Molding, laminate structure, and manufacturing method thereof

Abstract

To provide a molding.SOLUTION: In a molding 1 including a curved part 10, the curved part 10 includes a plurality of reinforcement sheets 20 buried in a fiber-mixed cement mortar mixed with a staple fiber for cement mortar reinforcement, the reinforcement sheet 20 is buried in the curved part 10 in a curved state of following up the curve of the curved part 10, and a thickness t10 of the curved part 10 is 3.0 mm or over and under 20.0 mm. A second face 10B opposite to a first face 10A of the curved part 10 comprises a non-fiber-mixed cement mortar not mixed with a staple fiber.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a molded body, a laminated structure, and methods for manufacturing the same.

Background Art

[0002] Conventionally, in a molded body made of a cement-based base material, a reinforcing material such as a mesh is embedded in the base material to increase the strength (Patent Documents 1 to 3).

[0003] The flat inorganic building material shown in Patent Document 1 embeds a mesh made of glass fiber to increase the strength. The flat body (glass mesh-reinforced lightweight board material) shown in Patent Document 2 embeds a mesh made of glass fiber to increase the strength. Further, the long fiber-reinforced composite member shown in Patent Document 3 embeds long fibers made of alkali-resistant glass fiber in an inorganic-based base material, and the long fibers are formed in a lattice shape.

[0004] Instead of such a reinforcing material such as a mesh, glass fiber-reinforced cement (Glass fiber Reinforced Cement) in which alkali-resistant glass fiber is contained in the base material to increase the strength has also been conventionally used. The molded body (hereinafter referred to as a GRC molded body) is widely used in the fields of architecture and civil engineering.

[0005] The GRC molded body is made of mortar or concrete reinforced with alkali-resistant glass fiber containing 16% or more of zirconia. As a molding method of this GRC molded body, mainly a direct spray (hereinafter referred to as DS) method and a premix (hereinafter referred to as PM) method are known.

[0006] In the DS method, roving in which alkali-resistant glass fibers are bundled is cut into lengths of, for example, 20.0 mm or more and 40.0 mm or less by a chopper of a spray gun, and sprayed onto a mold together with mortar or fresh concrete discharged from a pump to form a molded body.

[0007] On the one hand, in the PM method, alkali-resistant glass fibers that have been previously cut to a length of 5.0 mm or more and 25.0 mm or less are mixed with mortar or fresh concrete in a mixer, and then poured into a mold for molding, for example.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0009] By the way, when using a GRC molded body as an interior and exterior finishing material for structures such as buildings, in order to further enhance the appearance of the interior and exterior finishing materials, there is a desire to mold it into an aesthetically creative appearance instead of a flat appearance. For example, in a GRC molded body by the PM method in which the surface observed from the outside has a concave cross-sectional part and a convex cross-sectional part and alkali-resistant glass fibers are arranged in a three-dimensional direction, the thickness of the concave cross-sectional part is 50.0 mm or more and 100.0 mm or less in order to have the required strength, and it becomes heavier due to the convex part protruding from the concave cross-sectional part. Compared with this PM method, in the DS method, since the alkali-resistant glass fibers are arranged randomly in two dimensions, the thickness of the molded body can be reduced. However, usually, the thickness of one layer by spraying in the X direction and the Y direction is 5.0 mm or more, and multiple layers Since it is formed by layering, the thickness of the GRC molded body is, for example, 20.0 mm or more and 50.0 mm or less. Although it is desirable to make the thickness of the GRC molded body with an aesthetically creative appearance thinner, there is a risk that the bending strength may become weak. Further, not only in the case of alkali-resistant glass fibers, but also when molding a molded body containing short fibers such as carbon fibers into an aesthetically creative appearance, there is a desire to reduce the weight by making it thinner while ensuring the bending strength.

[0010] Therefore, an object of the present invention is to provide a molded body and a laminated structure having a curved surface portion, and a method for manufacturing these.

Means for Solving the Problems

[0011] The present invention is a molded body having a curved surface portion, wherein the curved surface portion includes a reinforcing sheet embedded in a fiber-mixed mortar in which short fibers for mortar reinforcement are mixed, and further, the thickness of the curved surface portion is 1.0 mm or more and less than 20.0 mm, and the reinforcing sheet is characterized in that it is curved following the curvature of the curved surface portion.

[0012] The fiber-mixed mortar is a hardened mixture (fiber-mixed mortar material) obtained by kneading cement, fine aggregate, water, and short fibers for mortar reinforcement. The mixture may contain admixtures such as silica fume, slag, fly ash, dolomite, and further a shrinkage reducing agent, a water reducing agent, and other additives. The short fibers for reinforcement are not limited in material, but are preferably alkali-resistant glass fibers. In this case, the molded body is configured as a GRC molded body. Since the curved surface portion embeds the reinforcing sheet, it is thin and has high bending strength. A plurality of reinforcing sheets may be embedded in the thickness direction of the curved surface portion. In this case, the average value of the thickness of the curved surface portion is, for example, 3.0 mm or more and less than 20.0 mm.

[0013] At least one of the first surface of the curved surface portion and the second surface located opposite to the first surface is made of the fiber-mixed mortar in which the short fibers are mixed. The molded body preferably has at least one of the first surface of the curved surface portion and the second surface located opposite to the first surface made of fiber - non - mixed mortar in which the short fibers are not mixed.

[0014] The fiber - non - mixed mortar is obtained by hardening a mixture (fiber - non - mixed mortar material) of cement, fine aggregate, and water without containing short fibers for mortar reinforcement. The mixture may contain admixtures such as silica fume, slag, fly ash, dolomite, and further shrinkage reducing agents, water reducing agents, and other additives. The fiber - mixed mortar material and the fiber - non - mixed mortar material are different in the presence or absence of short fiber mixing, and not limited to the case where the formulations of cement, fine aggregate, and water are the same, and those with different formulations may be used. When including admixtures and additives, the formulations of cement, fine aggregate, water, admixtures, and additives may be the same or different, and the fiber - mixed mortar material and the fiber - non - mixed mortar material may also differ in the presence or absence of admixture and additive mixing. By configuring the first surface and the second surface with fiber - non - mixed mortar, it is possible to prevent the short fibers from protruding to the outside.

[0015] The present invention is a method for manufacturing a molded body in which a reinforcing sheet is embedded in a curved surface portion, comprising: a first deposition step of depositing a first material on a convex or concave mold surface; a second deposition step of depositing at least one layer of a second material on the first material; and a curing step of curing the first material and the second material deposited on the mold surface, wherein the first material is a fiber - mixed mortar material in which short fibers for mortar reinforcement are mixed, or a laminate composed of a fiber - non - mixed mortar material in which the short fibers are not mixed and the fiber - mixed mortar material, and the second material is composed of the reinforcing sheet and the fiber - mixed mortar material manually laid on the reinforcing sheet.

[0016] "Hand-laying" means the hand-placement by an operator, that is, the operator uses a trowel or the like to apply the fiber-mixed mortar material onto the reinforcement sheet to deposit the fiber-mixed mortar material on the reinforcement sheet, and also means that the operator uses a trowel or the like to stack the fiber-mixed mortar material or the non-fiber-mixed mortar material. In this hand-laying, it is advisable to push the short fibers or aggregates of the fiber-mixed mortar material into the openings of the reinforcement sheet and then apply. By performing hand-laying (hand-placement) in this way, the fiber-mixed mortar material can be deposited on the reinforcement sheet with a thickness of, for example, 0.5 mm or more and 3.0 mm or less. In the conventional DS method, usually, the thickness of one layer by spraying in the X direction and the Y direction is 5.0 mm or more, and it is difficult to provide the fiber-mixed mortar material on the reinforcement sheet with a thickness of 3.0 mm or less. It is difficult to provide it on the reinforcement sheet with a thickness of 3.0 mm or less. By embedding the reinforcement sheet, a curved surface portion that is thin and has high flexural strength can be manufactured.

[0017] The laminated structure of the present invention is a laminated structure provided with a curved surface portion, the average value of the thickness of the curved surface portion is 1.0 mm or more and less than 20.0 mm, It has a base portion, a heat insulating material layer covering the outer surface of the base portion, and a fiber-reinforced mortar layer covering the outer surface of the heat insulating material layer. The fiber-reinforced mortar layer includes a fiber-mixed mortar in which short fibers for reinforcement are mixed, and a plurality of reinforcement sheets embedded in the fiber-mixed mortar and formed of a fiber reinforcing material having a mesh shape with a plurality of openings. The reinforcement sheet is curved following the curvature of the curved surface portion, An anchor member fixed to the base portion penetrates at least the lowermost reinforcement sheet in the heat insulating material layer and the fiber-reinforced mortar layer, and a flange member having a diameter larger than the opening of the reinforcement sheet is provided at its end.

[0018] The method for manufacturing the molded body of the present invention preferably further includes a third deposition step of depositing the fiber-free mortar material on the second material after the second deposition step and before the curing step, and the curing step cures the first material, the second material, and the fiber-free mortar material deposited on the mold surface. The method for manufacturing the molded body of the present invention preferably further includes a third deposition step of depositing the fiber-free mortar material on the fiber-reinforced mortar in which the fiber-reinforced mortar material has cured in the curing step, and an additional mortar curing step of curing the fiber-free mortar material deposited on the fiber-reinforced mortar.

[0019] By using a fiber-free mortar material that does not contain short fibers as the material constituting the uppermost surface among the materials deposited on the mold surface, it is possible to prevent the short fibers from protruding outside. Moreover, the appearance of the curved surface portion can be improved.

[0020] The method for manufacturing the laminated structure of the present invention is a method for manufacturing a laminated structure in which a reinforcing sheet is embedded in a curved surface portion, including a base construction step of constructing a base and fixing an anchor member to the outer surface of the base, a heat insulating material layer forming step of forming a heat insulating material layer covering the outer surface of the base in a state of penetrating the anchor member, and a fiber-reinforced mortar layer forming step of forming a fiber-reinforced mortar layer covering the outer surface of the heat insulating material layer. The outer surface of the heat insulating material layer is formed into a convex or concave curved surface. The fiber-reinforced mortar layer forming step includes a first deposition step of depositing a first material on the curved surface of the heat insulating material layer, a second deposition step of depositing a second material on the first material, and a curing step of curing the first material and the second material deposited on the curved surface. The first material is a fiber-reinforced mortar material mixed with short fibers for mortar reinforcement, or a laminated material composed of a fiber-free mortar material not mixed with the short fibers and the fiber-reinforced mortar material. The second material is composed of a plurality of reinforcing sheets laminated in the thickness direction and the fiber-mixed mortar material manually laid so as to embed these reinforcing sheets. Arrange the end of the anchor member protruding from the heat insulating material layer in a state where it penetrates at least one of the reinforcing sheets, and provide a flange member having a diameter larger than the opening of the reinforcing sheet at the end of the anchor member.

Advantages of the Invention

[0021] According to the present invention, the aesthetic creativity can be improved by having a curved surface portion. Further, in the present invention, since the reinforcing sheet is embedded following the bend of the curved surface portion, it has high bending strength and is lightweight, so that it can be suitably used as an interior and exterior material product.

Brief Description of the Drawings

[0022]

Figure 1

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Mode for Carrying Out the Invention

[0023] Hereinafter, the molded body 1 according to the embodiment of the present invention will be described with reference to the drawings. The molded body 1 of one embodiment shown in FIG. 1 includes a short fiber mixed portion 110 and a short fiber non-mixed portion 120 laminated on the short fiber mixed portion 110.

[0024] The short fiber mixed portion 110 is a portion mainly composed of fiber-mixed mortar in which a mixture obtained by kneading cement, fine aggregate, water, short fibers for mortar reinforcement, and admixtures (hereinafter sometimes referred to as fiber-mixed mortar material 30) is hardened. The short fibers mixed in the mortar are, for example, glass fibers, carbon fibers, and steel fibers, and preferably chopped strands in which a plurality of fibers are bundled. The chopped strands are, for example, rovings cut to a predetermined length of 6.0 mm, 9.0 mm, 13.0 mm, 19.0 mm, 25.0 mm, and preferably made of alkali-resistant AR glass fibers (JIS R3410) containing 16% or more of zirconia. The short fibers are randomly embedded in the mortar.

[0025] Hereinafter, on the premise that the short fiber mixed portion 110 is a mortar in which chopped strands made of glass fibers obtained by cutting a fiber bundle made of alkali-resistant AR glass containing 16% or more of zirconia into a predetermined length are mixed, that is, a GRC molded body made of glass fiber reinforced cement (hereinafter referred to as GRC).

[0026] The short fiber non-mixed portion 120 is a portion made of fiber non-mixed mortar in which a mixture of cement, fine aggregate, water, admixture, etc. is kneaded and short fibers are not mixed (hereinafter sometimes referred to as the fiber non-mixed mortar material 40) is cured.

[0027] The illustrated example shows the case where the molded body 1 is molded as the curved surface portion 10. The molded body may include the curved surface portion 10 at least partially. The curved surface portion 10 includes a first surface 10A and a second surface 10B located opposite to the first surface 10A. Hereinafter, the direction from the first surface 10A to the second surface 10B is referred to as the thickness direction d1. In the curved surface portion 10, both the first surface 10A and the second surface 10B are formed as convex curved surfaces protruding in the thickness direction d1. In the illustrated example, the case where the first surface 10A and the second surface 10B are formed in parallel with arcs of the same diameter is shown, and the case where the thickness direction d1 is vertical and the same everywhere in the curved surface portion 10 is taken as an example for explanation. However, the actual thickness at each location of the curved surface portion 10 is the minimum thickness when measured with a caliper, etc., and the thickness direction d1 from the first surface 10A to the second surface 10B may have different directions at each location of the curved surface portion 10.

[0028] The second surface 10B is composed of fiber non-mixed mortar in which short fibers are not mixed. Thereby, it is possible to prevent the short fibers from protruding from the surface. Note that the curved surface portion 11 shown in the first modification example of FIG. 2 is formed such that the first surface 10A and the second surface 10B are concave curved surfaces recessed in the direction from the second surface 10B opposite to the thickness direction d1 to the first surface 10A. Although not shown, the first surface 10A may also be composed of the short fiber non-mixed portion 120.

[0029] Furthermore, the short fiber mixing portion 110 of the curved surface portion 10 includes a plurality of reinforcing sheets 20 embedded in the thickness direction d1.

[0030] Each of the reinforcing sheets 20 is embedded in the curved surface portion 10 in a state of spreading in the surface directions of the first surface 10A and the second surface 10B. Each of the reinforcing sheets 20 in the illustrated example is embedded in the short fiber mixing portion 110 in a curved state that follows the bends of the first surface 10A and the second surface 10B of the curved surface portion 10 and is bent into a convex shape protruding in the thickness direction d1. In addition, when the first surface 10A and the second surface 10B of the curved surface portion 10 are formed as concave curved surfaces that are recessed in the direction from the second surface 10B opposite to the thickness direction d1 to the first surface 10A, as shown in FIG. 2, the plurality of reinforcing sheets 20 are embedded in the short fiber mixing portion 110 in a state of being bent into a concave shape that is recessed in the direction from the second surface 10B to the first surface 10A.

[0031] The thickness t10 from the first surface 10A to the second surface 10B of the curved surface portion 10 in which the plurality of reinforcing sheets 20 are embedded is set equally at any location of the curved surface portion 10. For example, the average value of the thickness t10 measured at 6 locations is 1.0 mm or more and less than 20.0 mm, preferably 5.0 mm or more and 13.0 mm or less, and more preferably 6.0 mm or more and 10.0 mm or less. If it is thinner than 3.0 mm, the strength of the product becomes weak, and if it is 20.0 mm or more, the weight increases, which is not preferable.

[0032] In the curved surface portion 10 provided with the short fiber non-mixed portion 120, the thickness t10 is the sum of the thickness t11 of the short fiber mixed portion 110 and the thickness t12 of the short fiber non-mixed portion 120 (t10 = t11 + t12). The average value of the thickness t12 measured at six locations of the short fiber non-mixed portion 120 is, for example, 0.5 mm or more and 3.0 mm or less. If the thickness t12 is less than 0.5 mm, the short fibers in the short fiber mixed portion 110 may be exposed. If the thickness t12 is greater than 3.0 mm, there is a risk of cracking. When one of the first surface 10A and the second surface 10B of the curved surface portion is formed of the short fiber non-mixed portion 120, the average value of the thickness t11 of the short fiber mixed portion 110 is, for example, 0.5 mm or more and 19.5 mm or less, preferably 4.5 mm or more and 12.5 mm or less, and more preferably 5.5 mm or more and 9.5 mm or less. Although not shown, when the first surface 10A and the second surface 10B are formed of the short fiber non-mixed portion 120, the average value of the thickness t11 of the short fiber mixed portion 110 is, for example, 1.0 mm or more and 19.0 mm or less, preferably 4.0 mm or more and 12.0 mm or less, and more preferably 5.0 mm or more and 9.0 mm or less. When the curved surface portion consists of only the short fiber mixed portion 110 without the short fiber non-mixed portion 120, the thickness t11 of the short fiber mixed portion 110 is, for example, 1.0 mm or more and less than 20.0 mm, preferably 5.0 mm or more and 13.0 mm or less, and more preferably 6.0 mm or more and 10.0 mm or less.

[0033] In the curved surface portion 10, for example, when the thickness t11 of the short fiber mixed portion 110 is 7.0 mm and the thickness is 1. 0 mm, if one reinforcing sheet 20 is embedded, as shown in the illustrated example, six reinforcing sheets 20 are embedded in the thickness direction d1. Each reinforcing sheet 20 is preferably provided at a predetermined interval in the thickness direction d1 without being unevenly distributed on the first surface 10A side or the second surface 10B side within the thickness t10.

[0034] Specifically, the average value of the depths h1 from the first surface 10A of the reinforcing sheet 20 provided closest to the first surface 10A, measured at six locations, is, for example, 0.5 mm or more and 3.0 mm or less. If the depth h1 is less than 0.5 mm, the reinforcing sheet 20 may be exposed, and if it is deeper than 3.0 mm, the bending strength decreases. The depth h2 from the second surface 10B of the reinforcing sheet 20 provided closest to the second surface 10B is set, for example, to 1.0 mm or more and 6.0 mm or less. 1.0 mm (depth h2) is the sum of the minimum thickness (0.5 mm) of the fiber-reinforced mortar on the second surface 10B side of the reinforcing sheet 20 and the minimum thickness (0.5 mm) of the short fiber non-reinforced portion 120 covering this fiber-reinforced mortar. Also, if the depth h2 is deeper than 6.0 mm, the bending strength decreases when a negative pressure is applied to the second surface 10B side. When the second surface 10B is formed of the short fiber non-reinforced portion 120, the space between the reinforcing sheet 20 provided closest to the second surface 10B and the short fiber non-reinforced portion 120 is composed of fiber-reinforced mortar, and this thickness is, for example, 0.5 mm or more and 3.0 mm or less. These depths h1 and h2 are the depths from the first surface 10A or the second surface 10B until reaching the reinforcing sheet 20. Furthermore, it is desirable that the reinforcing sheets 20 are buried separately from each other in the thickness direction d1, and the average value of the thicknesses t13 of the mortar between the reinforcing sheets 20, measured at six locations, is, for example, 0.5 mm or more and 3.0 mm or less. If the average value of the thickness t13 is less than 0.5 mm, the strength of the mortar between the reinforcing sheets 20 is low because the mortar is thin, and if it exceeds 3.0 mm, the weight of the molded body 1 may increase.

[0035] The six reinforcing sheets 20 are embedded at positions with different depths from the first surface 10A or the second surface 10B. Note that the reinforcing sheet 20 embedded at a predetermined depth is not limited to being composed of a single sheet. As shown in FIG. 12 described later, a plurality of reinforcing sheets 20 may be overlapped at their edges and embedded at substantially the same depth. In the curved surface portion 10 having a plurality of overlapping portions where the edges overlap each other at different depths, the overlapping portions with different depths are arranged so as not to be aligned in the thickness direction d1 of the curved surface portion 10. Thereby, the curved surface portion 10 can be formed to have substantially the same thickness. On the other hand, if a plurality of overlapping portions of the reinforcing sheet 20 are arranged side by side in the thickness direction d1 in the curved surface portion, that portion becomes thick and the weight thereon increases.

[0036] The number of the reinforcing sheets 20 is not limited to the illustrated example. For example, it is 2 or more and 20 or less, preferably 3 or more and 15 or less. Also, when the number of the reinforcing sheets 20 provided in the thickness direction d1 of the curved surface portion 10 is n, the ratio (t10 / n) between the average value of the thickness t10 of the curved surface portion 10 and the number n of the reinforcing sheets 20 is set as in the following (1), for example. On the other hand, if the ratio (t10 / n) is less than 0.4, the filling of the fiber-reinforced mortar material becomes poor, and if the ratio (t10 / n) is greater than 3.0, the bending strength of the GRC molded body decreases. 0.4 ≦ t11 / n ≦ 3.0 (1)

[0037] The curved surface portion 12 shown in the second modification example of FIG. 3 includes a short fiber mixed portion 110 and a short fiber non-mixed portion 120 laminated on the short fiber mixed portion 110. The first surface 10A is formed by the short fiber mixed portion 110, and the second surface 10B is formed by the short fiber non-mixed portion 120. Further, only one reinforcing sheet 20 is provided in the short fiber mixed portion 110 in the thickness direction d1 of the curved surface portion 12. This reinforcing sheet 20 is buried at a predetermined depth from the first surface 10A or the second surface 10B. Not limited to the case of consisting of one reinforcing sheet 20, as will be described later, it also includes the case where a plurality of reinforcing sheets 20 with substantially the same depth from the first surface 10A and the second surface 10B overlap at their ends. The average value of the thickness t20 from the first surface 10A to the second surface 10B of the curved surface portion 12 is, for example, 1.5 mm or more and 9.0 mm or less. When the average value of the thickness t20 is less than 1.5 mm, the product strength becomes low, and when the average value of the thickness t20 is 9.0 mm or more, the product weight becomes heavy. The average value of the thickness t21 of the short fiber mixed portion 110 is, for example, 1.0 mm or more and 6.0 mm or less. 1.0 mm is the sum of the minimum thicknesses (0.5 mm) of the fiber-mixed mortar on each of the first surface 10A side and the second surface 10B side of the reinforcing sheet 20, and 6.0 mm is the sum of the maximum thicknesses (3.0 mm) of the fiber-mixed mortar on each of the first surface 10A side and the second surface 10B side of the reinforcing sheet 20. The average value of the thickness t22 of the short fiber non-mixed portion 120 is, for example, 0.5 mm or more and 3.0 mm or less. These thicknesses t20, t21, and t22 are the same in the case where the first surface 10A is formed by the short fiber non-mixed portion 120, the second surface 10B is formed by the short fiber mixed portion 110, and only one reinforcing sheet 20 is provided in the thickness direction d1 of the short fiber mixed portion 110. Although not shown, in the curved surface portion where only one reinforcing sheet 20 is provided in the thickness direction d1 of the short fiber mixed portion 110 and the first surface 10A and the second surface 10B are formed by the short fiber non-mixed portion 120, the average value of the thickness of the curved surface portion is, for example, 2.0 mm or more and 12.0 mm or less, and the average value of the thickness of the short fiber mixed portion 110 is, for example, 1.0 mm or more and 6.0 mm or less. Also in this case, 1.0 mm is the sum of the minimum thicknesses (0.5 mm) of the fiber-mixed mortar on each of the first surface 10A side and the second surface 10B side of the reinforcing sheet 20. The average value of the thickness of each short fiber non-mixed portion 120 is, for example, 0.5 mm or more and 3.0 mm or less.Although not shown, when only one reinforcing sheet 20 is provided in the thickness direction d1 of the short fiber mixed portion 110, and the first surface 10A and the second surface 10B are formed by the short fiber mixed portion 110 and there is no short fiber non-mixed portion 120, in the curved surface portion, the average value of the thickness t20 of the curved surface portion (this corresponds to the average value of the thickness t21 of the short fiber mixed portion 110) is, for example, 1.0 mm or more and 6.0 mm or less. If the average value of the thickness t22 (t12) of the short fiber non-mixed portion 120 exceeds 3.0 mm, there is a risk of cracks occurring on the second surface 10B.

[0038] Next, the material and the like constituting the reinforcing sheet 20 will be described. The reinforcing sheet 20 is formed as a continuous fiber reinforcing material by weaving or knitting long fibers. The long fibers are composed of, for example, yarns or rovings such as glass fibers, carbon fibers, and aramid fibers. Preferably, a sheet woven from a yarn or roving obtained by bundling alkali-resistant AR glass fibers containing 16% or more of zirconia may be used. The yarn is formed by attaching a binder to monofilaments and converging them, and the roving is formed by bundling yarns. The chopped strands are usually formed by chopping a roving into a predetermined length.

[0039] The reinforcing sheet 20 also has a plurality of openings. The openings are sized such that at least a part of the mortar aggregate and short fibers can enter and partially penetrate the reinforcing sheet 20, and preferably, the size (dimension) allows the whole to pass through. The reinforcing sheet 20 shown in FIG. 4 is formed in a lattice shape with a plurality of openings 21. The size and shape of the openings 21 are not limited, but for example, the size is 5.0 mm square or 10.0 mm square. In the curved surface portion 10, the mortar has entered the openings 21 of the reinforcing sheet 20. The chopped strands in the mortar have also entered the openings 21. As the reinforcing sheet 20, a continuous fiber reinforcing material formed in a lattice shape from fiber reinforced plastics (Fiber Reinforced Plastics) can also be used.

[0040] As the reinforcing sheet 20, for example, an alkali-resistant glass fiber net having a plurality of openings can be used. Further, the reinforcing sheet 20 having a plurality of openings may be made of carbon fiber or basalt fiber (basalt fiber) developed for civil engineering.

[0041] Furthermore, the reinforcing sheet 20 is not limited to one in which reinforcing long fibers extend in one direction or in which long fibers extend in two directions, and may be one in which the directions of long fibers or short fibers are randomly arranged. A thin one such as a so-called continuous strand mat or a chopped strand mat may be used. The fibers constituting the chopped strand mat and the continuous strand mat are, for example, glass fibers (JIS K7010: E glass) with 0.8% or less of alkali (Na 2 O, K 2 O) or long fibers (yarns, rovings) or short fibers (chopped strands) formed by bundling alkali-resistant AR glass fibers containing 16% or more of zirconia. As the chopped strand mat, one in which a plurality of chopped strands are two-dimensionally oriented and held in a sheet shape by a binder can be used. The continuous strand mat may be one in which continuous yarns or rovings are stacked in the thickness direction d1 and held in a sheet shape by a binder. All of these reinforcing sheets 20 are formed so that the mortar aggregate and short fibers can pass through them when the curved surface portion 10 is manufactured.

[0042] A plurality of reinforcing sheets 20 embedded in the curved surface portion 10 may be provided in the thickness direction d1 with the same size of the openings 21, or may be embedded so that those with different sizes of the openings 21 are arranged in the thickness direction d1.

[0043] When the curved surface portion 10 is viewed from the first surface 10A side, its contour shape is not limited, but is formed, for example, in an elongated rectangular shape. Also, although not shown, the first surface 10A and the second surface 10B may be painted.

[0044] The molded body 1 composed of the curved surface portion 10 configured as such is provided on a structure and used as an interior and exterior finishing material. For example, in the molded body 1, the first surface 10A or the second surface 10B of the curved surface portion 10 is used for fixing to the structure portion.

[0045] (Manufacturing method) As shown in FIG. 5, the manufacturing method of the molded body 1 includes a first deposition step of depositing a first material M1 for molding the first surface 10A side of the curved surface portion 10 on a convex mold surface 51, a second deposition step of depositing a plurality of second materials M2 on the first material M1, a third deposition step of depositing a third material M3 for molding the second surface 10B of the curved surface portion 10 on the second material M2, and a curing step of curing the first material M1, the plurality of second materials M2, and the third material M3 deposited on the mold surface 51.

[0046] A. First deposition step In the first deposition step, the first material M1 is manually deposited on the mold surface 51 from a bucket or the like. The first material M1 is a base for placing the reinforcing sheet 20 as shown in FIG. 6 before placing the reinforcing sheet 20 on the mold surface 51 of the molding die 50. The mold surface 51 is formed as a convex curved surface protruding upward.

[0047] The first material M1 is composed of a fiber - mixed mortar material 30. As described above, the fiber - mixed mortar material 30 is a mixture obtained by kneading cement, water, fine aggregate, and alkali - resistant chopped strands, and does not exhibit the strength as mortar.

[0048] As the cement, ordinary Portland cement, early - strength Portland cement, super - early - strength Portland cement, medium - heat Portland cement, low - heat Portland cement, sulfate - resistant Portland cement, ordinary Portland cement (low - alkali type), early - strength Portland cement (low - alkali type), super - early - strength Portland cement (low - alkali type) shown in JIS R5210 can be used. Also, low - alkali type cement other than JIS R5210 may be used.

[0049] As admixtures, it may contain silica fume, slag, fly ash, dolomite, etc. Further, the fiber - mixed mortar material 30 may contain a shrinkage - reducing agent, a water - reducing agent, and other additives. Examples of the water - reducing agent include naphthalene sulfonic acid formalin high - condensate salt - based and polycarboxylic acid ether - based compounds, and examples of the shrinkage - reducing agent include alkylene oxide compounds of lower alcohols.

[0050] Hereinafter, the case where the fiber - mixed mortar material 30 is made by mixing ordinary Portland cement, silica sand, an admixture (silica fume), a water - reducing agent, chopped strand (AR glass), and water will be described. Also, the following fiber - non - mixed mortar material 40 does not contain short fibers compared with the fiber - mixed mortar material 30, and is a mixture of ordinary Portland cement, silica sand, an admixture (silica fume), a water - reducing agent, and water, in which the strength as mortar has not been developed. The fiber - mixed mortar material 30 and the fiber - non - mixed mortar material 40 differ in the presence or absence of short - fiber mixing, but not limited to the case where the same formulations of cement, fine aggregate, water, admixture, and additive are used, and those with different formulations may also be used. Also, the fiber - mixed mortar material 30 and the fiber - non - mixed mortar material 40 may differ in the presence or absence of admixture and additive mixing. The fiber - mixed mortar material 30 and the fiber - non - mixed mortar material 40 are not limited to the case where the same formulations of cement, fine aggregate, and water are used when no admixture and additive are mixed, and those with different formulations may also be used.

[0051] In the case of manually laying (handlaying) the fiber-reinforced mortar material 30 on the mold surface 51, an operator applies the fiber-reinforced mortar material 30 to the mold surface 51 with, for example, a trowel, levels and further spreads the surface of the fiber-reinforced mortar material 30 to cover the entire mold surface 51 with the fiber-reinforced mortar material 30. The average value of the thickness of the underlying fiber-reinforced mortar material 30 is, for example, 0.5 mm or more and 3.0 mm or less. By covering the surface of the mold surface 51 with the fiber-reinforced mortar material 30 before placing the reinforcing sheet 20 on the mold surface 51, it is possible to prevent the reinforcing sheet 20 from approaching the mold surface 51. When not allowing short fibers to protrude further from the first surface 10A of the molded body 1, as shown in FIG. 7, the first material M1 is a laminate composed of a fiber-free mortar material 40 manually laid on the mold surface 51 and a fiber-reinforced mortar material 30 manually laid on the fiber-free mortar material 40. The average value of the thickness of the fiber-free mortar material 40 is, for example, 0.5 mm or more and 3.0 mm or less. If the average value of the thickness of the fiber-free mortar material 40 is less than 0.5 mm, the glass fibers of the fiber-reinforced mortar material 30 may be exposed, and if the average value of the thickness of the fiber-free mortar material 40 exceeds 3.0 mm, cracks may occur. When manufacturing the curved surface portion 12 in which only one reinforcing sheet 20 is embedded in the thickness direction d1 as shown in FIG. 3, even when the first surface 10A is formed by the short fiber-free portion 120, the average value of the fiber-free mortar material 40 manually laid on the mold surface 51 is, for example, 0.5 mm or more and 3.0 mm or less.

[0052] B. Second Deposition Process As shown in FIG. 8, the second deposition process includes a laying process of laying the reinforcing sheet 20 on the fiber-reinforced mortar material 30 of the molding die 50 and a covering process of covering the reinforcing sheet 20 with the fiber-reinforced mortar material 30.

[0053] In the laying process, as shown in FIG. 9, the reinforcing sheet 20 is laid on the entire fiber-reinforced mortar material 30. As shown in FIG. 10, in the covering process, the fiber-mixed mortar material 30 is manually placed on the reinforcing sheet 20, and the reinforcing sheet 20 is embedded in the fiber-mixed mortar material 30. In this manual placement, an operator uses a trowel or the like to apply the fiber-mixed mortar material 30 onto the reinforcing sheet 20, levels the surface of the fiber-mixed mortar material 30 and further spreads it to cover the entire fiber-mixed mortar material 30. At this time, for example, it is desirable to push the fiber-mixed mortar material 30 into the opening 21 of the reinforcing sheet 20 with a trowel or the like so that at least a part of the aggregate and short fibers enters the opening 21 of the reinforcing sheet 20. Thereby, the fiber-mixed mortar material 30 of the second material M2 is placed in the opening 21 of the reinforcing sheet 20, and this fiber-mixed mortar material 30 is integrated with the first material M1 (fiber-mixed mortar material 30). Note that the average value of the thickness of the fiber-mixed mortar material 30 manually placed is, for example, 0.5 mm or more and 3.0 mm or less. If the average value of the thickness of the fiber-mixed mortar material 30 is less than 0.5 mm, the strength of the molded body becomes low, and if the average value of the thickness of the fiber-mixed mortar material 30 exceeds 3.0 mm, the weight becomes heavy. In this way, the second material M2 composed of the reinforcing sheet 20 and the fiber-mixed mortar material 30 manually placed thereon is further deposited on the mold surface 51.

[0054] Since the curved surface portion 10 of the present embodiment embeds six reinforcing sheets 20, in the second deposition process, the laying process and the covering process are repeated six times to deposit six layers of the second material M2. FIG. 11 shows a state in which six layers of the second material M2 are deposited on the mold surface 51. In the second deposition process, for each reinforcing sheet 20 provided at a different depth from the first surface 10A or the second surface 10B of the molded body 1, the second material M2 formed by manually placing the fiber-mixed mortar material 30 is deposited in one layer with a predetermined thickness. Note that, as shown in FIG. 3 for the molded body, in the second deposition process when only one reinforcing sheet 20 is provided in the thickness direction d1 of the curved surface portion 12, the laying process and the covering process are performed once, and then the process proceeds to the next third lamination process.

[0055] In the laying process, when laying a plurality of reinforcing sheets 20 on the fiber-mixed mortar material 30, the edges 22 of the reinforcing sheets 20 are overlapped with each other. In this way, when laying a plurality of reinforcing sheets 20 on the existing second material M2, the overlapping portion where the edges 22 of the plurality of reinforcing sheets 20 overlap with each other is shifted from the overlapping portion in the existing second material M2 to a position in the deposition direction d2 of the existing second material and arranged. FIG. 12 shows the fourth laying process. In the second deposition process, the second-layer second material M2 has an overlapping portion 210A. The overlapping portion 210B of the fourth-layer reinforcing sheet 20 is shifted from the position in the deposition direction d2 of the overlapping portion 210B of the second-layer second material M2, and two reinforcing sheets 20 are arranged on the third-layer second material M2.

[0056] The second deposition process is performed before the fiber-mixed mortar material 30 in the first deposition process exhibits strength and durability.

[0057] C. Third deposition process As shown in FIG. 13, in the third deposition process, the third material M3 is manually placed on the second material M2 from a bucket or the like. The third material M3 uses a fiber-free mortar material 40. In the manual placement (hand lay-up) of the fiber-free mortar material 40 onto the third material M3, an operator uses, for example, a trowel to level and further spread the surface of the fiber-free mortar material 40 to cover the entire second material M2 with the fiber-free mortar material 40. The average value of the thickness of the fiber-free mortar material 40 covering the second material M2 is, for example, 0.5 mm or more and 3.0 mm or less. If the average value of the thickness of the fiber-free mortar material 40 is less than 0.5 mm, the glass fibers of the second material M2 may be exposed. If the average value of the thickness of the fiber-free mortar material 40 exceeds 3.0 mm, cracks may occur on the second surface 10B of the molded body. The third deposition process is performed before the fiber-mixed mortar materials 30 in the first deposition process and the second deposition process exhibit strength and durability. In addition, as shown in FIG. 3 for the molded body, even in the third deposition step when only one reinforcing sheet 20 is provided in the thickness direction d1 of the curved surface portion 12, the average value of the thickness of the fiber-free mortar material 40 covering the second material M2 is, for example, 0.5 mm or more and 3.0 mm or less. If the average value of the thickness of the fiber-free mortar material 40 exceeds 3.0 mm, there is a risk of cracks occurring on the second surface 10B of the molded body.

[0058] D. Curing process In the curing process, with six reinforcing sheets 20 buried in the fiber-containing mortar material 30 in the deposition direction d2, the fiber-containing mortar material 30 is cured to exhibit strength and durability as mortar. For example, in the curing process, the hydration reaction of cement is promoted by storage at room temperature or in a steam atmosphere. After the curing process, the molded body 1 is completed, and six reinforcing sheets 20 are buried in the thickness direction d1 in the cured mortar.

[0059] The curved surface portion 10 thus formed is used as an interior and exterior finishing material of a structure and exhibits a good-looking appearance. Also, since the curved surface portion 10 has six reinforcing sheets 20 buried in the thickness direction d1, it has sufficient bending strength even when thin. Thus, it can be suitably used as an interior and exterior finishing material of a structure. In the manufacturing method of the molded body 1, the first material M1, the second material M2, and the third material M3 are deposited on the bent mold surface 51 by the first deposition step, the second deposition step, and the third deposition step, and further cured, whereby the curved surface portion 10 bent along the mold surface 51 can be formed. Also, by manually stacking (handlaying up) the first material M1, the second material M2, and the third material M3 on the mold surface 51 and the second material M2 with predetermined thicknesses (for example, 3.0 mm for the first material M1 and the second material M2, and 3.0 mm for the third material M3), the curved surface portion 10 can be formed thinly and with substantially the same thickness. In the conventional DS method, usually, the thickness of one layer by spraying in the X direction and the Y direction is 5.0 mm or more, and it is difficult to provide a fiber-containing mortar material on the reinforcing sheet with a thickness of 3.0 mm or less. It is difficult to provide a fiber-containing mortar material on the reinforcing sheet with a thickness of 3.0 mm or less.

[0060] The present invention can be implemented without being limited to the above description and illustrated examples. The number of the curved surface portions is not limited to one, and the shape of the curve can also be different. For example, the molded body may include the curved surface portion shown in one embodiment of FIG. 1 and the curved surface portion shown in the first modification example of FIG. 2. For forming the curved surface portion shown in FIG. 2, for example, the mold 60 shown in FIG. 14 is used. This mold 60 includes a concave mold surface 61 that is recessed downward, and the first material M1, a plurality of second materials M2, and the third material M3 are deposited on the mold surface 61. The laminate of the first material M1 may be composed of a fiber-mixed mortar material 30 manually stacked on the mold surface 51 and a fiber-unmixed mortar material 40 manually stacked on the fiber-mixed mortar material 30.

[0061] In the above embodiment, the third deposition step is performed after the second deposition step and before the curing step. However, the third deposition step is not performed after the second deposition step and before the curing step. In the curing step, the fiber-mixed mortar materials deposited in the first deposition step and the second deposition step are cured, and when they have hardened to form a fiber-mixed mortar (short fiber mixed portion) that exhibits the strength as mortar, a third deposition step of depositing the fiber-unmixed mortar material 40 on the fiber-mixed mortar (short fiber mixed portion) in which the fiber-mixed mortar material 30 has hardened may be performed. Further, after this third deposition step, an additional mortar curing step of curing the fiber-unmixed mortar material 40 deposited on the fiber-mixed mortar may be performed. The additional mortar curing step cures the fiber-unmixed mortar material 40 to exhibit strength and durability as mortar. For example, in the additional mortar curing step, the hydration reaction of cement is promoted by storing at room temperature or in a steam atmosphere.

[0062] FIGS. 15 to 19 show other embodiments of the present invention, and the same configuration as that of the molded body in one embodiment is applied to a part of the laminated structure. As shown in FIGS. 15 and 16, this laminated structure 71 has a base 72, a heat insulating material layer 73 covering the outer surface of the base 72, a fiber reinforced mortar layer 74 covering the outer periphery of the heat insulating material layer 73, and an outer surface finishing layer 75 covering the outer surface of the fiber reinforced mortar layer 74. The heat insulating material layer 73 and the fiber reinforced mortar layer 74 disposed outside the base 72 are an integral structure joined by anchor members 77 protruding from the base 72.

[0063] The base 72 is a formwork or a structure. The formwork is used when molding the materials constituting the heat insulating material layer 73 and the fiber reinforced mortar layer 74. Further, the formwork also becomes integral with the heat insulating material layer 73 and the fiber reinforced mortar layer 74 even after the molding is completed, and functions as a part that gives strength to the laminated structure 71. The base 72 may contain reinforcing materials such as reinforcing fibers and steel bars. The outer surface of this base 72 is formed in a convex curved surface shape as a whole, and a plurality of anchor members 77 are fixedly attached. Each anchor member 77 protrudes outward from the outer surface of the base 72. The anchor member 77 will be described later.

[0064] The heat insulating material layer 73 is made of a foam such as polyurethane foam. In this embodiment, it is constructed by spray foaming at the construction site as will be described later. For this reason, the outer surface of the heat insulating material layer 73 is generally formed in a curved surface shape along the outer surface of the base 72. Of course, regardless of the shape of the outer surface of the base 72 (even if the outer surface of the base 72 is a flat surface), it is possible to form the outer surface of the heat insulating material layer 73 in a curved surface shape. In the present invention, at least the outer surface of the heat insulating material layer 73 is formed in a curved surface shape.

[0065] Also, since it is formed by sequentially depositing while spraying, regardless of the shape (curved surface or flat surface) of the outer surface of the base 72, the outer surface of the heat insulating material layer 73 itself is also formed in a microscopically uneven shape. The thickness of the heat insulating material layer 73 is not particularly limited, but is formed, for example, to be 5 mm or more and 40 mm or less.

[0066] The fiber-reinforced mortar layer 74 has the same configuration as the molded body 1 in one embodiment, and includes a fiber-incorporated mortar (short fiber-incorporated portion) 81 in which short fibers for reinforcement are mixed, and a plurality of reinforcing sheets 82 made of a mesh-like fiber reinforcing material embedded in the fiber-incorporated mortar 81. The average value of the thickness t11 of the fiber-reinforced mortar layer (short fiber-incorporated portion) 74 is, for example, 0.5 mm or more and 19.5 mm or less, preferably 4.5 mm or more and 12.5 mm or less, and more preferably 5.5 mm or more and 9.5 mm or less. This thickness t11 is the thickness of the thinnest part due to the unevenness of the surface of the heat insulating material layer 77. Therefore, due to the recess formed on the surface of the heat insulating material layer 77, a thickened portion will occur in the fiber-reinforced mortar layer 74. Since the heat insulating material layer 73 is laminated with a predetermined thickness, the outer surface of the fiber-reinforced mortar layer 74 is formed in a curved surface shape.

[0067] The fiber-incorporated mortar (short fiber-incorporated portion) 81 and the reinforcing sheet 82 have the same configuration as the short fiber-incorporated portion 110 and the reinforcing sheet 20 described in one embodiment. The reinforcing sheet 82 is embedded in the fiber-reinforced mortar layer 74 in a state where a plurality of sheets are arranged to extend in the plane direction and spaced apart from each other. Further, since the reinforcing sheet 82 is mesh-like, at least a part of the aggregate and short fibers of the fiber-incorporated mortar 81 has entered. The number of the reinforcing sheets 82 is not limited to the illustrated example, but is, for example, 2 or more and 20 or less, preferably 3 or more and 15 or less. Also, it is desirable that the reinforcing sheets 82 are buried with a distance from each other in the thickness direction, and the average value of the thickness t13 of the fiber-incorporated mortar 81 between the reinforcing sheets 82 is, for example, 0.5 mm or more and 3.0 mm or less.

[0068] (Anchor member) The anchor member 77 is constituted by bolts fixed to the base portion 72, and a plurality of them are embedded in the base portion 72 at intervals in the surface direction of the base portion 72 while penetrating in the thickness direction. Therefore, the anchor member 77 protrudes from the outer surface of the base portion 72 in a direction orthogonal to the outer surface, penetrates the heat insulating material layer 73 and the fiber reinforced mortar layer 74, and is provided in a state of being embedded in the outer surface finishing layer 75. The entire anchor member 77 is covered with a resin tube 85 so that the heat insulating material layer 73 and the fiber reinforced mortar layer 74 do not enter the thread groove of the bolt (the tube is omitted in FIG. 15).

[0069] In this case, a plurality of reinforcing sheets 82 are embedded in the fiber reinforced mortar layer 74, and the anchor member 77 penetrates these reinforcing sheets 82 and protrudes to the outer surface of the fiber reinforced mortar layer 74. At least the tip of the anchor member 77 is formed with a male screw portion 77a, and a nut 86 with a washer is screwed onto the male screw portion 77a as a collar member. As a matter of course, the nut 86a of this nut with a washer is larger in diameter than the male screw portion (shaft portion) 77a of the anchor member 77 and is formed to be larger in diameter than the opening of the reinforcing sheet 82. Therefore, the nut with a washer (collar member) 86 is provided in a state of spreading in the radial direction at the tip of the anchor member 77, and by screwing this collar member 86 onto the male screw portion 77a of the anchor member 77, the fiber reinforced mortar layer 74 and the heat insulating material layer 73 are pressed in the thickness direction together with the reinforcing sheet 82.

[0070] In addition, the length of the anchor member 77 is formed to protrude by a length corresponding to the thickness of the collar member 86 from the outer surface of the fiber reinforced mortar layer 74 in this embodiment. However, the diameter and installation interval (pitch) of the anchor member 77 are not particularly limited and are appropriately set according to the thickness of the fiber reinforced mortar layer 74 and the like. For example, it may be arranged with a diameter of 8 mm or more and 22 mm or less and a pitch of 300 mm or more and 1200 mm or less.

[0071] (Outer surface finishing layer) The outer finishing layer 75 is, for example, a short fiber non-incorporated portion that does not contain short fibers for mortar reinforcement, and is formed by hardening a mixture (mortar) of cement, fine aggregate, and water in layers. Since this outer finishing layer 75 is formed on the outer surface of the fiber-reinforced mortar layer 74 with a predetermined thickness, it is formed in a curved surface shape and does not contain short fibers, so it is finished with a smooth surface. The mixture of this short fiber non-incorporated portion may contain admixtures such as silica fume, slag, fly ash, dolomite, and further shrinkage reducing agents, water reducing agents, and other additives. Similar to the fiber-incorporated mortar, cement, fine aggregate, and water are used, but not limited to the case where the same formulations are used, and different formulations may be used. Admixtures and additives may or may not be included. Even when these are included, the formulations of cement, fine aggregate, water, admixtures, and additives may be the same as or different from those of the fiber-incorporated mortar.

[0072] And the flange member 86 is embedded by this outer finishing layer 75, and the outer surface is finished as a smooth surface. In this case, even if a part of the short fibers mixed in the surface of the fiber-reinforced mortar layer 74 protrudes, the outer surface is finished smoothly by forming the outer finishing layer 75 thereon. The average value of the thickness t12 of this outer finishing layer (short fiber non-incorporated portion) 75 is, for example, 0.5 mm or more and 3.0 mm or less.

[0073] When this outer finishing layer 75 is provided, the thickness t10 of the curved surface portion is the sum of the thickness t11 of the fiber-reinforced mortar layer (short fiber incorporated portion) 74 and the thickness t12 of the outer finishing layer (short fiber non-incorporated portion) 75 (t10 = t11 + t12), which is 1.0 mm or more and less than 20.0 mm, preferably 5.0 mm or more and 13.0 mm or less, and more preferably 6.0 mm or more and 10.0 mm or less. In addition, when the outer finishing layer 75 is not provided, the thickness of the fiber-reinforced mortar layer 74 is finished to be 1.0 mm or more and less than 20.0 mm.

[0074] Next, a method for manufacturing the laminated structure configured as described above will be described. This laminated structure is constructed in the order of a base construction process, a heat insulating material layer formation process, a fiber reinforced mortar layer formation process, and an outer surface finishing layer formation process. Hereinafter, the details will be described in the order of the processes.

[0075] (Base construction process) The base 72 is a formwork or a structure, and the base ends of a plurality of anchor members 77 are embedded in the base 72, and the tip ends are provided in a state of protruding from the outer surface of the base 72. In addition, as shown in FIG. 17 etc., the anchor member 77 is in a state of being inserted into a resin sleeve 85.

[0076] (Heat insulating material layer formation process) As shown in FIG. 17, a heat insulating material layer 73 is formed on the outer surface of the base 72. This heat insulating material layer 73 is constructed by pumping a raw material in a fluid state containing polyurethane resin, a curing agent, etc. from a tank and spraying it onto the surface of the base 72 from a spray gun etc. together with compressed air from a compressor. Since the foam made of urethane foam etc. has self - adhesiveness, by spraying, it can firmly adhere to the surface of the base 72 and the deposits thereon without using an adhesive, and can cover these surfaces without gaps, and a continuous heat insulating material layer can be formed. In this case, since the resin tube 85 covers the anchor member 77, the sprayed heat insulating material does not enter the thread of the anchor member 77.

[0077] In this heat insulating material formation process, since it is formed by spraying and foaming the raw material on the outer surface of the base 72, the outer surface is formed in a shape along the outer surface of the base 72, and is formed in a curved surface along the curved surface of the base 72 whose outer peripheral surface is formed in a curved surface. Also, since the raw material sprayed on the surface of the base 72 adheres while locally foaming, unlike a molded body produced using a mold, as shown in FIG. 17, the surface of the heat insulating material layer 73 is formed in a micro - uneven shape. By controlling the degree of spraying, the degree of unevenness of the surface can also be arbitrarily controlled.

[0078] (Fiber reinforced mortar layer formation process) In the step of forming the fiber-reinforced mortar layer, first, fiber-incorporated mortar in a fluid state before curing (first material M1) is applied to the outer surface of the heat insulating material layer 73 to form a relatively thin first layer 81a that covers the outer surface of the heat insulating material layer 73 as shown in FIG. 18 (first deposition step). This first layer 81a serves as a base for placing the reinforcing sheet 82 on the outer surface of the heat insulating material layer 73. Its thickness is not particularly limited, but it is formed to be 0.5 mm or more and 3.0 mm or less. It suffices if it has a thickness such that the minute unevenness on the surface of the heat insulating material layer 73 is filled. The application of this fiber-incorporated mortar 81 is performed by the hand lay-up method in which an operator uses a trowel or the like to deposit it to a predetermined thickness. Since this construction method by hand lay-up is performed manually, it can flexibly cope with various shapes of the outer surface of the heat insulating material layer 73.

[0079] By forming this first layer 81a of the fiber-incorporated mortar 81, a part of the fiber-incorporated mortar 81 enters into the concave portions on the outer surface of the heat insulating material layer 73, and the unevenness is leveled by the fiber-incorporated mortar 81, and the outer surface of the first layer 81a is formed to be substantially flat.

[0080] Next, after placing the reinforcing sheet 82 on the surface of the first layer 81a, while depositing the fiber-incorporated mortar 81 in a fluid state again on this reinforcing sheet 82, the fiber-incorporated mortar 81 is spread so as to embed the reinforcing sheet 82, and then, the reinforcing sheet 82 is placed on it again, and the operation of applying the fiber-incorporated mortar 81 in the same manner is repeated, whereby a second material M2 composed of the reinforcing sheet 82 and the fiber-incorporated mortar 81 is laminated in a plurality of layers on the first material M1 (second deposition step).

[0081] In this way, the placement of the reinforcing sheet 82 and the application of the fiber-incorporated mortar 81 in a fluid state are alternately performed and laminated, but the anchor member 77 protruding from the heat insulating material layer 73 is inserted through each reinforcing sheet 82, and its tip is made to protrude outward from the fiber-reinforced mortar layer 74. By curing in this state, the fiber-reinforced mortar layer 74 formed by embedding a plurality of reinforcing sheets 82 in the fiber-incorporated mortar 81 is cured (curing step).

[0082] After the fiber-reinforced mortar layer 74 has hardened, a washer nut is attached as the flange member 86 to the anchor member 77 protruding from the surface thereof, and by screwing it into the male screw portion 77a, as shown in FIG. 19, the heat insulating material layer 73 and the fiber-reinforced mortar layer 74 are pressed in the axial direction of the anchor member 77. Note that the resin tube 85 covering the anchor member 77 is compressed in the direction of shortening its length by screwing the flange member 86 into the male screw portion 77a of the anchor member 77, and is left below the flange member 86. When the tube 85 is too long relative to the length of the anchor member 77, etc., the tip portion may be cut when attaching the flange member 86.

[0083] (Outer surface finishing layer forming step) Finally, an outer surface finishing layer 75 made of mortar without short fibers (fiber-free mortar) is formed on the fiber-reinforced mortar layer 74, and the flange member 86 is embedded in the outer surface finishing layer 75 (third deposition step). Even when a part of the short fibers protrudes from the fiber-reinforced mortar layer 74, by forming this outer surface finishing layer 75, the short fibers are buried in the outer surface finishing layer 75, and the surface of the outer surface finishing layer 75 is finished into a smooth surface.

[0084] In the external heat insulation wall structure constructed as described above, since the fiber-reinforced mortar layer 74 is integrated with a plurality of reinforcing sheets 82 and the fiber-incorporated mortar 81, it has excellent strength even if it is thin, and can firmly protect the heat insulating material layer 73 below it. In this case, since the heat insulating material layer 73 is composed of a sprayed foam, its outer surface is formed in an uneven shape, and the fiber-reinforced mortar layer 74 formed thereon is constructed by stacking while applying the fiber-incorporated mortar using a trowel or the like by the hand lay-up method by an operator. Therefore, the fiber-incorporated mortar 81 enters the minute unevenness on the surface of the heat insulating material layer 73, and the unevenness exhibits an anchor effect, so that the heat insulating material layer 73 and the fiber-reinforced mortar layer 74 are firmly integrated.

[0085] Furthermore, since the large-diameter flange member (nut with washer) 86 of the anchor member 77 fixed to the base 72 presses the heat insulating material layer 73 and the fiber-reinforced mortar layer 74 in the axial direction of the anchor member 77, not only the movement in the surface direction but also the axial movement of the anchor member 77 is restricted, and the heat insulating material layer 73 and the fiber-reinforced mortar layer 74 are firmly held by the anchor member 77 to the base 72, and the occurrence of their dropping can be surely prevented. Due to these synergistic effects, a laminated body structure with extremely high strength can be obtained.

Example

[0086] As samples, after stacking a fiber-mixed mortar material and a reinforcing sheet on a convex mold surface protruding upward, a molded body was manufactured through curing, and the thickness, flexural strength, dry shrinkage amount, and molding workability of the samples were confirmed. Each sample is bent as a whole like the molded body shown in Fig. 1, and a plurality of reinforcing sheets are embedded in the thickness direction.

[0087] The fiber-mixed mortar material is obtained by adding water to cement, fine aggregate, admixture, etc. and alkali-resistant glass fiber and kneading them. Samples 4 and 5 use cement paste instead of mortar, and furthermore, alkali-resistant glass fiber is mixed into the cement paste of sample 4. Each of samples 1 to 4 has a reinforcing sheet embedded, and sample 5 has a cold yarn embedded. The alkali-resistant glass fiber mixed into the cement uses chopped strands cut to a length of about 6.0 mm. The reinforcing sheet is made of alkali-resistant glass fiber and is formed in a lattice shape, and each opening has a size of 5.0 mm square. The admixture is microsilica (silica fume). Table 1 shows the materials of each sample and the number of reinforcing sheets. Note that the dimensions in a plan view from the first surface side of samples 1 to 4 are 200.0 mm in length and 200.0 mm in width, and the dimensions in a plan view from the first surface side of sample 5 are 150.0 mm in length and 150.0 mm in width.

[0088]

Table 1

[0089] (Measurement of Thickness) The thickness from the first side to the second side of each sample was measured. The measurement method was to measure 6 times using a vernier caliper and calculate the average value. The average value of the thickness of each sample is shown in Table 2.

[0090] (Measurement of Bending Strength) The dry strength and saturated water strength of each sample were measured. For the dry strength, the sample was dried in an atmosphere of 40°C for 24 hours, then cooled to room temperature and the sample was measured. The saturated water strength was measured after being immersed in water for 24 hours. The measurement was a three-point bending test with a central load. From the relationship of the thickness of the molded body, Samples 1 to 4 were measured at a span of 200.0 mm, and Sample 5 was measured at a span of 150.0 mm. Each sample was measured six times and the average value was calculated. The average value of the bending strength (dry strength and saturated water strength) of each sample is shown in Table 2.

[0091] (Measurement of Dry Shrinkage) After maintaining the saturated state in which the sample was sufficiently absorbed with water for 24 hours, the sample was dried in an atmosphere of 40°C for 24 hours, cooled to room temperature and measured. Chips were attached to the first side and the second side of the sample in the X direction and the Y direction respectively, and measured with a contact gauge. Each sample was measured three times and the average value was calculated. The average value of the dry shrinkage of each sample is shown in Table 2.

[0092] (Evaluation of Molding Workability) The molding workability of each mortar material was evaluated by the flow value [mm]. If the flow value was within the predetermined range, it was considered good, and if the flow value was less than the said range or greater than the said range, it was considered bad.

[0093]

Table 2

[0094] Samples 1 to 3 are GRC molded bodies, and for this GRC molded body, both the average value of the dry strength and the average value of the saturated water strength are greater than 15.00 [N / mm 2 , and the average value of the dry shrinkage amount is less than 500 [μm] required for the product. Sample 3 had poor moldability due to its high fluidity compared to Samples 1 and 2, but the flexural strength (average value of dry strength, average value of saturated water strength) and the average value of the dry shrinkage amount were good.

[0095] The molded body of Sample 4 did not contain fine aggregate and could not meet the condition that the average value of the dry shrinkage amount is 500 [μm] or less required for the product.

[0096] The molded body of Sample 5 had a plurality of cold yarns embedded in the thickness direction, but the average value of the saturated water strength was less than 15.00 [N / mm 2 , and it could not meet the condition that the average value of the dry shrinkage amount is 500 [μm] or less required for the product. Also, in Sample 5, the operation of stacking the cement paste and the cold yarn during production was cumbersome.

Explanation of Symbols

[0097] 1 Molded body 10, 11, 12 Curved surface part 10A First surface 10B Second surface 110 Short fiber mixing part 120 Short fiber non-mixing part 20 Reinforcing sheet 50, 60 Molding die 51, 61 Mold surface 71 Laminated structure 72 Base 73 Heat insulating material layer 74 Fiber reinforced mortar layer 75 Outer surface finishing layer 77 Anchor member 81 Fiber mixed mortar 82 Reinforcing sheet

Claims

1. A molded body having a curved surface portion, The curved surface portion includes a reinforcing sheet embedded in fiber-mixed mortar containing short fibers for reinforcing the mortar, Furthermore, the average thickness of the curved surface portion is 1.0 mm or more and less than 20.0 mm, A molded article, wherein the reinforcing sheet is curved to follow the curvature of the curved surface portion.

2. The molded body according to claim 1, characterized in that at least one of a first surface of the curved portion and a second surface opposite to the first surface is made of fiber-mixed mortar containing the short fibers.

3. The molded body according to claim 1, characterized in that at least one of the first surface of the curved portion and the second surface opposite to the first surface is made of non-fiber-containing mortar that does not contain the short fibers.

4. 2. The molded body according to claim 1, wherein a plurality of the reinforcing sheets are embedded in the thickness direction of the curved surface portion, and the average thickness of the curved surface portion is 3.0 mm or more and less than 20.0 mm.

5. The short fibers contained in the fiber-mixed mortar are alkali-resistant glass fibers, The molded article according to claim 1, characterized in that the molded article is a GRC molded article.

6. A laminated structure having a curved surface portion, The average thickness of the curved surface portion is 1.0 mm or more and less than 20.0 mm, The present invention has a base, an insulating material layer covering an outer surface of the base, and a fiber-reinforced mortar layer covering the outer surface of the insulating material layer, the fiber-reinforced mortar layer having fiber-mixed mortar mixed with short fibers for reinforcement, and a plurality of reinforcing sheets made of fiber reinforcing material embedded in the fiber-mixed mortar and having a plurality of openings to form a mesh-like structure, The reinforcing sheet is curved to follow the curvature of the curved surface portion, A laminated structure characterized in that an anchor member fixed to the base penetrates at least the bottom layer of the reinforcing sheet in the insulation layer and the fiber-reinforced mortar layer, and a flange member having a larger diameter than the opening of the reinforcing sheet is provided at its end.

7. A method for producing a molded body having a reinforcing sheet embedded in a curved surface portion, comprising the steps of: a first deposition step of depositing a first material onto a convex or concave mold surface; a second deposition step of depositing at least one layer of a second material on the first material; A curing process for curing the first material and the second material deposited on the mold surface, The first material is a fiber-mixed mortar material containing short fibers for reinforcing mortar, or a laminated material containing a fiber-free mortar material containing no short fibers and the fiber-mixed mortar material; The method for producing a molded body, wherein the second material comprises the reinforcing sheet and the fiber-mixed mortar material hand-laid on the reinforcing sheet.

8. The method further comprises a third depositing step of depositing the fiber-free mortar material on the second material after the second depositing step and before the curing step; The method for manufacturing a molded body according to claim 7 , characterized in that the curing step comprises curing the first material, the second material, and the fiber-free mortar material deposited on the mold surface.

9. The method for manufacturing a molded body described in claim 7, further comprising a third deposition process in which the fiber-mixed mortar material is deposited on top of the fiber-mixed mortar material hardened in the curing process, and an additional mortar curing process in which the fiber-mixed mortar material deposited on the fiber-mixed mortar is cured.

10. The method for producing a molded body according to any one of claims 7 to 9, characterized in that the short fibers contained in the fiber-mixed mortar material are alkali-resistant glass fibers.

11. A method for producing a laminated structure having a reinforcing sheet embedded in a curved surface portion, comprising the steps of: The method includes a base construction step of constructing a base and fixing an anchor member to an outer surface of the base, an insulation layer formation step of forming an insulation layer covering the outer surface of the base with the anchor member penetrating therethrough, and a fiber reinforced mortar layer formation step of forming a fiber reinforced mortar layer covering the outer surface of the insulation layer, The outer surface of the heat insulating layer is formed into a convex or concave curved surface, The fiber reinforced mortar layer forming step includes: a first depositing step of depositing a first material on the curved surface of the insulation layer; a second deposition step of depositing a second material on the first material; A curing process for curing the first material and the second material deposited on the curved surface, The first material is a fiber-mixed mortar material containing short fibers for reinforcing mortar, or a laminated material containing a fiber-free mortar material containing no short fibers and the fiber-mixed mortar material; The second material is composed of a plurality of reinforcing sheets laminated in a thickness direction and the fiber-mixed mortar material hand-laid so as to bury the reinforcing sheets, A method for manufacturing a laminated structure, characterized in that an end of an anchor member protruding from the insulation layer is positioned so as to penetrate at least one of the reinforcing sheets, and a flange member having a larger diameter than the opening of the reinforcing sheet is provided at the end of the anchor member.

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