EP1870217A2 - Method and mould for the manufacturing of floor slab of cementitious material resp. concrete - Google Patents

Abstract

The method involves placing face concrete and stone concrete in respective mold areas for manufacturing a floor slab (1) and grouting the concrete with a press stamp after placing the stone concrete. A press mold designed as a multiple mold with multiple individual molds is applied for simultaneous manufacturing of multiple slabs. Each individual mold is implemented at surfaces forming top side, boundary region and/or circumferential side (5) of the respective floor slab in a different manner.

Description

The invention relates to methods according to the preamble of claim 1 and to a mold according to the preamble of claim 5.

For the production of floor slabs from cementitious material, for example concrete, molds are known which consist of a mold and wear frame enclosing a mold space on the circumference and of a plate-shaped mold closure element (matrix) closing the mold space at the bottom, which e.g. made of hard rubber or a rubber-elastic plastic material. The mold frame is fastened, for example, in an opening of a first machine element of a molding press and the mold closure element in a recess of a second element of the molding press. To produce the plates are closed in the respective duch the mold closure element closed mold successively a intent and the top of the plate forming fine concrete, then forming a bottom of the plate coarse concrete and then compressed the header and the base by pressing with a stamp. After molding the respective plate blank, the mold for discharging this blank on the lower side is opened by moving away the mold element, and the blank is ejected downward.

It is also known, such prepared floor panels u.a after curing of the concrete. at the top as well as at the edge surrounding the top to edit.

It is also known, the production of concrete floor slabs with a profiling or side contour on the plate circumference, using a mold with a mold cavity enclosing a form and wear frame, which is profiled according to its inner surface of the side contour limiting the mold space. In this known method, a single concrete material is continuously used for the plates to be produced. Also does not take the form of a broken or rounded, the top enclosing edge.

The object of the invention is to provide a method and a form with which or in a rational manner the production of floor panels with intent and core with a visually appealing appearance is possible. To solve this problem, a method according to claim 1 and a mold, in particular mold according to claim 5 is executed.

For the purposes of the invention, "side contour" is to be understood as meaning a shape deviating from a plane surface of the peripheral sides of the base plates, preferably a curved or corrugated and in particular an irregularly curved or corrugated structure, preferably in the form that extends in any desired cross-sectional planes parallel to the top of the plate in each case the same circumferential course or the same peripheral structure results, d. H. Elevations and depressions formed by the side contour are oriented with their longitudinal extent perpendicular to the plane of the top of the plate and have a constant cross section in this axial direction.

The forming this side contour structuring on the respective shape space bounding inner surface of the forming and wear frame is then over the entire height of this frame, d. H. formed in the axial direction parallel to the frame axis continuously, in such a way that the respective shape space in any cutting planes perpendicular to the frame axis in each case has the same cross-section.

For the purposes of the invention, "structured plate top" is understood to mean a top surface which has a surface structuring formed by depressions and / or elevations or raised areas. For the purposes of the invention, "structured edge" is to be understood as a broken or rounded edge which, in plan view of the plate, has, for example, a rectilinear or essentially rectilinear or an irregular and / or a single or multiple curved course, at least in a partial region.

The peculiarity of the invention is that in each multiple mold in each case a plurality of bottom plates are produced simultaneously, with different side contour and / or with differently structured top plate, i. with different structuring on its upper side and on its edge bounding the upper side and / or on its peripheral side, so that after the laying of the plates a recurring and therefore visually disturbing appearance of the laid plate is avoided. Furthermore, it is possible to produce plates of the same size or different sizes in the respective multiple molds, again preferably with different structuring on their upper side and on their edge delimiting the upper side and / or on their peripheral side.

In a development of the invention, the method is, for example, also designed in such a way as
the pressing takes place in each case by means of a press ram which is adapted at its circumference to the surface of the associated individual molds forming the peripheral surface or the side contour of the respective bottom plate (1),
and or
in that a plurality of multiple molds are used on a turntable of a molding press, the individual molds corresponding to each other with respect to the position on the turntable being identical or substantially identical, at least with respect to the surfaces forming the side contour of the floor plates,
and or
that at least one multiple mold is used, in which the structuring of the individual forms, which is used for forming the surface structuring and / or for shaping the structured edge region of the floor panels, also differs from multiple mold to multiple mold,
and or
that at least one multiple mold is used, in which the molding space of each individual mold is delimited by surfaces of a molding or wear frame, which are formed over the entire height of the mold space with a continuous, a corrugated and / or irregularly shaped contour and / or profiling,
and or
in that at least one multiple mold is used, in which the mold bottom closing the respective mold space on its underside is designed as a deep-bed mold, each with at least one trough-like depression for each mold cavity,
and or
that at least one multiple mold is used, in which the mold base is made of a rubber-elastic material,
and or
in that at least one multiple mold is used in which the depth of the trough-like recesses (15) is smaller than the thickness of the base plates (1) to be produced,
and or
in that at least one multiple mold is used in which the depth of the depressions is at most 1/3 of the thickness of the base plates (1) to be produced,
and or
in that at least one multiple mold is used, in which the lower mold part (11) has a different structuring at the bottom of each depression (15).

In a further development of the invention, the mold for the manufacture of floor slabs, for example, is also formed, for example
in that the pressing takes place in each case by means of a press ram which is adapted at its circumference to the surface of the respective individual shapes forming the peripheral surface or the side contour of the respective base plate,
and or
in the case of several multiple molds on a turntable of a molding press, the individual molds corresponding to each other with respect to the position on the turntable are in each case identical or essentially identical, at least with regard to the surfaces forming the side contour of the floor plates,
and or
that the structuring of the individual forms serving to form the surface structuring and / or to form the structured edge region of the bottom plates is also different from multiple form to multiple form,
and or
that the shape space of each individual shape is limited by surfaces of a forming or wear frame, which are formed over the entire height of the mold space with a continuous, a corrugated and / or irregularly shaped contour and / or profiling,
and or
in that the mold bottom which closes the respective mold space on its underside is designed as a deep bed mold with at least one trough-like depression for each mold cavity,
and or
that the lower mold part consists of a rubber-elastic material,
and or
that the depth of the trough-like depressions is smaller than the thickness of the base plates to be produced,
and or
that the depth of the recesses is at most 1/3 of the thickness of the base plates to be produced,
and or
that the lower mold part at the bottom of each depression has a different structuring.

The aforementioned features are each individually and in any combination possible.

Further developments, advantages and applications of the invention will become apparent from the following description of exemplary embodiments and from the figures. In this case, all described and / or illustrated features alone or in any combination are fundamentally the subject of the invention, regardless of their summary in the claims or their dependency. Also, the content of the claims is made an integral part of the description.

Fig. 1

in vereinfachter Darstellung und in Draufsicht mehrere gemeinsam hergestellte Bodenplatten aus zementgebundenem Material;

Fig. 2

in vereinfachter Darstellung und in Seitenansicht eine der Bodenplatten der Figur 1;

Fig. 3

in vergrößerter Darstellung einen Teilschnitt durch eine Mehrfachform zum gleichzeitigen Herstellen mehrerer Platten der Figuren 1 und 2;

Fig. 4

in vereinfachter Darstellung eine Draufsicht auf eine Mehrfachform zum Herstellen der Platten der Figuren 1 und 2;

Fig. 5

in sehr vereinfachter schematischer Darstellung eine Presse zum Formen der Platten der Figuren 1 und 2.

The invention will be explained in more detail below with reference to the figures of an embodiment. Show it:

Fig. 1

in simplified representation and in plan view, several jointly produced floor panels made of cement-bonded material;

Fig. 2

in a simplified representation and in side view of one of the bottom plates of Figure 1;

Fig. 3

in an enlarged view a partial section through a multiple mold for simultaneously producing a plurality of plates of Figures 1 and 2;

Fig. 4

in a simplified representation of a plan view of a multiple mold for producing the plates of Figures 1 and 2;

Fig. 5

in a very simplified schematic representation of a press for forming the plates of Figures 1 and 2.

The plates indicated generally at 1 in Figures 1 and 2 are made from a cementitious material, with an upper surface of the plate 1 forming header 2 made of a high quality concrete or fine concrete (facing concrete) and with a the underside of each plate. 1 forming core or base 3 of a coarser concrete (core concrete).

The plates 1 are each made in multiple use, i. four plates 1 are manufactured together and form a plate or production unit 1.1.

each in the illustrated embodiment, substantially square plate 1 has at its peripheral sides a curved in plan view of the plate side contour 4 and is structured at its top at 5, ie provided with projections or depressions. Furthermore, the edge enclosing the top 6 is broken in the sectional plane perpendicular to the top, ie rounded and at the same time irregular, ie formed following the curved peripheral contour, so that for the plate 1, at least after laying a rustic or a natural stone plate corresponding optical appearance results.

The curved side or peripheral contour 4, the structuring 5 and the rounded and at the same time irregular edge 6 will already be formed in the production of the plate 1, so that a post-processing of the plate 1 to produce e.g. the structuring 5 and the broken edge 6 is not required.

The structuring, i. In particular, the formation of the lateral and circumferential contour 4, the surface structuring 5 and the structuring of the irregularly extending edge is deliberately chosen differently in the plates 1 each plate or manufacturing unit 1.1, so that after laying the plates 1 in the laid surface no optical conspicuous, similar structuring especially adjacent panels visually disturbing appear in appearance, but the laid panels 1 in terms of their structuring a purely random and rather rustic visual appearance convey. In particular, the plates 1 of each plate or production unit 1.1 are also structured differently from one another at their entire edge 6.

The forming of the plates 1 takes place, for example, on a conventional machine or molding press 7, which i.a. a clocked around a vertical axis rotatable turntable 7.1 has, are provided on the plurality of multiple molds 8 distributed at equal angular intervals about the axis of rotation.

Each multiple mold 8 consists of several individual molds 8.1, wherein the number of individual molds in each case corresponds to the number of plates 1 of each disk unit 1.1, ie in the illustrated embodiment, each multiple mold 8 has four individual molds 8.1. To achieve the different structuring of the plates 1 in each plate unit 1.1, the individual shapes 8.1 of each multiple mold 8 are formed differently. However, the multiple molds 8 on the turntable are identical in each case, so that the additional functional elements provided on the molding press, which cooperate with the multiple molds 8 or the individual molds 8.1, can be made suitable for all multiple molds.

Each individual form 8.1 is of a used in an opening of the turntable form or wear frame 9, the form spaces 10 of the individual forms 8.1 limited at the periphery with web-like frame elements and separated from each other and the peripheral surface of the respective plate 1 forms, as well as a plate-like, the Underside of the respective individual form 8.1 forming or the respective mold space 10 of each individual form 8.1 downwards final molding 11, for example, made of a rubber-elastic material, eg Hard rubber is made and provided for all individual forms 8.1 together. Each multiple form 8 thus consists of several, i. in the illustrated embodiment, four mold cavities 10 forming Verschließrahmen 9 and from the molding space 10 at the bottom final molding 11 with several, i. in the illustrated embodiment with a total of four trough-like depressions 15th

The lower mold part 11 is provided on a machine part 12, which is moved with the turntable 7.1, but can be lowered for removal of the plate blank produced by compression molding but based on the turntable 7.1.

The preparation is carried out in such a way that in a first working position in the respective closed by the lower mold part 8 8 first form the intent forming intent or fine concrete, which also has a relatively high water content, and then in a further working position of the base. 3 forming core concrete are introduced, which also has a lower water content than the fine concrete. At least after the introduction of the core concrete is carried out using a mold or press die 9.1 pressing the concrete in each mold cavity 10 and then at a further working position the dispensing or ejecting and forwarding of the plate blank thus prepared after lowering the closure element 11 for the storage of Plate blanks during setting or hardening of the concrete.

For shaping the irregularly curved or wavy side contour 4, the profiling or structuring 5 of the top plate and the rounded or broken edge 6 already in the production of the plate blank is the forming and wear frame 9 at its the form spaces 10 bounding inner surfaces over the entire frame height with a side contour 4 corresponding contour provided according to the invention over the entire height of the inner surface of the forming and wear frame extends.

The ram 9.1 of each individual form 8.1 is adapted at its periphery to the inner cross section of the mold space 10, d. H. Each punch 9.1 has on its outer circumference also the side contour 4 of the floor panels 1 to be produced corresponding contour. The number of punches 9.1 is equal to the number of mold cavities 10 or individual molds 8.1 of the multiple molds 8.

For forming the broken, irregularly extending edge 6, the lower mold part 11 is provided as a deep-bed mold, each having a peripheral edge portion 14 having trough-like depressions 15, each with a recess 15 for each mold space or for each individual form 8.1. The edge forms a flat surface 14. 1, against which the mold frame 9 with its lower end face rests fully over the closed multi-mold 8 and thereby ensures a tight seal of the multiple mold 8 and the individual molds 8.1 at the transition between the mold frame 9 and the mold bottom 1. To the surface 14.1 joins the respective mold space 10 towards a surface 14.2, which is down to the bottom 15.1 of the trough-like recess 15 extending and the shape of the edge 6 is correspondingly concave curved. In addition, the area 14.2 of the waviness of the edge is corrugated accordingly, d. H. she has a changing steepness. Furthermore, the transition between the surfaces 14.1 and 14.2 of the side contour 4 follows so that the surface 14.2 merges as seamlessly or continuously as possible into the respective inner surface of the mold frame 9.1 forming the side contour 4 at this transition.

It is essential in the production of the base plates 1 and in the aids used for this production, namely the multiple mold 8, the mold frame 9 and the punch 9.1, etc.,
that the side contour 4 forming shaping of the inner surface of the mold and Wear frame is formed over the entire height of this frame, that the transition between the surfaces 14.1 and 14.2 follows exactly in the course of the side contour 4,
that the punch 9.1 is adapted at its peripheral surface to the inner cross section of the respective mold space 10 or the course of the lateral contour 4 forming inner surfaces of the forming and wear frame 9, so that on the one hand the bottom plates 1 are produced in the desired shape without disturbing transitions, on the other hand during demolding a plate blank after molding no material remains in the mold frame as well as in the lower mold part remain.

Essential for this is u. a. Also, that the side contour 4 of the bottom plates 1 forming contour of the inner surfaces of the forming and wear frame extends over the entire height of this frame, so that with the adapted to the cross section of the respective mold space 10 press dies 9.1, the respective blank is completely ejected during removal and Here also no material remains in the form and wear frame 9 remain. It is also essential that on the one hand by the facing concrete with a relatively high proportion of water, the top of the corresponding bottom plate 1 is optimally formed, but that absorbed by the subsequently introduced core concrete with a lower water content excess water from the facing concrete from the core concrete and so the adhesion of the first very wet facing concrete is prevented at the formed with the trough-shaped recess 15 lower mold part 11.

It is also advantageous in the illustrated embodiment that the depth of the trough-like depression 15 is significantly smaller than the thickness of the base plates produced.

To produce the structuring 5 on the top side of the plate, the bottom 15.1 of the trough-like depression 15 is correspondingly provided with a complementary profiling or structuring 13.

In a preferred embodiment of the invention, the respective wear frame 9 at its the individual mold spaces 10 limiting inner surfaces over the entire height on a continuous, wavy or irregular side contour, specifically for forming a corresponding side contour of the plates 1. The bottom of the 11 with the individual Trough-like recesses 15 forms a Tiefbettmatrize for each mold space 10. The mold and wear frame 9 and the mold base or the local trough-like depressions 15 are adapted to each other that the formed by the forming and wear frame 9 boundary surfaces of each mold space or each individual form 8.1 steplessly and seamlessly pass into the trough-like depression or the edge area.

The depth of the recesses 15 is in any case smaller than the thickness of the plates 1 produced and is for example in the range of max. 1/3 of the thickness of these plates.

In order to use at the individual working positions of the molding press functional elements, in particular ram 9.1 as well as stamp for discharging the plate blanks from the individual forms 8.1, which are adapted to the particular shape of the individual molds 8.1 and in particular also to the formed by the mold frame 9 cross-sections Form spaces 10 of the individual forms 8.1, although these individual forms 8.1 of each multiple mold 8 in particular in their respective side contour 4 of the plates 1 forming surfaces of the forming and wear frame 9 are formed differently from their position with respect to the turntable corresponding to each other forms 8.1 However, multiple molds 8 are identical at least to the mold surfaces formed by the respective mold and wear frame 9. Such corresponding individual shapes 8.1 are then those individual forms having the same radial distance from the axis of rotation of the turntable 7.1 and based on the direction of rotation of the turntable 7.1 each have the same positioning within the multiple molds 8.Hierdurch, it is possible to cooperate with the individual forms and At the different working positions provided stamp suitable for all multiple forms 8 fit.

The individual forms 8.1 of all multiple molds 8 are then preferably structured differently on their surfaces which produce the surface structuring 5 and the structuring on the edge region 4, which surfaces do not interact directly with a pressing die 9.1 or another stamp-like functional element of the molding press 7. As a result, the plates 1 on their after laying particularly eye-catching surfaces on an arbitrary, different structuring, so that a visually disturbing uniformity is avoided with laid plates particularly effective.

The invention has been described above by means of exemplary embodiments. It is understood that numerous changes and modifications are possible.

LIST OF REFERENCE NUMBERS

1

baseplate

2

intent

3

Base

4

side contour

5

Structuring on the top of the board

6

rounded and irregular edge

7

Press

7.1

turntable

8th

Multiple Form

8.1

Single form

9

Shaping and wear frame

9.1

stamp

10

cavity

11

Die or plate-shaped mold base

12

Lowerable element of the turntable 7

13

structuring

14

surrounding border

14.1, 14.2

area

15

trough-like depression

16

recess

A

Lowering movement of the mold element 11

Claims (10)

A method for producing floor slabs of cement-bonded material or concrete with a the top of the respective bottom plate (1) forming attachment (2) made of fine or facing concrete and with a bottom of the respective bottom plate (1) forming core (3) made of a core concrete , by molding in a respective mold space (10) of a mold (8), wherein the mold space (10) at its periphery by a forming and wear frame (9) and on its underside by a lower mold part (11) is limited, and wherein the production of the bottom plates in the respective mold space (10) first of the intent forming facing concrete and then the core (3) forming core concrete are introduced and at least after the introduction of the core concrete pressing with a ram (9.1), characterized
formed by the use of a multiple mold (8) formed with multiple individual shapes (8.1) for simultaneously producing a plurality of concrete slabs (1), each individual form of the multiple mold (8) at its the top and / or the edge region (5.1) and / or the peripheral side (5) of the respective bottom plate forming surfaces is designed differently. A method according to claim 1, characterized in that the pressing takes place in each case by means of a press ram (9.1) which is adapted at its periphery of the peripheral surface or the side contour (4) of the respective bottom plate (1) forming surface of the associated individual forms (8.1) , A method according to claim 1 or 2, characterized
by the use of a plurality of multiple molds (8) on a turntable (7.1) of a molding press (7), the individual molds (8.1) corresponding to one another with respect to the position on the turntable (7.1) being at least as far as the side contour (4) of the bottom plates (1) forming surfaces are each identical or substantially identical executed,
and or
by the use of at least one multiple mold (8), in which the structuring of the individual molds (8.1) serving to form the surface structuring (5) and / or to form the structured edge region (6) of the bottom plates (1) also depends on multiple molds (8) Multiple shape (8) is different,
and or
by the use of at least one multiple mold (8), in which the mold space (10) of each individual mold (8.1) is delimited by surfaces of a mold or wear frame (9) having a continuous one over the entire height of the mold cavity (9) corrugated and / or irregularly shaped contour and / or profiling are formed,
and or
by the use of at least one multiple mold (8), in which the mold bottom part (11) closing the respective mold space (10) is formed as a deep bed mold with at least one trough-like depression for each mold cavity (10),
and or
by the use of at least one multiple mold (8), in which the lower mold part (11) consists of a rubber-elastic material. Method according to one of the preceding claims, characterized by the use of at least one multiple mold (8), in which the depth of the trough-like depressions (15) is smaller than the thickness of the base plates (1) to be produced,
and or
by the use of at least one multiple mold (8) in which the depth of the depressions is at most 1/3 of the thickness of the bottom plates (1) to be produced,
and or
by the use of at least one multiple mold (8), in which the lower mold part (11) has a different structuring at the bottom of each depression (15). Press mold for producing floor slabs of cement-bonded material or concrete with an attachment (2) of fine or facing concrete forming the upper side of the respective floor slab (1) and with a core (3) of a core concrete forming the underside of the respective floor slab (1) each in a mold space (10) of the mold, which is bounded at its periphery by a forming and wear frame (9) and on its underside by a lower mold part (11),
characterized,
that the mold (8) is designed as a multiple mold with a plurality of individual molds (8.1) for simultaneously producing a plurality of concrete slabs (1), and that each individual shape of the multiple mold (8) at its the top and / or edge region (5.1) and / or the Peripheral side (5) of the respective bottom plate forming surfaces is designed differently,
wherein the pressing, for example, in each case by means of a press ram (9.1), which is adapted at its periphery of the peripheral surface or the side contour (4) of the respective bottom plate (1) forming surface of the associated individual forms (8.1). Press mold according to Claim 5, characterized in that, in the case of several multiple molds (8) on a turntable (7.1) of a molding press (7), the individual molds (8.1) corresponding to one another on the turntable (7.1) at least with regard to the side contour (4) of FIG Floor panels (1) forming surfaces are each identical or substantially identical. Press mold according to one of the preceding claims, characterized in that the structuring of the individual molds (8.1) serving to form the surface structuring (5) and / or to form the structured edge region (6) of the bottom plates (1) also extends from multiple molds (8) Multiple form (8) is different. Press mold according to one of the preceding claims, characterized
that the mold cavity (10) is limited each individual mold (8.1) of surfaces of a mold or wear frame (9) over the entire height of the mold space (9) with a continuous, a corrugated and / or irregularly shaped contour and / or profiling are trained
and or
in that the lower mold part (11) which closes the respective mold space (10) on its underside is designed as a deep-bed mold with at least one trough-like depression for each mold space (10). Press mold according to one of the preceding claims, characterized in that the lower mold part (11) consists of a rubber-elastic material. Press mold according to one of the preceding claims, characterized
that the depth of the trough-like depressions (15) is smaller than the thickness of the bottom plates (1) to be produced,
and or
that the depth of the recesses is at most 1/3 of the thickness of the bottom plates (1) to be produced,
and or
that the mold bottom part (11) at the bottom of each recess (15) having a different structure.

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