Manufacturing method of stacking blocks

Abstract

To provide a stacked block production method which is improved in moldability and mass productivity in concrete stacked blocks.SOLUTION: Provided is a stacked block production method of having form set means A, material filling means B, pressing means C, pushing-up means D, removing means E and dry extraction means F. The form set means A has a process of mounting a bottom plate 11 on a lower part of an outer frame 6, thereafter setting a horizontal partition plate 12 at a center so as to be a standard frame part 14 and inserting and mounting a first form 15 made of a synthetic resin material on the bottom plate 11 of the standard frame part 14. The material filling means B has a process of filling a concrete material m into the standard frame part 14. The pressing means C has a process of pressing the concrete material m in the standard frame part 14 by a pressing part 26 disposed with a second form 29 at a lower bottom face. The push-up means D has a process of pushing up the bottom plate 11. The removing means E has a process of mounting stacked blocks 1 or the like on a removing arm 37 so as to be transferred to a prescribed place, and drying is executed by the dry extraction means F to produce the stacked blocks 1.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to stacking blocks used when constructing an exterior wall or retaining soil for a flower bed etc.

Background Art

[0002] Conventionally, in many cases, for an exterior wall, a plurality of concrete blocks having through holes penetrating vertically are stacked to the desired height. At this time, reinforcing bars extending vertically are inserted into the through holes and filled with mortar to increase the strength.

[0003] Also, for those where strength and height are not particularly required, such as retaining soil for a flower bed, construction is carried out by simply stacking concrete blocks without using reinforcing bars or by filling mortar between the blocks.

[0004] Recently, it is not uncommon to construct a flower bed etc. oneself as so-called DIY (Do-It-Yourself), like a Sunday handyman, especially in the field of gardening, without relying on a professional.

[0005] In this case, instead of high-difficulty construction using reinforcing bars and mortar as carried out by a professional, stacking several highly designed concrete blocks is the mainstream. However, even if it is several layers, it is currently not easy to stack them accurately and neatly.

[0006] On the other hand, a technique for easily positioning and stacking concrete blocks has been devised, for example, a block in which a convex portion on the upper surface and a concave portion on the lower surface are substantially fitted together, like the gardening block according to Patent Document 1, but it is not currently widespread.

[0007] Thus, despite having a very simple structure in which a convex portion is formed on one surface and a concave portion is formed on the opposing surface, it has not become widespread. This is because such a structure is inherently difficult to mold, and even with block molding equipment such as that described in Patent Document 2, which is intended for mass production, there are not only problems with moldability, but also with the complicated storage and handling required after molding until drying and solidification. These factors significantly hinder mass production, and manufacturing technology has yet to be established. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] Japanese Utility Model Publication No. 57-074248 [Patent Document 2] Japanese Patent Application Publication No. 10-202636 [Overview of the project] [Problems that the invention aims to solve]

[0009] Of course, using the block molding apparatus described in Patent Document 2, by arranging multiple molds that create protrusions (or recesses) in the upper mold and multiple molds that create recesses (or protrusions) in the lower mold of the formwork into which the concrete material is filled, it is possible to mold multiple blocks of the desired shape simultaneously, which is an advantage.

[0010] However, as mentioned above, after molding, the blocks must be moved to a storage location along with the lower mold on which they are placed until they dry and solidify. Furthermore, individual blocks cannot be handled until they have solidified, and there are issues with moldability during manufacturing, which inevitably leads to a decrease in product yield.

[0011] In particular, in a manufacturing method that uses a mold that creates a protrusion on the upper mold and a mold that creates a recess on the lower mold, and presses the upper mold toward the lower mold, it is difficult to fill the inside of the upper mold with a sufficient amount of concrete material, and therefore it is not possible to properly pressurize the protrusion.

[0012] Furthermore, in a manufacturing method that uses a mold that creates a recess in the upper mold and a mold that creates a convex part in the lower mold, and presses the upper mold toward the lower mold, the metal mold forming the lower mold must be made thicker, which makes it very expensive and also presents problems in terms of weight, making it difficult to handle.

[0013] This invention has been made in view of the above circumstances, and aims to provide a method for manufacturing concrete stacking blocks that improves moldability and mass production efficiency. [Means for solving the problem]

[0014] To achieve the above objectives, the present invention provides the following:

[0015] The invention according to claim 1 is a method for manufacturing stacked blocks comprising a formwork setting means, a material filling means, a pressing means, a lifting means, a removal means, and a drying extraction means, wherein the formwork setting means has a plurality of vertical partition plates arranged parallel to each other at predetermined intervals. At the same time, multiple mounting pieces are erected at predetermined intervals, perpendicular to the lower end of the vertical partition plate and in contact with it. The outer frame is rectangular with open top and bottom. On the aforementioned mounting piece Multiple bottom plates are placed on the outer frame bottomAfter partially closing the section, a horizontal partition plate perpendicular to the vertical partition plate is set in the center of the vertical partition plate, forming a reference frame section with multiple concave spaces formed by the outer frame, the vertical partition plate, the bottom plate, and the horizontal partition plate. Then, a first mold made of synthetic resin material is inserted and placed on the bottom plate of the reference frame section. The material filling means fills a predetermined amount of concrete material in advance and places a material container, which is at least open at the bottom, on a stage that is substantially flush with the upper end of the outer frame behind the outer frame and is movable back and forth, and moves forward to fill the reference frame section within the outer frame with the concrete material. After that, the material container moves backward, and the pressing means is located above the outer frame and has multiple second molds arranged on its lower bottom surface. The present invention provides a method for manufacturing stacked blocks, characterized in that, after the pressing part descends and the second formwork presses the concrete material in the reference frame, the pressing part retracts upward, the pushing means is located below the outer frame and pushes up the bottom plate until the lower bottom surface of the bottom plate exceeds the upper end of the outer frame, the removal means inserts the removal arm into the gap between the outer frame and the bottom plate, the pushing means descends and places the bottom plate on which the stacked block made of the first formwork, the horizontal partition plate and the molded concrete material is placed on the removal arm, the removal arm moves it to a predetermined location, and the stacked block is manufactured by drying and extracting the block.

[0016] The invention according to claim 2 provides a method for manufacturing stacking blocks according to claim 1, characterized in that the first formwork has at least one downwardly tapered convex portion through which the central portion penetrates, and the second formwork has at least one downwardly tapered concave portion protruding from its lower bottom surface.

[0017] The invention according to claim 3 provides a method for manufacturing stacked blocks as described in claim 2, characterized in that the first mold has an upper molded portion that is rectangular in plan view and forms the convex portion, and a chamfered molded wall that extends upward around the entire circumference of the upper molded portion and has a sharply inclined tip that extends upward from the inside.

[0018] The invention according to claim 4 provides a method for manufacturing stacked blocks according to claim 3, characterized in that the first formwork comprises a support wall extending downward around the entire circumference of the upper molding section and a plurality of ribs projecting downward from the lower surface of the upper molding section to the height of the support wall. [Effects of the Invention]

[0020] According to the invention described in claim 1, a method for manufacturing stacked blocks comprising a formwork setting means, a material filling means, a pressing means, a lifting means, a removal means, and a drying extraction means, wherein the formwork setting means comprises a plurality of vertical partition plates arranged parallel to each other at predetermined intervals. At the same time, multiple mounting pieces are erected at predetermined intervals, perpendicular to the lower end of the vertical partition plate and in contact with it. The outer frame is rectangular with open top and bottom. On the aforementioned mounting piece After placing multiple bottom plates to partially close the bottom of the outer frame, a horizontal partition plate perpendicular to the vertical partition plate is set in the center of the vertical partition plate to form a standard frame section with multiple concave spaces formed by the outer frame, vertical partition plate, bottom plate, and horizontal partition plate. Then, a first formwork made of synthetic resin material is inserted and placed on the bottom plate of the standard frame section. The material filling means fills a predetermined amount of concrete material in advance and places a material container, which is at least open at the bottom, on a stage that is substantially flush with the upper end of the outer frame at the rear of the outer frame and is movable back and forth, and moves forward to fill the standard frame section inside the outer frame with concrete material. After the material container moves backward, the pressing means moves a pressing section located above the outer frame and with multiple second formworks arranged on its lower bottom surface downward so that the second formworks press the concrete material inside the standard frame section. The pressing part retracts upward, the pushing means is located below the outer frame and pushes the bottom plate up until the lower bottom surface of the bottom plate exceeds the upper end of the outer frame, the removal means inserts the removal arm into the gap between the outer frame and the bottom plate, and then the pushing means descends to place the bottom plate on which the stacked blocks made of the first formwork, horizontal partition plates and molded concrete material are placed on the removal arm, then the removal arm moves it to a predetermined location, and the stacked blocks are manufactured by drying and extracting them with the drying and extracting means. As a result, after the removal means, each stacked block is placed on its respective first formwork, so even before the concrete material hardens, the first formwork can be grasped and the stacked blocks can be handled indirectly and individually, and handling in the drying and extracting means is also easier.

[0021] Also, since the bottom plate and the vertical partition plate can be removed after the taking-out means, the number of bottom plates and vertical partition plates required for sequential manufacturing can be reused, so the number of bottom plates and vertical partition plates to be prepared can be minimized.

[0022] Furthermore, after the stacking block is solidified, the number of first molds required for sequential manufacturing can be removed from the stacking block and easily reused, so the number of first molds to be prepared can be minimized.

[0023] Moreover, since the first mold is made of a synthetic resin material, the mold release property can be enhanced by the minute deformation during pressing by the second mold, so the product yield can be improved and the mass productivity can be enhanced.

[0024] According to the invention described in claim 2, since the first mold forms at least one convex portion with a reduced diameter downward and a penetrated central portion, and the second mold forms at least one concave portion with a reduced diameter downward protruding from the lower bottom surface, the upper part becomes concave and the lower part becomes convex during molding, so the molding property can be further enhanced.

[0025] According to the invention described in claim 3, since the first mold has a rectangular upper molding portion in plan view forming the convex portion and a chamfered molding wall extending upward over the entire circumference of the upper molding portion and having an inclined surface with a sharp tip directed upward from the inside, the molding property of this part can be improved, so a beautiful chamfer can be formed at the outer peripheral corner of the upper surface of the stacking block having a convex portion on the upper side in the completed body.

[0026] According to the invention described in claim 4, since the first mold consists of a placement wall extending downward over the entire circumference of the upper molding portion and a plurality of ribs protruding downward from the lower surface of the upper molding portion to the height of the placement wall, a moderate and minute deformation can be caused in the first mold during pressing by the second mold toward the first mold, so the mold release property and the molding property can be enhanced, resulting in further improvement of the product yield and further enhancement of the mass productivity.

Brief Description of the Drawings

[0028] [Figure 1]This is a simplified flowchart showing the process for manufacturing stacking blocks according to this embodiment. [Figure 2] (a) is a perspective view showing the placement of the bottom plate onto the outer frame as a formwork setting means, and (b) is a perspective view showing the setting of the lateral partition plates. [Figure 3] This is a perspective view showing the placement of the first formwork onto the base plate as a formwork setting means. [Figure 4] (a) is a perspective view showing the filling of concrete material into the outer frame by a material container as a material filling means, and (b) is a perspective view showing the material container in a retracted position. [Figure 5] This is a perspective view showing the pressing of concrete material by the second formwork as a pressing means. [Figure 6] This is a perspective view showing the lifting of components other than the vertical partition plates within the outer frame as a means of pushing up. [Figure 7] This is a perspective view showing the removal of components, etc., by an removal arm as a means of removal. [Figure 8] This is a perspective view of the second formwork, the downward-facing stacking blocks, and the first formwork, showing their orientation and positional relationship during pressing. [Figure 9] This is a perspective view of the second formwork, the upward-facing stacking blocks, and the first formwork, shown in the opposite direction and positional relationship to when the pressure was applied. [Figure 10] This is a cross-sectional view shown in the orientation and positional relationship of Figure 8. [Figure 11] (a) is a plan view of the first formwork, and (b) is a bottom view. [Figure 12] This is a partial cross-sectional view of the manufacturing apparatus after the formwork setting means has been installed. [Figure 13] This is a partial cross-sectional view of the manufacturing apparatus after the material filling means has been completed. [Figure 14] This is a partial cross-sectional view showing the pressing of concrete material by the second formwork as a pressing means. [Figure 15] This is a partially perforated cross-sectional view showing the moment just before the pressing of the concrete material by the second formwork is completed as a pressing means. [Figure 16] This is a partially transparent cross-sectional view showing the lifting mechanism, specifically the lifting section, for stacked blocks and the like. [Modes for carrying out the invention]

[0029] The gist of the method for manufacturing stacking blocks according to the present invention is a method for manufacturing stacking blocks comprising a formwork setting means, a material filling means, a pressing means, a pushing means, a removal means, and a drying extraction means, wherein the formwork setting means is a rectangular frame-shaped outer frame with multiple vertical partition plates installed parallel to each other at predetermined intervals, and multiple bottom plates are placed on the lower part of the outer frame to substantially close the bottom of the outer frame, and then horizontal partition plates perpendicular to the vertical partition plates are set in the center of the vertical partition plates to form a reference frame section with multiple concave spaces formed by the outer frame, vertical partition plates, bottom plates, and horizontal partition plates, and then a first formwork made of synthetic resin material is inserted and placed on the bottom plate of the reference frame section, and the material filling means is a stage that is at least open at the bottom, in which a predetermined amount of concrete material has been filled in advance and is placed at the rear of the outer frame so as to be movable back and forth on a stage that is substantially flush with the upper end of the outer frame. The material container moves forward to fill the standard frame section within the outer frame with concrete material, after which the material container retracts backward. The pressing means, located above the outer frame, has a pressing section with multiple second formworks arranged on its lower bottom surface that descends to press the concrete material within the standard frame section with the second formworks, after which the pressing section retracts upward. The pushing means, located below the outer frame, pushes up the bottom plate until the lower bottom surface of the bottom plate exceeds the upper end of the outer frame. The removal means inserts a removal arm into the gap between the outer frame and the bottom plate, then the pushing means descends to place the bottom plate, on which the stacking block consisting of the first formwork, a horizontal partition plate, and molded concrete material is placed, onto the removal arm. The removal arm then moves the stacking block to a predetermined location, and the stacking block is dried by a drying extraction means to manufacture it. In other words, the aim is to provide a method for manufacturing stacking blocks made of concrete that improves moldability and mass production efficiency.

[0030] Hereinafter, a method for manufacturing stacking blocks according to the present invention and an embodiment of the stacking block 1 will be described with reference to the drawings. In this description, structures and parts that are identical or symmetrical on both sides will, in principle, be denoted by the same reference numerals, and only one side will be described, with the other side being omitted as appropriate.

[0031] Furthermore, in this explanation, the top and bottom of the first formwork 15 and the second formwork 29 are described as follows, as shown in Figure 8: for the first formwork 15, the side with the rib 20 is the bottom; and for the second formwork 29, the side with the concave portion 30 is the bottom.

[0032] Furthermore, in this explanation, when describing the stacking block 1 shown in Figure 9, that is, the stacking block 1 as a completed unit, the side with the convex portion will be referred to as the upper side and the side with the concave portion as the lower side.

[0033] Furthermore, although the concrete material m in this embodiment is described as a so-called zero-slump ultra-hard concrete, the concrete material m is not particularly limited as long as the stacking block 1 according to the present invention can be manufactured.

[0034] The method for manufacturing a stacked block according to an embodiment of the present invention, as shown in Figures 1, 2 to 7, is a method for manufacturing a stacked block 1 comprising a formwork setting means A, a material filling means B, a pressing means C, a pushing means D, a removal means E, and a drying extraction means F, wherein the formwork setting means A is a rectangular frame-shaped outer frame 6 with multiple vertical partition plates 9 arranged parallel to each other at predetermined intervals, and multiple bottom plates 11 are placed on the lower part of the outer frame 6 to substantially close the bottom of the outer frame 6, then horizontal partition plates 12 perpendicular to the vertical partition plates 9 are set in the center of the vertical partition plates 9 to form a reference frame section 14 with multiple concave spaces formed by the outer frame 6, vertical partition plates 9, bottom plates 11, and horizontal partition plates 12, and then a first formwork 15 made of synthetic resin material is inserted and placed on the bottom plate 11 of the reference frame section 14, and the material filling means B is a stage 23 that is substantially flush with the upper end of the outer frame 6 and filled with a predetermined amount of concrete material m in advance, and is placed so as to be movable back and forth behind the outer frame 6 After the downward-opening material container 24 moves forward to fill the standard frame section 14 within the outer frame 6 with concrete material m, the material container 24 retracts backward. The pressing means C is located above the outer frame 6 and has a pressing section 26 with multiple second molds 29 arranged on its lower bottom surface. The pressing section 26 descends to press the concrete material m within the standard frame section 14 with the second molds 29, after which the pressing section 26 retracts upward. The pushing-up means D is located below the outer frame 6 and pushes up the bottom plate 11 until its lower bottom surface exceeds the upper end of the outer frame 6. The removal means E inserts the removal arm 37 into the gap between the outer frame 6 and the bottom plate 11. Then, the pushing-up means D descends to place the bottom plate 11, on which the stacking block 1 consisting of the first mold 15, the horizontal partition plate 12, and the molded concrete material m is placed, onto the removal arm 37. The stacking block 1 is then moved to a predetermined location by the removal arm 37 and dried by the drying extraction means F to manufacture the stacking block 1.

[0035] Furthermore, as shown in Figures 8 to 11, the first formwork 15 has at least one downwardly tapered convex portion 18 through which the central portion 19 penetrates, and the second formwork 29 has at least one downwardly tapered concave portion 30 protruding from its lower bottom surface.

[0036] Furthermore, the first formwork 15 has a rectangular upper molding section 17 in plan view with a convex portion 18, and a chamfered molding wall 16 that extends upward around the entire circumference of the upper molding section 17 and forms a sharp, inclined surface from the inside upward.

[0037] Furthermore, the first formwork 15 consists of a mounting wall 21 that extends downward around the entire circumference of the upper molding section 17, and a plurality of ribs 20 (20a, 20b) that protrude downward from the lower surface of the upper molding section 17 to the height of the mounting wall 21.

[0038] Furthermore, by using this method for manufacturing stacking blocks, it is possible to provide inexpensive, highly accurate, and aesthetically pleasing stacking blocks 1, which are possible due to their high moldability and mass-producibility.

[0039] Furthermore, the stacking block 1 according to this embodiment has chamfers 4 on the outer corners of its upper surface, two frustoconical protrusions 2 projecting upward from its upper surface, and two recesses 3 on its lower bottom surface facing the protrusions, which are shaped to substantially fit with the protrusions 2. This allows the stacking block 1 to be stacked upward with precision and stability while substantially fitting the protrusions 2 and recesses 3 together.

[0040] It should be noted that the number of protrusions 2 and recesses 3 in the stacking block 1 according to this embodiment is not limited to two, nor is the shape of the protrusions 2 and recesses 3 limited to a frustoconical shape. Furthermore, it goes without saying that the manufacturing method described below can also be modified in various ways within the scope of the present invention.

[0041] The method for manufacturing stacked blocks according to this embodiment will be described in detail below.

[0042] As shown in Figure 2(a), the formwork setting means A consists of three rectangular vertical partition plates 9, with their longitudinal directions facing front and back, positioned parallel to each other at predetermined intervals and in a substantially fixed state inside a rectangular outer frame 6 that is open at the top and bottom. Four rectangular bottom plates 11 are then placed vertically with their sides facing the outside to substantially close the bottom of the outer frame 6.

[0043] Furthermore, groove-shaped outer frame grooves 7 are formed in the center of the left and right inner circumferential walls of the outer frame 6, extending vertically across the outer frame, into which the left and right ends of the horizontal partition plates 12 are inserted and engaged. Additionally, groove-shaped vertical partition engagement grooves 10 are formed at the upper central edge of the vertical partition plate 9, which engage with the horizontal partition plate 12. On the left and right inner circumferential walls of the outer frame 6 and at the lower ends of the vertical partition plates 9, for example, as shown in Figures 12 and 16, multiple elongated rectangular plate-shaped mounting pieces 8 are installed at predetermined intervals between the left and right inner circumferential walls of the outer frame 6, contacting the vertical partition plates 9 perpendicularly, so that each bottom plate 11 can be placed in contact with it.

[0044] Next, as shown in Figure 2(b), a rectangular horizontal partition plate 12 is placed perpendicular to the vertical partition plate 9, with its long side facing left and right, and its sides facing horizontally. It is then inserted from above into the outer frame groove 7 and the vertical partition engagement groove 10.

[0045] Furthermore, the horizontal partition plate 12 has three groove-shaped horizontal partition engagement grooves 13 that engage with the three vertical partition engagement grooves 10, extending downward from near the upper end of the horizontal partition plate 12.

[0046] In this way, by inserting and setting the horizontal partition plate 12, a base frame section 14 is formed with the outer frame 6, vertical partition plate 9, bottom plate 11, and horizontal partition plate 12, creating eight concave spaces, as shown in Figure 3. Then, the first mold 15 made of synthetic resin material is inserted and placed on the bottom plate 11 of the base frame section 14, resulting in the arrangement shown in Figure 12.

[0047] As shown in Figures 8 to 11, the first formwork 15 consists of a rectangular upper molding section 17 in plan view, a chamfered molding wall 16 that extends upward around the entire circumference of the upper molding section 17 and forms a sharply inclined surface from the inside upward, a band-shaped mounting wall 21 that extends downward around the entire circumference of the upper molding section 17, and a plurality of ribs 20 that protrude downward from the lower surface of the upper molding section 17 to the height of the mounting wall 21.

[0048] Furthermore, the upper molding section 17 has two adjacent frustoconical convex sections 18, through which the central section 19 penetrates and which taper downwards toward the mounting wall 21.

[0049] Furthermore, the rib 20 consists of eight cylindrical small ribs 20a formed at four equal intervals on the periphery of each convex portion 18, and a larger cylindrical rib 20b with a larger diameter than the small ribs 20a formed in the gap between the two convex portions 18.

[0050] The shape and position of the rib 20 are not limited to this embodiment and can be modified in various ways.

[0051] The ribs 20 and the lower end surfaces of the mounting wall 21 are located on the same plane, and by inserting the first formwork 15 into the reference frame section 14 with the chamfered molding wall 16 facing upwards, the ribs 20 and the lower end surfaces of the mounting wall 21 are stably placed in contact with the bottom plate 11, as shown in Figure 12.

[0052] In Figures 4(b) and 12, the pressing section 26, which has multiple second molds 29 arranged on its lower bottom surface, is located above the outer frame 6, while the lifting section 32, which allows the lower bottom surface of the bottom plate 11 to be pushed upward, is located below it.

[0053] Next, as shown in Figure 4(a), after the formwork setting means A is completed, the worker performs a switch operation (not shown), which moves the material container 24, which is filled with a predetermined amount of concrete material m, forward to where the outer frame 6 is located, thereby filling the standard frame portion 14 inside the outer frame 6 with concrete material m.

[0054] Specifically, a stage 23 is provided around the periphery of the outer frame 6, which is substantially flush with the upper end of the outer frame 6. A rectangular-framed material container 24, which is vertically open and can move freely back and forth, is provided on the stage 23 at the rear of the outer frame 6.

[0055] Furthermore, concrete material m is automatically supplied into the material container 24 from above by a hopper (not shown) or the like where the concrete material m is stored. When the material container 24, which has been filled with a predetermined amount of concrete material m, moves toward the outer frame 6, the concrete material m falls into and fills the standard frame section 14 within the outer frame 6.

[0056] Then, when the concrete material m is filled into the standard frame section 14 to an extent that exceeds the upper end of the outer frame 6, the material container 24 retracts to the rear, and the material filling means B is completed as shown in Figures 4(b) and 13.

[0057] Furthermore, concrete material m is automatically supplied again to the material container 24 that has been moved to the rear, in preparation for the start of the next material filling means B.

[0058] Next, the pressing means C consists of a pressing section 26 located above the outer frame 6, with a plurality of second formwork 29 positioned on its lower bottom surface with the concave section 30 facing downwards. As shown in Figures 5 and 14, the pressing section 26 descends and the second formwork 29 press against the concrete material m inside the base frame 14 while vibrating, compressing the concrete material m as shown in Figure 15. After that, the pressing section 26 retracts upward.

[0059] The pressing section 26 consists of a pressurizing vibration device 27 that uses hydraulics, air, an electric motor, or the like as a driving means to apply pressure and is equipped with an electric vibration generating means, a pressing base 28 at its lower end on which the second formwork 29 can be freely positioned in a hanging state, and the second formwork 29.

[0060] Furthermore, the vibration impact can be increased by suspending the second formwork 29 from the pressing base 28 via a spring material (not shown).

[0061] Furthermore, the second formwork 29 is rectangular in shape and made of metal. As shown in Figures 8 to 10, it has two adjacent frustoconical recessed sections 30 projecting from its lower bottom surface, with a downwardly tapering diameter. The distance between the two recessed sections 30 is equal to the distance between the two convex sections 18 of the first formwork 15, and the shape of the recessed sections 30 is formed to substantially fit into the convex sections 18.

[0062] Next, as shown in Figures 6 and 16, the lifting means D uses a lifting section 32 that allows the lower bottom surface of the bottom plate 11 to be freely pushed upward until the lower bottom surface of the bottom plate 11 exceeds the upper end of the outer frame 6.

[0063] The lifting section 32 consists of a lifting device 33 that uses hydraulics, air, an electric motor, etc. as a means of lifting, and a lifting base 35 at the upper end of the lifting device 33, which has eight rod-shaped push-up sections 34 erected at positions directly below the approximate center of each bottom plate 11 to push up the bottom plate 11.

[0064] Next, the removal means E inserts a fork-shaped removal arm 37, which avoids contact with the push-up part 34, into the gap between the outer frame 6 and the bottom plate 11. Then, the lifting part 32, which is the pushing means D, descends to place the bottom plate 11 on which the stacked block 1, consisting of the first formwork 15, the horizontal partition plate 12, and the molded concrete material m, is placed on the removal arm 37. After that, as shown in Figure 7, the removal arm 37 moves it to a predetermined location.

[0065] Subsequently, the concrete material m is dried using the drying and extraction means F, and the stacked block 1 shown in Figure 9 is completed.

[0066] In the drying and extraction means F, natural drying or a drying oven can be used.

[0067] As described above, the method for manufacturing stacked blocks according to this embodiment is a formwork setting means A A method for manufacturing stacking blocks 1 comprising a material filling means B, a pressing means C, a pushing means D, a removal means E, and a drying extraction means F, wherein the formwork setting means A is a rectangular frame-shaped outer frame 6 with multiple vertical partition plates 9 installed parallel to each other at predetermined intervals, and multiple bottom plates 11 are placed on the lower part of the outer frame 6 to substantially close the bottom of the outer frame 6, and then horizontal partition plates 12 perpendicular to the vertical partition plates 9 are set in the center of the vertical partition plates 9 to form a reference frame with multiple concave spaces formed by the outer frame 6, vertical partition plates 9, bottom plates 11, and horizontal partition plates 12. After forming part 14, a first mold 15 made of synthetic resin material is inserted and placed on the bottom plate 11 of the reference frame part 14. The material filling means B fills a predetermined amount of concrete material m in advance and places a material container 24, which is at least open at the bottom, on a stage 23 that is substantially flush with the upper end of the outer frame 6 at the rear of the outer frame 6 and is movable back and forth. The material container 24 moves forward to fill the reference frame part 14 inside the outer frame 6 with concrete material m. After the material container 24 moves backward, the pressing means C is located above the outer frame 6 and has multiple The pressing part 26, which is positioned on the lower bottom surface of the second formwork 29, descends and presses the concrete material m inside the base frame 14 with the second formwork 29. After that, the pressing part 26 retracts upward, the pushing means D, which is located below the outer frame 6, pushes up the bottom plate 11 until the lower bottom surface of the bottom plate 11 exceeds the upper end of the outer frame 6, and the removal means E inserts the removal arm 37 into the gap between the outer frame 6 and the bottom plate 11. After that, the pushing means D descends, and the first formwork 15, the horizontal partition plate 12, and the molded concrete are placed on the removal arm 37. After placing the stacking block 1 made of concrete material on the base plate 11, the stacking block 1 is moved to a predetermined location by the removal arm 37 and dried by the drying extraction means F to manufacture the stacking block 1. As a result, after the removal means E, each stacking block 1 is placed on its respective first formwork 15, so even before the concrete material m hardens, the stacking block 1 can be handled individually indirectly by gripping the first formwork 15, and handling by the drying extraction means F is also made easier.

[0068] Furthermore, since the bottom plate 11 and vertical partition plates 9 can be removed after the removal means E, the number of bottom plates 11 and vertical partition plates 9 required for sequential manufacturing can be reused, thus minimizing the number of bottom plates 11 and vertical partition plates 9 that need to be prepared.

[0069] Furthermore, after the stacking block 1 has solidified, the number of first molds 15 required for sequential manufacturing can be easily removed from the stacking block 1 and reused, thus minimizing the number of first molds 15 that need to be prepared.

[0070] Furthermore, since the first mold 15 is made of synthetic resin material, the release properties can be improved by the slight deformation during pressing by the second mold 29, thereby improving product yield and increasing mass production efficiency.

[0071] Furthermore, the first mold 15 has at least one downwardly tapered convex portion 18 through which the central portion 19 penetrates, and the second mold 29 has at least one downwardly tapered concave portion 30 protruding from its lower bottom surface. As a result, the upper part becomes concave and the lower part convex during molding, which further improves moldability.

[0072] Furthermore, the first formwork 15 has a rectangular upper molding section 17 in plan view with a convex portion 18, and a chamfered molding wall 16 that extends upward around the entire circumference of the upper molding section 17 and forms a sharply inclined surface from the inside upward. As a result, the moldability of this section can be improved, and a clean chamfer 4 can be formed on the outer corner of the upper surface of the stacking block 1, which has a convex portion on the upper side in the finished product.

[0073] Furthermore, since the first mold 15 consists of a mounting wall 21 that extends downward around the entire circumference of the upper molding section 17 and a plurality of ribs 20 that protrude downward from the lower surface of the upper molding section 17 to the height of the mounting wall 21, it is possible to create a moderate and minute deformation in the first mold 15 when pressed by the second mold 29 toward the first mold 15, thereby improving release properties and moldability, which in turn leads to further improvements in product yield and mass production capabilities.

[0074] Furthermore, the stacking block 1 manufactured using the above-described manufacturing method can provide an inexpensive, highly accurate, and aesthetically pleasing stacking block 1 due to its high moldability and mass-producibility.

[0075] Although the manufacturing method of the stacking block and preferred embodiments of the stacking block 1 according to this embodiment of the present invention have been described above, the present invention is not limited to any particular embodiment, and various modifications and changes are possible. [Explanation of Symbols]

[0076] A. Formwork setting means B Material filling means C Pressing means D Push-up means E Extraction method F Dry extraction means m Concrete materials 1 stacking block 6 Outer frame 9 Vertical partition plates 11 Bottom plate 12 Horizontal partition plate 14. Standard Frame Section 15. First formwork 16 Chamfered molded wall 17 Upper molding part 18 Convex part 19 Central part 20 Ribs 21 Mounting wall 23 stages 24 Material container 26 Pressing part 29 Second formwork 30 Concave section 37. Extraction arm

Claims

1. A method for manufacturing stacked blocks comprising a formwork setting means, a material filling means, a pressing means, a lifting means, a removal means, and a drying extraction means, The formwork setting means includes a rectangular outer frame with an open top and bottom, on which a plurality of mounting pieces are installed parallel to each other at predetermined intervals, and which are mounted at predetermined intervals perpendicular to the lower ends of the vertical partition plates, and on which a plurality of bottom plates are placed to substantially close the bottom of the outer frame, and then a horizontal partition plate perpendicular to the vertical partition plates is set in the center of the vertical partition plates, thereby forming a reference frame section with a plurality of concave spaces formed by the outer frame, the vertical partition plates, the bottom plates and the horizontal partition plates, and then a first formwork made of synthetic resin material is inserted and placed on the bottom plate of the reference frame section. The material filling means has a material container, which is at least open at the bottom, pre-filled with a predetermined amount of concrete material and placed on a stage that is substantially flush with the upper end of the outer frame at the rear of the outer frame and is movable back and forth, and moves forward to fill the reference frame portion within the outer frame with the concrete material, after which the material container retracts to the rear. The pressing means is located above the outer frame, and a pressing section, which has multiple second formworks arranged on its lower bottom surface, descends to press the concrete material within the reference frame section with the second formworks, after which the pressing section retracts upward. The pushing means is located below the outer frame and pushes the bottom plate up until the lower bottom surface of the bottom plate exceeds the upper end of the outer frame. The method for manufacturing stacked blocks is characterized in that the removal means inserts a removal arm into the gap between the outer frame and the bottom plate, the pushing means descends to place the bottom plate on which the stacked block made of the first formwork, the horizontal partition plate and the molded concrete material is placed on the removal arm, the removal arm moves it to a predetermined location, and the stacked block is manufactured by drying and extracting the block.

2. The method for manufacturing stacking blocks according to claim 1, characterized in that the first formwork has at least one convex portion with a downwardly tapered diameter that penetrates the central part, and the second formwork has at least one concave portion with a downwardly tapered diameter that protrudes from the lower bottom surface.

3. The method for manufacturing stacking blocks according to claim 2, characterized in that the first formwork has an upper molding section that is rectangular in plan view and forms the convex portion, and a chamfered molding wall that extends upward around the entire circumference of the upper molding section and has a sharply inclined tip that extends upward from the inside.

4. The method for manufacturing stacked blocks according to claim 3, characterized in that the first formwork comprises a support wall extending downward around the entire circumference of the upper molding section and a plurality of ribs protruding downward from the lower surface of the upper molding section to the height of the support wall.

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