EP0778112B1 - Process for making wall elements - Google Patents

Abstract

Walling blocks of concrete or similar material with variable dimensions and/or shape are made in open mould boxes (1) by placing at least one blanking piece (12) within the mould box (1). The blanking piece (12) is made of elastic, compressible material and is in the shape of a rectangular prism with a height (H) in the unloaded state corresponding to the height of the box (1). The remaining space (16) is filled with concrete (15) which is then compressed by a plunger (14) covering the cross-section of the box so that the blanking piece (12) is compressed at the same time. The side walls (3,4,5,6) of the box are then removed, the plunger (14) is raised, the blanking piece (12) is released and the walling block (20) allowed to harden.

Description

The invention relates to a method for producing wall elements made of concrete or similar building material with variable dimensions and / or shaping on a production line and one of these methods implementing manufacturing plant.

The wall elements mentioned can be more, for example or less large-sized bricks to make industrially prefabricated Act wall segments or entire wall panels, which are preferably made in Forms filled and compacted concrete, but also from corresponding Building materials - e.g. based on calcium silicate hydrate become.

Known manufacturing plants have a mold box open at the top a floor and vertical sidewalls that match the format of the item to be manufactured Wall element pretends. By means of a filling device which in the Usually consists of a filling box open at the bottom, the molding box with customarily arranged concrete material (or a corresponding building material) filled, which can be lowered into the mold box from above Ram is compressed.

This known manufacturing system has disadvantages in that one and the same molding box and the one that matches the format Press stamps only ever made wall elements of a single format can be. In the event of a format change, the production system must be converted weden by using different-sized mold boxes and press stamps become. This undesirably limits the capacity of one Manufacturing facility. They also have to be of different sizes for the production Wall elements according to different formats Molded boxes and press dies are manufactured and kept in stock, which means a considerable investment and storage effort.

A certain remedy for the problem discussed above creates already a manufacturing system, as known from DE 44 08 845 A1 is. In this manufacturing system, there is at least one side wall of the molding box with a variable distance to the opposite side wall positionable. This ensures that one dimension of the molding box, for example, its length can be set variably. In order to use one and the same press stamp for different mold box sizes to be able to use, one side wall of the molding box is height-adjustable, so that they are under the action of the press ram can give way down when it is lowered into the molding box.

The known manufacturing system already has a certain variability achieved in terms of a dimension of the wall element. A however, complete industrial prefabrication of building exterior walls requires greater flexibility in the shape of the individual wall elements. With such a prefabrication, an outer wall of the building is used disassembled into different wall elements "like a puzzle", optimally should be achievable that all wall openings e.g. For Windows, doors, wall openings for ventilation and sloping ones Wall closures, such as in the gable area of an outer wall into which Shape of the individual wall elements included in their manufacture can be. So it is not enough to just produce different formats to be able to, but it must be in the individual wall elements Cutouts, slants, etc. can be trained. This is in itself in the production of masonry elements with the well-known manufacturing plant not possible.

DE 1 036 740 B describes a mold with a mold recess body known for the production of wall elements made of concrete, the two sheet metal profiles includes which define a cavity. The lower sheet profile lies with its bottom plate on the bottom plate of a molding box, while the cover plate of the upper sheet metal profile one when compacting the concrete material retracting ram touches. Between the two plates extend compression springs that when lifting the ram Push the upper sheet profile back into its starting position before loading. Due to the relatively complicated structure, such a shape-cutting body is not for the economical production of any wall element elevation forms or of recesses with special dimensions in Suitable for wall elements.

From FR 66710 E there are cut-out bodies for the production of insulating plates known. The cavity body consist of a relative stiff material such as B. metal and can from individual standard elements be put together.

The invention is therefore based on the object of a method for Manufacture of wall elements on a production line with an essential cuboid, open-topped mold box indicate that a high degree of flexibility with regard to dimensioning and shaping of the wall elements thus made possible.

This object is achieved by a method with those specified in claim 1 Process steps solved. The crux of the invention is Use of recess bodies made of an elastically compressible Material in the molding box, this molding recess body Have the shape of a straight prism with a height in the unloaded state, which corresponds to the height of the molding box. With the help of this mold cavity can usually be a cuboid within the Basic shape-containing mold box a practically any tear-open shape of the wall element can be reached. So through in their Base area triangular shape recess body bevels on the wall element are generated, such as in the gable area of an outer wall of a building wall element to be placed are necessary.

Surprisingly, it has now developed in the course of the invention emphasized that despite the elastically compressible shape-saving body its simplicity very well suited for the purpose of the invention are. Indeed, it was found that the body acted upon it through the press ram and the associated compression survive on the order of about 10% of their height without damage. This essentially takes place only in the printing direction of the press ram directional compression of the cavity body instead of rectangular either the molding box itself has a rigid boundary surface for form the surfaces of the mold recess bodies lying thereon or that adjoining the corresponding molding surface of the molding recess body Concrete material due to the pressurization by the Press stamp builds up a corresponding back pressure, which bulges the form recess body practically transverse to the pressing direction of the ram completely prevented.

In this respect, the shaped surfaces of the recess bodies remain despite them Flexibility and compressibility.

Furthermore, the use of the compressible form recess body has an effect also in connection with the demolding of the compressed wall element cheap. Expand when relieving the mold recess body these again, so that their adjoining the concrete material Carry out a form shift to the concrete material. This prevents the concrete material from adhering to the mold surfaces of the mold recess body effectively prevented. The latter can do a lot can be easily removed without affecting the surface quality of the wall element affect.

In the subclaims 2 to 5 are advantageous developments of the invention Procedure specified. So in a manufacturing cycle Several wall elements are produced in a molding box at the same time are created by using separate mold spaces be trained in the molding box. The form recess body thus form Subdivisions in the molding box.

It can be advantageous for shape-cutting bodies with a limited base area be the mold recess body on the inside of the mold box - e.g. on the floor or in the lower area of the side wall - preferably to be fixed by a detachable adhesive. This prevents that the cavity body during the filling process of Mold box with concrete material is crazy or falls over.

Furthermore, it is advantageous in the context of the method according to the invention to use a set of basic cavity bodies which e.g. dimensioned according to regularly recurring components in house construction and shaped. As an example here are recess bodies for standardized door or window openings or for wall openings name in which ventilation fans are used. For the latter wall openings are required with a clear cross section of 20 cm x 20 cm. Accordingly, a shape recess body has Formation of such a wall passage this base area and one of the Mold box height corresponding height of 40 cm if a wall element should be manufactured with a standard thickness of 36 cm.

Fig. 1A bis F

schematische Vertikalschnitte durch eine Fertigungsanlage für Mauerelemente in nacheinanderfolgenden Schritten des erfindungsgemäßen Verfahrens,

Fig. 2 bis 4

schematische Vertikalschnitte durch die Fertigungsanlage mit unterschiedlichen Ausführungsformen von Formaussparungskörpern,

Fig. 5

eine schematische Draufsicht auf einen befüllten Formkasten mit eingesetzten Formaussparungskörpern,

Fig 6

einen schematischen Vertikalschnitt durch eine Fertigungsanlage mit einen Formaussparungskörper in einer weiteren Ausführungsform.

The claim 6 characterizes a manufacturing plant for wall elements made of concrete or the like building material for performing the method according to one of the claims discussed above. Advantageous refinements of this production system can be found in subclaims 7 to 11. In order to avoid repetition, reference is made to the explanation of this production system in the following description, in which exemplary embodiments of the method according to the invention and the production system used for this are explained in more detail with reference to the accompanying drawings. Show it

1A to F

schematic vertical sections through a production plant for wall elements in successive steps of the method according to the invention,

2 to 4

schematic vertical sections through the production plant with different embodiments of shape-cutting bodies,

Fig. 5

1 shows a schematic top view of a filled molding box with inserted molding recess bodies,

Fig. 6

a schematic vertical section through a manufacturing plant with a shape-saving body in a further embodiment.

The manufacturing plant shown in FIGS. 1A to E has an open top Molding box 1, which consists of a base plate 2 and four vertical Side walls 3, 4, 5, 6 (see also Fig. 5) is composed. The four Side walls 3 to 6 are rigidly connected to one another in a frame-like manner via a lifting device, not shown, from the underlay sheet 2 can be lifted off.

For filling the molding box 1 with concrete material with the side walls lowered 3 to 6, a filling device 7 is provided, which with respect 1A to C the starting position of the molding box 1 shown laterally is arranged above the same. It has a fixed base plate 8 on, aligned in the vertical direction with the upper edge 9 of the Shaped box 1 is arranged. Furthermore, the filling device 7 has a open at the bottom, funnel-shaped filling box 10, of above by a conveyor with concrete material, not shown can be filled. The concrete material is on a conventional concrete mixing plant done.

The filling box is for introducing the concrete material into the molding box 1 10 can be moved back and forth in the horizontal direction over the molding box 1, whereby the concrete material through the lower filling opening 11 of the filling box 10 can fall into the mold box 1. The width of the fill opening 11 corresponds to the width b (see FIG. 5) of the molding box 1, the extent the back and forth movement depends on its length 1.

In order to be able to produce relatively large wall elements, the is Length 1 of the molding box 1 for example 2 m, its width b e.g. 1 m and the height h 40 cm. The height direction of the molding box 1 corresponds to remaining the thickness direction of the wall element produced therein, so that with a molded box a height of 40 cm due to the still to be explained Compacting the concrete material with a wall element Standard thickness of 36.5 cm can be produced.

In order to be able to produce wall elements that differ from the rectangular ones The basic shape and basic dimensions of the molding box 1 are different according to the method of the present invention, the recess body 12 made of an elastically compressible material, e.g. polystyrene foam inserted into the empty molding box 1. This shape recess body 12 basically have the shape of a straight prism with a height H on, which corresponds to the height h of the molding box 1. In the shown in Fig. 1 In the exemplary embodiment, the shape recess body 12 has the basic shape a right-angled triangle, and is - as in the circled detail view 1A - at one end of the molding box 1 used so that its practically from the hypotenuse of the base Formed surface 13, the formation of a wall element with a sloping side surface allows. This side surface can e.g. form part of the end of a gable wall on the aisle side.

The description of the actual manufacturing plant is still relevant to add that a press ram 14 is provided above the molding box 1 is, via a hydraulic drive device, not shown can be lowered down into the molding box 1. Accordingly, the Press ram 14 on a base that the clear base of Molding box 1 corresponds, that is, in the present case, just under 2 m x 1 m is.

The sequence of the method according to the invention is to be discussed as follows:

After the individual preparation of the molding box 1 by inserting the or the shape-cutting body 12 desired in each case is the one with concrete material filled filling box 10 moved over the molding box 1, so that the concrete material 15 in the molding box 1 remaining free 16 is filled (Fig. 1A). By trailing edge 17 of Filling opening 11 of the filling box 10 becomes the surface of the concrete material 15 smoothed out, so that the molding space 16 completely and cleanly with concrete material 15 is filled (Fig. 1B).

The ram 14 is then lowered (arrows 18 in 1C) and thus moves into the molding box 1. This will make the concrete material 15 compresses and at the same time the shape recess body 12 compressed in the vertical direction. The compression of the concrete material 15 can additionally be supported by a vibration excitation of the molding box 1 become. For this purpose, the washer 2 is on a not shown Vibrating device stored.

Regarding the compression process, it should be noted that the shape-saving body 12 only compressed in the vertical direction, but not in bulges in the horizontal direction, since that prevailing in the concrete material 15 Compaction pressure counteracts such a bulging tendency. Despite the The elasticity of the mold recess body 12 thus remains the mold surface 13 just.

In the shut down state of the ram 14, the the side walls 3 to 6 forming frame of the molding box 1 with the help of Lifting device, not shown, to a level above the ram 14 lifted up (arrows 19 in Fig. 1D). This will make it wall element 20 formed from the concrete material 15 and the shape-saving body 12 laterally removed.

As shown in FIG. 1E, the press ram 14 is also subsequently together with the frame part of the side walls 3 to 6 further up lifted off (arrows 19, 21). As a result, the shape recess body 12 relieves and expands vertically to its original Shape. So he stands above the wall element 20 upwards, as in 1E is shown. The shape cutout body 12 can now removed (arrow 22) and the wall element 20 on the washer 2 to completely hardened away (Fig. 1F).

It should be noted that as a manufacturing facility also fundamentally a system according to DE 44 08 845 A1 can be used, in which one Side wall (e.g. side wall 3) is designed to be variably displaceable. In Leave connection with the method according to the invention shown here then very different with a set of fewer mold recess bodies 12 Achieve designs of wall elements.

As is clear from FIGS. 2 to 4, shape cutout bodies 12 be designed as a full body (Fig. 2). The one shown in Fig. 3 An embodiment of the invention is that designated as a whole by 12 ' Molding recess body in a vertical plane in two part bodies 23, 24 shared. 4, the shape recess body 12 " divided into two partial bodies 25, 26 in a horizontal plane. This embodiment is beneficial if a complete removal of the cavity body 12 "is difficult.

Fig. 5 makes the high variability for the shape of the with the invention Method of producing wall elements 20 ', 20 "on one obvious example clearly.

So by using different, individually shaped and specific Cut-out body cut out of a block of polystyrene foam 12, as shown in Fig. 5 in their design and arrangement are in a manufacturing cycle in a molding box 1 Forming separate mold spaces with the help of these mold recess bodies 12 two wall elements 20 ', 20 "(or more thereof) produced simultaneously become. The wall element 20 'is additionally a small one Wall opening 27 with the aid of the shape cutout body 12 located there provided that without the inventive method in a complex manner should be sawn out of the wall element 20 '. This wall opening 27 is used, for example, to insert a fan for the motor Ventilation of a bathroom.

The shape cutout body 12 can also have partially round basic shapes have, as shown in Fig. 5 below. The one in the wall element 20 "round arch formed by the corresponding shape recess body 12 28 can for example in the installed state of the wall element 20 " form the lintel of an arched window.

5, it should also be noted that, for example, the two cavity body 12 at the wall opening 27 and the Round arch 28 on the underlay sheet 2 by means of a releasable adhesive connection are attached. This will cause this to fall over with a relatively small one Stand-provided mold recess body 12 when filling the mold box 1 avoided with concrete material.

6 shows a further alternative embodiment for a shape recess body 12 shown. The latter is in with a rigid substructure Form of a box 29 open at the top, in which an elastically compressible Partial body 30 is inserted. Box 29 is for example through four vertical sheet metal walls arranged in a plan view in a rectangular shape 6, three walls 31, 32, 33 of which are visible in FIG. The height H 'of the box 29 corresponds to the thickness d of the to be manufactured Wall element 20. Halfway up the box 29 is between the Sheet metal walls 31, 32, 33 welded an intermediate floor 34 on which the cuboidal, elastically compressible partial body 30 sits. Its top 35 is aligned in the unloaded state with the upper edge 9 of the Molding box 1.

During the compression process analogous to FIG. 1C, the press ram 14 now moves in the molding box 1 until it ends with the upper edges 36 of the box 29.

The advantage of this type of cavity bodies is that the difference in height during compaction is evened out during the compaction process however, a clean end edge to the wall element 20 is obtained since practically the entire mold surface 13 of the mold recess body 12 consists of sheet metal. The part of the made of polystyrene foam Partial body 30, which is the degree of compaction of the concrete material 15th must compensate, is compressed to the height of the box 29.

Claims (11)

1. A method for the manufacture of wall elements from concrete or similar building material with variable dimensioning and/or shaping on a manufacturing plant that has an upwards open molding box (1), comprising the following steps:

   inserting, in the molding box (1), at least one mold-cavity body (12, 12', 12") of flexibly compressible material, with the at least one mold-cavity body (12, 12', 12"), when not loaded, having the shape of a straight prism of a height (H) that corresponds to the height (h) of the molding box (1);

   filling the remaining mold space (16) of the molding box (1) with concrete (15);

   compacting the concrete (15) by insertion, from above into the molding box (1), of a molding plug (14) the working face of which corresponds to the basal surface of the molding box (1), this being accompanied with simultaneous compression of the at least one mold-cavity body (12, 12', 12");

   removing the side walls (3, 4, 5, 6) of the molding box (1);

   lifting the molding plug (14) upwards with simultaneous relief of the at least one mold-cavity body (12, 12', 12");

   removing the at least one mold-cavity body (12, 12', 12"); and

   curing the wall element (20, 20', 20").
2. A method according to claim 1, characterized in that several wall elements (20', 20") are simultaneously manufactured during a manufacturing cycle in a molding box (1) by separate molding spaces (16, 16') being formed by the aid of mold-cavity bodies (12).
3. A method according to claim 1 or 2, characterized in that the at least one mold-cavity body (12, 12', 12") is fixed to the inside of the molding box (1).
4. A method according to claim 3, characterized in that the at least one mold-cavity body (12, 12', 12") is fixed to the inner wall of the molding box (1) by detachable gluing.
5. A method according to one of claims 1 to 4, characterized in that mold-cavity bodies (12, 12', 12") are used from a set of base mold-cavity bodies that are dimensioned and shaped, preferably conforming to building elements as regularly and repeatedly occurring in house building.
6. A manufacturing plant for wall elements from concrete or similar building material for putting into practice the method according to one of claims 1 to 5, comprising

   an upwards open molding box (1) with a bottom (8) and vertical side walls (3, 4, 5, 6);

   a charging tray (7) for charging the molding box (1) with concrete (15); and

   a molding plug (14) that is lowered from above into the molding box (1), compacting the charged concrete (15) into wall elements (20, 20', 20");

   characterized by
   at least one mold-cavity body (12, 12', 12") of flexibly compressible material, which is insertable into the molding box (1) and which, when not loaded, has the shape of a straight prism of a height (H) that corresponds to the height (h) of the molding box (1).
7. A manufacturing plant according to claim 6, characterized in that the at least one mold-cavity body (12, 12', 12") is divided along a vertical plane.
8. A manufacturing plant according to claim 6, characterized in that the at least one mold-cavity body (12, 12', 12") is divided along a horizontal plane.
9. A manufacturing plant according to one of claims 6 to 8, characterized in that the entire mold-cavity body (12) consists of flexibly compressible material, preferably polystyrene foam.
10. A manufacturing plant according to claim 6, characterized in that the at least one mold-cavity body (12) has a rigid substructure (29) with a flexibly compressible partial body (30) placed thereon.
11. A manufacturing plant according to claim 10, characterized in that the substructure has the shape of an upwards open box (29), the height of which corresponds to the thickness (d) of the wall element and in the upward opening of which is disposed the partial body (30) that, when not loaded, projects above the box.

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