EP1590141A1 - Mould having flexible sidewalls with support members for moulding building products - Google Patents

Mould having flexible sidewalls with support members for moulding building products

Info

Publication number
EP1590141A1
EP1590141A1 EP03815121A EP03815121A EP1590141A1 EP 1590141 A1 EP1590141 A1 EP 1590141A1 EP 03815121 A EP03815121 A EP 03815121A EP 03815121 A EP03815121 A EP 03815121A EP 1590141 A1 EP1590141 A1 EP 1590141A1
Authority
EP
European Patent Office
Prior art keywords
mould
side wall
mould according
support members
ofthe
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03815121A
Other languages
German (de)
French (fr)
Inventor
Brian Jones
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Numold (UK) Ltd
Original Assignee
Numold (UK) Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from GB0300660A external-priority patent/GB0300660D0/en
Application filed by Numold (UK) Ltd filed Critical Numold (UK) Ltd
Publication of EP1590141A1 publication Critical patent/EP1590141A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/0002Auxiliary parts or elements of the mould
    • B28B7/0014Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/06Moulds with flexible parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/10Moulds with means incorporated therein, or carried thereby, for ejecting or detaching the moulded article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/36Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/44Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/48Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
    • B29C33/50Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/0064Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/20Moulds for making shaped articles with undercut recesses, e.g. dovetails
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/36Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • B28B7/364Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber

Definitions

  • This invention relates to a mould and in particular to a mould suitable for use
  • blocks produced using the mould could be used in, for example, walling or cladding,
  • mould This may be achieved by using a vacuum support device to support the
  • the flexibility of the side wall is such as to permit deflection thereof to allow
  • the bracing arrangement may comprise a plurality of support members
  • mould is designed to produce moulded products having undercut or textured side
  • An upper lip may be provided around part or all of the side wall, the support
  • the support members being braced between the lip and the side wall.
  • the support members are
  • the support members may be generally vertically extending, but
  • the support members extend at an angle to the vertical, and are spaced apart from one another.
  • the support members extend at an angle to the vertical, and are spaced apart from one another.
  • bracing members may be provided, the bracing members extending between the support members.
  • the bracing members may also engage the sidewall and/or the lip, where provided.
  • the mould of the invention may be used either in a free-standing, self-
  • a carrier for example in the form of a steel
  • the mould is of the self-supporting type, it may still be used on a tray
  • the fixing means may comprise, for example, adhesive or a fixing
  • the fixing device may comprise, for example, a large headed
  • the fixing means may be of one or more of the types mentioned above.
  • the mould may include an integral lip or flange
  • the lip or flange may be provided close to or at
  • the top of the mould but in a currently preferred embodiment is located coplanar
  • the support members are
  • mould side wall is of generally uniform thickness, it will be appreciated that the
  • the dimensions of the support members may also vary.
  • arrangement includes one or more support members spaced from the upstanding
  • the mould may include an outwardly extending flange
  • the support member co-operating with the flange to enhance the rigidity of the mould whilst retaining the
  • the support member may overlie a part of the base of
  • the mould and be used in securing the base of the mould to, for example, a carrier
  • mould for use in the manufacture of a building product, and anchorage means to
  • the anchorage means may take the form of adhesive or a mechanical fixing
  • means may alternatively, or additionally, include an arrangement for securing the
  • lip or flange for example a clamping device.
  • the invention also relates to a method of removing a moulded product from
  • a flexible mould comprising anchoring the mould in such a manner as to allow the
  • Figure 1 is a perspective view of a mould in accordance with an embodiment
  • Figure 2 is a perspective view illustrating an alternative embodiment
  • Figure 7 is a plan view of an alternative embodiment
  • Figure 8 is a sectional view illustrating the arrangement of Figure 7;
  • Figure 9 illustrates a vacuum demould station
  • Figure 10 is a perspective view illustrating a further alternative embodiment
  • Figures 11 to 16 are side and sectional views illustrating other alternative
  • Figure 1 illustrates a mould 10 of a flexible, rubber-like material intended for
  • the mould 10 may be of a
  • the mould 10 comprises a bottom wall 12 from the
  • the mould 10 is intended for use
  • the side wall 14 may be shaped to form
  • a texture or pattern to the sides of the paving stone may be shaped to include at least one region which, in the cast paving stone, is of undercut form.
  • paving stone may be of undercut form around substantially all of its periphery if
  • Each support member takes the form of a rib, which is
  • each rib 18 is moulded integrally with the side wall 14. In the arrangement illustrated, each rib 18
  • each rib 18 is also integrally formed with the lip 16, the lower end of each rib 18 being
  • the mould 10 is positioned upon a tray 10 consisting
  • the purpose of the tray is to
  • moulds one-upon-another, for example whilst containing concrete or a similar
  • the members 24 are spaced from the side wall
  • the mould 10 is secured to the tray 20. This may be achieved by using
  • the mould 10 may be secured to the tray
  • one or more mechanical fixing means may be used.
  • the mould may then be subject to vibrations or the like to cause the material to
  • the mould 10 is then moved with the tray 20 for storage until such time
  • trays 20 associated with a number of moulds 10 may be stacked upon one another
  • the tray 20 is moved to a station in
  • supporting device can be used to move the paving stone to a suitable storage
  • the vacuum supporting device can then be operated to release the paving
  • the strengthening ribs 18 are designed to provide sufficient rigidity to the
  • undercut regions of the cast paving stone can be removed from the mount without
  • the spacing of the ribs 18 may be uniform around the mould 10 or, as illustrated, the spacing of the ribs 18 may be irregular, an
  • FIG. 2 illustrates a mould 30 similar to the mould 10 illustrated in Figure 1
  • the mould 10 of Figure 1 is that in the arrangement illustrated in Figure 1, the ribs
  • braces 40 are inter-connected by a series of cross braces 40. The provision of such braces
  • FIG. 3 illustrates an arrangement similar to that of Figure 2, but in which
  • braces 40 are replaced by curved brace members 42, the function of which is to enhance the rigidity of the side wall of the mould whilst mamtaining a sufficient
  • Figures 4 and 5 illustrate a further alternative in which the ribs 18 are shaped
  • edges 44 furthest from the side wall 34 are of concave arcuate forms
  • the paving stone may be at least partially automated.
  • FIG. 6 illustrates another alternative in which the ribs 38 take the form of
  • hollow tubes Although shown as being arranged to extend generally vertically in
  • tubes is thought to be advantageous in that the tubes may partially collapse or compress under stress, for example whilst the moulded product is being removed
  • FIGS 7 and 8 illustrate the application of the invention to an alternative
  • Trie technique involves the use of a mould 50 of relatively low
  • the mould 50 comprises a bottom wall 52 from the periphery of
  • the mould 50 is used in conjunction with a supporting frame in the form of a steel
  • the side wall 54 of the mould 50 is of relatively low
  • the mould 50 is intended for
  • each rib 60 is formed on the mould 50.
  • Each rib 60 is formed on the mould 50.
  • each rib 60 serves as a support member to increase the strength of the side wall 54, each rib 60 extending generally vertically and being formed integrally both with the side wall
  • each rib 60 is chosen such that each rib 60
  • the ribs 60 serve to increase the rigidity of the
  • the mould 50 is preferably
  • Figure 7 illustrates suitable locations 62 for the application of adhesive between the
  • a mechanical fixing device 64 in the form of a large headed bolt may be used.
  • the material to be cast is
  • the mould is moved to a station in which the product is removed
  • Figure 9 show the carrier 58 secured in position in a vacuum demould station.
  • An additional flange 66 conveniently in the form of a frame forming part of the
  • vacuum demould station equipment is used to clamp the lip 56 to the carrier 58.
  • vacuum suction unit 68 is used to lift the moulded product. As the product is lifted,
  • the mould is secured or anchored, using the adhesive, fixing device and flange 66,
  • ribs 70 each of which is angled to the vertical.
  • the ribs 70 are each angled to the vertical.
  • each rib is
  • ribs 70 are all angled by approximately the same amount to the vertical, but the
  • Each rib 70 forms a generally V-shaped, shallow groove 72
  • V-shaped groove includes a limb which, when viewed
  • each groove extends over the full height ofthe associated rib
  • each rib 70 is of tapering thickness, tapering from a maximum thickness, of around 5mm adjacent the side wall 74 ofthe mould to a minimum thickness of around 3mm
  • the mould is provided with an outwardly extending flange 76 which lies in
  • the flange 76 is arranged such that, in use, as shown
  • clamping member 84 may be clamped to the tray 82, the flange 76 being trapped
  • clamping member 84 may take the form of a plywood or similar member that can
  • mould may be supplied either free-standing or mounted upon a carrier and Figures 13 and 14 illustrate, respectively, the mounting of a free-standing mould and
  • thickness 40 to 50mm and constructed of, for example, timber or a composite
  • tray or pallet using, for example, nails or screws.
  • moulded ribs to enhance the rigidity of the side walls of the moulds.
  • the wall 90 includes an outwardly projecting flange 94.
  • the side wall 92 includes, at
  • Strengthening ribs 98 may
  • a sfrengthening member 100 is provided to brace the flange 96 against the
  • a cavity 102 is
  • the strengthening member 100 takes the form of a length of
  • Figure 16 illustrates the use of a length of angle iron as the sfrengthening member
  • mould is intended for use in the manufacture of a paving stone having a
  • the outer surface ofthe side wall will not be flat
  • any ribs or bracing members will also be shaped to comply with the shaping of
  • Another advantage is that the flexibility ofthe mould may be enhanced.
  • the ribs may be of modified
  • mould has a generally corrugated appearance, if desired.
  • the invention is, in
  • mould as typically occurs in the moulding process.
  • the invention may also be used in the manufacture of for example
  • moulded building products for example roofing tiles, floor tiles, and
  • bricks or blocks for use in walling or cladding including decorative bricks and

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)

Abstract

A mould suitable for use in the manufacture of a molded building product comprises a bottom wall (12) and an upstanding side wall (14), the upstanding side wall (14) being flexible so as to permit deflection thereof to allow removal of a set molded product from the mould, and a plurality of support members (18) secured to the upstanding wall (14) to increase the rigidity of the side wall (14).

Description

MOULD HAVING FELXIBLE SIDEWALLS WITH SUPPORT MEMBERS FOR MOULDING BUILDING
PRODUCTS
This invention relates to a mould and in particular to a mould suitable for use
in the moulding of concrete or similar material to form building products or the like,
for example in the form of paving stones, tiles, bricks or blocks. The bricks or
blocks produced using the mould could be used in, for example, walling or cladding,
but it will be appreciated that they may be used in other applications.
It is increasingly desirable to be able to automate the process for
manufacturing moulded building materials. One area in which automation has been
reasonably successful is in the removal of the moulded product, once set, from its
mould. This may be achieved by using a vacuum support device to support the
moulded product and to lift the product out of its mould. This technique has been
found to be successful when used in conjunction with rigid moulds. Although this
technique may be suitable for use in the manufacture of paving stones having
sloping side walls or side walls perpendicular to the front or top face of the stone,
automated removal of a rigid mount from a product having undercut side walls has
not been possible without damaging or destroying the mould or the product.
According to the present invention there is provided a mould suitable for use
in the manufacture of a moulded building product comprising a bottom wall and a
flexible upstanding side wall, and a bracing arrangement to enhance the rigidity of the side wall.
The flexibility of the side wall is such as to permit deflection thereof to allow
removal of a set moulded product from the mould.
The bracing arrangement may comprise a plurality of support members
secured to the upstanding wall to increase the rigidity of the side wall.
Such an arrangement is advantageous in that the mould can be designed to be
sufficiently rigid to withstand the side loads applied thereto by the material to the
cast, before the material sets, and to withstand any other side loads which are
applied during the moulding process, but sufficiently flexible to allow the mould to
be used in, for example an automated vacuum demould operation even where the
mould is designed to produce moulded products having undercut or textured side
walls.
An upper lip may be provided around part or all of the side wall, the support
members being braced between the lip and the side wall. The support members are
preferably integral with the lip and the side wall. Such an arrangement enhances the
ability of the mould to withstand the application of side loads, whilst retaining a
sufficient degree of flexibility.
The support members may be generally vertically extending, but
arrangements are also possible in which the support members extend at an angle to the vertical, and are spaced apart from one another. By way of example, in one
currently preferred embodiment the support members are arranged at an angle of
between about 15° and 25°, preferably about 20°, to the vertical. It will be
appreciated, however, that other angles may be used. Additional bracing members
may be provided, the bracing members extending between the support members.
The bracing members may also engage the sidewall and/or the lip, where provided.
The mould of the invention may be used either in a free-standing, self-
supporting moulding technique, or in a technique in which additional support is
given to the side wall of the mould by a carrier, for example in the form of a steel
or timber carrier tray.
Where the mould is of the self-supporting type, it may still be used on a tray
or support to allow a number of moulds to be stacked upon one another. In such
circumstances, fixing means are conveniently provided to secure the mould to the
tray or support. The fixing means may comprise, for example, adhesive or a fixing
device moulded into the bottom wall or otherwise attached to the bottom wall or the
lower face thereof. The fixing device may comprise, for example, a large headed
fixing stud. If desired several such devices may be used. Other possibilities include
incorporating a mesh provided with one or more fixing studs into the bottom wall
or bonding a base plate to the bottom wall during the manufacture of the mould. Where the mould is to be used as a liner for a tray, again fixing means may
be used. The fixing means may be of one or more of the types mentioned above.
Additionally, or alternatively, the mould may include an integral lip or flange
projecting outwardly therefrom and intended to be clamped to the tray to secure the
periphery of the mould to the tray. The lip or flange may be provided close to or at
the top of the mould, but in a currently preferred embodiment is located coplanar
with the base of the mould. When used as a liner, the support members are
preferably designed so as to engage the side walls of the tray to provide the desired
degree of rigidity to the side wall of the mould. Where the mould is used in the
manufacture of a product having a patterned or textured surface, and where the
mould side wall is of generally uniform thickness, it will be appreciated that the
spacing of the mould side wall from the side wall of the tray may not be uniform and
so the dimensions of the support members may also vary.
In the arrangements mentioned hereinbefore, the bracing arrangement
includes a plurality of support members secured to the upstanding wall. However
this need not be the case and arrangements are envisaged in which the bracing
arrangement includes one or more support members spaced from the upstanding
wall. By way of example, the mould may include an outwardly extending flange
secured to or integral with an upper part of the upstanding wall, the support member co-operating with the flange to enhance the rigidity of the mould whilst retaining the
desired degree of flexibility. The support member may overlie a part of the base of
the mould and be used in securing the base of the mould to, for example, a carrier
tray.
According to another aspect of the invention there is provided a flexible
mould for use in the manufacture of a building product, and anchorage means to
permit the mould to be anchored, to allow the mould to flex whilst a moulded
product is pulled therefrom.
The anchorage means may take the form of adhesive or a mechanical fixing
device, for example of the type referred to hereinbefore, securing the mould to a
carrier member. Where the mould includes a peripheral lip or flange, the anchorage
means may alternatively, or additionally, include an arrangement for securing the
lip or flange, for example a clamping device.
The invention also relates to a method of removing a moulded product from
a flexible mould comprising anchoring the mould in such a manner as to allow the
side wall thereof to flex, supporting the moulded product, and pulling the moulded
product from the mould.
The invention will further be described, by way of example, with reference
to the accompanying drawings, in which: Figure 1 is a perspective view of a mould in accordance with an embodiment
of the invention;
Figure 2 is a perspective view illustrating an alternative embodiment;
Figures 3 to 6 illustrate modifications to the arrangement of Figure 2;
Figure 7 is a plan view of an alternative embodiment;
Figure 8 is a sectional view illustrating the arrangement of Figure 7;
Figure 9 illustrates a vacuum demould station;
Figure 10 is a perspective view illustrating a further alternative embodiment;
and
Figures 11 to 16 are side and sectional views illustrating other alternative
arrangements.
Figure 1 illustrates a mould 10 of a flexible, rubber-like material intended for
use in the casting of paving stones. For example, the mould 10 may be of a
polyurethane material. The mould 10 comprises a bottom wall 12 from the
periphery of which a side wall 14 extends. The upstanding sidewall 14 terminates
at an upper lip or flange 16. As shown in Figure 1, the mould 10 is intended for use
in the manufacture of a paving stone of irregular shape although this need not be the
case. Although not clear from the drawings, the side wall 14 may be shaped to form
a texture or pattern to the sides of the paving stone and may be shaped to include at least one region which, in the cast paving stone, is of undercut form. Indeed, the
paving stone may be of undercut form around substantially all of its periphery if
desired, such features not being easy to provide using traditional moulds without
damaging or destroying the mould when removing the cast product therefrom.
On the outer surface of the mould 10, a plurality of sfreng ening support
members are formed. Each support member takes the form of a rib, which is
moulded integrally with the side wall 14. In the arrangement illustrated, each rib 18
is also integrally formed with the lip 16, the lower end of each rib 18 being
substantially co-planar with the lower surface of the bottom wall 12.
As shown in Figure 1, the mould 10 is positioned upon a tray 10 consisting
of a plywood base 22 and a pair of side members 24. The purpose of the tray is to
allow the mould 10 to be moved relatively easily and to allow stacking of a number
of moulds one-upon-another, for example whilst containing concrete or a similar
material before the material has set. The members 24 are spaced from the side wall
14 of the mould 10, thus it will be appreciated that the members 24 do not serve to
provide a stiffening function for the mould 10.
In use, the mould 10 is secured to the tray 20. This may be achieved by using
any suitable fixing means. For example, the mould 10 may be secured to the tray
20 using adhesive. Alternatively, or in addition to the use of adhesive, one or more mechanical fixing means may be used. One example of a suitable fixing means
takes the form of a large headed bolt 26, the head of which is moulded into the
bottom wall 12 of the mould 10 during the manufacture thereof, the threaded shank
of the bolt extending through an opening formed in the base member 22, a nut 26a
or the like then being secured to the threaded shank to secure the mould 10 to the
tray 20.
Although a specific example of a suitable mechanical fixing device has been
given, it will be appreciated that a number of alternative techniques may be used to
secure the mould 10 to the tray 20, and the invention encompasses the use of any
such techniques and is not restricted to the specific arrangements described herein.
Further, arrangements are possible in which the mould 10 is not secured to the tray
20.
In use, concrete or a similar material is poured into the mould 10. If desired,
the mould may then be subject to vibrations or the like to cause the material to
spread evenly around the mould and to release, for example, air bubbles from the
material. The mould 10 is then moved with the tray 20 for storage until such time
as the concrete or other material has set. As briefly mentioned hereinbefore, the
trays 20 associated with a number of moulds 10 may be stacked upon one another
to facilitate the manufacture and storage of a number of paving stones in a relatively small area.
Once it has been determined that the concrete or other material used in the
manufacture of the paving stone has set, then the tray 20 is moved to a station in
which the moulded paving stone is to be removed. One suitable at least partially
automated technique for use in the removal of the moulded paving stone is to
support the moulded paving stone using a vacuum supporting device. The paving
stone is then lifted away from the tray 20 and mould 10 to remove the stone from
the mould. Once the paving stone has been removed from the mould, the vacuum
supporting device can be used to move the paving stone to a suitable storage
location. The vacuum supporting device can then be operated to release the paving
stone ready for use in the removal of the stone from another mould.
The strengthening ribs 18 are designed to provide sufficient rigidity to the
side wall 14 to enable the side wall 14 to withstand the side loads which are applied
thereto by the concrete material prior to setting thereof, but to afford sufficient
flexibility to the side wall 14 to allow the side wall 14 to flex during the operation
of removing the moulded paving stone from the mould such that any protrusions or
undercut regions of the cast paving stone can be removed from the mount without
causing damage either to the paving stone or to the mould.
It will be appreciated that the spacing of the ribs 18 may be uniform around the mould 10 or, as illustrated, the spacing of the ribs 18 may be irregular, an
increased number of ribs 18 being provided in regions of the mould requiring a
greater degree of rigidity, fewer ribs 18 being required where a greater degree of
flexibility is required, for example in the operation to remove the paving stone from
the mould.
Figure 2 illustrates a mould 30 similar to the mould 10 illustrated in Figure 1
but designed for use in the manufacture of a paving stone of generally rectangular
form, but again including patterned or textured side walls and/or undercut regions.
Use of the mould 30 illustrated in Figure 2 is in a manner similar to that described
above in relation to Figure 1.
One important difference between the mould 30 illustrated in Figure 2 and
the mould 10 of Figure 1 is that in the arrangement illustrated in Figure 1, the ribs
38 are inter-connected by a series of cross braces 40. The provision of such braces
between the ribs 38 and which engage the side wall 34 further enhances the rigidity
of the side wall 34, but still allows sufficient flexibility thereof to allow the mould
30 to be used in the manufacture of paving stones having textured side walls or
undercut regions.
Figure 3 illustrates an arrangement similar to that of Figure 2, but in which
the braces 40 are replaced by curved brace members 42, the function of which is to enhance the rigidity of the side wall of the mould whilst mamtaining a sufficient
degree of flexibility
Figures 4 and 5 illustrate a further alternative in which the ribs 18 are shaped
such that the edges 44 furthest from the side wall 34 are of concave arcuate forms
as shown in Figure 5. As with the arrangements described hereinbefore, it is thought
that the provision of ribs 38 of the form illustrated in Figure 5 can be used to provide
a sufficiently good stiffness or rigidity to the side walls 34 during moulding to
withstand the side loads applied by the concrete material prior to setting thereof and
resulting from any vibrations which may be applied to the mould during the
moulding process whilst remaining sufficiently flexible to allow the side wall to
deflect when the moulded product is being removed, thereby permitting relatively
easy removal of the mould from the cast paving stone without causing damage to the
mould or the paving stone. In particular, the operation of removal of the mould from
the paving stone may be at least partially automated.
Figure 6 illustrates another alternative in which the ribs 38 take the form of
hollow tubes. Although shown as being arranged to extend generally vertically in
the arrangement of Figure 6, this need not be the case and arrangements are possible
in which the ribs or tubes extend at an angle to the vertical. The provision of hollow
tubes is thought to be advantageous in that the tubes may partially collapse or compress under stress, for example whilst the moulded product is being removed
from the mould.
Figures 7 and 8 illustrate the application of the invention to an alternative
moulding technique. Trie technique involves the use of a mould 50 of relatively low
wall thickness. The mould 50 comprises a bottom wall 52 from the periphery of
which a side wall 54 upstands, the side wall 54 having at its upper edge, a lip 56.
The mould 50 is used in conjunction with a supporting frame in the form of a steel
or timber carrier 58.
As shown in Figure 7, the side wall 54 of the mould 50 is of relatively low,
generally uniform thickness. In the example illustrated, the mould 50 is intended for
use in the manufacture of paving stone of generally square or rectangular shape.
However, the side walls of the paving stone to be manufactured are not truly straight
but rather are of textured or patterned form and may form undercut regions in the
moulded product. As a result the side wall 54 of the mould 50 does not lie against
the side wall of the tray 58 but rather a space is formed therebetween. The space is
of irregular dimensions resulting from the desired shaping of the paving stone to be
manufactured, and the fact that the side wall is of generally uniform thickness.
As illustrated, a series of ribs 60 are formed on the mould 50. Each rib 60
serves as a support member to increase the strength of the side wall 54, each rib 60 extending generally vertically and being formed integrally both with the side wall
54 and the lip 56. The dimensions of each rib 60 are chosen such that each rib 60
engages the side wall of the tray 58, further enhancing the rigidity of the side wall.
As a result, it will be appreciated that the ribs 60 serve to increase the rigidity of the
side wall 54 of the mould 50 thereby ensuring that the mould 50 is of sufficient
rigidity to withstand the side loads applied to the side wall 54 thereof during the
mould process. However, the ribs 60 permit the side wall 54 of the mould 50 to
have sufficient flexibility to allow any protrusions or under cut regions of the cast
paving stone to be removed from the mould 50 using a vacuum demould system for
example of the type described hereinbefore without causing damage to the cast
paving stone or to the mould.
As with the arrangement described hereinbefore, the mould 50 is preferably
secured to the tray 58 prior to the application of concrete or another material to be
cast to the mould 50. The technique by which the mould 50 is secured to the tray
58 may be any of the techniques described herein. By way of illustration only,
Figure 7 illustrates suitable locations 62 for the application of adhesive between the
bottom wall 52 of the mould 50 and the tray 58. It further shows a location in which
a mechanical fixing device 64 in the form of a large headed bolt may be used.
However, it will be appreciated that other fixing techniques may be used in accordance with the invention, as mentioned herein.
After securing or anchoring the mould to the tray, the material to be cast is
introduced into the mould, vibrations applied, if desired, and the material allowed
to set. Once set, the mould is moved to a station in which the product is removed
from the mould. A suitable station is shown in Figure 9.
Figure 9 show the carrier 58 secured in position in a vacuum demould station.
An additional flange 66, conveniently in the form of a frame forming part of the
vacuum demould station equipment, is used to clamp the lip 56 to the carrier 58. A
vacuum suction unit 68 is used to lift the moulded product. As the product is lifted,
the edges of the mould will tend to lift with the product, and the manner in which
the mould is secured or anchored, using the adhesive, fixing device and flange 66,
results in the mould flexing away from the product allowing air to enter between the
mould and the product. Even where a release agent is used, cementitious mouldings
tend to adhere to polyurethane moulds, and the flexing ofthe mould away from the
product breaks such adhesion. Continued liftmg ofme product from the mould can
thus take place. The flexing ofthe side wall ofthe mould further ensures that any
relatively deep patterning or texture, and any undercut parts ofthe moulded product
are removed from the associated parts ofthe mould without damage either to the
mould or to the product. Figures 11 and 12 illustrate a modification to the arrangements described
hereinbefore in which the mould is provided with support members in the form of
ribs 70, each of which is angled to the vertical. The ribs 70 are each angled to the
vertical at an angle falling within the range 15° to 25°, and preferably each rib is
angled at about 20° to the vertical. It will be appreciated that this angle is not
critical, and that the invention applies to arrangements in which the ribs are not
angled, or the angling ofthe ribs falls outside of this range. In the illustrations, the
ribs 70 are all angled by approximately the same amount to the vertical, but the
degree of tilting ofthe ribs 70, and the direction in which the tilting occurs may vary
from that illustrated. Each rib 70 forms a generally V-shaped, shallow groove 72
which it is thought assists in providing the required degree of flexibility to the
mould. Although the illustrated arrangement makes use of a V-shaped groove, it is
thought that the shape ofthe groove is not critical. Figures 13 and 14 illustrate
arrangements in which the V-shaped groove includes a limb which, when viewed
in the manner illustrated in Figures 13 and 14, appears to extend vertically but, of
course, is tilted at approximately 20° to the vertical as shown in Figure 11.
Although as illustrated each groove extends over the full height ofthe associated rib,
arrangements are possible in which this is not the case. As shown in the drawings,
each rib 70 is of tapering thickness, tapering from a maximum thickness, of around 5mm adjacent the side wall 74 ofthe mould to a minimum thickness of around 3mm
remote from the side wall 74 ofthe mould.
The mould is provided with an outwardly extending flange 76 which lies in
the same plane as the base wall 78 ofthe mould, forming a continuation thereof. As
can be seen from Figure 12, the flange 76 projects beyond the lip 80 provided at the
upper periphery ofthe mould. The flange 76 is arranged such that, in use, as shown
in Figures 13 and 14, with the mould supported upon a suitable tray or pallet 82, a
clamping member 84 may be clamped to the tray 82, the flange 76 being trapped
therebetween thereby clamping the periphery of the mould to the tray 82. The
clamping member 84 may take the form of a plywood or similar member that can
be nailed, screwed, stapled or otherwise secured to the tray 82 to clamp the mould
thereto. It will be appreciated that, if desired, this securing technique may be used
in conjunction with any ofthe techniques described hereinbefore, and also that this
technique may be used in any ofthe arrangements described hereinbefore.
Although the arrangement illustrated in Figures 11 and 12 is of a free¬
standing, self-supporting mould carried, in use, by a tray, it will be appreciated that
the features thereof may be incorporated into a mould intended to be used on a tray
and in which the tray assists in supporting the side walls o the mould, in use. The
mould may be supplied either free-standing or mounted upon a carrier and Figures 13 and 14 illustrate, respectively, the mounting of a free-standing mould and
a mould pre-mounted upon a carrier to a relatively thick pallet, for example of
thickness 40 to 50mm and constructed of, for example, timber or a composite
construction. In the arrangement of Figure 14, the carrier would be secured to the
tray or pallet using, for example, nails or screws.
The arrangements describedhereinbefore make use of integrally or otherwise
moulded ribs to enhance the rigidity of the side walls of the moulds. It will be
appreciated, however, that this need not be the case. Figures 15 and 16 illustrate
parts of moulds, each comprising a bottom wall 90 and a side wall 92. The bottom
wall 90 includes an outwardly projecting flange 94. The side wall 92 includes, at
or near its upper edge, an outwardly extending flange 96. Strengthening ribs 98 may
or may not be provided, as desired.
A sfrengthening member 100 is provided to brace the flange 96 against the
flange 94, thereby enhancing the rigidity of the side wall 92. A cavity 102 is
provided between the strengthening member 10 and the side wall 92, allowing a
degree of flexing of the side wall 92 so as to permit the removal of a moulded
product from the mould.
In addition to serving to strengthen the side wall 92, the strengthening
member may further serve as a clamping member for use in clamping the mould to a carrier. In Figure 15, the strengthening member 100 takes the form of a length of
wood which can be screwed to a carrier 104, clamping the flange 94 therebetween.
Figure 16 illustrates the use of a length of angle iron as the sfrengthening member
100 which is bolted to the carrier 104, again clamping the flange 94.
In all ofthe arrangements described hereinbefore, the side wall ofthe mould
is preferably of generally uniform thickness. It will be appreciated, therefore, that
where the mould is intended for use in the manufacture of a paving stone having a
textured or patterned side wall, the outer surface ofthe side wall will not be flat,
thus any ribs or bracing members will also be shaped to comply with the shaping of
the side wall. One advantage of providing a side wall of generally uniform thickness
is that the quantity of material used in the manufacture of the mould is reduced.
Another advantage is that the flexibility ofthe mould may be enhanced.
It will be appreciated that the invention may be modified in a number of
ways. For example although the arrangements described hereinbefore make use of
the provision of a plurality of clearly identifiable ribs, the ribs may be of modified
cross-sectional shape with the result that the outer surface ofthe side wall ofthe
mould has a generally corrugated appearance, if desired. The invention is, in
essence, the provision of a mould with a relatively 1hin side wall to give the desired
degree of flexibility necessary to permit the removal of textured, patterned or undercut paving stones from the mould whilst providing means for enhancing the
rigidity of the mould by the provision of support members around the mould to
allow the mould to withstand the side loadings applied thereto during the moulding
process, for example as a result ofthe application of concrete or a sirnilar material
to the mould or resulting from the application of, for example, vibrations to the
mould as typically occurs in the moulding process. Although particularly beneficial
when used in the manufacture of paving stones having textured, patterned or
undercut regions, the invention may also be used in the manufacture of for example
straight-sided, unpatterned paving stones.
Although the description hereinbefore is of the use of the mould in the
manufacture of paving stones, it will be appreciated that the invention is not
restricted to the moulding of paving stones and may be used in the manufacture of
a range of moulded building products, for example roofing tiles, floor tiles, and
bricks or blocks for use in walling or cladding, including decorative bricks and
blocks, a mould for one of which is shown in Figure 10.

Claims

1. A mould suitable for use in the manufacture of a moulded building product
comprising a bottom wall and an upstanding side wall, the upstanding side wall
being flexible so as to permit deflection thereof to allow removal of a set moulded
product from the mould, and a bracing arrangement to enhance the rigidity ofthe
side wall.
2. A mould according to Claim 1, wherein the bracing arrangement comprises
a plurality of support members secured to the upstanding wall.
3. A mould according to Claim 2, further comprising an upper lip provided
around part or all ofthe side wall, the support members being braced between the
tip and the side wall.
4. A mould according to Claim 3, wherein the support members are integral
with the lip and the side wall.
5. A mould according to anyone of Claims 2 to 4, wherein the support members
are generally vertically extending.
6. A mould according to any of Claims 2 to 4, wherein the support members
extend at an angle to the vertical, and are spaced apart from one another.
7. A mould according to Claim 6, wherein the support members are angled to
the vertical by an angle of between about 15° and 25°.
8. A mould according to Claim 7, wherein the support members are angled to
the vertical at an angle of about 20°.
9. A mould according to any of Claims 1 to 8, further comprising additional
bracing members extending between the support members.
10. A mould according to anyone ofthe preceding claims, wherein the bracing
arrangement includes a strengthening member arranged to brace a flange associated
with an upper part ofthe side wall against a flange associated with the bottom wall.
11. A mould according to Claim 10, wherein a cavity is defined between the side
wall and the strengthening member.
12. A mould according to any ofthe preceding claims, further comprising fixing
means to secure the mould to a tray or support.
13. A mould according to Claim 12, wherein the fixing means comprises at least
one of a fixing device moulded into the bottom wall or otherwise attached to the
bottom wall or the lower face thereof, or an adhesive material.
14. A mould according to Claim 13, wherein the fixing device comprises a large
headed fixing stud.
15. A mould according to any of Claims 12 to 14, wherein the fixing means
includes an integral lip or flange projecting outwardly from the mould and intended
to be clamped to the tray to secure the periphery ofthe mould to the tray.
16. A mould according to Claim 15, wherein the Up or flange is provided co-
planar with the base ofthe mould.
17. A flexible mould for use in he manufacture of a building product, and
anchorage means to permit the mould to be anchored, to aUow the mould to flex
whilst a moulded product is puUed therefrom.
18. Amould accordingto Claim 17, wherein the anchorage means takes the form
of adhesive or at least one mechanical fixing device securing the mould to a carrier
member.
19. A mould according to Claim 17 or Claim 18, wherein the mould includes a
peripheral Up or flange, and the anchorage means includes an arrangement for
securing the Up or flange to a carrier member.
20. A mould substantially as hereinbefore described with reference to any one
ofthe accompanying drawings.
EP03815121A 2003-01-11 2003-11-24 Mould having flexible sidewalls with support members for moulding building products Withdrawn EP1590141A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
GB0300660A GB0300660D0 (en) 2003-01-11 2003-01-11 Mould
GB0300660 2003-01-11
GB0315038 2003-06-27
GB0315038A GB0315038D0 (en) 2003-01-11 2003-06-27 Mould
PCT/GB2003/005085 WO2004062866A1 (en) 2003-01-11 2003-11-24 Mould having flexible sidewalls with support members for moulding building products

Publications (1)

Publication Number Publication Date
EP1590141A1 true EP1590141A1 (en) 2005-11-02

Family

ID=29781630

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03815121A Withdrawn EP1590141A1 (en) 2003-01-11 2003-11-24 Mould having flexible sidewalls with support members for moulding building products

Country Status (4)

Country Link
EP (1) EP1590141A1 (en)
AU (1) AU2003303669A1 (en)
GB (1) GB2397270B (en)
WO (1) WO2004062866A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005018087B4 (en) * 2005-04-19 2008-12-18 Schindler Steinbearbeitungsmaschinen-Anlagentechnik Gmbh Casting mold pallet and plant for the production of cast concrete
EP2155455A2 (en) * 2007-05-18 2010-02-24 Newton Concrete Aps Amorphous formwork
ITMI20132011A1 (en) 2013-12-02 2015-06-03 Vh S R L MOLD FOR COVERING PRODUCTS FOR BUILDING AND PLANT FOR THE MANUFACTURE OF SUCH COVERING PRODUCTS
GB2573293A (en) * 2018-04-30 2019-11-06 Team Elite Ltd Method of casting a textured concrete walling slab

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BE519562A (en) *
GB599969A (en) * 1944-08-02 1948-03-25 Sncase Improvement in seaplanes with retractable stabilizer side-floats
GB679574A (en) * 1950-01-13 1952-09-17 Percy Burrows Steer A formwork or shuttering for use in the production of concrete structural members
US3520967A (en) * 1966-10-31 1970-07-21 George J Kreier Jr Method for making thin concrete panels
US3883109A (en) * 1967-10-06 1975-05-13 Pre Cast Concrete Products Lim Mold for making meter box covers and the like
GB1219011A (en) * 1968-02-09 1971-01-13 Easicast Rubber Moulds Ltd Mould and casting method
FR2199283A5 (en) * 1972-09-11 1974-04-05 Dynamit Nobel Ag Sheet thermoplastic mould box - for staircase treads of concrete or synthetic marble, can be reused and easily demoulded
FR2219633A5 (en) * 1973-02-23 1974-09-20 Sopreba
DE3712480A1 (en) * 1987-04-13 1988-11-03 Hoetzel Beton Gmbh DEVICE FOR PRODUCING AN ARTIFICIAL STONE
GB8718934D0 (en) * 1987-08-11 1987-09-16 Stockport Fencing Ltd Concrete posts
GB2229667A (en) * 1989-03-07 1990-10-03 Timothy John Richards Petal mould and moulding process
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See references of WO2004062866A1 *

Also Published As

Publication number Publication date
GB2397270A (en) 2004-07-21
WO2004062866A1 (en) 2004-07-29
GB2397270B (en) 2005-02-23
AU2003303669A1 (en) 2004-08-10
GB0327230D0 (en) 2003-12-24

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