Decorative formwork

Abstract

This decorative formwork is used to apply decorative designs to the surface of concrete after it has hardened during the concrete pouring process for forming structures. By using foamed urethane as the base material, resin molds can be used, reducing mold manufacturing costs, increasing design variations, and minimizing concrete chipping during demolding. [Solution] The decorative formwork 1 used to form a predetermined design surface on the surface of a structure has a design forming section 4 that is inversely opposed to the design surface, and comprises a base material 2 made of foamed urethane and a wooden panel 3 integrally fixed to a surface of the base material 2 that is different from the design forming section 4. Since the foamed urethane is integrated with the wooden panel, the thermal expansion and contraction of the foamed urethane can be suppressed by the panel, and the occurrence of steps and misalignments between products can be reduced.

Description

Technical Field

[0001] The present disclosure relates to a decorative formwork used for applying a design to the surface of concrete after hardening when placing concrete for forming a structure.

Background Art

[0002] In a structure where a tile-covered wall is constructed as an outer wall, according to the provisions of the Building Standards Law, a regular inspection is obligatory to prevent the peeling and falling off of tiles, so the running cost for such inspection is increasing. Therefore, in recent years, a decorative formwork having a design forming portion provided on the inner surface of the formwork used at the time of placing concrete has come to be used. By using this decorative formwork, it is possible to directly form a design surface such as a tile pattern or a brick pattern that is reversed from the design forming portion on the surface of the hardened concrete, and an outer wall material such as tiles becomes unnecessary. The applicant of the present case also provides a decorative formwork as disclosed in Patent Document 1. This decorative formwork is formed by forming a design forming portion having lattice-shaped ribs that are reversed from a tile pattern on one surface of a plate-shaped base material formed of a hard resin.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The decorative formwork described in Patent Document 1 above is made of thermoplastic resin and therefore requires heating to approximately 200°C for molding. Consequently, the mold used to produce the decorative formwork must be made of metal capable of withstanding high temperatures and pressures. This results in high manufacturing costs for the mold, and because it can only be manufactured by end milling (machining), it is limited to geometric designs such as tile patterns and rib patterns, resulting in a limited variety of designs that can be applied to the concrete surface. Furthermore, because the decorative formwork was made of hard resin, there was a problem of chipping occurring in the concrete when it was removed from the concrete structure.

[0005] Therefore, the purpose of this disclosure is to provide a decorative formwork that can reduce the manufacturing cost of the mold, increase the variations in design, and reduce the likelihood of concrete chipping during demolding. [Means for solving the problem]

[0006] To achieve the above objective, this disclosure provides a decorative formwork used to form a predetermined decorative surface on the surface of a structure, Having a design forming portion that is inverse to the aforementioned design surface, the base material is made of foamed urethane, A wooden panel integrally fixed to a surface of the substrate different from the design-forming portion, It is characterized by containing the following. Another aspect of the present disclosure is characterized in that, in the above configuration, the substrate is formed in a box shape in which the panel is housed in an opening formed on the opposite side of the design forming portion, and the periphery of the panel is covered by a peripheral wall portion that forms the opening. Another aspect of the present disclosure is characterized in that, in the above configuration, the surface of the panel that is surrounded by the peripheral wall and exposed within the opening is protected by a coating layer. Another aspect of the present disclosure is characterized in that, in the above configuration, the peripheral wall portion has elasticity that allows it to be pre-compressed in the thickness direction due to the proximity of the peripheral wall portions when a plurality of the decorative formworks are arranged side by side. Another aspect of the present disclosure is characterized in that, in the above configuration, no adhesive is interposed between the substrates and the panel that are fixed to each other. Another aspect of this disclosure is characterized in that, in the above configuration, the design surface is a design of a natural object. Another aspect of the present disclosure is characterized in that, in the above configuration, the design of the natural material is a wood grain pattern, a stone pattern, or a sandstone pattern. Another aspect of the present disclosure is characterized in that, in the above configuration, the decorative formwork has dimensions of 600 mm to 900 mm in width and 1000 mm to 1800 mm in height. [Effects of the Invention]

[0007] According to this disclosure, by using foamed urethane as the base material, resin molds can be used. Therefore, compared to metal molds, the manufacturing cost of the molds can be reduced, and weight reduction can also be achieved. In addition, it becomes possible to accommodate designs of natural objects, thus increasing the variety of designs. Furthermore, because the design-forming portion of the foamed urethane base material is elastic, chipping of the concrete during demolding becomes less likely. Furthermore, since the foamed urethane that forms the base material is integrated with the wood panel, the thermal expansion and contraction of the foamed urethane can be suppressed by the panel, reducing the occurrence of steps and misalignments between products. In particular, the rigidity ensured by the panel has the advantage of reducing restrictions on the construction site. For example, even when workers stand on the decorative formwork used in areas that are viewed from above, such as eaves or exterior corridors, or when reinforcing bars are placed on top of the decorative formwork, there is no risk of damage like with polystyrene foam decorative formwork. According to another aspect of this disclosure, in addition to the above effects, since the panel is housed in an opening of a box-shaped substrate and the periphery of the panel is covered by the peripheral wall forming the opening, water resistance and durability can be ensured even if the panel is made of wood, and an improvement in quality can be expected. According to another aspect of this disclosure, in addition to the above effects, since the surface of the panel that is surrounded by the peripheral wall and exposed within the opening is protected by the coating layer, waterproofing can be obtained with the coating layer without covering the panel within the opening with foamed urethane. This reduces the amount of foamed urethane used, leading to lower costs and lighter weight. According to another aspect of this disclosure, in addition to the above effects, the peripheral wall portion has elasticity that allows it to be pre-compressed in the thickness direction due to the proximity of the peripheral wall portions when multiple decorative formworks are installed side by side, thereby improving the sealing performance between the decorative formworks. According to another aspect of this disclosure, in addition to the above effects, since no adhesive is interposed between the substrates and panels that are fixed to each other, the process of applying adhesive can be omitted, which reduces manufacturing time and costs, and also contributes to environmental protection. According to another aspect of this disclosure, in addition to the above effects, since the design surface is a natural object design, the aesthetic appeal of the concrete structure can be enhanced. According to another aspect of this disclosure, in addition to the above effects, the design of the natural material is a wood grain pattern, a stone pattern, or a sandstone pattern. A wood grain pattern results in a warm design, while a stone pattern or a sandstone pattern results in a luxurious design. According to another aspect of this disclosure, in addition to the above effects, since the decorative formwork is 600 mm to 900 mm wide and 1000 mm to 1800 mm high, the size of the smallest unit of decorative formwork becomes larger, leading to a reduction in assembly man-hours. [Brief explanation of the drawing]

[0008] [Figure 1] This is a front view of the decorative formwork. [Figure 2] This is a rear view of the decorative formwork. [Figure 3] This is a cross-sectional view along line AA in Figure 2. [Figure 4] Figure 2 is a cross-sectional view along line BB. [Figure 5] This is an enlarged view of section a in Figure 3. [Figure 6] This is an enlarged view of section b in Figure 4. [Figure 7]It is a perspective view showing the construction state of the decorative formwork.

Mode for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present disclosure will be described based on the drawings. FIG. 1 is a front view showing an example of the decorative formwork, FIG. 2 is a rear view, FIG. 3 is a sectional view taken along line A-A, and FIG. 4 is a sectional view taken along line B-B. The decorative formwork 1 is in the shape of a vertically long rectangular plate when viewed from the front, with a width W of 600 mm and a height H of 1500 mm. The decorative formwork 1 is composed of a base material 2 and a panel 3 that are fixed to each other. The base material 2 is formed of foamed urethane and has a thickness of 18.5 mm. On the front surface of the base material 2, a design forming portion 4 is formed. The design forming portion 4 has a shape that is reversed from the design surface formed on the surface of the concrete structure. Here, the design surface has a wood grain pattern and a thickness of about 1.5 mm. The wood grain pattern is an example of the design of natural objects of the present disclosure. As shown in FIGS. 5 and 6, a peripheral wall portion 5 that protrudes toward the back side is formed over the entire circumference on the outer periphery of the base material 2. Therefore, the base material 2 has a shallow-bottom box shape with a vertically long rectangular opening 6 formed on the back by the peripheral wall portion 5. The peripheral wall portion 5 has a thickness of 2 mm to 4 mm and a rising height of 12 mm. The thickness of the base material 2 excluding the peripheral wall portion 5 is 6.5 mm.

[0010] The panel 3 is a plywood that is slightly smaller in size in the vertical and horizontal directions than the base material 2 and is housed in the opening 6 on the back side of the base material 2. The back surface of the panel 3 is substantially flush with the rear end surface of the peripheral wall portion 5 in the housed state in the opening 6. The thickness of the panel 3 is, for example, 12 mm. Therefore, the panel 3 is in a state where the entire circumference is covered by the peripheral wall portion 5, and only the back surface is exposed on the back surface of the decorative formwork 1. A waterproof material such as resin is applied to the back surface of the panel 3 to form a coating layer 7.

[0011] The base material 2 and the panel 3 of the decorative formwork 1 are integrally molded using a resin mold (not shown). The foamed urethane injected into the resin mold is soft foamed urethane, and the foaming ratio is about 2 to 3 times. Specifically, the panel 3 is set in the cavity of a resin mold with a design surface formed on the inner surface facing the front in a direction where the coating layer 7 is on the back, and urethane foam is injected into the cavity. Then, the injected urethane foam fills the cavity and also penetrates around the panel 3 and cures. Thereby, a box-shaped base material 2 with a design formation part 4 formed on the front and a peripheral wall part 5 having an opening 6 integrally formed on the back side is obtained, and the panel 3 is in a state of being accommodated in the opening 6. The specific gravity of the base material 2 is 0.4 to 0.6, and it has elasticity due to urethane foam. The urethane foam injected into the cavity soaks into the panel 3 over the entire area in contact with the panel 3. Therefore, even without an adhesive intervening, the base material 2 and the panel 3 are naturally integrated. In particular, the peripheral wall part 5 cured on the peripheral surface of the panel 3 covers the peripheral surface in a close contact state, so the sealing property between the panel 3 and the peripheral wall part 5 is ensured.

[0012] As configured above, the decorative formwork 1, as shown in FIG. 7, has horizontal bars 10 in the vertical direction attached to the back at a predetermined interval in the horizontal direction, and a plurality of sheets are combined vertically and horizontally according to the concrete placement area of the structure. Then, the horizontal bars 10 of each decorative formwork 1 are connected and integrated with pipes 11 arranged in the horizontal direction on the back side. This is built into the placement position where the reinforcing bars 12 are arranged, with the design formation part 4 facing the side that will be the design surface of the concrete. On the other side across the reinforcing bars 12, a formwork 13 made of plywood or the like with horizontal bars 10 and pipes 11 assembled on the back in the same manner is built in. Since the decorative formwork 1 has a size of 1500 mm, which is larger in height than conventional ones, even in an apartment building with a height of about 3000 mm per floor, it can be dealt with by arranging two sheets side by side in the height direction.

[0013] Then, a separator 14 is passed through between the decorative formwork 1 and the formwork 13, and the Foam-Tie (registered trademark) 15 provided at each end of each separator 14 is locked to the pipe 11 from the outside to fix the decorative formwork 1 and the formwork 13. After that, concrete is placed between the decorative formwork 1 and the formwork 13. Between adjacent decorative formwork panels 1,1 in the vertical, horizontal, and vertical directions, the adjacent peripheral wall sections 5,5 are pre-compressed and elastically deformed, thereby improving the sealing performance between the decorative formwork panels 1,1. As a result, leakage of fresh concrete or water from between the decorative formwork panels 1,1 is prevented. After the concrete has hardened, when the decorative formwork 1 and formwork 13 are removed, a wood grain pattern is formed on the concrete surface on the decorative formwork 1 side, with the decorative forming part 4 of the decorative formwork 1 reversed. Because the base material 2 is made of foamed urethane, the risk of chipping of the concrete during removal is reduced. The demolded decorative formwork 1 can be reused repeatedly, either after the battens 10 and pipes 11 have been removed, or with the battens 10 and pipes 11 still attached, as long as no damage occurs.

[0014] The decorative formwork 1 in the above configuration has a design forming portion 4 that is inverse to a predetermined design surface formed on the surface of the structure, and comprises a base material 2 made of foamed urethane and a wooden panel 3 integrally fixed to a surface of the base material 2 that is different from the design forming portion 4. This configuration allows the use of resin molds by making the base material 2 from foamed urethane. Therefore, compared to metal molds, the manufacturing cost of the molds can be reduced, and weight reduction can also be achieved. Furthermore, it becomes possible to accommodate designs of natural objects, thus increasing the variety of designs. Furthermore, because the design-forming portion 4 of the base material 2, which is made of foamed urethane, is elastic, chipping of the concrete is less likely to occur during demolding. Furthermore, since the foamed urethane forming the base material 2 is integrated with the wood panel 3, the thermal expansion and contraction of the foamed urethane can be suppressed by the panel 3, reducing the occurrence of steps and misalignments between products. In particular, the rigidity ensured by the panel 3 has the advantage of reducing restrictions on the construction site. For example, even when workers stand on the decorative formwork 1 used in areas that are viewed from above, such as eaves or exterior corridors, or when reinforcing bars are placed on top of the decorative formwork 1, there is no risk of damage like with polystyrene foam decorative formwork.

[0015] The base material 2 is formed in a box shape into which the panel 3 is housed in an opening 6 formed on the opposite side from the design forming section 4, and the periphery of the panel 3 is covered by the peripheral wall section 5 that forms the opening 6. Therefore, even if panel 3 is made of wood, water resistance and durability can be ensured, and an improvement in quality can be expected. The decorative formwork 1 is susceptible to moisture from the external environment (rain, snow, humidity, etc.) as well as moisture from the concrete, which can cause problems such as corrosion, swelling, deformation, and dimensional inaccuracies in the wooden panel 3. However, in this case, the entire perimeter of the panel 3 is covered with a tightly adhering peripheral wall 5, making it less susceptible to the effects of moisture from the external environment and preventing problems such as corrosion and deformation. The surface of the panel 3, which is surrounded by the peripheral wall portion 5 and exposed within the opening 6, is protected by a coating layer 7. Therefore, since waterproofing can be achieved with the coating layer 7 without covering the panel 3 inside the opening 6 with foamed urethane, the amount of foamed urethane used can be reduced, leading to lower costs and lighter weight.

[0016] The peripheral wall portion 5 has elasticity that allows it to be pre-compressed in the thickness direction due to the proximity of the peripheral wall portions 5, 5, when multiple decorative formworks 1, 1, 1 are installed. Therefore, the sealing performance between decorative formwork 1,1 can be improved. When moisture seeps out of the concrete from the joint line between decorative formwork 1,1, it becomes cement-rich and the color of the joint line darkens, but this can be prevented from causing such color unevenness at the joint line. No adhesive is interposed between the substrate 2 and the panel 3, which are fixed to each other. Therefore, the process of applying adhesive can be omitted, which reduces production time and costs, and also contributes to environmental protection. The design is based on natural objects. Therefore, the aesthetic appeal of concrete structures can be enhanced. The design of natural objects is based on wood grain patterns. Therefore, it results in a warm and inviting design.

[0017] The decorative formwork 1 measures 600mm in width and 1500mm in height. Therefore, the size of the smallest unit of decorative formwork 1 becomes larger. For example, when used on the exterior wall of an apartment building where the height of one floor is approximately 3000 mm, conventionally three pieces were installed side by side in the height direction, but with decorative formwork 1, it is sufficient to install two pieces side by side in the height direction. This leads to a reduction in assembly man-hours. In addition, because the number of pieces installed in the height direction has been reduced from three to two, the number of joints in the design between the upper and lower decorative formwork 1,1 has been reduced from two to one, resulting in a more continuous design surface.

[0018] The following describes examples of changes to this disclosure. The panels are not limited to plywood; they may also be made from solid wood or laminated wood. The panel may have a coating layer applied to both the front and back surfaces beforehand. In this case, there is no need to pay attention to the orientation of the front and back surfaces during molding. However, the coating layer does not have to be applied to the front surface of the panel. In this case, the surface that becomes the back surface may also be covered with foamed urethane. The foaming ratio and specific gravity of the polyurethane foam are not limited to the values ​​above and can be changed as appropriate. The thickness of the base material, the thickness of the design-forming portion, and the height of the rising portion of the peripheral wall are not limited to the above values ​​and can be changed as appropriate. The thickness of the surrounding walls can also be changed as needed. The thickness of the surrounding walls can be varied on the top, bottom, left, and right sides. The peripheral wall portion may be eliminated, and the base material and the panel may be integrally fixed together to the same size. An adhesive may be interposed between the substrate and the panel. The design surface is not limited to wood grain patterns; it may also feature other natural elements such as stone or sandstone patterns. Furthermore, the design surface is not limited to natural elements; it may also feature other geometric designs such as tile or rib patterns. The size of the decorative formwork is not limited to the 600mm wide x 1500mm high example above; it can be changed as needed. For example, the width can be selected within the range of 600mm to 900mm, and the height between 1000mm and 1800mm. The front view shape of decorative formwork is not limited to vertical rectangles; other front view shapes such as horizontal rectangles and squares can also be used. It is also possible to combine decorative formwork with different front view shapes during construction. [Explanation of Symbols]

[0019] 1. Decorative formwork, 2. Base material, 3. Panel, 4. Design forming section, 5. Peripheral wall section, 6. Opening, 7. Coating layer, 10. Battens, 11. Pipe, 12. Reinforcement bars, 13. Formwork.

Claims

1. A decorative formwork used to form a predetermined design surface on the surface of a structure, Having a design forming portion that is inverse to the aforementioned design surface, the base material is made of foamed urethane, A wooden panel integrally fixed to a surface of the substrate different from the design-forming portion, A decorative formwork characterized by comprising the following:

2. The decorative formwork according to claim 1, characterized in that the base material is formed in a box shape in which the panel is housed in an opening formed on the opposite side of the design forming portion, and the periphery of the panel is covered by the peripheral wall portion that forms the opening.

3. The decorative formwork according to claim 2, characterized in that the surface of the panel, surrounded by the peripheral wall portion and exposed within the opening, is protected by a coating layer.

4. The decorative formwork according to claim 2 or 3, characterized in that the peripheral wall portion has elasticity that allows it to be pre-compressed in the thickness direction due to the proximity of the peripheral wall portions when a plurality of the decorative formworks are arranged side by side.

5. The decorative formwork according to any one of claims 1 to 3, characterized in that no adhesive is interposed between the substrate and the panel that are fixed to each other.

6. The decorative formwork according to any one of claims 1 to 3, characterized in that the design surface is a design of a natural object.

7. The decorative formwork according to claim 6, characterized in that the design of the natural material is a wood grain pattern, a stone pattern, or a sandstone pattern.

8. A decorative formwork according to any one of claims 1 to 3, characterized in that it has a width of 600 mm or more and a height of 1000 mm or more and a height of 1800 mm or less.

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