EP1995029B1 - Method for manufacturing a moulded brick and a moulded brick filling device - Google Patents

Description

The present invention relates to a method according to the preamble of claim 1 for producing a molded block comprising a molded brick body having at least one passage passing through the shaped stone body, wherein at least one insulating element having a longitudinal dimension substantially corresponding to a length of the channel, by generating a Vacuum is introduced into the channel in this.

Furthermore, the invention relates to a shaped stone filling device according to the preamble of patent claim 5 for filling a molded block comprising a molded brick body having at least one channel passing through the shaped brick body, comprising a vacuum generating unit for generating a negative pressure in the channel and an insulating member providing unit for providing at least one insulating member having a longitudinal dimension , which substantially corresponds to a length of the channel, at an entrance of the channel, so that the insulating element by means of the negative pressure substantially completely in the channel can be introduced.

Wall building materials or wall-forming building materials in the form of bricks made of brick or concrete material are known from the prior art, which have channels filled with an insulating material. The insulating materials used are, in particular, insulating materials made from mineral wool. Such building materials are characterized by excellent thermal insulation.

When using insulating elements, in particular mineral wool, so-called mineral wool pads, to fill the channels, they are pressed regularly according to the prior art in the channels, wherein for laterally guiding and reducing the friction between the pad and the channel wall, a sleeve or nozzle is used and wherein the correspondingly inserted pads over a length of the channels have a certain excess in order to facilitate the pressing of the pads in the channels. The supernatants caused thereby by the insulating elements with respect to the channels are then cut in a further process step, which is correspondingly time consuming and costly. If the supernatants are cut off uncleanly, the usability may also be impaired.

From the WO 82 / 00041A1 are a generic method and a generic device for introducing insulating material in hollow blocks known, wherein under a hollow block for introducing the Isoliermateriais a negative pressure is generated.

From the US 3,343,251 For example, there is known a method for filling a tile brick, wherein a negative pressure is applied to one side of the block by means of a suction nozzle in order to draw a noise dampening material, such as mineral wool or the like, completely into the block by means of the negative pressure. Then the suction nozzle is removed.

The invention has for its object to provide a method and an apparatus of the type mentioned in each case, in which the introduction of the insulating elements with less effort and higher accuracy can be realized, in particular to reduce the cost of a mechanical finishing.

The invention solves this problem by means of a method having the features of patent claim 1 and by means of a shaped stone filling device having the features of patent claim 5.

Advantageous developments of the method according to the invention and of the device according to the invention are the subject matter of subclaims whose wording is incorporated by reference into the description in order to avoid unnecessary text repetitions.

According to the invention, a method for producing a molded block, which has a shaped stone body with at least one channel passing through the shaped stone body, is characterized in that the negative pressure in the channel is controlled as a function of a momentary insertion depth of the insulating element into the channel, wherein in particular the negative pressure is reduced before the insulation element exits the channel again. To this end. Valves are provided with valve tappets, which gradually close the insulating elements during insertion, up to a complete interruption of the negative pressure effect. In this way, an almost perfect filling of the form stone can be achieved. Slightly incomplete introduced insulation elements can then be completely introduced into the channel in a simple manner by mechanical means, in particular, are pressed in, for which device preferably a Rolleneneihheit is used.

According to the invention, a shaped stone filling device for filling a molded block, which has a shaped stone body with at least one channel passing through the shaped stone body, is characterized in that the vacuum generating unit has control means which are designed to control the negative pressure as a function of a depth of insertion of the insulating element into the channel. The said control means comprise vacuum depressing means in the form of Vehtilstößeln, wherein the insulating elements act themselves on the valve stem and the corresponding valves gradually close when they are introduced into the molded block, resulting in a reduction and in the end to a complete interruption of the negative pressure. In this way, the introduction process for the insulating elements is in some way self-regulating.

A use of excessively long insulating elements, as required when pressing in insulation elements in the form of blocks, is therefore no longer necessary.

In a further development of the method according to the invention a plurality of insulating elements are introduced simultaneously into corresponding, mutually parallel channels of the molded block, so that the method compared to known methods in which each channel is filled one after the other, allows a corresponding reduction of the processing time. Thus, in the course of the embodiment of the method according to the invention described above, it is possible to fill up to 30 shaped bricks (eg bricks) per minute, whereas with the above-mentioned sequential filling process only about 10 bricks per minute can be processed.

The shaped stone filling device according to the invention is not limited to specific cross sections or cross-sectional shapes of the insulating elements to be introduced. In particular, it can be provided in a development that at least some insulating material elements have the same dimensions, in particular a same cross-section. Alternatively or additionally, some of the insulating material elements may also have different dimensions, in particular different cross sections. The cross sections may differ in shape (round, angular, ...) and / or cross-sectional area.

In order to enable the control already mentioned above, in particular to reduce the negative pressure in the channels, another development of the shaped stone filling device according to the invention provides that separate negative pressure control means are provided in particular for each channel. These respond in a further development of the invention, when the insulating element has been introduced to a predetermined insertion depth in the channel. Vorteilhafferweise said means are activated or actuated by the introduced insulating element itself, which allows a control technology relatively simple embodiment of the device.

Figur 1

eine Ausgestaltung der erfindungsgemäßen Formsteinfüllvorrichtung in Seitenansicht;

Figur 2

die Ausgestaltung der erfindungsgemäßen Formsteinfüllvorrichtung gemäß Figur 1 in Draufsicht; und

Figur 3

ein Ablaufdiagramm einer Ausgestaltung des erfindungsgemäßen Verfahrens zum Herstellen eines Formsteins.

Further features and advantages of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawing. It shows:

FIG. 1

an embodiment of the shaped stone filling device according to the invention in side view;

FIG. 2

the embodiment of the molded block according to the invention according to FIG. 1 in plan view; and

FIG. 3

a flow diagram of an embodiment of the inventive method for producing a molded block.

FIG. 1 shows an embodiment of a shaped stone filling device 1 according to the invention for filling a molded block 2. In the context of the present invention, the shaped brick 2 can be, for example, a shaped block Brick material (bricks), to act a concrete block or a block made of any other material. The molded block 2 is substantially cuboid-shaped and has a molded brick body 2a, which is penetrated by a number of mutually parallel channels 2b-f. The channels 2b-f are provided for receiving respective elongated insulating elements 3b-f and extend continuously from the molded block top through the block to the bottom of the block. The insulating elements 3b-f may consist, for example, mineral wool or any other, in particular structurally suitable, insulating material or a mixture of such insulating materials. The insulating elements 3b-f are arranged in an insulating element providing unit 4 which has a number of chambers 4b-f in the manner of a magazine, each chamber 4b-f each containing an insulating element 3b-f.

The chambers 4b-f, the insulating elements 3b-f and / or the channels 2b-f may have the same or similar cross sections, in particular round or rectangular cross sections. The chambers 4b-f are tapered frustoconically at their front ends 4b "-f" facing the shaped brick 2 in order to facilitate the introduction of the insulating elements 3b-f into the channels 2b-f.

A longitudinal extent of the as such approximately rod-shaped insulating elements 3b-f corresponds substantially, that is, to certain tolerances, a respective length L of the channels 2b-f.

Furthermore, the shaped stone filling device 1 comprises a vacuum generating unit 5, which is composed of a suction head 6, a vacuum line 7 and a vacuum accumulator or vacuum pump, not shown, wherein the vacuum line 7 connects the vacuum accumulator with the suction head 6. The suction head 6 has a number of suction lines 6b-f whose number and arrangement corresponds precisely to the number or arrangement of the channels 2b-f of the shaped block 2. In the present case, the channels 2b-f and the suction lines 6b-f are arranged in the manner of a regular matrix with rows and columns, of which in the sectional view according to FIG FIG. 1 only one column is visible. A corresponding arrangement is also found for the chambers 4b-f of the insulating element providing unit 4.

In connection with each suction line 6b-f, the suction head 6 has in each case controlled valve means 6g-k, via which the corresponding suction lines 6b-f can be opened and closed in a controlled manner. At their ends opposite the valve or control means 6g-k, the suction pipes 6b-f are united within the suction head 6 (not shown) and connected together to the vacuum pipe 7.

The Dämmstoffelementbereitstellungsseinheit 4 and the vacuum unit 5 (ie, at least the suction head 6) are on the shaped block 2 and movable away from this, which in FIG. 1 is symbolized by double arrows P and P '. In this way, the chambers 4b-f or the insulating elements 3b-f contained therein can each be combined with a first end of the corresponding channels 2b-f (also referred to below as the channel start). The same applies with regard to the suction lines 6b-f and the respective other end of the channels 2b-f (hereinafter also referred to as the channel end).

• Für den Formstein 2 bzw. weitere Formsteine ist eine geeignete Fördereinrichtung, wie ein Förderband oder dergleichen, vorgesehen (in Figur 1 nicht gezeigt), durch die der Formstein 2 in den Bereich zwischen der Dämmstoffelementbereitstellungseinheit 4 und der Unterdruckerzeugungseinheit 5 hineingefördert wird. Dies ist in der Darstellung gemäß Figur 1 bereits erfolgt. In dieser Stellung werden sowohl die Dämmstoffelementbereitstellungseinheit 4 als auch die Unterdruckerzeugungseinheit 5, d. h. der Saugkopf 6 gemäß den Doppelpfeilen P bzw. P' an den Formstein 2 herangeführt, so dass die Kammern 4b-f mit ihrem jeweiligen verjüngten Ende 4b"-f" in den zugeordneten Kanalanfang der Kanäle 2b-f eingreifen. Vorzugsweise wird die Dämmstoffelementbereitstellungseinheit 4 mindestens soweit an den Formstein 2 herangeführt, dass die einzelnen Kammern 4b-f selbst an dem Formstein 2 in Anlage treten.

Hereinafter, the operation of the above-described molded block filling apparatus 1 will be described in detail.

• For the shaped brick 2 or further shaped blocks, a suitable conveying device, such as a conveyor belt or the like, is provided (in FIG FIG. 1 not shown), through which the molded block 2 is conveyed into the area between the insulating material supplying unit 4 and the negative pressure generating unit 5. This is in the illustration according to FIG. 1 already done. In this position, both the Dämmstoffelementbereitstellungsseinheit 4 and the vacuum generating unit 5, ie the suction head 6 according to the double arrows P and P 'brought to the shaped block 2, so that the chambers 4b-f with their respective tapered end 4b "-f" in engage the associated channel beginning of the channels 2b-f. Preferably, the Dämmstoffelementbereitstellungseinheit 4 is at least as far brought to the shaped block 2, that the individual chambers 4b-f itself on the shaped block 2 in abutment.

In parallel, the suction head 6 is moved up to the shaped block 2, that the suction lines 6b-f with the respective associated end of the channels 2b-f come into vacuum technical operative connection. In this context, the term "active vacuum connection" means that via the suction lines 6b-f and the suction head 6 and the vacuum line 7, the channel interior of the channels 2b-f with the vacuum reservoir (not shown) is connectable. In this way, a negative pressure can be generated in the channels 2b-f.

This is done in the following to such an extent that the insulating elements 3b-f are introduced into the respective channel 2b-f by, in particular, sudden generation of the negative pressure. Figuratively speaking, the insulating elements 3b-f according to the invention "sucked" into the relevant channel 2b-f. Since the respective longitudinal dimensions of the insulating elements 3b-f essentially correspond to the channel length L, in this way the channels 2b-f of the shaped block 2 can be filled simultaneously and practically completely so that the shaped block 2 is completely filled in a single process step and subsequently conveyed further can.

In practice, however, it is to be avoided that the insulating elements 3b-f introduced into the channels 2b-f by the action of negative pressure at least partially emerge again at the respective channel end, which can be brought about by excessive underpressure.

For this purpose, the suction head 6 in the region of the suction lines 6b-f on the aforementioned valve or control means 6g-k. By means of the valve or control means 6g-k, a separate negative pressure control is performed for each channel 2b-f. In the present case, the valve or control means 6g-k are actuated by the advancing insulating elements 3b-f themselves: The valve or control means 6g-k engage in suction nozzle 6 applied to the shaped block 2 in the corresponding channels 2b-f, so that the insulating elements 3b-f with their respective front end on the valve or control means 2g-k come into contact before they leave the channels 2b-f at the end of the channel again. This results in a gradual reduction of the negative pressure via a mechanical action of the insulating elements 3b-f on the valve or control means 6g-k, since the corresponding channels 2b-f are increasingly cut off from the suction lines 6b-f become. It happens, just before the insulating elements 3b-f completely reach the respective end of the channel, to a complete termination of the suction. In this way, it is avoided that the insulating elements at the channel end again emerge from the shaped block 2, which is because of a so-called "dowel effect" (since the laterally arranged on the Dämmstoffelementoberfläche fibers are aligned when inserted into the channel in the insertion direction and thereby barbs similar pushing back oppose). in a subsequent processing step is difficult to undo.

The valve or control means are designed as valve tappets whose function - as stated - is to decelerate the insulation elements in a timely manner. Accordingly, the activation of the valve or control means 6g-k takes place when the insulating elements 3b-f have been introduced into the corresponding channel 2b-f up to a respective predetermined penetration depth, the insertion depth being just the channel length L less an engagement length of the respective valve channel. or control means 6g-k into the channel 2b-f.

It may happen that the insulating elements 3b-f at the respective channel entrances still protrude to a certain extent from the channels 2b-f, which possibly makes a corresponding mechanical reworking necessary. A corresponding device will be described below with reference to FIG. 2 However, nevertheless, in the embodiment according to FIG. 1 are used, although it is not explicitly shown there.

FIG. 2 shows the embodiment of the shaped stone filling device 1 according to the invention FIG. 1 in plan view.

As FIG. 2 shows, the channels 2b, 2b 'of the shaped block in plan view different dimensions, in particular different cross-sections. Correspondingly, the insulating material calculation unit 4 has chambers 4b, 4b 'with pointed forward ends 4b ", 4b"', in which insulation elements 3b, 3b 'for introduction into the channels 2b, 2b' are arranged. The channel 2b, the insulating element 3b and the channel 4b with front end 4b "correspond to the same named elements in FIG. 1 ,

In addition to the elements already described is in FIG. 2 8 also shows a conveying device 8 in the form of a conveyor belt, through which the shaped block 2 and correspondingly further shaped blocks are conveyed in the direction of the arrow P. In the conveying direction P "with reference to the illustrated position of the shaped brick 2, the shaped stone filling device 1 according to FIG FIG. 2 a mechanical insertion unit 9, which in the present case is designed as a reel unit and is movable in the direction of the double arrow P '"The reel unit 9 is rotatably mounted in the direction of the double arrow P4.

When the shaped brick 2 is moved in the direction of the arrow P "by means of the conveyor 8 on the mechanical loading unit 9, it is possible with their help in a simple manner, at the channel starts of the block 2 protruding insulation material of the insulating elements 3b, 3b 'mechanically completely in the As the length of the insulating elements 3b, 3b 'corresponds substantially straight to the channel length L, no re-emergence of the insulating elements 3b, 3b' occurs at the respective channel end.

FIG. 3 shows a flowchart of an embodiment of the inventive method for producing a molded block, in particular one of the above with reference to Figures 1 and 2 described devices can be used. However, the method will be described below without reference to a specific embodiment of a device to be used therefor.

The process starts with step S100. Subsequently, in step S102, a molded block to be filled with at least one insulating member, such as a brick or the like, is conveyed to a processing area of the used block filling apparatus. Then, in step S104, the at least one insulating element is provided for introduction into the molded block, wherein the molded block for this purpose has at least one channel into which the insulating element is to be introduced.

Subsequently, a negative pressure is generated in the channel in step S106, so that the insulating element is introduced ("sucked") into the channel.

In a subsequent step S108 it is determined whether the introduced insulating element has reached a predetermined depth of introduction into the channel. If this is the case (j), then in S110 the applied negative pressure is reduced. Otherwise, the negative pressure remains unchanged and the method returns to step S108, which it loops through accordingly.

The reduction of the negative pressure in step S110 is followed in step S112 by a check as to whether the introduced insulating element has already reached its final insertion depth. If this is the case (j), the negative pressure is completely turned off in step S114. Otherwise, step S112 is repeated in a loop. Alternatively (dashed line in Figure 3), the method may also return to step S110, which corresponds to a continued reduction of the negative pressure. It should be noted that the last-mentioned variant in the embodiments of the molded block according to the invention according to FIG. 1 and FIG. 2 is realized, in which the negative pressure is gradually reduced by continuous advance of the insulating elements and acting on the valve stem gradually.

In an optional step S116, following step S114, it is possible to check whether the insulating element has been completely introduced into the molded stone channel, ie that no projection on the side of the channel exists. If this is the case (j), in a subsequent step S118, the finished molded block is conveyed out of the area of action of the molded block filler, and the process ends with step S120. Otherwise (n in connection with step S116), prior to step S118, in an intermediate step S122, a mechanical, complete introduction of the insulating element in the molded stone channel takes place, as described above with reference to FIG FIG. 2 has already been described in detail with reference to the mechanical feed unit / reel unit 9.

The query in step S116 is - as stated - only optional. In particular, in the embodiment according to FIG. 2 can be carried out by means of the reel unit 9, a mechanical action on the shaped block 2 regardless of a protrusion of the insulating elements without such a query in each case. Alternatively, however, in connection with the reel unit 9, a suitable monitoring unit (not shown in the figures) may be provided, which effects a mechanical action of the reel unit 9 on the shaped brick 2 or the projecting insulating material only if an insulation protrusion exists.

Claims (14)

1. Method of producing a shaped brick (2) which has a shaped brick body (2a) having at least one channel (2b-f, 2b') passing through the shaped brick body (2a), wherein at least one insulating element (3b-f, 3b') having a longitudinal dimension that corresponds substantially to a length (L) of the channel (2b-f, 2b') is introduced into the channel (2b-f, 2b') by generation of a vacuum therein, the vacuum being controlled in dependence upon an instantaneous introduction depth of the insulating element (3b-f, 3b') into the channel (2b-f, 2b'), characterised in that the insulating elements (3b-f, 3b') themselves act on vacuum-reducing means in the form of valve stems (6g-k) and, on introduction into the shaped brick (2), gradually close the corresponding valves, resulting in a reduction and ultimately complete discontinuation of the action of the vacuum.
2. Method according to claim 1, characterised in that the shaped brick body (2a) has a plurality of channels (2b-f, 2b') passing through the shaped brick body (2a), and an insulating element (3b-f, 3b') is introduced into each of at least a number of the channels (2b-f, 2b'), the introduction of the insulating elements (3b-f, 3b') taking place substantially simultaneously.
3. Method according to claim 1 or 2, characterised in that the vacuum is reduced before the insulating element (3b-f, 3b') re-emerges from a channel (2b-f, 2b') at the end of the channel.
4. Method according to any one of claims to 3, characterised in that an incompletely introduced insulating element (3b-f, 3b') is introduced, especially pushed, fully into the channel (2b-f, 2b') by mechanical means (9).
5. Shaped brick filling device (1) for filling a shaped brick (2) which has a shaped brick body (2a) having at least one channel (2b-f, 2b') passing through the shaped brick body (2a), comprising a vacuum-generating unit (5) for generating a vacuum in the channel (2b-f, 2b') and an insulating element preparation unit (4) for preparing at least one insulating element (3b-f, 3b') having a longitudinal dimension that corresponds substantially to a length (L) of the channel (2b-f, 2b') at the entrance to a channel (2b-f, 2b'), so that the insulating element (3b-f, 3b') is introducible substantially fully into the channel (2b-f, 2b') by means of the vacuum, the vacuum-generating unit (5) having control means (6g-k) which are arranged to control the vacuum in dependence upon an introduction depth of the insulating element (3b-f, 3b') into the channel (2b-f, 2b'),
   characterised in that the control means (6g-k) have vacuum-reducing means in the form of valve stems (6g-k) which are arranged in such a way that the corresponding valves are closable gradually by the insulating elements (3b-f, 3b') on introduction into the shaped brick (2) until the action of the vacuum has been completely discontinued.
6. Shaped brick filling device (1) according to claim 5, characterised in that the insulating element preparation unit (4) is arranged for preparation, especially simultaneous preparation, of a plurality of insulating elements (3b-f, 3b') at corresponding channel entrances of the shaped brick (2).
7. Shaped brick filling device (1) according to claim 5 or 6, characterised in that the vacuum-generating unit (5) is arranged to generate the vacuum, especially simultaneously, in corresponding channels (2b-f, 2b') of the shaped brick (2).
8. Shaped brick filling device (1) according to claim 6 or 7, characterised in that at least some of the insulating elements (3b-f, 3b') have the same dimensions, especially the same cross-section.
9. Shaped brick filling device (1) according to any one of claims 6 to 8, characterised in that at least some of the insulating elements (3b-f, 3b') have different dimensions, especially different cross-sections.
10. Shaped brick filling device (1) according to any one of claims 5 to 9, characterised in that, in the case of a plurality of simultaneously prepared insulating elements (3b-f, 3b'), separate vacuum control is provided for each channel (2b-f, 2b') by corresponding control means (6g-k, 6g').
11. Shaped brick filling device (1) according to any one of claims 5 to 10, characterised in that the control means (6g-k, 6g') comprise vacuum-reducing means for bringing about a reduction in the vacuum, which means are in the form of valve means projecting into the channel in question (2b-f, 2b').
12. Shaped brick filling device (1) according to claim 11, characterised in that the vacuum-reducing means are actuatable by the introduced insulating element (3b-f, 3b').
13. Shaped brick filling device (1) according to any one of claims 5 to 12, characterised by a mechanical introduction unit (9) arranged downstream of the vacuum-generating unit (5), which unit (9) is arranged to introduce, especially push, an incompletely introduced insulating element (3b-f, 3b') into the channel (2b-f, 2b') by mechanical means.
14. Shaped brick filling device (1) according claim 13, characterised in that the mechanical introduction unit (9) is in the form of a roller unit which co-operates with the shaped brick (2) for mechanical introduction of the insulating element (3b-f, 3b') in the region of a relevant channel entrance.

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