 13 is formed. As shown in FIG. 4A, the paste-like cement-based cured product 14 forming a part of the outer shell 13 is thinned to the height position corresponding to the thickness of the imitation brick 1 on the inner surface of the mold body 6. A mortar-shaped cement-based cured product 15 which is uniformly applied and forms a part of the inner outer shell 12 on the mold body 6 is poured as shown in FIG. The core material 9 is positioned and placed on the cement-based cured product 15 by a jig (not shown), and the core material 9 is pushed down as shown in FIG. A mortar-shaped cement-based cured product 16 that forms the remainder of the inner outer shell 12 in a state where the core material 9 is pressed is poured as shown in FIG. As shown in FIG. 4 (e), a paste-like cement-based hardened material 17 that forms the remainder of the outer outer shell 13 is applied thinly and uniformly on the inner surface of the pressing mold 7 as in the case of the mold body 6. The mold body 6 is sealed with the pressing mold 7. Then, the pressing mold 7 is pressed by pressing means (not shown) through a rigid reinforcing frame (not shown), and is pressed and held until each cement-based cured product 14, 15, 16, 17 is cured. As a result, there is no boundary between the cement-based cured products 14, 15, 16, and 17 shown in FIG. 4 (e) at the time of curing, and an integrated outer outer shell 13 and inner outer shell 12 that are seamless are formed. Is done. The paste-like cement-based cured products 14 and 17 forming the outer outer shell 13 are mortar-shaped cement-based cured products 15 in which the mixing ratio of aggregates such as sand and light-weight particles forms the inner outer shell 12. , 16 is preferable. Thereby, the imitation brick 1 excellent in aesthetics in combination with weight reduction can be shape | molded.
[0025]
For example, as a specific example of the imitation brick 1 shown in FIG. 3, a product having outer dimensions of 235 mm in length, 115 mm in width, 50 mm in thickness, an inner shell thickness of 9 mm, and an outer shell thickness of 1 mm is manufactured. The case will be described. Manufacturing conditions are the same as the case of the specific example of the imitation brick 1 shown in FIG. 1 about the formwork 5, the core material 9, and the adhesive agent 10. FIG. The material of the inner outer shell 12 is cement as a main curing material, and the foamed resin particles and the pearlite particles as aggregates are more troublesome than those in the case of the imitation brick shown in FIG. It is a mortar that is mixed to some extent and kneaded with water just before pouring into the mold body 6. The material of the outer outer shell 13 is a paste-like material in which cement is used as a hardened main material, sand is used as an aggregate, pigment is mixed therein, and water is added and kneaded immediately before pouring into the mold body 6. Is. At that time, the mixing rate of sand as an aggregate is set to be small enough to ensure hardness, familiarity with the formwork surface, applicability and the like.
[0026]
At the time of manufacture, paste-form cementitious hardened material 14 is thinly applied to the inner surface of mold body 6 to a position corresponding to the height of imitation brick 1 to a thickness of about 1 mm of outer shell 13, and fluidized cementitious hardened material. 15 is poured by about 12 mm, which is slightly thicker than the inner shell 12 having a thickness of 9 mm. After completion of the compaction, the core material 9 is placed on the cement-based hardened material 15, and the remaining cement-based hardened material 16 is poured so as to cover the core material 9, while the upper surface of the cement-based hardened material 16 is smoothly acclimatized. Adjust the amount of excess and deficiency so that the height is 2 mm. After smoothing the upper surface of the cement-based cured product 16, the pressing mold 7 coated with a paste-like cement-based cured product 17 as thin as about 1 mm on the surface is dropped into the mold body 6 and temporarily placed. The subsequent operations are the same as in the case of the specific example shown in FIG. 1, and the cement-based cured products 14, 15, 16, and 17 are demolded after solidifying.
[0027]
The obtained imitation brick 1 was somewhat lighter than the specific example of the imitation brick 1 shown in FIG. The surface of the imitation brick 1 has no joints, pores, almost no aggregate, and has a more beautiful fired brick pattern than the specific example of the imitation brick 1 shown in FIG. The surface shape of the fired bricks produced overseas was copied.
[0028]
In each embodiment, the core material 9 is not limited to a single lightweight material, but is hard enough not to flow through the particles of the lightweight material and an adhesive such as cement, an acrylic adhesive, a solvent adhesive, and the like. It may be kneaded into the above. At the time of manufacture, a cement-based cured product that is a material of the outer shell 3 or the inner outer shell 12 is poured into the mold body 6 so as to have the thickness of the outer shell 3 or the inner outer shell 12, and the core material 9 is used as a jig or the like. It is used and placed so as to be in the center of the mold body 6, and the remaining cement-based cured product is poured into the mold body 6 and pressed by the presser mold 7 to be molded. The core material 9 is also solidified with the solidification of each cement-based cured product, and becomes an integral core 2 when the imitation brick 1 is molded. As in the case of the integral core material 9, the structure is light and has a predetermined strength.
[0029]
【The invention's effect】
According to the imitation brick of the present invention, it is a structure that is integrally wrapped with an outer shell made of a cement-based cured product so that a core made of a lightweight material is located in the center, so that the required weight is reduced while securing the required strength. We were able to. Thereby, for example, when producing interior goods, since it is easy to carry at the time of construction and does not apply a big burden, construction can be performed easily. In addition, because the manufactured interior goods are lightweight, the load on the installation location is reduced and the safety at the time of collapse is improved.
[0030]
According to the imitation brick formed by the mold consisting of the bowl-shaped formwork body and the presser formwork mounted on the upper part of the formwork body, the seam is not formed on the entire surface, the structure is dense, and the mold is formed on the entire surface. Since the surface texture of the frame was copied, it was excellent in aesthetics and could be used for interior use. Moreover, according to the imitation brick molded with the mold made with the fired brick, the fired brick pattern was neatly copied over the entire surface, and a high quality product with excellent texture was obtained. In particular, when the outer shell has a two-layer structure consisting of an inner outer shell and an outer outer shell, surface quality and hardness are ensured by the outer outer shell. Since a cement-based hardened material mixed to such an extent that the strength is not impaired can be used, a lighter one was obtained.
[0031]
According to the imitation brick of the present invention, the outer shell and the core are lower in hardness than the fired brick, can be nailed, and can be easily sawed, so that various processing can be performed and the degree of freedom in use is increased.
[Brief description of the drawings]
FIG. 1 is an explanatory diagram of a first embodiment of the present invention, and is a perspective view partially showing a cross section.
FIG. 2 is an explanatory diagram of a method for manufacturing the imitation brick according to the first embodiment of the present invention, and shows the manufacturing process in cross-sectional view. (A) is a preparation stage, (b) is a stage in which a cement-based hardened material that forms a part of the outer shell is poured, and (c) is a stage in which the core is placed in the center of the mold in plan view and pushed down by a predetermined amount. , (D) shows a stage where a cement-based cured product forming the remainder of the outer shell is poured so as to cover the core, and (e) shows a stage where the pressed mold is held under pressure.
FIG. 3 is an explanatory diagram of a second embodiment of the present invention, and is a perspective view partially showing a cross section.
FIG. 4 is an explanatory diagram of a method for manufacturing a counterfeit brick according to a second embodiment of the present invention, and shows manufacturing steps in cross-sectional views. (A) is a step of applying a cement-based cured product forming a part of the outer shell to the inner surface of the mold body, (b) is a step of pouring a cement-based cured product forming a part of the inner outer shell, c) is a stage where the core is placed in the center of the mold in plan view and pushed down by a predetermined amount, and (d) is a stage where a cement-based hardened material that forms the remainder of the inner shell is poured over the core. e) shows a stage where the cement-based hardened material that forms the remainder of the outer shell is held under pressure by a pressing mold that is applied to the inner surface.
[Explanation of symbols]
1 Imitation brick 2 Core
3 Outer shell 4 Adhesive
5 Formwork 6 Formwork body
7 Pressing formwork
8, 11 Cement-based hardened material that is the material of the outer shell
9 Core material 10 Adhesive
12 Inner shell 13 Outer shell
14, 17 Cement-based hardened material that is the material of the outer shell
15, 16 Cement-based hardened material that is the material of the inner shell

Claims (1)

A core (2) consisting of lightweight material disposed in the center, becomes from this core outer shell made of cementitious cured material formed integrally wrapped (2) (3), the outer shell (3) inner In the method of manufacturing the imitation brick which is the two layers of the outer shell (12) and the outer outer shell (13), the bowl-shaped formwork body (6) and the formwork body (6) formed deeper than the thickness of the imitation brick. Ri Do since pressing mold to be mounted on the upper (7), the material is a process for the preparation of imitation brick molding in a mold an elastic material or FRP resin (5), an outer shell (13) A paste-like hardened cement (14) that forms a part is uniformly applied to the inner surface of the mold body (6), the outer side of which is held by a rigid reinforcing material, to a height corresponding to the thickness of the imitation brick (1). Pour a fluid cement-based hardened material (15) that forms part of the inner shell (12). A core material (9) made of a lightweight material is placed on the cement-based cured product (15) so as to be in the center position of the mold body (6) in plan view, and the core material (9) is crushed to reduce the core material (9). The cemented cured product (15) is pushed into the fluidized cementitious cured product (15) to a position corresponding to the thickness of the inner outer shell (12) to form the remainder of the inner outer shell (12). The cemented cured product (16) is poured into the mold body (6) so as to cover the core material (9), and the cemented cured product (16) is smoothed. A pressing mold (7) in which a paste-like cement-based hardened material (17) that forms the remainder of the outer shell (13) on the inner surface so as to press the upper surface of (16) is uniformly applied to the mold body (6 close mounted within the upper part of), cement holding the upper surface of the pressing mold a rigid reinforcement Method for producing imitation bricks, characterized in that the system cured product (14, 15, 16, 17) is formed by rolling held until solidified.

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