Device and method for manufacturing disaster prevention block

Abstract

A lower form 30 has a horizontal bottom plate 31 defining a bottom surface 100b, outer peripheral surface guides 33, 34 defining an outer peripheral surface, and a suspension core 37 in which an upper end section 37a is fixed to a horizontal section 2c of a suspension plate 2, a gap t is present between a lower end section 37b and the bottom plate 31, and said suspension core 37 defines a central hole 104 opened in the center of an upper surface. An upper form 20 includes a pair of shoes 22, 23 having a slit 21 in sliding contact with the horizontal section 2c, upper surface-defining sections 22b, 23b defining protrusions 101, 102 formed on the upper surface, central push-in sections 22a, 23a defining a central groove section 103 recessed inside the protrusions 101, 102, and outer peripheral surfaces 22d, 23d in sliding contact with the inner surfaces of the outer peripheral surface guides 33, 34. The pair of shoes 22, 23 are arranged in linear symmetry with the slit 21 at the center thereof.

Description

Disaster prevention block manufacturing device and disaster prevention block manufacturing method

[0001] The present invention relates to a manufacturing device for disaster prevention blocks to be installed on slopes that come into contact with flowing water bodies such as reservoirs and rivers, and a manufacturing method for disaster prevention blocks using the same.

[0002] Block mats, which are made by integrating multiple concrete blocks with a filter sheet made of synthetic fiber, are used near reservoirs, creeks, rivers, etc. to protect slopes and prevent erosion.

[0003] Patent Document 1 (JP 2019-15108 A) discloses a technique for attaching multiple disaster prevention blocks in the same orientation to one side of a filter sheet. Patent Document 2 (JP 2010-133152 A) discloses a method for manufacturing a similar block mat. Disaster prevention here primarily refers to preventing water accidents, and the blocks have uneven edges that allow for handholds.

[0004] However, when viewed from above, most of the area of ​​conventional disaster prevention blocks is flat and smooth, which means that hands and feet would slip and it would be extremely difficult to escape by hand, leaving doubts about their practical effectiveness.

[0005] Furthermore, Patent Document 3 (Japanese Utility Model Application Publication No. 7-18809) discloses a technique for using a hanging core when manufacturing two blocks, but does not disclose or suggest how to configure it when manufacturing three or more blocks. Furthermore, all of the cores are penetrating from top to bottom, which does not address the need to prevent plants from growing above ground. JP 2019-15108 A, JP 2010-133152 A, Japanese Utility Model Application Publication No. 7-18809 A

[0006] Therefore, an object of the present invention is to provide a technology that can manufacture disaster prevention blocks that are effective in preventing water accidents with sufficient efficiency for practical use.

[0007] The disaster prevention block manufacturing device according to the first invention comprises a machine frame, a plurality of formwork units arranged side by side in a first direction on the horizontal plane of the machine frame, m units arranged side by side in a first direction and n units arranged side by side in a second direction perpendicular to the first direction, where m and n are natural numbers of 3 or more, and each of the formwork units has a plurality of upper formworks and a plurality of lower formworks that correspond one-to-one in the vertical direction to the plurality of upper formworks, a vibrator supported by the machine frame and applying vibrations to the plurality of upper formworks and the plurality of lower formworks, a lifting mechanism built into the machine frame and changing the relative positions of the plurality of upper formworks and the plurality of lower formworks in the vertical direction, and n hanging plates whose horizontal parts are erected along the center lines of the m lower formworks arranged side by side in the first direction and whose both ends stand up from the machine frame, and each of the plurality of lower formworks is arranged horizontally to define the bottom surface of the disaster prevention block. The disaster prevention block has a bottom plate, an outer peripheral surface guide that defines the front, back, and both left and right side surfaces, and a hanging core whose upper end is fixed to the horizontal part of the hanging plate and has a gap between its lower end and the bottom plate and that defines a central hole opened in the center of the top surface of the disaster prevention block, and each of the multiple upper formworks has a slit that slides against the horizontal part of the hanging plate along the center line and a pair of shoes arranged symmetrically around the center line, and the pair of shoes has a heater, an upper surface defining part that defines a pair of protrusions formed on the top surface of the disaster prevention block, a central pushing part that defines a central groove part recessed between the pair of protrusions, and an outer peripheral surface that slides against the inner surface of the outer peripheral surface guide, and the multiple upper formworks and multiple lower formworks are immediately demolded and m x n products are transported out.

[0008] With this configuration, m x n (9) or more disaster prevention blocks can be manufactured in one operation with sufficient efficiency for practical use.

[0009] In addition, the horizontal part of the hanging plate slides against the slit in the upper formwork, and the outer surface of the shoe slides against the outer surface guide of the lower formwork, thereby ensuring good positional accuracy in the lifting and lowering direction of the upper and lower formworks, which can be a problem when multiple pieces are being cut.

[0010] The upper surface defining portion defines a pair of protrusions formed on the upper surface of the disaster prevention block, and the central pushing portion defines a central groove portion inside these protrusions.

[0011] Therefore, users can easily support their own weight by placing their hands or feet on the pair of protrusions located in the center of the top surface of the disaster prevention block and the central groove between them, making it extremely easy to escape from a pond or other such area.

[0012] In addition, the hanging core forms a central hole in the center of the top surface of the disaster prevention block, allowing users to place their hands or feet in the central hole as well as the central groove to more easily support their own weight, making it easier to escape from a pond or other such area.

[0013] Furthermore, because there is a gap between the lower end of the hanging core and the bottom plate, there is no hole penetrating the disaster prevention block, and the lower part of the disaster prevention block is sealed off by the disaster prevention block. This meets the need to prevent vegetation from growing. Also, when material is supplied between the upper and lower formworks while they are separated, the material will contact the lower formwork before the upper formwork due to its own weight, and will then wrap around the hanging core and enter the gap. This allows the material to be filled into the gap as well.

[0014] In addition to the features of the first invention, the disaster prevention block manufacturing device of the second invention further comprises a pair of shoes each having a taper defining portion that defines an outer groove portion recessed on the outside of the pair of protrusions.

[0015] With this configuration, the tapered defining portion defines the outer groove portion on the outside of the pair of protrusions, so that users can easily escape by hooking their hands or feet not only in the center of the disaster prevention block but also on the outside.

[0016] The disaster prevention block manufacturing device according to the third invention is, in addition to the second invention, such that each of the plurality of lower formworks further has a pair of fixed cores that define side holes that are recessed further than the outer groove portion.

[0017] With this configuration, users can easily escape from the outside of the disaster prevention block by placing their hands and feet in the side holes in addition to the outer grooves.

[0018] The fourth invention relates to a manufacturing device for disaster prevention blocks, which, in addition to the first invention, is characterized in that the material constituting the disaster prevention blocks is a zero-slump porous compound.

[0019] This structure makes the outer surface of the disaster prevention block rough and non-slip, allowing users to easily escape by placing their hands or feet on the disaster prevention block. Furthermore, the immediate demolding allows for efficient production of multiple disaster prevention blocks.

[0020] According to the present invention, a large number of disaster prevention blocks (m x n or more) can be obtained in a series of unit operations.

[0021] The positions of the upper and lower formwork in the lifting direction, which can be a problem when multiple pieces are being cut, are accurately adjusted by the horizontal part of the hanging plate sliding against the slit in the upper formwork and the outer surface of the shoe sliding against the outer surface guide of the lower formwork.

[0022] Users can easily support their own weight by placing their hands or feet on the pair of protrusions located in the center of the top surface of the disaster prevention block, the central groove between them, and also on the central hole. This makes it extremely easy to escape from a pond, etc.

[0023] By filling the gaps with material, there are no holes that penetrate the disaster prevention block. Therefore, the area below the disaster prevention block is sealed off by the disaster prevention block, preventing the overgrowth of plants.

[0024] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0025] Figure 1 is a side view showing a disaster prevention block manufacturing device in one embodiment of the present invention in its initial position, Figure 2 is a plan view of the same device taken along line A-A in Figure 1, Figure 3 is a side view of the same device when material is being supplied, Figure 4 is a side view of the same device when the upper formwork and lower formwork are in close contact with each other, and Figure 5 is a flowchart showing each step of a disaster prevention block manufacturing method in one embodiment of the present invention.

[0026] 1 and 2, the following elements are supported on a box-shaped machine frame 1. A plurality of form units 10, each consisting of a plurality of upper form frames 20 and a plurality of lower form frames 30 corresponding to the plurality of upper form frames 20 in a one-to-one relationship in the vertical direction, where m and n are natural numbers of 3 or greater, are arranged side by side on the horizontal plane of the machine frame 1, m in a first direction x and n in a second direction y perpendicular to the first direction x.

[0027] In this embodiment, m = 3, n = 5, and m x n = 15. Of course, these numerical values ​​are merely examples and may be changed in various ways.

[0028] The machine frame 1 has a built-in lifting mechanism (not shown) consisting of a hydraulic cylinder or the like, which changes the relative vertical positions of the upper form frames 20 and the lower form frames 30. For ease of illustration, the drawings show the lower form frames 30 held at a constant height, while the vertical position of the upper form frames 20 is changed by the lifting mechanism, but this is merely an example.

[0029] More preferably, each of the plurality of upper formworks 20 and the plurality of lower formworks 30 is provided with a lifting mechanism so that the plurality of upper formworks 20 and the plurality of lower formworks 30 can be raised and lowered independently of each other.

[0030] However, it is sufficient if the relative vertical positions of the multiple upper formworks 20 and the multiple lower formworks 30 can be changed, and various modifications will fall within the scope of protection of the present invention as long as this condition is met.

[0031] On the opposite side of the lower formwork 30 of the machine frame 1, a vibrator 4 is arranged to apply vibrations to the plurality of upper formworks 20 and the plurality of lower formworks 30, and the vibrator 4 is provided with a pendulum 5.

[0032] As shown in Figure 2, n (five in this embodiment) hanging plates 2 with the first direction x as their longitudinal direction are arranged along the center line of m (three in this embodiment) formwork units 10 arranged in the first direction x.

[0033] Both ends 2a, 2b of the hanging plate 2 rise above a certain height of the casing 1, and the portion between the ends 2a, 2b forms a horizontal portion 2c that is a certain distance higher than the certain height of the casing 1. The hanging plate 2 is at the same vertical position as the lower formwork 20, but is supported by the casing 1, not by the lower formwork 20 itself.

[0034] Each of the m×n form units 10 has the same configuration. The configuration of a single form unit 10 consisting of a single upper form 20 and a single lower form 20 will be described below with reference to Figures 6 to 9.

[0035] Figure 6 is a perspective view showing a single formwork unit (separated state) in one embodiment of the present invention, Figure 7 is a partial cross-sectional view showing the same single formwork unit (separated state), Figure 8 is a partial cross-sectional view showing the same single formwork unit (closed state), and Figure 9 is a perspective view of a disaster prevention block in one embodiment of the present invention.

[0036] 9, the disaster prevention block 100 in this embodiment is rectangular in plan view. To accommodate this, the lower formwork 30 has the following elements.

[0037] The horizontal bottom plate 31 defines the bottom surface 100b of the disaster prevention block 100.

[0038] The outer peripheral surface guide 34 defines the outer peripheral surface 100a consisting of the front, back, and both left and right side surfaces of the disaster prevention block 100.

[0039] The hanging core 37 defines a central hole 104 that is opened in the center of the upper surface of the disaster prevention block 100. The hanging core 37 has an upper end 37a fixed to the horizontal portion 2c (located on the center line L in Figure 7) of the hanging plate 2, and a lower end 37b located above the upper surface 31a of the bottom plate 31 and not reaching the upper surface 31a of the bottom plate 31, so that a gap t is formed between the lower end 37b and the upper surface 31a of the bottom plate 31.

[0040] In this way, the hanging core 37 is placed on the lower formwork 30 side and supported by the horizontal part 2c of the hanging plate 2, and a gap t is formed, which has the following technical advantages.

[0041] As will be described later, when the upper formwork 20 and the lower formwork 30 are separated and a material made of ready-mixed concrete is supplied between them, the material is in an uncompacted, loose state, and due to its own weight, it comes into contact with the lower formwork 30 before the upper formwork 20. At this time, the hanging core 37 is already present in the lower formwork 30, and a gap t exists between the lower end 37b of the hanging core 37 and the bottom plate 31.

[0042] Therefore, the material that has entered the lower form 30 flows around the hanging core 37 in the direction indicated by the arrow N in Figure 7 and reaches the gap t. This allows the material to be smoothly fed (filled) into the gap t as well.

[0043] If instead of doing this, a hanging core or an equivalent member were provided on the upper form 20 side, as described above, the material would come into contact with the lower form 30 before the upper form 20, so when the upper form 20 approaches the lower form 30, a considerable thickness of material would already be present near the center, and the hanging core or an equivalent member would have to be pushed in while pushing aside the thick material. In reality, this is extremely difficult, nearly impossible.

[0044] The upper formwork 20, which corresponds one-to-one to the lower formwork 30 in the vertical direction, has the following elements.

[0045] A coaxial slit 21 is formed on the center line L in FIG. 7, and the slit 21 is in sliding contact with the horizontal portion 2 c of the hanging plate 2 .

[0046] The pair of shoes 22, 23, consisting of a right shoe 22 and a left shoe 23, are arranged symmetrically with respect to the slit 21 (i.e., the center line L).

[0047] The pair of shoes 22, 23 incorporate a heater (not shown) and have upper surface defining portions 22b, 23b that define a pair of protrusions 101, 102 formed on the upper surface of the disaster prevention block 100, central pushing portions 22a, 23a that define a central groove portion 103 recessed inside the pair of protrusions 101, 102, and outer peripheral surfaces 22d, 23d that slide against the inner surfaces of the outer peripheral surface guides 33, 34.

[0048] The taper defining portions 22c, 23c define outer groove portions (right groove portion 105 and left groove portion 106) recessed on the outside of the pair of protrusions 101, 102 of the disaster prevention block 100.

[0049] The pair of fixed cores 35, 36 define side holes (right hole 107 and left hole 108) that are recessed further than the right groove 105 and left groove 106. The angle θ formed by the tapered surfaces 35a, 36a formed on the lower parts of the fixed cores 35, 36 is preferably set to a large value (for example, 32° to 48°). This is preferable because it allows for better concrete filling in this vicinity.

[0050] The material is supplied between the upper formwork 20 and the lower formwork 30, and the upper formwork 20 is lowered relative to the lower formwork 30 until it reaches its limit, at which point the material is filled as shown by the hatching slanting upward to the right in FIG. 8.

[0051] In this state, the vibrator 4 is operated to compact the material, and at the same time, the heaters built into the shoes 22 and 23 are operated to heat the upper surface of the disaster prevention block 100. This allows moisture to be quickly removed from the upper surface, which is very uneven, and prevents problems such as chipping or concrete sticking to the formwork when demolding.

[0052] Next, with reference to Figure 5, we will explain each step of the manufacturing method for disaster prevention blocks using the disaster prevention block manufacturing device configured as above. First, in step 1, the materials are prepared. Specifically, cement, fine aggregate, and coarse aggregate stored in a storage area are transported to a mixing plant (not shown) and mixed to a zero-slump state. The moisture content is about 30% by weight, and the materials are made loose.

[0053] Next, in step 2, as shown in FIG. 1, the apparatus is set to an initial position where the upper formwork 20 and the lower formwork 30 are spaced apart.

[0054] Next, in step 3, as shown in Figure 3, the material is supplied between the upper formwork 20 and the lower formwork 30. As described above, the material contacts the lower formwork 30 before the upper formwork 20, and flows into the gap t, while also filling the peripheries of the tapered surfaces 35a and 36a.

[0055] Next, in step 4, the upper formwork 20 is lowered and brought into close contact with the lower formwork 30.

[0056] Next, in step 5, the vibrator 4 is activated to apply vibrations and compact the material, and in step 6, the heaters built into the shoes 22 and 23 are used to heat the upper surface of the disaster prevention block 100, which has a lot of irregularities, and quickly evaporate the moisture. This makes it possible to take measures to prevent defects such as chipping from occurring when the block is demolded.

[0057] Steps 5 and 6 may be performed in the reverse order or simultaneously.

[0058] After the series of operations is completed, the upper formwork 20 and the lower formwork 30 are raised and the molds are immediately demolded in step 7. As a result, m×n products are obtained in step 8. The explanation of the subsequent steps will be omitted.

[0059] After the required curing period, the resulting disaster prevention blocks are attached to a sheet made of synthetic fiber or the like and laid on the slope of the reservoir, centering on the water's edge. This allows for easy escape in the unlikely event of an accident where a person falls into the water. The disaster prevention effects described in this specification reflect the results of demonstration tests conducted by the Japan Society of Water Rescue and are proven.

[0060] For example, as shown in Figure 10, if the disaster prevention blocks of this embodiment are installed as described above, a set of right-side groove section 105, central groove section 103, and left-side groove section 106, and a set of right-side hole 107, central hole 104, and left-side hole 108 will be lined up at regular intervals, so that users can place their hands or feet in these recesses and climb up the slope 110 near the water surface 111.

[0061] Furthermore, it has been demonstrated that a member of the Water Rescue Society who holds a diver's license was able to escape by simply holding the child in both hands (i.e., with both hands occupied) and placing his / her feet in the recess.

[0062] The disaster prevention block manufacturing device according to this embodiment makes it possible to mass-produce disaster prevention blocks with a considerable degree of efficiency (for example, about 500 cubic meters per day).

[0063] 1A side view of a manufacturing device for disaster prevention blocks in an embodiment of the present invention in the initial position; 2A plan view of a manufacturing device for disaster prevention blocks in an embodiment of the present invention taken along line A-A in Figure 1; 3A side view of a manufacturing device for disaster prevention blocks in an embodiment of the present invention during material supply; 4A side view of a manufacturing device for disaster prevention blocks in an embodiment of the present invention when the upper formwork and the lower formwork are in close contact; 5A flow chart showing each step of a manufacturing method for disaster prevention blocks in an embodiment of the present invention; 6A perspective view of a single formwork unit (separated state) in an embodiment of the present invention; 7A partial cross-sectional view of a single formwork unit (separated state) in an embodiment of the present invention; 8A partial cross-sectional view of a single formwork unit (closed state) in an embodiment of the present invention; 9A perspective view of a disaster prevention block in an embodiment of the present invention; 10A illustration showing a user climbing a slope on which multiple disaster prevention blocks are installed in an embodiment of the present invention

[0064] DESCRIPTION OF SYMBOLS 1 Machine frame 2 Hanging plate 2a, 2b Upright portion 2c Horizontal portion 4 Vibrator 5 Pendulum 10 Formwork unit 20 Upper formwork 21 Slit 22 Right shoe 23 Left shoe 22a, 23a Central pushing portion 22b, 23b Upper surface defining portion 22c, 23c Taper defining portion 22d, 23d Outer surface defining portion 30 Lower formwork 31 Bottom surface 31a Upper surface 32 Wall 33, 34 Outer surface guide 35, 36 Fixed core 37 Hanging core 37a Upper end portion 37b Lower end portion 37c Peripheral surface 100 Disaster prevention block 100a Peripheral surface 100b Bottom surface 101 First protrusion 102 Second protrusion 103 Central groove portion 104 Central hole 105 Right side groove 106 Left side groove 107 Right hole 108 Left side hole 110 Slope 111 Water surface L Center line t Gap

Claims

1. A disaster prevention block manufacturing device comprising: a machine frame; a plurality of formwork units, m of which are arranged in a first direction and n of which are arranged in a second direction perpendicular to the first direction on the horizontal plane of the machine frame, where m and n are natural numbers of 3 or more, and each formwork unit has a plurality of upper formworks and a plurality of lower formworks that correspond one-to-one in the vertical direction to the plurality of upper formworks; a vibrator supported by the machine frame and applies vibrations to the plurality of upper formworks and the plurality of lower formworks; a lifting mechanism built into the machine frame and changes the relative vertical positions of the plurality of upper formworks and the plurality of lower formworks; and n hanging plates, the horizontal section of which is erected along the center line of the m lower formworks arranged in a row in the first direction and both ends of which stand up from the machine frame, wherein each of the plurality of lower formworks has: a horizontal base plate that defines the bottom surface of the disaster prevention block; outer peripheral surface guides that define the front, back, and both left and right sides of the disaster prevention block; a hanging core having an upper end fixed to the horizontal portion of the hanging plate, a gap existing between its lower end and the bottom plate, and defining a central hole opened in the center of the upper surface of the disaster prevention block, each of the multiple upper formworks having a slit that slides against the horizontal portion of the hanging plate along the center line, and a pair of shoes arranged line-symmetrically about the center line, the pair of shoes having a heater, an upper surface defining portion that defines a pair of protrusions formed on the upper surface of the disaster prevention block, a central pushing portion that defines a central groove portion recessed between the pair of protrusions, and an outer peripheral surface that slides against the inner surface of the outer peripheral surface guide, and the multiple upper formworks and the multiple lower formworks are instantly demolded, and m x n products are removed.

2. A disaster prevention block manufacturing device as described in claim 1, wherein the pair of shoes further have taper defining portions that define outer groove portions recessed on the outside of the pair of protrusions.

3. A disaster prevention block manufacturing device as described in claim 2, wherein each of the plurality of lower formworks further has a pair of fixed cores defining side holes that are recessed further than the outer groove portion.

4. A manufacturing device for disaster prevention blocks as described in any one of claims 1 to 3, wherein the material constituting the disaster prevention blocks is a zero slump porous compound.

5. A method for manufacturing a disaster prevention block, comprising the steps of: setting a plurality of upper formworks, m in number in a first direction and n in number in a second direction perpendicular to the first direction, in the horizontal plane of a machine frame, and a plurality of lower formworks corresponding one-to-one in the up-down direction to the plurality of upper formworks, to initial positions spaced apart; supplying a material prepared by zero-slump porous compounding between the plurality of upper formworks and the plurality of lower formworks; bringing the plurality of upper formworks and the plurality of lower formworks into close contact with each other, applying vibrations with a vibrator, and heating the top side of a product with a heater built into the upper formwork; and immediately demolding the plurality of upper formworks and the plurality of lower formworks and removing m x n products, wherein each of the plurality of lower formworks has: a horizontal base plate that defines the bottom surface of the disaster prevention block; outer peripheral surface guides that define the front, back, and both left and right sides of the disaster prevention block; a hanging core having an upper end fixed to the horizontal portion of the hanging plate, a gap existing between the lower end and the bottom plate, and defining a central hole opened in the center of the upper surface of the disaster prevention block; each of the multiple upper formworks having a slit that slides against the horizontal portion of the hanging plate along the center line, and a pair of shoes arranged line-symmetrically around the center line, the pair of shoes having a heater, an upper surface defining portion that defines a pair of protrusions formed on the upper surface of the disaster prevention block, a central push-in portion that defines a central groove portion recessed between the pair of protrusions, and an outer peripheral surface that slides against the inner surface of the outer peripheral surface guide.

6. A method for manufacturing a disaster prevention block as described in claim 5, wherein the pair of shoes further have taper defining portions that define outer groove portions recessed on the outside of the pair of protrusions.

7. A method for manufacturing a disaster prevention block as described in claim 6, wherein each of the plurality of lower formworks further has a pair of fixed cores defining side holes recessed further than the outer groove portion.

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