CN109760177B - Foam mould and method for forming special-shaped concrete decorative component by using same - Google Patents
Foam mould and method for forming special-shaped concrete decorative component by using same Download PDFInfo
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- CN109760177B CN109760177B CN201811642063.1A CN201811642063A CN109760177B CN 109760177 B CN109760177 B CN 109760177B CN 201811642063 A CN201811642063 A CN 201811642063A CN 109760177 B CN109760177 B CN 109760177B
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Abstract
The invention belongs to the technical field of decorative concrete member molds, and particularly relates to a foam mold which comprises a foam plate structure, wherein the foam plate structure comprises a foam base plate and a foam bottom plate, wherein the foam base plate is provided with a special-shaped cavity which is linearly cut by a foam cutting machine, and the foam bottom plate is bonded on the lower bottom surface of the foam base plate to seal one end of the special-shaped cavity; by adopting the technical scheme of the invention, the special-shaped component with a special complex shape can be quickly manufactured, the foam material is adopted as the forming mold, the mold is convenient to detach, the component is not easy to damage, the manufacturing cost is low, and the popularization and the use are easy.
Description
Technical Field
The invention belongs to the technical field of decorative concrete member molds, and particularly relates to a foam mold and a method for molding a special-shaped concrete decorative member by using the foam mold.
Background
With the increasing progress of building technology and the continuous pursuit of people to concepts of green, natural, environmental protection, health and the like, the concrete and the building material with the largest consumption in the field of construction engineering also have leap-type development and disintegration in use. In recent years, the trend of adopting concrete materials to manufacture landscape components, concrete household articles and creative ornaments has appeared, the products not only have good decoration, but also have the characteristics of high strength, good durability, environmental protection and the like of the concrete materials, and the simple beauty of the products is gradually appreciated by people. The concrete product is made according to the designed artistic modeling by utilizing the characteristic that the concrete can be plastically formed, is a concrete decoration means developed recently, and the common concrete product is designed into a certain modeling on the premise of meeting the design function, so that the concrete product is attractive, durable, economical and practical. However, for some special-shaped components or decorative components with special complex shapes, the mold is the most limited, on one hand, the cost for opening the mold and manufacturing the mold is high, however, the decorative components are usually designed into ornaments with different shapes according to the needs, so the cost of the mold for molding the components with limited number is too high, and the design and the manufacture of the special-shaped decorative components are severely restricted; on the other hand, the dies made of metal materials, plastics, rubber or glass fiber reinforced plastics have the problems of difficult die removal and easy damage to components. Aiming at the situation, the invention provides a novel method for manufacturing a concrete decorative member, aiming at solving the problems of high cost and difficult mold removal of a mold in the manufacturing of the member.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a foam mold and a method for molding a special-shaped concrete decorative component by using the foam mold, which can quickly manufacture a special-shaped component with a special complex shape, adopts a foam material as a molding mold, is convenient to disassemble the mold, is not easy to damage the component, is low in manufacturing cost and is easy to popularize and use.
In order to solve the technical problem, the invention provides a foam mold which comprises a foam plate structure, wherein the foam plate structure comprises a foam base plate and a foam bottom plate, the foam base plate is provided with a special-shaped cavity which is linearly cut by a foam cutting machine, and the foam bottom plate is adhered to the lower bottom surface of the foam base plate to seal one end of the special-shaped cavity.
Preferably, the foam board further comprises a sealed space formed outside the foam board structure, and the sealed space avoids the upper part of the special-shaped cavity.
Preferably, the plastic plate further comprises a plastic film, and the space between the plastic film and the foam plate structure is a sealed space.
Preferably, the foam base plate and the foam bottom plate both adopt soft foam with multiple inner pore channels.
Preferably, the foam base sheet is of a length and width consistent with the foam base sheet.
A method of forming a profiled concrete trim member by means of a foam mould, comprising the steps of:
step one, designing a cutting track diagram: performing linear cutting programming according to the designed special-shaped component diagram to form a cutting track diagram;
step two, precutting: selecting a foam material with proper hardness and size specification to cut in the horizontal direction to form a foam base plate and a foam bottom plate, and ensuring that the thickness of the horizontally cut foam base plate is consistent with the width of the special-shaped component;
step three, wire cutting: fixing the pre-cut foam base plate on a cutting machine, adjusting the feed position to be consistent with the cutting position of the cutting locus diagram, and starting the cutting machine to perform linear cutting until the cutting is finished;
step four, bonding and sealing: taking out the foam body cut by the linear cutting, forming a special-shaped cavity with the same size as the special-shaped component on the foam base plate, bonding the cutting seam at the feed position by using special foam rubber, bonding the foam base plate on the lower bottom surface of the foam base plate by using the foam rubber, sealing one end of the special-shaped cavity, and finishing the manufacture of the foam plate structure;
step five, spraying a release agent: before pouring concrete, spraying a release agent on the cavity wall of the special-shaped cavity, and wiping the cavity wall with a clean wet towel to form an isolation layer on the cavity wall of the special-shaped cavity;
step six, pouring concrete or mortar: pouring concrete or mortar mixture into the special-shaped cavity, and covering and maintaining by using a plastic film after pouring is finished;
step seven, removing the mold: and (3) removing the form of the member after the strength of the concrete or mortar reaches 80% -90% of the design strength, and removing the foam plate structure around the special-shaped member, wherein the concrete steps are as follows:
1) manufacturing a plastic film: manufacturing a plastic film matched with the foam board structure, wherein the plastic film comprises a hollow part with the same shape as the special-shaped cavity;
2) sealing a plastic film: the edges of the hollow-out parts of the plastic films are aligned with the edges of the special-shaped cavities and are in sealing fit with the edges of the special-shaped cavities, the plastic films are in sealing connection with the foam plate structure by using adhesive tapes in the sealing process, the adjacent ends of the plastic films are also in sealing connection by using the adhesive tapes, and the space between the plastic films and the foam plate structure is in a sealing state;
3) vacuumizing the plastic film by using a vacuum machine, wherein the foam board structure is compressed under atmospheric pressure, and the cavity wall of the special-shaped cavity is gradually separated from the concrete;
4) taking out the special-shaped component;
5) ending the vacuum pumping operation, gradually recovering the shape of the foam board structure, and then repeating the steps;
and step eight, carrying out surface treatment on the special-shaped component after the mould is removed, and brushing transparent protective paint on the surface of the special-shaped component.
Preferably, in the first step, the cutting track diagram is a side view profile or a top view profile of the profiled member.
Preferably, in the second step, the foam base plate and the foam bottom plate need to meet the requirements of flatness, compactness and no water absorption.
Preferably, in the fifth step, the release agent is a water-soluble release agent.
Preferably, in the sixth step, the maximum particle size of the aggregate of the concrete or mortar mixture for pouring is less than or equal to 1/4 of the minimum cross-sectional dimension of the profiled element, the concrete or mortar mixture should have good fluidity and cohesiveness, the concrete should meet the technical requirements of self-compacting concrete, and the mortar should meet the technical requirements of self-leveling mortar.
The method for forming the special-shaped concrete decorative member by using the foam mould has the beneficial effects that:
1. the method can be used for drawing a graph on a computer, is convenient and fast to operate, can quickly generate an individualized design drawing, controls a cutting machine through the computer, performs line cutting on the foam material according to a design track drawing, and cuts the special-shaped cavity, namely the shape of a special-shaped component, which is generated after the cutting is finished;
2. because the space between plastic film and the foam board structure is the confined space, through the operation of carrying out the evacuation to this confined space for the foam board structure slightly contracts, in the shrink process, separate gradually between the chamber wall of dysmorphism cavity and the dysmorphism component, the drawing of patterns process is simple easily to be operated, and can not harm foam board structure and dysmorphism component itself, has guaranteed the product quality of dysmorphism component, has also realized the reuse to the foam mould simultaneously, very big degree's reduction manufacturing cost.
Drawings
FIG. 1 is an illustration of a cutting trace made by a computer according to an embodiment of the present invention;
FIG. 2 is a schematic view of a foam mold configured according to the cutting trace diagram of FIG. 1;
FIG. 3 is a schematic structural view of a profiled member formed by the foam mold of FIG. 2;
FIG. 4 is a cross-sectional view of a foam mold in an embodiment of the present invention;
FIG. 5 is a schematic view of the structure of a plastic film in an embodiment of the present invention;
FIG. 6 is a flow chart of a method for forming a profiled element by a foam mold according to an embodiment of the present invention.
Wherein: a foam base sheet 1; a foam base plate 2; a profiled element 3; a special-shaped cavity 4; cutting trace fig. 5; a sealed space 6; a plastic film 7; a hollowed-out portion 8.
Detailed Description
The technical scheme of the invention is further explained by combining the drawings and the embodiment as follows:
as shown in fig. 1 to 4, a foam mold comprises a foam board structure, the foam board structure comprises a foam base board 1 and a foam bottom board 2, wherein the foam base board 1 and the foam bottom board 2 both adopt soft foam, the length and the width of the foam bottom board 2 are consistent with those of the foam base board 1, a special-shaped cavity 4 formed by linear cutting through a foam cutting machine is arranged on the foam base board 1, and the foam bottom board 2 is bonded on the lower bottom surface of the foam base board 1 to seal one end of the special-shaped cavity 4. And a sealed space 6 formed outside the foam board structure, wherein the sealed space 6 avoids the upper part of the special-shaped cavity 4. The plastic film 7 is also included, and the space between the plastic film 7 and the foam board structure is a sealed space 6.
As shown in fig. 5 and 6, a method for forming a profiled concrete decorative member by a foam mold includes the following steps:
step one, designing a cutting track diagram 5: performing linear cutting programming according to the designed special-shaped component 3 figure, and forming a cutting track figure 5 in a control computer of the cutting machine, wherein the cutting track figure 5 is a side view outline or a top view outline of the special-shaped component;
step two, precutting: selecting a foam material with proper hardness and size specification to cut in the horizontal direction to form a foam base plate 1 and a foam bottom plate 2, ensuring that the thickness of the horizontally cut foam base plate 1 is consistent with the width of the special-shaped component 3, and the foam base plate 1 and the foam bottom plate 2 need to meet the requirements of flatness, compactness and no water absorption;
step three, wire cutting: fixing the pre-cut foam base plate 1 on a cutting machine, adjusting the feed position to be consistent with the cutting position of a cutting track diagram 5, and starting the cutting machine to perform linear cutting until the cutting is finished;
step four, bonding and sealing: taking out the foam body cut by the linear cutting, forming a special-shaped cavity 4 with the same size as the special-shaped component 3 on the foam base plate 1, bonding the cutting seam at the feed position by using special foam rubber, bonding the foam base plate 2 on the lower bottom surface of the foam base plate 1 by using the foam rubber, sealing one end of the special-shaped cavity 4, and finishing the manufacturing of the foam plate structure;
step five, spraying a release agent: before concrete is poured, spraying a release agent on the cavity wall of the special-shaped cavity 4, and wiping the cavity wall with a clean wet towel to form an isolation layer on the cavity wall of the special-shaped cavity, wherein the release agent is a water-soluble release agent;
step six, pouring concrete or mortar: pouring concrete or mortar mixture into the special-shaped cavity 4, wherein the maximum particle size of aggregate of the concrete or mortar mixture for pouring is less than or equal to 1/4 of the minimum section size of the special-shaped component 3, the concrete or mortar mixture has good fluidity and cohesiveness, the concrete meets the technical requirements of self-compacting concrete, the mortar meets the technical requirements of self-leveling mortar, and after pouring is finished, plastic film is adopted for covering and curing;
step seven, removing the mold: and (3) after the strength of the concrete or mortar reaches 80% of the design strength, removing the member form, and removing the foam plate structure around the special-shaped member 3, wherein the concrete steps are as follows:
1. manufacturing a plastic film: manufacturing a plastic film 7 matched with the foam board structure, wherein the plastic film 7 comprises a hollow part 8 with the same shape as the special-shaped cavity 4;
2. and (3) sealing the plastic film 7: the edge of the hollow part 8 of the plastic film 7 is aligned with the edge of the special-shaped cavity 4 and is sealed and attached, the plastic film 7 is hermetically connected with the foam board structure by using an adhesive tape in the sealing process, the adjacent ends of the plastic film 7 are also hermetically connected by using the adhesive tape, and the space between the plastic film 7 and the foam board structure is in a sealed state;
3. the vacuum machine is adopted to vacuumize the plastic film 7, and the foam board structure adopts the soft foam with multiple pore channels inside, so that the foam board structure is compressed under the atmospheric pressure in the process of vacuumizing the foam board structure, the cavity wall of the special-shaped cavity 4 is gradually separated from the concrete, at the moment, the special-shaped component 3 can be smoothly taken out, and the taking-out process can be realized without damaging the foam board structure; the vacuumizing operation is finished after the special-shaped component 3 is taken out, the vacuum state in the plastic film 7 disappears, and the internal air pressure is gradually recovered to be consistent with the external air pressure, so that the shape of the foam plate structure is gradually recovered, the steps can be repeatedly operated, the concrete special-shaped component 3 is manufactured.
And step eight, carrying out surface treatment on the special-shaped component 3 after the mould is removed, and coating a transparent protective coating on the surface of the special-shaped component 3, wherein the transparent protective coating has good cohesiveness with the surface of the component, good weather resistance and water resistance, and no corrosiveness to concrete, and can protect the special-shaped component 3 from being damaged by the external environment for a long time and keep the texture of the concrete.
In the above embodiment, in the second step, before pre-cutting, the material specification of the foam material is checked to meet the requirement of the order, that is, the foam base plate 1 and the foam base plate 2 need to meet the requirement of flatness, compactness and no water absorption, the cutting tool is adjusted and fixed, the cutting speed is adjusted, after the cutting machine is determined to operate normally, the start position is manually adjusted, the program is started, cutting is started, the sizes of the foam base plate 1 and the foam base plate 2 after first cutting are repeatedly checked, the thickness of the foam base plate 1 after horizontal cutting is ensured to be consistent with the width of the special-shaped component 3, after the determination is correct, batch cutting is performed, and the next process is not performed accurately when the sizes do not meet the requirement.
In the third step, before the wire cutting, checking and rechecking a cutting track graph 5 in a computer, adjusting and fixing a cutting tool, adjusting the cutting speed, wherein the cutting speed of the cutting machine is determined according to the area of the foam basic board 1, the smoothness of the cutting surface is quickly ensured, after the cutting machine is confirmed to normally operate, manually adjusting a starting position, starting a program, starting cutting, repeatedly checking the foam basic board 1 after the cutting is carried out for the first time, after the correctness is determined, carrying out batch cutting, checking the size of the special-shaped cavity 4 formed after the cutting is finished, and entering the next process if the size does not meet the requirement.
And step six, blending and stirring the concrete and the mortar, wherein the proportion of the concrete and the mortar is strictly weighed according to the numerical value of the production task list, the concrete and the mortar are fully and uniformly blended according to the proportion, the maximum particle size of the aggregate of the concrete or mortar mixture for pouring is ensured to be less than or equal to 1/4 of the minimum section size of the special-shaped component 3, the concrete or mortar mixture has good fluidity and cohesiveness, and the concrete meets the technical requirements of self-compacting concrete.
In the embodiment, the shaped cavity 4 is cut along a cutting track diagram 5, wherein the cutting track diagram 5 is only used as an example of a design diagram, and in actual operation, any cutting track diagram can be designed and different foam board structures can be cut and formed by a cutting machine.
The method can be used for drawing a graph on a computer, is convenient and fast to operate, can quickly generate an individualized design drawing, controls a cutting machine through the computer, performs line cutting on the foam material according to a design track drawing, and generates the special-shaped cavity 4 after the cutting is finished, namely the shape of the special-shaped component 3;
because the space between plastic film 7 and the foam slab structure is the confined space, through the operation of carrying out the evacuation to this confined space, make the foam slab structure slightly shrink, in the shrink process, separate gradually between the chamber wall of dysmorphism cavity 4 and the dysmorphism component 3, the drawing of patterns process is simple easily operated, and can not harm foam slab structure and dysmorphism component 3 itself, the product quality of dysmorphism component 3 has been guaranteed, also realized the reuse to the foam mold simultaneously, very big degree's reduction manufacturing cost, in order to reduce the influence that leaks gas and cause, also can adhere one deck sealing adhesive tape on the chamber wall of dysmorphism cavity 4, the thickness of plastic film 7 also can suitably increase or bring the improvement intensity through sealed glue.
The above is only a preferred embodiment of the invention, and it should be noted that, for those skilled in the art, it can make several changes and modifications without departing from the structure of the invention, and these should also be regarded as the protection scope of the invention, which will not affect the effect of the invention and the practicability of the patent.
Claims (8)
1. The utility model provides a foam mould, includes the foam slab structure, the foam slab structure includes foam base plate and foam bottom plate, its characterized in that, be equipped with the dysmorphism cavity that forms through the linear cutting of foam cutting machine on the foam base plate, the foam bottom plate bonds the lower bottom surface of foam base plate will the one end of dysmorphism cavity is sealed, still including forming the outside enclosure space of foam slab structure, enclosure space avoids the top of dysmorphism cavity still includes the plastic film, the plastic film with space between the foam slab structure is enclosure space.
2. A foam mould according to claim 1, wherein the foam base plate and the foam sole plate are of soft foam with internal porous channels.
3. A foam mould according to claim 2, wherein the foam base plate is of the same length and width as the foam base plate.
4. A method for forming a special-shaped concrete decorative member by a foam mould is characterized by comprising the following steps:
step one, designing a cutting track diagram: performing linear cutting programming according to the designed special-shaped component diagram to form a cutting track diagram;
step two, precutting: selecting a foam material with proper hardness and size specification to cut in the horizontal direction to form a foam base plate and a foam bottom plate, and ensuring that the thickness of the horizontally cut foam base plate is consistent with the width of the special-shaped component;
step three, wire cutting: fixing the pre-cut foam base plate on a cutting machine, adjusting the feed position to be consistent with the cutting position of the cutting locus diagram, and starting the cutting machine to perform linear cutting until the cutting is finished;
step four, bonding and sealing: taking out the foam body cut by the linear cutting, forming a special-shaped cavity with the same size as the special-shaped component on the foam base plate, bonding the cutting seam at the feed position by using special foam rubber, bonding the foam base plate on the lower bottom surface of the foam base plate by using the foam rubber, sealing one end of the special-shaped cavity, and finishing the manufacture of the foam plate structure;
step five, spraying a release agent: before pouring concrete, spraying a release agent on the cavity wall of the special-shaped cavity, and wiping the cavity wall with a clean wet towel to form an isolation layer on the cavity wall of the special-shaped cavity;
step six, pouring concrete or mortar: pouring concrete or mortar mixture into the special-shaped cavity, and covering and maintaining by using a plastic film after pouring is finished;
step seven, removing the mold: and (3) removing the form of the member after the strength of the concrete or mortar reaches 80% -90% of the design strength, and removing the foam plate structure around the special-shaped member, wherein the concrete steps are as follows:
1) manufacturing a plastic film: manufacturing a plastic film matched with the foam board structure, wherein the plastic film comprises a hollow part with the same shape as the special-shaped cavity;
2) sealing a plastic film: the edges of the hollow-out parts of the plastic films are aligned with the edges of the special-shaped cavities and are in sealing fit with the edges of the special-shaped cavities, the plastic films are in sealing connection with the foam plate structure by using adhesive tapes in the sealing process, the adjacent ends of the plastic films are also in sealing connection by using the adhesive tapes, and the space between the plastic films and the foam plate structure is in a sealing state;
3) vacuumizing the plastic film by using a vacuum machine, wherein the foam board structure is compressed under atmospheric pressure, and the cavity wall of the special-shaped cavity is gradually separated from the concrete;
4) taking out the special-shaped component;
5) ending the vacuum pumping operation, gradually recovering the shape of the foam board structure, and then repeating the steps;
and step eight, carrying out surface treatment on the special-shaped component after the mould is removed, and brushing transparent protective paint on the surface of the special-shaped component.
5. The method for foam mold forming of profiled concrete decorative element of claim 4, wherein in step one, the cutting trace is a side view profile or a top view profile of the profiled element.
6. The method for forming a special-shaped concrete decorative member by using the foam mold as claimed in claim 4, wherein in the second step, the foam base plate and the foam bottom plate are required to meet the requirements of flatness, compactness and no water absorption.
7. The method for foam mold forming of profiled concrete decorative elements according to claim 4, wherein in step five, the mold release agent is a water-soluble mold release agent.
8. The method for forming the special-shaped concrete decorative member by the foam mold according to claim 4, wherein in the sixth step, the maximum particle size of the aggregate of the concrete or mortar mixture for pouring is less than or equal to 1/4 of the minimum cross-sectional dimension of the special-shaped member, the concrete or mortar mixture has good fluidity and cohesiveness, the concrete meets the technical requirements of self-compacting concrete, and the mortar meets the technical requirements of self-leveling mortar.
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| CN201811642063.1A CN109760177B (en) | 2018-12-29 | 2018-12-29 | Foam mould and method for forming special-shaped concrete decorative component by using same |
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| CN109760177A CN109760177A (en) | 2019-05-17 |
| CN109760177B true CN109760177B (en) | 2020-07-21 |
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| CN112523502B (en) * | 2020-12-14 | 2022-07-08 | 广东二十冶建设有限公司 | Machining die and construction method of hollow decorative column |
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| US20050016123A1 (en) * | 2003-07-25 | 2005-01-27 | R. I. Lampus Company | Insert apparatus for a mold, method of manufacturing a concrete unit, method of installing a wall and method of retrofitting an existing mold |
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| CN1509906A (en) * | 2002-12-23 | 2004-07-07 | 冯永琴 | Mould produced by PS foam particles |
| CN2680774Y (en) * | 2004-02-06 | 2005-02-23 | 王宏军 | Environmental protection concrete release agent free formwork |
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