DE102010023936A1 - Method for providing a surface structure for shaped bricks - Google Patents

Abstract

The invention shows a method for providing a surface structure for shaped stones, comprising in a first method step the definition of boundary conditions for the surface structure, which in particular a structure type and / or a structure size and / or a topography scale and / or a complexity size and / or a roughness parameter. In a second method step, the surface structure is then generated by calculation in a computer, taking into account the specified boundary conditions. Furthermore, the invention relates to a mold for producing a shaped block and a shaped block itself.

Description

The invention relates to a method for providing a surface structure for concrete blocks and a mold for producing a concrete block with a surface structure and a concrete block with a surface structure.

Concrete blocks are usually made in shapes that determine the geometric dimensions of the concrete block. On the later visible surfaces of the concrete block to be produced, the corresponding molds generally have structured surfaces which transfer their structure to the concrete during the forming and compacting process, so that the desired structure is later impressed in the surface of the concrete block and its appearance substantially helped shape. It is an endeavor to represent such surfaces as realistically and realistically as possible, with the expert choice of material of the concrete or coloring of the material creates a character, which is modeled in nature occurring materials or often of which it is difficult to distinguish. Here are u. a. Sandstone structures, but also various layer rocks, such. As slate or granite to name as an example.

A disadvantage of the existing method is that the surface structures which have to be introduced into the molds must be removed from real existing surfaces in order to provide a lifelike and realistic surface structure for the concrete block. Here, a considerable effort is made to collect appropriate patterns, while meeting the required individuality of the requested product variety. To provide the surface structures, fragments or entire existing surfaces must be precisely scanned, whereby the data obtained can be transferred, for example by means of a copying-milling device, to a printing block of a mold for concrete blocks. In addition, a variety of nature templates must be present to provide the required variety of surface structures.

The invention therefore has the task of providing variable and flexible, but lifelike surface structures for concrete blocks and thereby minimize the effort required to provide appropriate structures.

This object is achieved by a method with the method steps of claim 1. Advantageous developments and expedient embodiments are specified in the dependent method claims. In accordance with the stated object, furthermore, a mold for producing the concrete block, which has at least one surface structure as a stamp produced according to the invention, is claimed in the context of the invention. Furthermore, the concrete block produced according to the invention is the subject of the present patent application.

The method according to the invention for providing a surface structure for concrete blocks comprises in a first method step the definition of boundary conditions for the surface structure, which may in particular comprise a structure type and / or a structure size and / or a topography scale and / or a complexity variable and / or a roughness parameter. In a second method step, the surface structure is then generated by calculation in a computer taking into account the specified boundary conditions.

The exclusive calculation of the surface structure in a computer on the basis of given boundary conditions eliminates the time-consuming finding and providing of copy templates for lifelike surface structures. The realism of the structure produced in this way is given by the specification of the boundary conditions, for example, the Strukturart includes parameters for specifying the material, such as sandstone, slate or the like. Under the structure size, the geometric dimensions of the later to be produced from the structure form stamp are considered. A topography scale comprises the elevations or subsidences above or below an imaginary planar surface, which also contribute significantly to the appearance of the surface structure. The complexity size represents, for example, the diversity of the surface structure, wherein in particular these variables can be chosen to be characteristic of different materials. In addition, a roughness parameter provides information about the subsequent appearance of the surface structure, wherein roughness in particular for physical properties may be of importance, for example, the slip resistance of floor coverings or the susceptibility to contamination.

In an advantageous development of the method according to the invention, provision is made for the boundary conditions to be available as matched data sets in a database and to be taken from them. Correspondingly coordinated datasets may already have specifications for characteristic material designs and material types, so that, for example, sandstone surfaces can have other specification parameters, such as iron splits. In addition, successful parameter combinations can be saved and later used again.

In an expedient embodiment of the method according to the invention, the calculation of the surface structure is generated from a base surface and an overlay thereon with a parameter surface, in particular a structure height parameter surface, wherein the parameter surface is generated statistically and preferably in a statistic higher-order function comprises the predetermined boundary conditions.

The statistical generation of the parameter surface ensures that the surface structure produced in each case has an individual and unique appearance, with the overriding function of the boundary conditions providing a specification about the category of the structure, for example about the type of material to be mimicked.

In a development of the method according to the invention, it is provided that in a further method step, the generated surface structure is converted into a polygon structure, in particular into a 3D polygon structure, preferably in a triangular surface grid.

The implementation in a polygon structure allows a much more compact storage of the data, and in particular gives access to 3D-based manipulation methods, since such structures allow surface processing, whereby adjacent surface elements according to the existing polygon structure with affected, quasi-interacting can be pulled along, and so the overall appearance of the surface remains in a natural state.

In a further embodiment of the method according to the invention, in a further method step an adaptation of the calculated surface structure according to production parameters, in particular for providing stacking points, for releasability, for adapting tiling properties, for adapting packaging properties and / or for adapting the surface aesthetics is undertaken.

The surface structure generated according to the invention may possibly still be present in a state that is problematic for the production after it has been produced. In particular, concrete blocks are required to be stackable on pallets without destroying the surface structure. For this stack points are to be arranged, on which the weight of the overlying concrete block is worn without destroying filigree structures. Furthermore, it should be provided for the shaping and compacting process that there are as far as possible no undercuts or areas with negative curvature, which would lead to the demoulding of the concrete form stone from the production form that the surface structure is destroyed because the form engages structural components and the resulting structure tears out. Even the so-called tiling properties, which provide a smooth transition from adjoining concrete blocks, can be adjusted in a further process step. For storage and correspondingly efficient delivery, the packaging is also an essential adaptation aspect, which must be taken into account in production to the extent that optimum use of space, for example on a Euro pallet, is desired. Last but not least, it should be mentioned that even slight corrections to the surface aesthetics or to the physical property of the surface have to be made, for example so that no puddles of water can form on bottom plates, but always sufficient drainage of water to seepage points, for example at the edge regions of the concrete blocks or in the Joints is provided.

In a further expedient additional step of the method according to the invention it is provided that an automatic or semi-automatic generation of transitions of the surface structure is produced in a side surface structure, wherein the side surface structure is predetermined, or was also prepared by a method according to the above-described method for providing a surface structure ,

Often there is a need for not only a surface of a concrete block having a visually appealing and faithfully simulated surface structure, but, for example, in the scope of boundary walls or curbs, several surfaces with an adapted surface structure are required. It is important that the surface structures are not considered detached from each other, since in this way the lifelike impression would be lost at the contact edges of the respective surfaces and these artificially shaped edges would clearly emerge. The inventive development of the method, this impression is interrupted because the transitions of the surface structures are coordinated.

In a further expedient embodiment of the method it is provided that the manufacturing parameters conditional adjustments and the generation of transitions to the structures can be done manually, automatically or even semi-automatically. In this way, depending on the individual character of the required Surface structure and fully automatic production of corresponding concrete blocks conceivable.

In a further expedient development of the method according to the invention, it is provided that in a next method step, a transfer of the calculated surface structure, which may also have undergone adjustments, preferably by means of a machining process or by means of a laser engraving on a stamp plate for a mold for concrete blocks. Optionally, the stamp plate may be firmly integrated in the mold, and / or transfer directly to the mold.

Furthermore, the invention relates to a mold for the production of a concrete block, wherein the mold has at least one shaping surface which carries a surface structure, which in turn has been prepared or calculated according to the method described above for producing a surface structure.

In this way, a simplified and thus produced inexpensively surface structure can be transferred by means of the mold for producing a concrete block on a surface of the concrete block.

Furthermore, the invention relates to a concrete block produced according to the method described above with at least one structured surface.

Furthermore, the invention relates to a concrete block, which is characterized in that at least one surface has a surface structure which has been calculated exclusively in a computer. Such a concrete block according to the invention has a nature-like or nature-based surface on at least one of its surfaces, so that it is often difficult or impossible for the viewer to distinguish whether he considered this, for example, a sandstone surface, a broken slate surface or similar lifelike surfaces Depending on the amount of computation required to calculate the surface structure in a computer, a correspondingly close proximity to reality is to be achieved, it being essential for the concrete block according to the invention that the complete surface structure has been calculated from the computer, and does not correspond to a natural template occurring in nature.

Furthermore, the invention relates to a mold for producing a concrete block, which is characterized in that the mold has at least one shaping surface which carries a surface structure which has also been calculated exclusively with a computer and produces a nature-inspired surface image on the concrete block.

Further details of the invention will be described in detail in exemplary embodiments shown.

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1a a side view of a mold top for the production of concrete blocks,

1b a top view of a mold part,

2 an exemplary flowchart of a method according to the invention,

3 an exemplary flowchart of a further continuation of the method according to the invention,

4a a detail of form honeycombs,

4b a pressure piece,

4c a concrete block produced according to the invention,

4d a concrete block produced according to the invention without a structured sidewall.

Show in detail 1a and 1b a common form top 1 and a common lower mold part 2 in a side view or top view. The form top 1 has a plurality of punches on its underside 3 on, which in turn on its underside a screw-on 4 wear. On the mounting plate 4 becomes a pressure piece 5 screwed to produce a concrete block. The stamps 3 with the mounting plates 4 and the pressure pieces 5 are arranged such that when lowering the upper mold 1 on the mold base 2 the pressure pieces 5 in the mold honeycomb 6 engage accurately, and compacting contained therein concrete substances or similar substances suitable for stone production in one or more steps and thereby optionally produce a surface structure on one or more surfaces of the stone. The honeycombs 6 be through the mold frame 7 formed, which may also be provided by a method according to the invention with a structure.

2 shows the sequence of a method according to the invention for producing a surface structure of a concrete block. In a first In this case, boundary conditions I are specified for the surface structure.

The boundary conditions include, among others, the structure type 21 which, for example, provides information about the naturally occurring material to be sensed, such as sandstone, slate, granite or the like. Furthermore, a structure size 22 which, for example, describes the dimension of the entire structure to be generated in the plane in the XY direction. The third size of the boundary condition can be a topography scale 23 be provided, which for example represents the possible elevations of the structure in the Z direction. In this case, a limit value and / or a distribution of the elevations may be provided, which may be present on the surface structure. The provision of a complexity quantity 24 represents the possible variations of the structure in the X-, Y- and Z-direction, whereby fine and filigree surface structures, such as fine sandstone surfaces rather have a small complexity size and rough, raw, broken structures in their complexity size rather large values. Furthermore, it is possible to use a roughness parameter as a boundary condition 25 which describes the averaged complexity of the surface structure, and often has a considerable influence on the physical properties we influence slip resistance and / or abrasion of a generated surface structure for the later resulting concrete block.

The correspondingly predetermined in a first process step I boundary conditions 21 to 25 are then in a second process step II to a computer 26 which is based on the physical parameters of the boundary conditions 21 to 25 in a second method step II, the surface structure 27 calculated three-dimensionally, without which a component of the structure itself was specified.

In the 3 the further progress of an embodiment according to the invention is described. From the generated three-dimensional surface 27 can then in a further process step III by superposition with a polygon structure 30 a simplified machinable 3D structure are created on which manipulations of individual points or areas are possible. The 3D structure for manipulation allows manipulations in its surrounding area to form a near-impact in the structure. As a result, moving surface elements do not form sharp edges, but instead have a kind of elastic entrainment effect on the surrounding elements, so that a naturally appearing surface is retained. Such methods are known, for example, from 3D computer art. In this way it is avoided that, for example, sharp edges or structural changes are essential to the natural and realistic optical appearance of the surface structure 27 impact.

In a further method step IV may be on the polygon structure 30 or possibly also the calculated structure 27 be influenced in the context of desired production parameters. By way of example, four essential production parameters are mentioned, although the list is not intended to be exhaustive in the present case, but rather all functional and production-related parameter adjustments should be included.

As a manufacturing parameter, for example, the revision of the generated surface structure 27 respectively. 30 to provide stacking points 31 at different stacking points 32 be achieved in that individual areas of the surface structure are raised or lowered sufficiently to come to a uniform level for plane-parallel stacking.

Also possible undercuts generated by the statistics in the surface structure generation 33 must be eliminated by the production-related parameter adjustment in order to remove a concrete block from the molded honeycomb 6 To avoid a destruction of the surface structure by tearing out of structural elements by the existing undercuts. This avoids that existing undercuts are engaged behind by the stone materials, which has adverse effects on the structure to be generated.

From the generated surface structures or from a correspondingly large surface structure, it is then also possible to select cutouts which optimize the packaging 34 be assembled to provide optimum occupancy of transport devices, such as europallets, and / or to provide laying patterns.

In the margins of the generated surface structures can also adjustments in the context of tiling 35 be made for tripping or uneven edge transitions 36 be avoided when laying the concrete blocks produced according to the invention.

Furthermore, adjustments such as water drainage channels, tread areas, edge shapes or phases or similar changes are conceivable and possible.

After the manufacturing parameters in a step IV on the surface 27 or 30 have been applied, the resulting surface for transfer to a forming component, such as a pressure piece 5 or a mold wall of the mold honeycomb of a mold can be used to make a concrete block. Here are different transmission methods 37 applied, wherein the cutting transfer method, for example by means of a CNC milling machine or by laser engraving is exemplified.

4a shows a section of a mold or the form of honeycombs 6 a mold, which has a structure produced according to the invention on the side walls of the mold honeycomb. The honeycombs 6 wear at their longitudinally directed side walls according to the invention produced surface structures 40 , which are applied to concrete blocks to be produced. The front side and back (not shown) existing smooth side walls 41 serve, for example, to provide flush abutting surfaces when concrete blocks produced according to the invention are to be laid as far as possible without a gap. For better removability of the finished conglomerates each form of honeycomb may have a taper, which increases the cross section downwards.

4b shows an example of a pressure piece 5 with a surface structure produced according to the invention 42 , which in the production of concrete blocks from above into the honeycombs 6 introduced to compacted concrete for the production of a concrete block in one or more steps, thereby imprinting the surface structure.

4c shows a schematic representation of a concrete block according to the invention produced 43 which is on its upper surface 44 , on its right-hand side surface 45 and along a right-sided phase 46 a structure prepared according to the invention 48 having. The front side 49 as well as the rear side, not shown, have no surface structuring in the present case.

4d shows a schematic representation of a concrete block 50 in which a structure 51 was applied only on the surface and the side surfaces 52 . 53 as well as the phase 54 has no structuring. Of course, other combinations of structuring on the individual surfaces of the concrete blocks are conceivable, depending on what kind of stone to be produced.

However, the invention is not limited to the illustrated embodiment. In particular, the invention is not limited to the mere production of concrete blocks, but rather includes all those blocks that make use of comparable methods using forms with structured side walls and / or structured pressure pieces. Rather, the invention also encompasses all those embodiments which also make use of the concept essential to the invention.

LIST OF REFERENCE NUMBERS

1

Mold top

2

Mold part

3

stamp

4

screwing

5

Pressure piece

6

Formwabe

7

mold frame

21

of structure

21

structure size

22

topography scale

23

complexity variable

24

roughness

25

computer

26

surface structure

30

polygon structure

31

stacking point

32

stacking location

33

undercuts

34

packaging

35

tiling

36

Edge transitions

37

transfer process

40

surface structures

41

side walls

42

surface structure

43

Concrete block

44

Upper surface

45

side surface

46

phase

48

structure

49

front

50

Concrete block

51

structure

52

side surface

53

side surface

54

phase

Claims (12)

Method for providing a surface structure for shaped blocks, in particular concrete blocks, wherein in a first step boundary conditions for the surface structure are given, which in particular comprise a structure type and / or a structure size and / or a Topographieskala and / or a complexity variable and / or a roughness parameter, and in a second process step the Surface structure is generated by calculation in a computer under consideration of the boundary conditions. A method according to claim 1, characterized in that the boundary conditions are taken as concerted records of a database. Method according to one of the preceding claims, characterized in that the surface structure is calculated from a base surface by superposition with a parameter surface, in particular a structure height parameter surface, wherein the parameter surface is generated statistically and preferably in one of the statistics superordinate function comprises the boundary conditions. Method according to one of the preceding claims, characterized in that in a further process step, a conversion into a polygon structure, in particular a 3-D polygonal structure, preferably a triangular surface grating takes place. Method according to one of the preceding claims, characterized in that in a further process step, an adaptation of the calculated surface structure according to manufacturing parameters, in particular for the provision of stacking points, demoulding, adaptation of tiling properties, adapting Paketierungseigenschaften and / or adapting the surface aesthetics. Method according to one of the preceding claims, characterized in that in a further method step, an automatic or semi-automatic generation of transitions of the surface structure is generated in a side surface structure, wherein the side surface structure is predetermined, or was also prepared by a method according to one of the preceding claims. Method according to one of the preceding claims, characterized in that the adjustments in the context of the further method steps according to claim 5 and / or 6, manually, automatically or semi-automatically. Method according to one of the preceding claims, characterized in that in a further process step, a transfer of the surface structure, preferably by means of machining or by laser engraving, takes place on a stamp plate or a concrete block mold. Mold for producing a molded block, characterized in that at least one shaping surface of the mold has a surface structure which has been calculated by a method according to at least one of claims 1 to 6. A shaped block, characterized in that at least one surface has a surface structure which has been calculated by a method according to at least one of claims 1 to 6. Form stone, characterized in that at least one surface has a surface structure which has been calculated exclusively in a computer. Mold for producing a molded block, characterized in that at least one shaping surface of the mold has a surface structure which has been calculated exclusively in a computer.

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