EP0140890A1 - Portable modular casting mold system - Google Patents

Abstract

Portable modular casting mold (18) which can be assembled from individual towable frames (38, 46 and 48). Each frame forms part of the trailer in combination with wheeled units (40,42). The portable modular casting mold (18) allows the casting system to be used in relatively small constructions, since the modular casting mold can be moved and reused indefinitely in successive constructions. Each frame (38, 46 and 48) supports a series of external and internal wall formwork and ceiling formwork. The orientation of the ceiling and wall formwork allows the desired molded product (24) to be molded into the modular casting mold (18). A shoulder joint (196) makes it possible to form a seal between the individual forms of walls and ceilings. A corner joint (234) makes it possible to form a seal between adjacent edges of intersecting wall formwork. A shoulder angle (258) connects the shoulder joints (196) and the corner joints (234) when two wall forms and a ceiling form intersect. Several assemblies of threshold seals (156, 158 and 160) make it possible to form a seal between facing formworks. The threshold assemblies define the bottom of the wall of the molded product (24). The threshold assemblies form grooves on the bottom of the wall of the molded product to allow jointing under pressure and to form a blocking joint preventing movement of the final molded product.

Description

PORTABLE MODULAR CASTING MOLD SYSTEM

TECHNICAL FIELD

This invention relates to the molding of structures, and in particular to the molding of concrete building modules.

BACKGROUND ART

The irolding of modular concrete building structures, having steel reinforcing bars or welded wire fabric forming a core within the structures, has been found to be an effective construction technique. U.S. Patent No. 3,714,304, issued January 30, 1973 to J. W. Carner and Frank B. Anderson discloses a method of casting concrete habitable buildings in concrete modules. In the past, a modular casting moid (MCM) has been employed to receive the steel or wire fabric core and form concrete about the cord into the desired molded product shape. The modular casting mold includes wall forms and ceiling forms which guide and form concrete poured within the modular casting mold to form the walls and ceiling of the molded product. The reinforcing core, formed from the steel reinforcing bars or wire, is commonly inserted into the modular casting mold between the wall forms and adjacent the ceiling forms prior to pouring the concrete. Subsequently, sufficient concrete is poured into the modular casting mold to form the desired final molded product, the reinforcing structure being completely encased within the concrete to strengthen the product.

The modular casting mold includes vibrators on the forms for consolidating the concrete and urging intimate contact between the concrete and the forms to insure a smooth architectural finish to the molded product. Steam curing is typically employed to accelerate the setting of the concrete. The wall and ceiling forms in the modular casting mold can be moved away from the molded concrete product when the concrete has cured sufficiently to support itself. Further steam curing can also then be employed.

The modular casting mold concept provides a great deal of flexibility in final concrete product design. By blocking off certain ceiling and wall forms, many configurations of final concrete structures are possible. By putting block outs along the wall and ceiling forms, doors and windows and other openings can be formed in the molded concrete structure. All electrical, communication and plumbing connections can be mounted on the reinforcing structure prior to pouring the concrete into the modular casting mold. Block outs in the concrete structure leave the terminal ends of the wiring and plumbing exposed for connection to electrical, communication and plumbing fixtures. The resulting molded concrete structures can often form whole rooms with four walls and a ceiling, or even multiple rooms with interior dividing walls, including closets and bathrooms.

Indexing rods assist in the assembly of and are secured to the reinforcing structure cast into the molded structure. The indexing rods are also used as lift points to lift the reinforcing structure and the molded structure from the modular casting mold.

Matching apertures are also formed in each of the molded structures to receive the indexing rods from another molded structure to guide and position the structures together in alignment to form the building desired. The indexing rods on each structure are secured in the matching apertures of the mating structure to provide continuity in the steel or wire fabric core throughout the entire building. Each module is also pressure grouted to a foundation or another structure for sealing.

The weight of the molded concrete structures makes it desirable to have the modular casting mold and supporting equipment as near the actual building site as possible. The modular casting mold must be sufficiently sturdy to support the weight of the wall and ceiling forms, the concrete and reinforcing structures and the dynamic forces exerted by the vibrators. The weight of the modular casting mold itself can exceed 100 tons. The modular casting mold heretofore used has required a substantial period of time for assembly and is considered essentially a permanent structure. A permanent modular casting mold is suitable for large construction projects. Housing developments, commonly found in the developing countries, where a single construction project might include the assembly of 1500 separate complete structures, requiring 27,000 separate molded concrete structures are typical of such large projects. For smaller construction projects, more common in the industrialized nations, the construction and assembly of a virtually permanent modular casting mold adjacent the construction site is not cost efficient. A need therefore exists to develop a system employing the advantages of the modular casting mold system that is portable, therefore eliminating the requirement of a large investment in a permanent, single site modular casting mold. SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a portable modular casting mold is provided. The portable modular casting mold includes a plurality of rigid frame members, each of the rigid frame members being portable. Means are provided for securing the plurality of rigid frame members together in a desired orientation to form a base frame for the modular casting mold. Means are also provided and mounted on the base frame for forming a hardenable material into a desired shape.

In accordance with another aspect of the present invention, each of the rigid frame members in the portable modular casting mold forms a portion of a trailer for transporting the rigid frame members.

In accordance with another aspect of the present invention, a haunch seal for sealing between a wall form. and a ceiling form in a modular casting mold for molding a hardenable material is provided. The haunch seal includes a flexible material, a first means to secure the flexible material to said wall form along the top edge thereof and second means for securing said flexible material to said ceiling form to support a hardenable material while permitting relative movement between the wall and ceiling forms.

In accordance with another aspect of the present invention, the haunch seal for sealing between a wall form and a ceiling form in a modular casting mold includes a first member for securing the flexible material to a wall form. The first member has a portion extending at approximately a 45° angle from the vertical and toward the ceiling form. A second member, securing the flexible material to the ceiling form, has a portion extending at approximately 45° from the vertical and toward the wall form. The flexible material is supported by the portions of the first and second members for supporting the hardenable material. A gap of predetermined distance is provided between the adjacent edges of the portions on the first and second members when the wall and ceiling forms are positioned for forming the hardenable material which permits downward movement of the ceiling form and inward movement of the wall form toward the ceiling form.

In accordance with yet another aspect of the present invention, a corner seal is provided for sealing between wall forms in a modular casting mold for molding a hardenable material, each of said wall forms having a vertical edge. The corner seal includes a flexible material for sealing between the vertical edges of the wall forms and means to support the flexible material on the wall forms while permitting said wall forms to move relative to each other.

In accordance with still another aspect of the present invention, a sill seal is provided for sealing between two wall forms in facing relation in a modular casting mold for molding a hardenable material. The sill seal includes a rigid member and a plurality of wall seals mounted between the rigid member and each of the wall forms. A top seal extends along the rigid member between the wall forms to create a groove along the bottom edge of the product formed upon hardening of the hardenable material. BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention and its advantages will be apparent from the following Detailed Description when taken in conjunction with the accompanying Drawings, in which: FIGURE L is an illustrative view of a casting mold plant layout using a portable modular casting mold;

FIGURE 2a is an illustrative view of the portable modular casting mold in assembled form and in the disassembled form ready for trailering;

FIGURE 2b is an illustrative view of a wheel unit and gooseneck hitch assembly used to transport the trailer frames; FIGURE 3 is an elevation view illustrating a single trailer frame of the modular casting mold in the trailerable condition and illustrating the connection of the wheel units together to permit movement of the wheel units independent of the trailer frame;

FIGURE 4 is an illustrative view of the portable modular casting mold and some of the variety of structural shapes formable in the modular casting mold; FIGURE 5 is a plan view of the three trailer frames secured together to form the base frame of the modular casting mold;

FIGURE 6a is a cross-sectional view of a sill seal and seal supporting structure for a sill seal parallel the length of the trailer frames and positioned between two of the trailer frames;

FIGURE 6b is a detailed drawing of the sill seal assembly; FIGURE 7 is a schematic plan view of the wall forms and wall frames supported on the base frame illustrated in FIGURE 5;

FIGURE 8 is a vertical section view of the modular casting mold at a corner wall section illustrating the base frame, wall form frames, wall forms and ceiling forms of the modular casting mold;

FIGURE 9 is a partial plan view of the modular casting mold immediately below the ceiling molds illustrating the use of the hydraulic top locking pins;

FIGURE 10 is a partial plan view of the modular casting mold illustrating the hydraulic cylinders employed to move the wall forms away from the molded structure;

FIGURE 11 is a partial plan view illustrating the rifle bars and bottom locking pins, as well as an actuator screw and actuator screw mounting plate employed to move the wall frames and wall forms relative to the base frame;

FIGURE 12 is a cross-sectional view of a sill seal and supporting structure for a sill seal extending along a portion of a trailer frame member and providing for passage of a bottom locking pin therethrough;

FIGURE 13 is a cross-sectional view of a sill seal and supporting structure for a sill seal extending perpendicular a trailer frame member without providing for passage of a bottom locking pin;

FIGURE 14 is a view of a typical rifle bar employed in the portable modular casting mold for use in locking locking pins between two wall forms; FIGURE 15 is a detailed view of a locking pin illustrated in FIGURE 15;

FIGURE 16 is a perspective view of the corners formed by the intersection of interior wall forms and a ceiling form, illustrating the use of a haunch seal and a corner seal forming a portion of the present invention to create the interior of a room;

FIGURE 17 is a cross-sectional view taken along lines 17-17 in the direction of the arrows in FIGURE 16 illustrating the haunch seal;

FIGURE 18 is a cross-sectional view taken along line 18-18 in FIGURE 16 illustrating the corner seal; and

FIGURE 19 is an exploded view of the seals employed at the intersection of wall and sealing forms illustrating the haunch corner seal;

FIGURE 20 is a cross-sectional view of a first modification of the haunch seal and illustrates the use of a wall block out permitting the attachment of insulation to the molded product after molding;

FIGURE 21 is a cross-sectional view of the first modification of the haunch seal illustrating the freedom of motion between the wall and ceiling forms to which the haunch seal is secured; and

FIGURE 22 is a cross-section of the molded product having insulation attached thereto and covered by an interior wall surface.

DETAILED DESCRIPTION

Referring now to the Drawings, wherein like reference characters designate like or corresponding parts throughout several views, a portable casting mold plant 10 is illustrated in FIGURE 1. Generally, the mold plant 10 includes a rebar jig 12 for assembling rebar to form a rebar cage 14 having a shape to form the core of the desired final molded product 24. During assembly of cages 14, rough electrical, communication and plumbing connections can be attached thereto. The rebar cages 14 formed in the rebar jig 12 can be stored in storage area 16 until ready to be encased in concrete in the modular casting mold 18. The modular casting mold 18 includes various wall and ceiling forms which guide and support concrete poured into the modular casting mold 18 to form the desired final molded product 24. The gantry crane 20 will move a rebar cage 14 into the modular casting mold 18 prior to pouring concrete. A placer/finisher conveyor 22 is then used to pour concrete into the modular casting mold to encapsulate the rebar cage. Vibrators in the modular casting mold 18 consolidate the concrete and insure that the concrete completely fills the desired forms. After steam curing for a sufficient time to permit the concrete to support its own weight, the various wall and ceiling forms will be moved away from the concrete. When the concrete has set sufficiently for removal from the modular casting mold 18, the gantry crane 20 will remove the completed mold product 24 to the finishing area 26. FIGURE 4 illustrates various molded products 24 that can be formed with the modular casting mold 18. For example, molded product 24a is a relatively simple four walled structure without a ceiling and with only a single door opening. Molded product 24b is an open sided structure supported by four posts with a full ceiling. Molded product 24c is a more complex structure with an overhanging ceiling 28 with several full walls and several partial walls. Molded product 24d illustrates the adaptability of the modular casting mold 18 in providing for internal walls such as wall 30. The assembly of a number of the molded products can readily create an entire building such as a hotel, apartment complex, or high rise office building.

With reference to FIGURES 4 and 7, the modular casting mold 18 has a number of interior wall forms, such as forms 112, 113, 114 and 115, and a number of exterior wall forms, such as forms 100, 102, 104, 106, 108 and 110. As can be seen in FIGURE 7, facing wall forms such as forms 100 and 114 define a gap 117 between them corresponding to the desired wall thickness of the molded product 24. Sill assemblies 156, 158 and 160, shown in FIGURES 6a, 12 and 13, extend between the facing wall forms near their lower edges to confine the concrete between the forms. Vertical block outs 37, shown in FIGURE 9 between facing wall forms, extend from the sill assemblies to the top of the wall forms to confine the concrete and define the vertical edges of the molded product 24. Corners are formed in molded product 24 at the intersection of wall forms. Corner seals 234 prevent loss of concrete at the intersection of the wall forms as shown in FIGURE 16. Ceiling forms, such as ceiling forms 400, 402, 404, 406 and 408 shown in FIGURES 4, 8 and 9, define the ceiling of the molded product 24. Haunch seals 196 and haunch corner seals 258 seal between the wall and ceiling forms. The corner seals 234, haunch seals 196 and haunch corner seals 258 all permit relative motion between wall and ceiling forms to move the forms away from the molded product 24, a significant advantage because no disassembly or assembly of seals are required for the next mold.

The casting mold plant previously employed has a relatively permanent modular casting mold. The capital investment in the modular casting mold previously used somewhat limited the availability of the modular casting mold system on construction projects. The modular casting mold 18 has been constructed as a portable structure as will be readily apparent from the discussion hereafter. The modular casting mold 18 is designed to be broken down into several components for easier transportation. Even so, the weight of the individual components made their shipment on conventional truck trailer combination units impractical. The frame of modular casting mold 18 therefore is employed for a dual function: supporting the movable forms in the modular casting mold, and forming a part of the actual trailer itself.

As can be seen in FIGURES 2a and 3, the modular casting mold 18 is formed of three main substructures 32, 34 and 36. The main substructure 32 includes a trailer frame 38 which not only acts to form a rigid base for the remainder of the substructure but also as a portion of a trailer which, in combination with wheel unit 40 and gooseneck hitch assembly 49 shown in FIGURE 2b, can be trailed behind a motorized unit 42. The main substructure 34 incorporates a similar trailer frame 46. The main substructure 36 incorporates a similar trailer frame 48.

Each of the trailer frames 38 and 48 can be connected directly to the wheel unit 40 and motorized unit 42 through pins 43 mounted at both ends of the trailer frames. An opening 45 is also formed in the trailer frame ends to accept a locking pin 47 in gooseneck hitch assembly 49 of wheel unit 40 as seen in FIGURE 2b. The motorized unit 42 can be used for transportation to and from the job site. The units 40 and 42 can then be connected directly as shown in FIGURE 3 and returned for movement of the next main substructure. For movement of trailer frame 46, a fourth axle is used on wheel unit 40 and an additional two axle truck 41 is used with unit 42. The wheel units can be of the type manufactured by Talbert Trailers, Inc. of W. 47th St. at Route 66, Lyons, Illinois, 60534, and provided with a HYDRONECK hydraulic lifting gooseneck for attachment to pins 43 to lift and support trailer frames 38, 46 and 48. Reference will now be made to FIGURE 5, which illustrates the trailer frames 38, 46 and 48 in greater detail. As illustrated, the trailer frame 46 is the largest of the three frames. It generally includes two main longitudinal I-beams 50 and a series of transverse I-beams 52. Other longitudinal I-beams 54 form rectangular frames within the trailer frame 46. The trailer frames 38 and 48 are similarly constructed. Each of the trailer frames 38 and 48 also have two major longitudinal I-beams 51 which are interconnected by transverse I-beams 53 with shorter longitudinal I-beams 55 forming rectangular frames within the trailer frame.

The trailer frames are secured together in a desired relation by a plurality of fastener assemblies 56. When fastened together by the fastener assemblies 56, the trailer frames 38, 46 and 48 combine to form a rigid base frame 58 which may be supported off the ground by a number of screw jacks 59, as seen in FIGURE 8, or by other suitable support. As can be seen on trailer frames 38, 46 and 48 in FIGURE 5, a series of linear actuators 62 a-1 are rotatably mounted between longitudinal I-beams 51 and transverse I-beams 52. One end of the linear actuators rotatably mounted in the I-beams 50 and 52 supports two gears 64 for cooperation with chains 66. A single motor 68 on each frame 38 and 48 and two motors 68 on frame 46 drive gears 64 secured to the motor shafts thereof and, in turn, rotates each of the linear actuators through the chains 66. Linear actuators 62a, 62d, 62g and 62j can be positioned parallel frames 38 and 48 as shown in phantom lines in FIGURE 5. When parallel frames 38 and 48, motors 68 on frames 46 rotate actuators 62a, 62d, 62g and 62j. Each of the linear actuators 62 has a threaded portion 70, as seen in FIGURE 8, with acme threads having a 1 in 2 pitch. A drive nut 72 is threaded on portion 70 on each of the linear actuators 62. Drive nuts 72 include trunnions 92 for mounting as described hereafter.

It will be apparent that rotation of a motor 68 on trailer frames 38 and 48 will rotate the linear actuators 62 thereon to move the drive nuts 72 in a direction parallel the transverse beams 53. The chains and gears are sized so that the movement of each drive nut 72 on trailer frames 38 and 48 is identical to the movement of the other drive nuts on the trailer frame when driven by the common motor 68 on the trailer.

The trailer frame 46 has two pairs of linear actuators 62 mounted as shown in FIGURE 5 which extend generally parallel the longitudinal I-beams 50 and 54. Two linear actuators 62b and 62c are provided at one end of the trailer frame 46 and are powered by a single motor 68 interconnected by chains 66. Again, the drive nuts 72 will be moved an identical distance manner in a direction parallel the I-beams 50 and 54 when motor 68 rotates. A similar pair of linear actuators 62h and 62i is present at the opposite end of the trailer frame which also provide for identical motion in the drive nuts 72 threaded thereon. With reference now to FIGURE 6a, a fastener assembly 56 will be described in greater detail. The assembly 56 includes a spreader 74 which is positioned between adjoining longitudinal I-beams 50 and 51 on two abutting trailer frames to properly position the trailer frames in relationship to one another. The spreader 74 is a hollow member having a generally diamond shaped cross section. Diamond shaped apertures are formed in the longitudinal I- beams 50 and 51 having the approximate dimensions of the interior cross section of the spreader 74 which permits a solid bullet 76 to be passed through the apertures and spreader 74. One end of the bullet has a flange 78 to abut I-beam 50 with a handle 80 to simplify movement of the bullet 76. A cap 82 is positioned over the extension of the bullet 76 through the adjacent I-beam 51 and a screw 84 is used to secure the cap 82 to the bullet 76 and rigidly connect the trailer frames.

Reference is now directed to FIGURE 7. Corner wall frames 86a, 86b, 86c and 86d are positioned on top of each of the four corners of the base frame 58. Each corner wall frame 86 is provided with two drive nut bracket plates 88 and 89. One drive nut bracket plate supports drive nut brackets 90, as best seen in FIGURE 8. Each of support brackets 90 has an aperture formed therein for receiving one of the trunnions 92 extending from each drive nut 72. As can be seen with reference to both FIGURES 5 and 7, the bracket plate 88 on corner wall frame 86a would be secured to the drive nut 72 directly beneath it on linear actuator 62a with a bracket 90 as seen in FIGURE 8. The bracket plate 89 is provided if the linear actuator 62a shown in FIGURE 5 is mounted for rotation along an axis parallel to the longitudinal I-beams 51 and 55 rather than perpendicular thereto. As can be readily understood, rotation of the motor 68 on the trailer frame 38 will cause the corner wall frame 86a to move either toward or away from the trailer frame 46. Rollers 94, such as seen on wall frame 96a in FIGURE 8, permit the corner wall frame to be supported by the base frame 58, yet move in relation thereto. The other frames 86 are movable in the identical fashion.

Intermediate wall frames 96 are mounted on the trailer frames 38 and 48. The wall frames 96 are connected to the intermediate drive nuts 72 on linear actuators 62f, 62e, 621 and 62k on each of these frames through drive nut bracket plates 88 and support brackets 90 for movement toward and away from the base frame 58 upon rotation of the motors 68 on the individual trailer frames 38 and 48. As will be apparent, rotation of the motors 68 on the trailer frames 38 and 48 will move the corner wall frames 86 and intermediate wall frame 96 in the same direction for the same distance. Intermediate wall frames 98 are supported on the portion of the base frame 58 formed by the trailer frame 46. Each of the wall frames 98 is connected to an adjacent pair of drive nuts 72 on linear actuators 62b, 62c, 62h and 62i on trailer frame 46 through bracket plates 88 for movement towards and away from the center of the trailer frame 46.

The wall frames 86, 96 and 98 support individual exterior wall forms, exemplified by exterior wall forms 100, 102, 104, 106, 108 and 110 as seen in FIGURE 7. Interior wall forms, such as interior wall forms 112 through 115, are supported on the base frame 58. Generally, the wall forms are set to define a gap 117 of predetermined width between a given interior wall form and the facing exterior wall form. Ceiling forms 400, 402, 404, 406 and 408 define the interior ceilings of the molded product 24. A portion of the rebar cage 14 is placed in this gap 117 and over ceiling forms 400-408 and concrete is poured to fill the gap 117 to form a wall of the molded product 24 and cover ceiling forms 400-408 to define the ceilings of molded product 24. Both the interior and exterior wall forms and ceiling forms must be moved away from the molded product for curing and removal of the molded product, hence each of the wall forms must be movable relative to the stationary base frame 58. During actual pouring of concrete, locking pins 132 and 134, described hereinafter, lock the facing wall forms with great precision so that the gap 117 is uniform along the length of the wall forms. The locking pins 132 and 134 permit variation of the gap width in discrete increments to allow different wall thicknesses in the molded product 24. The wall forms are arranged so that no wall form must extend between trailer frames. This feature greatly simplifies the assembly and disassembly of the modular casting mold 18.

The exterior wall forms are secured to the wall frames by brackets 116, as seen in FIGURE 8 between wall form 100a and wall frame 96a, which permit limited motion of the wall forms relative to the wall frames. Exterior wall forms 104 and 106 are similarly secured by brackets 116 to the corner wall frames 86. The exterior wall forms 108 and 110 are mounted by brackets 116 on the intermediate wall frames 98.

Interior wall forms 112 and 114 are supported directly on the base frame 58 on the portion formed by trailer frame 46. The interior wall forms 112 and 114 form a square box which can expand and shrink under the activity of various hydraulic cylinders 215 shown in FIGURE 10 and described in greater detail hereinafter. Wall forms 113 and 115 form two similar boxes which can also be expanded and contracted by cylinders 215.

When the wall forms are in the relative position as shown in FIGURE 7, locked together by locking pins 132 and 134, and the abutting edges thereof are sealed in a manner described hereinafter, concrete can be poured into the gaps 117 defined between facing wall forms, such as exterior wall form 100 and interior wall form 114, to form the walls of the desired molded product 24. Each of the drive nut bracket plates 88 and 89 have a plurality of holes 124 formed therethrough to mount the individual support brackets 90 as seen in FIGURE 11. By securing the support brackets to the proper holes

124, the range of motion of motors 68 and nuts 72 can be maintained identical despite variation in the desired wall thickness of the molded product 24. Sufficient holes 124 are provided to give adequate versatility in wall thickness for the particular products desired.

After the concrete has been poured and has set for a sufficient time to retain its shape without support, the motors 68 are actuated to move the exterior wall forms away from the molded product and hydraulic cylinders 215 move the interior wall forms away from the molded product for further curing, and finally, for removal from the modular casting mold 18. FIGURE 8 illustrates in greater detail the interrelationship of the base frame 58, intermediate wall frame 96a, exterior wall form 102a, exterior wall form 100a, interior wall form 112a and interior wall form 114a. During the pouring of concrete or other hardenable material, individual wall forms in facing relation are prevented from separating by a series of top locking pins 132 and bottom locking pins 134 as seen in FIGURE 8. One end of the bottom lock pin 134 as seen in FIGURE 8 is secured within the interior wall form 114a by a bolt 136. Bolt 136 passes through one of the holes 138 formed in the locking pin 132, as seen in FIGURE 15, to secure the pin 134 to collar 139 on wall form 114a. The opposite end of the locking pin 134, having a taper 140, is secured by a rifle bar 142, described in greater detail hereafter, to the exterior wall form 100a. The bottom locking pin 134 is square in cross section.

The top locking pin 132 is similarly secured relative to the exterior wall form 100a by a bolt 136 in one of the holes 138 in the locking pin 132. The opposite end of the locking pin 132, having a taper 144 over substantially its entire length, is secured by a rifle bar 146 to the interior wall form 114a.

As mentioned previously, the locking pins 132 and 134 are employed only during actual pouring and setting of concrete or other hardenable material in the modular casting mold and until the material can support its shape without support by the wall forms. At that point, the rifle bars 142 and 146 are operated to release the locking pins and permit the wall forms to separate from the molded products 24.

As seen in FIGURE 10, each of the mold walls is formed of a plate 148 with a series of vertical angle members 150 and horizontal gussets 152. Ceiling forms 400-408 are similarly constructed. Air operated vibrators 154, as seen in FIGURE 8, are mounted at various locations along the wall forms and ceiling forms to vibrate the concrete or hardenable material during pouring to insure that the material is distributed everywhere within the mold. A vibration frequency between 10,000 to 16,000 Hz has been found to be effective. The vibration distributes the material in the wall forms and ceiling forms to provide smooth surfaces on the molded product 24 and consolidates the material to a uniform density.

The bottom edges or sills of the walls of the molded product 24 are formed by sill assemblies such as sill assemblies 156, 158 or 160, as seen in FIGURES 6a, 13 and 14, respectively. If an adequate seal is not provided at the sill, slurry in the concrete will be lost, leaving aggregate , and resulting in poor strength and appearance. Sill assembly 156, as shown in FIGURES 6a and 6b, will be employed where the lower edge or sill of the wall of the molded product lies parallel to and directly above the spreaders 74 between the individual trailer frames. The sill assembly 156 includes a gusset 162 mounted on a spreader 74 which supports a sill base 164. The sill base 164 is threaded to a sill 166 by threaded rod 186, which, in turn, supports a sill seal assembly 168. The sill seal assembly 168 includes parallel extruded aluminum seal frames 170 and 172 which each have grooves 174 therein of semicircular cross section. Grooves 174 receive neoprene wall seals 176 to seal between the seal frames 170 and 172 and the wall forms adjacent thereto to prevent fluids from leaking past the sill seal assembly. Each of the neoprene wall seals 176 has a generally cylindrical cross section from which extend three protrusions 178, each forming a line of sealing between the seal assembly and a wall form.

A neoprene top seal 180 prevents the hardenable material from leaking between the seal frames 170 and 172. The seal frames 170 and 172 each define a slot 181 for receiving a portion of the neoprene top seal 180 in sealing engagement. The seal 180 has an outer convex surface 182 which forms a groove in the bottom of the wall of the molded product. This groove in the molded product is suitable for pressure application of grout to seal the bottom of the wall against the sealing of the next lower molded product or a foundation. The concave nature of the groove formed by surface 182 also permits the grout to act as a tennon to prevent movement of the walls, critical for stability in earthquake prone areas. The sill seal assembly 168 and sill 166 extend in a continuous manner along the entire length of the sill desired on the molded product 24. The end of the wall in the molded product 24 is created by vertical barrier block outs 37 between the facing wall forms as seen in FIGURE 37. Sufficient sill bases 164 are used to support the sill seal assembly 168 and sill 166. When sill seal assemblies intersect at right angles, they are sealed together at their intersection.

The threaded rod 186, which connects the sill assembly 168, base 164 and sill 166, permits the interposition of a sill extension, not shown, which moves the seal assembly 168 upward relative to the spreader 74. This permits the height of the walls of molded product 24 to be readily varied based solely on the length of the sill extension interposed between the sill base 164 and sill 166.

FIGURE 12 illustrates the sill assembly 158 used when the sill of the molded product is parallel to and above an I-beam in one of the trailer frames and provisions must be made to permit a bottom locking pin 134 to pass beneath the sill. The sill assembly 158 includes a channel 188 adapted to permit passage of the bottom locking pin 134. The sill assembly 160, seen in FIGURE 13, would be employed in a situation where the desired sill of the molded product extends generally perpendicular to an I-beam in the trailer frame. The I-beam 54 in the frame would support the sill stand 192, which in turn would support the sill 166 and sill seal assembly 168 as shown. Sill stand 192 can be varied in length to form walls of desired height in the molded product 24.

By the use of ceiling mold forms, such as ceiling forms 402b and 406 illustrated in FIGURE 8, the modular casting mold 18 can mold a molded product 24 having walls and an interconnecting ceiling. As can be seen in FIGURE 8, when the concrete or hardenable material is poured into the mold, encapsulating the rebar cage 14, the material will cover the ceiling form 194 to a thickness denoted by distance t. A haunch seal 196 forms the corner of the molded product between a wall and ceiling. A wall extension 198, secured between the exterior wall form 100a and ceiling mold form 402b, seen in FIGURE 8, forms the edge of the ceiling of molded product 24 with the surface 202. A haunch seal 196 can be substituted for the wall extension 198 and a barrier 201 erected along form 200 to form a ceiling overhang.

After pouring the concrete or hardenable material, and allowing the molded product to cure to the point where it will support itself, it is necessary to lower the ceiling mold forms 400-408 in contact with the molded product to break the suction found therebetween before final curing and removal of the molded product 24 is possible. The ceiling mold forms 400-408 are supported on vertical support brackets 204 which are secured to plates on the trailer frames or wall frames such as plates 206 seen in FIGURE 5 and FIGURE 8. Ceiling forms 400, 402 and 404 between the exterior wall forms are supported on the wall frames just below them. Ceiling forms 406, 408 and 410 between the interior wall forms are support from the base frame 48. Along each vertical support bracket 204 is positioned a double acting hydraulic cylinder 208 which permits the ceiling mold forms to move vertically a predetermined distance between a raised position for molding and a lowered position for removing the molded product. The hydraulic cylinder stroke of cylinders 208 may be two inches, for example. Braces 210 can be positioned between the vertical support brackets 204 and the trailer frames to insure a rigid mount for the ceiling mold forms.

As will be apparent from FIGURE 9, the top locking pins 132 will actually pass through the molded product. In order to separate facing wall forms, the locking pins 132 must be withdrawn. Hydraulic rams 212 are mounted on the wall forms to operate each of the locking pins 132 as seen in FIGURE 9. Double acting hydraulic cylinders 214 interconnect adjacent edges of selected exterior wall forms as seen in FIGURE 10. The cylinders 214 move the selected exterior wall forms away from the molded product a distance sufficient to break the suction between the wall forms and molded product 24. A distance of 3/4" has been found adequate. No cylinders 214 are needed to move the exterior wall forms that extend perpendicular the direction of motion of the drive nuts 72 to which the wall forms are secured through a wall frame. Movement of the drive nuts 72 will draw the wall forms away from the molded product. Corner wall frames 86 have extra cylinders 214 in the event the linear actuators are altered to move the frames 86 through plates 89. Brackets 116 provide freedom for the selected wall forms to move relative to the supporting wall frame the 3/4". Typically, two hydraulic cylinders 214 are interconnected between each selected exterior wall intersections and are spaced vertically from each other. Hydraulic cylinder brackets 216 mount the ends of the cylinders to the wall forms. Double acting hydraulic cylinders 215 are secured between each intersecting edge of the interior wall forms, permitting the interior wall forms to be separated inwardly from the molded product 24.

When the concrete or hardenable material is sufficiently cured to support the shape desired, the individual hydraulic cylinders 208 are operated to lower the ceiling mold forms to separate the ceiling mold forms from the ceiling of the molded product. Simultaneously, the hydraulic cylinders 214 and 215 are operated to draw the abutting edges of the wall mold forms together to separate the wall mold forms from the walls of the molded product 24. It can be seen, for example, that four interior wall forms, each connected to the adjacent wall forms by hydraulic cylinders 215, will actually simultaneously move the interconnected wall forms away from the walls of the molded product 24 to break any suction that could prevent an efficient removal of the molded product 24 from the modular casting mold 18. In addition to the movement of the interior and exterior wall forms away from the walls of the molded product 24 by cylinders 214 and 215, the motors 68 are operated to move the outer wall forms away from the walls of the molded product 24. The use of the acme thread on the linear actuators 62 permits the extent of this motion to be relatively large compared to the motion of the hydraulic cylinders 214 and 215, for example, approximately 2 1/2 feet. This permits personnel to enter the 2 1/2 foot gap between the outer wall forms and the outer walls of the molded product 24 to remove block outs forming windows and doors in the walls. In addition, the personnel can clean the form, finish rough areas or otherwise do touch up jobs on the outer surface as needed. FIGURES 11, 14 and 15 illustrate in greater detail typical rifle bars 142 and 146. It will be understood that the operating principles of rifle bars 142 and 146 are identical. The rifle bar 146 shown in FIGURE 14 includes bar 218 slidably mounted in supports 220 on a wall form. One or more double acting hydraulic cylinders 222 operate to move the bar linearly within the supports 220. Wedges 224 are mounted along the bar at various distances to cooperate with the individual top locking pins 132. The wedges 224 will be completely unconnected with the top locking pins 132 when freedom of motion between facing wall forms is desired. However, when the wall forms are to be secured in a fixed relation, the cylinders 222 are activated to drive the wedges 224 into a slot 226 formed in each of the top locking pins 132 to secure the wall forms in a fixed separation. A perspective view of a bottom locking pin 134 is illustrated in FIGURE 15. As can be seen, a plurality of holes 138 are positioned in the pin 134 at uniform distances for insertion of a bolt 136 to permit the pin 134 to be adapted for varied wall thicknesses in the final molded product 24.

FIGURE 16 is a perspective view of the surface of intersecting interior wall forms 115a and 113b and ceiling form 408b. The combination of the wall forms 115a, 113b and ceiling form 408b would form the interior intersection of two perpendicular walls and a ceiling in the molded product 24. The haunch seals 196 between each wall form and the ceiling form provides a smooth architectural interface between the ceiling form and the interior wall forms and the corner seal 234 provides a smooth architectural intersection between the edges of the interior wall forms 115a and 113b.

FIGURE 17 illustrates a cross-sectional view of a haunch seal 196. A ceiling form aluminum extrusion member 236 is securely fastened to the ceiling form along its outer edge. A neoprene flexible belt 238, in turn, is securely attached to the ceiling form extrusion member 236 in a fluid tight manner at slot 239. The belt 238 can comprise a common reinforced conveyor belt or extrusion and can have a thickness, for example, of approximately 3/8 or 7/16 inches. The belt 238 can also be formed of hot melt rubber, urethane, or any other suitable material. An interior wall form aluminum extrusion member 240 is secured to the upper edge of each of the interior wall forms and is also secured to the belt 238 in a fluid tight manner at slot 241. Extrusion members 236 and 240 can also be formed from a suitable material other than aluminum, or formed by a method other than extrusion. As can be seen in FIGURE 18, the resilient belt 238 is shaped by the extrusion members 236 and 240 into a quarter cylinder having a radius R which provides a smooth transition between the horizontal ceiling form 408b and the vertical interior wall form 113b.

FIGURE 18 is a cross sectional view of the corner seal 234 which is positioned between the edges 242 and 244 of the intersecting wall forms 113b and

115a. The corner seal 234 includes a flexible rubber hose 246 which extends the entire vertical length of the interior wall forms and is urged against the edges 242 and 244 to provide a fluid tight seal. Hose 246 can also be formed of a neoprene extrusion or other suitable material. The hose 246 is supported by a plurality of angle brackets 248 and 250 mounted on the interior wall forms 113b and 115a, respectively, which cooperate with a bracket 252 and bushings 253 directly connected to the hose 246 through a number of studs 254 fastened to a half moon shaped support 256 within the hose 246. A clearance hole is provided in bracket 252 for studs 254. Studs 254 are secured to bracket 252 by nuts 253 on bracket 252 to adjust hose 246 toward bracket 252. Jack screws 257 are threaded to bracket 252 and abut an outside cylinder section 259 in contact with hose 246 to adjust hose 246 outward. The angle brackets 248 and 250 permit the bracket 252 and bushing 253 to slide between the brackets and wall forms to prevent damage to hose 246 as the interior wall forms are moved together by the hydraulic cylinders 215 interconnecting them adjacent the edges 242 and 244. A two inch outer diameter, one and one-half inch inner diameter, Goodyear 2 B.D. Contender hose has been found suitable for use as hose 246.

FIGURE 19 is an exploded view of the haunch corner seal 258, which provides a fluid tight intersection for the haunch seals 196 and corner seal 234. The haunch corner seal 258 is preferably an injection molded neoprene rubber piece which is adapted to be secured in a fluid tight manner to the haunch seals 196 along seam lines 261. The corner seal 258 is further formed with a rod 260 which extends vertically downward adjacent the corner line 262 and which is sized to fit within the top of the hose 246 to form a fluid tight interconnection with a smooth contour between the haunch corner line 262 and rubber hose 246. If desired, an alternate haunch corner seal 258 can be formed by cutting the intersecting haunch seals 196 along 45º angles and bonding the edges together to form the corner. With the seals described hereinabove, the interior corners of a room in the molded product employing these seals have an architectural pleasing quarter cylindrical cross section. Also, the seals 196, 234 and 258 provide freedom of motion between the various wall and ceiling forms for moving the forms away from the molded product 24.

FIGURES 20 and 21 illustrate a cross-sectional view of a first modification of the haunch seal 196 identified as haunch seal 300. The haunch seal 300 includes a wall form aluminum extrusion member 302 secured along the top of the wall form 113b. A sealing form aluminum extrusion member 304 is mounted on the ceiling form 232. Members 302 and 304 can also be formed from alternate materials and formed by a method other than extrusion. A flexible belt 238, again formed of a flexible material comprising a conveyor belt or extrusion formed of neoprene, hot melt rubber, urethane or any other suitable material, extends between the extrusion members 302 and 304 and is secured thereto within slots 306 and 308 formed in the extrusion members 302 and 304, respectively. The belt 238 is secured to the extrusion members 302 and 304 in a fluid tight manner to prevent the concrete or other hardenable material in the molded product 24 from leaking through the haunch seal 300.

The wall form aluminum extrusion member 302 has a portion 310 extending toward the ceiling form 232 at an angle θ . The ceiling form aluminum extrusion member 304 has a similar portion 312 extending toward the wall form 113b at an angle α . In the preferred construction, the angles θ and α are approximately 45°. A gap 314 separates the facing edges of the portions 310 and 312 when the wall and ceiling forms are positioned to mold the concrete of molded product 24 as shown in FIGURE 20. As can be seen in FIGURE 20, the portions 310 and 312 provide direct support to the belt 238 to support the weight of the concrete or hardenable material in the molded product 24. However, the gap 314 is sufficiently large to permit the ceiling form 408b to be dropped vertically, as shown in FIGURE 21, to separate the ceiling form 408b from the molded product 24. Simultaneously, or subsequently, the wall form 113b is moved inwardly, away from the wall of the molded product 24 and toward the ceiling form 408b as shown in FIGURE 21. The extrusion members 302 and 304 permit this relative motion without interfernce and further act to draw a substantial portion of the belt 238 away from the molded product 24 as shown in FIGURE 21. The haunch seal 300 defines a surface 316 extending between the wall and ceiling portions of the molded product 24 extending at a 45° angle to the vertical. FIGURES 20, 21 and 22 illustrate the use of an insulation block out 318 which permits the installation of thermal insulation in the molded product 24 after curing. The insulation block out 318 is mounted on the outer surface of the interior wall forms such as the wall form 113b and defines an inset 320 in the wall of the molded product 24. This inset 320 can be filled with an insulating material 322 as seen in FIGURE 22. An interior wall surface 324 can be secured to the wall of the molded product 24 to provide an architectural interior surface to the molded product.

As is apparent from the description above, the present invention provides a portable modular casting mold which can be readily moved to a site for construction and assembled with the minimum of effort. This permits the modular casting mold concept to be used in a greater variety of applications, particularly where lesser numbers of actual molded products are necessary to form the final structure than necessary previously. In addition, the provision of effective seals between the mold walls and ceiling molds provide for efficient molding and a pleasing appearance to the final product.

Although one embodiment of the present invention has been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiment disclosed, but is capable of numerous rearrangements, modifications and substitutions of parts and elements without departing from the scope and spirit of the invention.

Claims

1. A modular casting mold having a base frame, comprising: a plurality of rigid frame members, each of said rigid frame members being portable; means for securing said plurality of rigid frame members together in a desired orientation to form a base frame for the modular casting mold; and means mounted on said base frame for forming a hardenable material into a desired shape.

2. The modular casting mold of Claim 1 wherein each of said rigid frame members forms a portion of a trailer to transport said rigid frame members.

3. The modular casting mold of Claim 1 being moved by use of first and second wheeled units for towing by a vehicle, said modular casting mold further comprising: means for connecting a first end of a rigid frame member to said first wheeled unit and means for attaching the end opposite said first end of the rigid frame member to said second wheeled unit for transporting the rigid frame member.

4. The modular casting mold of Claim 1 wherein said means mounted on said base frame comprise wall and ceiling mold forms, each of said rigid frame members supporting wall and ceiling mold forms, the securing of the rigid frame members together in the desired orientation to form a base frame orienting the wall and ceiling mold forms supported thereon to permit forming of the hardenable material into the desired shape.

5. A portable modular casting mold having a base frame for forming a hardenable material into a desired shape, comprising: a plurality of rigid trailer frames, each of said trailer frames being trailerable and adapted for attachment to first and second wheel units at opposite ends of the trailer frames for trailering; a plurality of fastener assemblies for securing the rigid trailer frames together in a preselected orientation to define the base frame; and wall forms mounted on each of said rigid trailer frames so that when the trailer frames are secured together in the preselected orientation, the wall forms permit pouring of hardenable material therein to form the desired shape.

6. The portable modular casting mold of Claim 5 wherein each of said fastener assemblies includes: a spreader of predetermined length for separating the rigid trailer frames, said spreader having a passage therethrough, each of the rigid trailer frames separated thereby having an aperture formed therein aligned with the passage through the spreader ; a bullet having a flange thereon for insertion through the apertures in the facing trailer frames and the passage through the spreader, the flange contacting the edge of one of the rigid trailer frames about the aperture therethrough; and means acting between the other rigid trailer frame and the bullet to rigidly secure the trailer frames together.

7. The portable modular casting mold of Claim 5 further comprising ceiling forms mounted on selected ones of said rigid trailer frames so that when the trailer frames are secured together in the preselected orientation, the wall forms and ceiling forms permit pouring of hardenable material therein to form the desired shape.

8. The portable modular casting mold of Claim 5 further comprising a plurality of wall frames to support the wall forms thereon, said wall frames being movable relative to the rigid trailer frames when secured together in the preselected orientation to permit selected ones of said wall forms to move away from the hardenable material when the hardenable material is sufficiently cured to hold its shape.

9. The portable modular casting mold of Claim 8 further comprising a plurality of linear actuators rotatably mounted on selected ones of said trailer frames and drive nuts threadably attached to said linear actuators, rotation of said linear actuators moving the drive nuts in a linear direction, said wall frames being connected to selected ones of said drive nuts so that rotation of a linear actuator moves the wall forms secured to the wall frames connected thereto.

10. The portable modular casting mold of Claim 5 further comprising a plurality of locking pins for locking the wall forms in a position so that the hardenable material poured therebetween forms the desired shape.

11. The portable modular casting mold of Claim 5 wherein each of said rigid trailer frames has at least one pin secured at each end of the trailer frame for cooperating with a wheel unit for trailering the trailer frame.

12. The portable modular casting mold of Claim 5 further having at least one ceiling form and a haunch seal for sealing between a wall form and a ceiling form comprising: a flexible material; first means for joining the flexible material to said wall form along the top edge of the wall form; and second means for joining the flexible material to said ceiling form along the edge of the ceiling form to support a hardenable material while permitting relative movement between the wall and ceiling forms.

13. The portable modular casting mold of Claim 5 further comprising a corner seal for sealing between the edges of intersecting wall forms including: a flexible material for sealing between the edges of the wall forms; and means to support said flexible material on said wall forms while permitting said wall forms to move relative to each other.

14. The portable modular casting mold of Claim 5 further comprising a sill seal for sealing between two wall forms in facing relation including: a rigid member positioned between the wall forms; a plurality of wall seals mounted between the rigid member and each of the wall forms; and a top seal extending along the rigid member between the wall forms to create a groove along the bottom edge of the molded wall.

15. A haunch seal for sealing between a wall form and a ceiling form in a modular casting mold for molding a hardenable material to form a molded product, comprising: a flexible material; first means for joining the flexible material to said wall form along the top edge of the wall form; and second means for joining the flexible material to said ceiling form along the edge of the ceiling form to support a hardenable material while permitting relative movement between the wall and ceiling forms.

16. The haunch seal of Claim 15 wherein said flexible material is a belt.

17. The haunch seal of Claim 15 wherein said first and second means each comprise members for attachment to the forms, each of said members having a slot for receiving a portion of the flexible material to seal the flexible material to the member and means for fixing the flexible material within the slot.

18. The haunch seal of Claim 15 wherein said first means comprises a first member having a portion extending at approximately 45° from vertical and extending toward the ceiling form, and said second means comprises a second member having a portion extending at approximately 45º to the vertical and toward the wall form, a gap of predetermined distance separating proximate edges of the portions on the first and second members when the wall and ceiling forms are positioned for molding a hardenable material, the gap permitting vertical downward movement of the ceiling form and inward movement of the wall form toward the ceiling form to separate the wall and ceiling forms from the molded product, the portions of said first and second members supporting the flexible material during molding of the hardenable material.

19. The haunch seal of Claim 15 further for sealing between intersecting wall forms and a ceiling form in a modular casting mold for molding a hardenable material to form a molded product, said haunch seal further comprising a haunch corner formed of flexible material.

20. The haunch seal of Claim 15 wherein said first and second means shape said flexible material therebetween into a quarter cylinder to provide a decorative haunch corner to the molded product.

21. The haunch seal of Claim 18 wherein said first and second member shape said flexible material therebetween into a planar surface extending at an 45° angle to the vertical to provide a decorative haunch corner to the molded product.

22. The haunch seal of Claim 15 wherein said flexible material comprises a conveyor belt formed of a material selected from the group comprising neoprene, hot melt rubber and urethane.

23. The haunch seal of Claim 15 wherein said flexible material comprises an extrusion formed of a material selected from the group comprising neoprene, hot melt rubber and urethane.

24. A corner seal for sealing between the edges of intersecting wall forms in a modular casting mold for molding a hardenable material to form a molded product, comprising: a flexible material for sealing between the edges of the wall forms; and means to support said flexible material on said wall forms while permitting said wall forms to move relative to each other.

25. The corner seal of Claim 24 wherein said flexible material comprises a flexible tube.

26. The corner seal of Claim 25 wherein said flexible tube is formed of rubber having reinforcement layers therein.

27. The corner seal of Claim 25 wherein said flexible tube is formed of a neoprene extrusion.

28. The corner seal of Claim 24 further for use with a ceiling form sealed to each of said wall forms with a haunch seal, a haunch corner being provided for sealing the intersection of the wall and ceiling forms, the haunch corner having a pin extending downward between the edges of the wall forms, the flexible material cooperating with said pin on the haunch corner to form a smooth seal transition between the corner seal and haunch seal.

29. A sill seal for sealing between two wall forms in facing relation in a modular casting mold for molding a hardenable material into a molded product, comprising: a rigid member positioned between the wall forms, a plurality of wall seals mounted between the rigid member and each of the wall forms; and a top seal extending along the rigid member between the wall forms to create a groove along the bottom edge of the molded product.

30. The sill seal of Claim 29 wherein said rigid member includes a sill and first and second rigid members mounted on said sill, each of said rigid members having grooves formed therein having a semicircular cross section and opening against one of the wall forms and a slot for receiving a portion of the top seal.

31. The sill seal of Claim 29 wherein each of said plurality of wall seals comprises a compressible neoprene material having a circular cross section adapted for engagement with a groove in said rigid member and a plurality of protrusions extending outwardly from the radius of the circular cross section and the groove for engagement with a mold wall for sealing.