Static structures (e.g. – buildings) – Ornamental: color – thickness variation – or dissimilar... – Visible discrete elements in cast material
Reexamination Certificate
1999-01-19
2001-09-25
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Ornamental: color, thickness variation, or dissimilar...
Visible discrete elements in cast material
C052S596000, C052S309170, C052S311100, C052S747120, C428S143000
Reexamination Certificate
active
06293065
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a high strength porous concrete structure which is applied to a water permeable pavement, a draining pavement, a sound insulating board, a sound-proofing barrier, a sound absorbing block for acoustic, a block for plants, a riverbed block, a water purifying matrix, a gas absorbing matrix, a decorative board for building, a fish reef, a block for fish reef or a block for breeding algae and to a method of manufacturing the high strength porous concrete structure.
BACKGROUND OF THE INVENTION
Porous concrete structures are conventionally, for example, made of cement, rough aggregates and water, and each of which is kneaded and cured to be used for water permeable pavements or draining pavements.
However, the porous concrete structures have such an arrangement in which each of the rough aggregates is connected with cement paste and kept in contact at a point. As a result, the porous concrete structures are low in both flexural strength and compressive strength and also it is difficult to increase resistance to fly loss. In other words, for a pavement made of the porous concrete structure having the above arrangement it easily causes fly loss of rough aggregates locating on the surface thereof when a big stress is applied to the surface thereof every time vehicles frequently brake.
Further since the porous concrete structures have a porous arrangement, resistance to a freeze-thaw effect is very low. Therefore, it is not recommendable to use the porous concrete structures in a cold district.
SUMMARY OF THE INVENTION
In order to solve the above-mentioned problems, the invention is intended to provide a high strength porous concrete structure having an arrangement of porous as a whole or having an arrangement in which a surface portion alone is porous by forming a plurality of lumps which are exposed to the surface of the structure and whose configuration corresponds to a configuration of an original material to be transferred such as rough aggregates and each of which is integrally made of the same concrete tissue with a gap formed between the lumps which is through to a back side of the lumps.
The invention is also intended to provide a method of manufacturing the high strength porous concrete structure having the above-mentioned arrangement with ease which comprises the steps of transferring a surface configuration of an object exposing an original material to be transferred such as a porous concrete structure using rough aggregates into an elastically deformable form made of a thermoplastic material and placing mortar or concrete into the form.
The high strength porous concrete structure
1
in accordance with the invention is, as shown in
FIGS. 1 and 2
, that a plurality of lumps
2
whose configuration conforms to a configuration of rough aggregates as an original material to be transferred are interconnected and exposed to a surface
1
a
of the high strength porous concrete structure
1
and a gap
3
formed between the lumps
2
is through to a back side
2
b
of the lumps
2
, and is characterized by that the lumps
2
are integrally made of the same concrete tissue
4
.
In accordance with the arrangement, at least a surface portion
1
A of the high strength porous concrete structure
1
becomes porous because of its stereostructure formed by a plurality of lumps
2
whose configuration conform to the original material to be transferred and the gap
3
which is through to the back side
2
b
of the lumps
2
. As a result of this, if the high strength porous concrete structure
1
is used, for example, as a pavement, the surface portion
1
A produces an effect of water permeability and if the high strength porous concrete structure
1
is used as a wall or a block for acoustic, the surface portion
1
A produces an effect of sound-absorbing. In addition, if the the high strength porous concrete structure
1
is used as a block for plants or a riverbed block, the gap
3
formed between the lumps
2
works as a space to keep a plant seed, soil or a fertilizer. Further if the high strength porous concrete structure
1
is used as a water purifying matrix or a gas absorbing matrix, the gap
3
works as a space to breed algae for water purification or a space to keep a catalyst for gas absorption. From the viewpoint of its appearance, the high strength porous concrete structure
1
can also be used as a decorative board for building because its appearance closely resembles that of a conventional porous concrete structure
6
which is made of cement, rough aggregates
10
and water, and each of which is kneaded and cured as shown in FIG.
10
.
Unlike the conventional porous concrete structure
6
, the high strength porous concrete structure
1
has such an arrangement in which each of the lumps
2
is made of the same concrete tissue
4
and the lumps
2
being exposed to the surface
1
a
are integrally formed. As a result of this, a bond strength between the lumps
2
on the surface of the high strength porous concrete structure
1
is very high beyond comparison with that of the conventional porous concrete structure
6
where each of the rough aggregates
10
is connected with a thin cement paste layer
11
and kept in contact at a point. Therefore the high strength porous concrete structure
1
shows a far higher reading in both flexural strength and compressive strength than that of the conventional porous concrete structure
6
. Fly loss also can easily be improved when it is used as a pavement.
In addition, if a conventional porous concrete structure is used as a draining pavement or a sound insulating board, it has to be made two-layered, thereby to complicate a manufacturing process. More particularly, in case used as the draining pavement, porous concrete tissue comprising rough aggregates and cement paste should be provided in order to form a water permeable layer on a surface side of the pavement and an ordinal concrete tissue comprising rough aggregates, fine aggregates and cement paste should be provided under the porous concrete tissue in order to form a solid tight layer which does not permeate water. Similarly, in case used as the sound insulating board, a porous concrete tissue comprising rough aggregates and cement paste should be provided in order to form a layer having a sound absorbing function on a surface side of the sound insulating board and an ordinal concrete tissue comprising rough aggregates, fine aggregates and cement paste should be provided back of the porous concrete tissue in order to form a solid tight layer which insulates sound. As mentioned above, it is inevitable to place concrete material of different combination at least twice in order to form a two-layered structure comprising a porous concrete layer made of rough aggregates and cement paste and an ordinal solid concrete layer. This causes a problem of increasing a number of processing steps and of lacking integrity because of two-layered structure.
In order to solve the above problems the high strength porous concrete structure
1
of the invention has an arrangement wherein the lumps
2
whose configuration conforms to rough aggregates as an original material to be transferred are made of the same concrete tissue
4
. As a result, in case that a solid tight backing portion
1
B is to be formed back of the porous surface portion
1
A, the backing portion
1
B can be continuously and integrally formed with the lumps
2
of the same concrete tissue
4
as shown in
FIGS. 1 and 2
. Then there is no need to place a porous concrete material comprising rough aggregates and cement paste for a surface portion and an ordinary concrete material for a backing portion separately, which makes it possible to form the porous surface portion
1
A and the solid backing portion
1
B simultaneously with a single process of placing concrete.
In one form of the embodiment, the lump
2
, as shown in
FIG. 3
where a magnified cross section of a part of the lump
2
is shown, may have an arrangement where a plurality of continuous air bubbles
5
are entrained in
Kobayashi Tetsuo
Suzuki Hiroaki
Tachibana Kikuo
Tanahashi Tatsuji
Banner & Witcoff , Ltd.
Kent Christopher T.
Sumitomo Osaka Cement Co. Ltd.
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