Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
  • B28B3/003—Pressing by means acting upon the material via flexible mould wall parts, e.g. by means of inflatable cores, isostatic presses
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
  • B28B3/006—Pressing by atmospheric pressure, as a result of vacuum generation or by gas or liquid pressure acting directly upon the material, e.g. jets of compressed air
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
  • B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
  • B28B3/024—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form the pressure on the material being transmitted through flexible or resilient wall parts, e.g. flexible cushions on the ramming surface, resilient wall parts pressing as a result of deformation caused by ram pressure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/0002—Auxiliary parts or elements of the mould
  • B28B7/0014—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps
  • B28B7/0023—Fastening means for mould parts, e.g. for attaching mould walls on mould tables; Mould clamps using vacuum
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B7/00—Moulds; Cores; Mandrels
  • B28B7/06—Moulds with flexible parts

Definitions

• the present invention relates to a device for molding parts of a molding material, for example concrete and a method for manufacturing parts of said material by molding.
• the document WO2007 / 001794 in the name of the Applicant, describes a method of manufacturing concrete parts consisting of introducing a material to be molded into a mold, disposing the mold in an envelope, making a depression in the envelope of to maintain the walls of the mold, and to deform the mold. After setting the concrete, the mold can be removed from the envelope. Molded parts can be manufactured by this process in a simple manner. Depression is generally carried out in the mold using a vacuum pump, which operates by suction of the air present in the envelope.
• the present invention provides a molding device comprising: an envelope;
• a vacuum outlet adapted to allow a gas flow to pass to form a depression in the envelope
• a shutter element adapted to interrupt said gas flow after formation of the depression
• a means different from the envelope and the deformation member, adapted to exert pressure on at least a portion of the mold, possibly with the interposition of the envelope, once the depression is formed.
• the device further comprises a vacuum pump and a connecting element adapted to connect the vacuum pump to the envelope.
• the shutter element is integrated in the vacuum pump.
• the mold comprises at least first and second opposite faces.
• the deformation member is adapted to apply a first pressure on the mold, with interruption of the envelope, on the side of the first face.
• Said means is adapted to apply a second pressure on the mold, with interruption of the envelope, on the side of the second face.
• the deformation member is chosen from a group comprising a jack and a jig.
• said means comprises at least one load having a mass greater than one kilogram and intended to rest on at least a portion of the mold, possibly with interposition of the envelope, once the depression is formed.
• said means has a shape at least partly complementary to the template.
• the device further comprises at least one drainage element in the form of a sheet or a membrane in the envelope.
• the device further comprises at least two drainage elements in the envelope, the mold being interposed between the two drainage elements.
• the invention also relates to a manufacturing method, comprising the following steps:
• the vacuum outlet is connected to a vacuum pump via a connecting element.
• the step of producing the vacuum comprises starting the vacuum pump and the step of stopping the gas flow comprises stopping the vacuum pump.
• the step of stopping the gas flow comprises at least partial sealing of the connecting element.
• the mold is deformed by a deformation member chosen from a group comprising a jack and a jig.
• the mold comprises at least first and second opposite faces.
• the deformation member applies a first pressure on the mold, with interruption of the envelope, on the side of the first face.
• Said means applies a second pressure on the mold, with interruption of the envelope, on the side of the second face.
• the step of applying a pressure comprises disposing at least one load on at least one part of the mold, possibly with the interposition of the envelope.
• said means applies a second substantially uniform pressure on the mold, with interruption of the envelope, on more than half of the second face.
• the Applicant has shown that the shrinkage was at least partly due to an aspiration of the water vapor present in the envelope by the vacuum pump when it is connected to the envelope by taking vacuum to form depression in the envelope. This results in an accelerated drying of the molding material which can lead to undesirable deformations of the molded part.
• the Applicant has shown that, once formed, the vacuum present in the envelope is only slowly reabsorbed even if the gas flow, which led to the formation of the vacuum in the envelope, is stopped.
• the mold is then advantageously maintained by the envelope during the deformation of the mold and simultaneously the duration during which water vapor is extracted from the envelope is reduced. Undesirable drying of the molding material is thus reduced and the shrinkage of the molding material is reduced.
• hydraulic binder for example, a powdery material which, mixed with water, forms a paste which sets and hardens as a result of reactions and processes of hydration, and which after curing, retains its strength and stability even under water.
• concrete is meant for example a mixture of hydraulic binder, aggregates, water, optionally additives, and possibly mineral additives, such as high performance concrete, very high performance concrete, self-consolidating concrete, self-leveling concrete, concrete autocompactant, cast concrete, ready-mix concrete or colored concrete.
• concrete is meant, for example, concretes having undergone a finishing operation such as bush-hammered concrete, deactivated or washed concrete, or polished concrete. According to this definition, prestressed concrete is also meant.
• cement includes mortars. In this specific case, the concrete comprises a mixture of hydraulic binder, sand, water and possibly additives and possibly mineral additions.
• cement according to the invention denotes indistinctly fresh concrete or hardened concrete.
• aggregates designates, for example, gravel, chippings and / or sand.
• setting is meant according to the present invention the transition to the solid state by chemical reaction of hydration of a hydraulic binder.
• the setting is usually followed by a hardening period.
• hardening is meant according to the present invention the acquisition of the mechanical properties of a hydraulic binder, after the end of setting.
• FIGS. 1 and 2 are respectively an exploded schematic perspective view and an exploded lateral section of a molding device according to a first embodiment of the invention
• Figures 3 to 6 show the molding device according to the first embodiment of the invention at successive stages of an exemplary process for manufacturing molded parts according to the invention
• Figure 7 is an exploded schematic perspective view of a molding device according to a second embodiment of the invention
• Figures 8 and 9 show the molding device according to the second embodiment of the invention at successive stages of an exemplary method of manufacturing molded parts according to the invention.
• Figures 1 and 2 show schematically a molding device 10 according to a first embodiment of the invention, respectively according to an exploded view in perspective and according to an exploded side section.
• the device 10 can be used for molding parts having particular shapes.
• aesthetically pleasing coverings for architectural or engineering works can be realized.
• Parts with aesthetic shapes can be made with a starting material of the concrete type.
• the device 10 comprises a casing 12 and a mold 14 which, during part of the molding process, is arranged in the casing 12.
• the mold 14 is adapted to receive the material used for the production of the parts, the concrete for example.
• the casing 12 comprises a vacuum outlet 15 adapted to be connected to a vacuum pump 16 by a connecting element 17, for example a tube or a pipe.
• the vacuum pump 16 is, for example, a vane pump (lubricated or dry), a piston pump, a liquid ring pump, a diaphragm pump, a vacuum ejector using steam or a compressed gas, a pump Roots or a dry pump (without lubricant).
• the vacuum tap 15 is in a closed state, that is to say that it does not let any gas flow pass.
• the vacuum pump 16 is adapted to create a vacuum, or empty, in the casing 12 relative to the atmospheric pressure.
• a vacuum in the casing 12 with respect to the atmospheric pressure can be obtained with the vacuum pump 16, for example -0.5 bar or less, for example -0.8 bar or less for example equal to -0.9 bar.
• the device 10 can be sufficiently stiffened by the depression in the casing 12 so that the material to be molded does not move inside the mold 14 when the mold 14 is subjected to deformation. The material can thus remain of constant thickness in the mold 14.
• the constituent elements of the molding device 10 are made integral by the depression.
• the envelope 12 and / or the mold 14 may each be provided with two lips on their periphery which are pressed against each other under the effect of the depression.
• lips provide a simple way of closing the envelope 12 and the mold 14 respectively.
• the use of mechanical closure means can thus be avoided.
• the lips may also be made with a bead on one of the lips and a groove on the other of the lips, the depression causing the penetration of the bead in the groove so as to improve the sealing of the casing 12 and / or of the mold 14.
• the pumping of the material which is in the mold 14 is avoided. Indeed, by taking vacuum 15, the air trapped in the envelope 12 is sucked. If the vacuum outlet 15 could directly create a vacuum in the mold 14, the molding material could be pumped as well. Thus, the molding material is confined by the mold 14 inside the casing 12, and simultaneously a depression can be formed in the casing 12.
• the envelope 12 comprises for example an upper portion 121 and a lower portion 122.
• the mold 14 is disposed between the lower 122 and upper 121.
• the mold 14 rests on the lower portion 122.
• the mold 14 can be sandwiched by the envelope 12 in a simple way.
• the envelope 12 is preferably made of a flexible material.
• the envelope 12 because of its flexibility, can be deformed.
• the envelope 12 is also flexible to promote the formation of the depression in the envelope 12.
• the envelope because of its flexibility, can match the shape of the mold 14 under the effect of depression.
• the envelope 12 is made of a plastic material.
• the mold 14 may comprise an upper shell 141 and a lower shell 142.
• the lower shell 142 of the mold 14 rests on the lower part 122 of the envelope 12.
• the molding material can be confined in a simple manner by the mold 14. material is distributed on the lower shell 142 of the mold, then the mold 14 is closed using the upper shell 141.
• the mold 14 is preferably made of a flexible material. The flexibility of the mold 14 has several advantages: the mold 14 can deform under the action of a deformation member; the mold 14 promotes the confinement of the material in the mold under the effect of the depression formed in the envelope 12; and a better contact between the mold 14 and the molding material can be obtained.
• the mold 14 is made of silicone or polyurethane.
• the casing 12 is provided with the vacuum tap 15.
• the vacuum tap 15 is on the upper casing 121.
• the casing 12 can rest in operation on a support via its part. 122.
• the mold 14 resting on the lower portion 122 of the casing 12, it is preferable to provide the vacuum outlet 15 on the upper portion 121 of the casing 12 to facilitate the formation of the depression.
• the device 10 comprises a closure element 18 which is adapted, when the vacuum is formed in the casing 12, to interrupt any gas flow by the vacuum tap 15.
• the vacuum in the casing 12 can be maintained while interrupting However, following the stopping of the vacuum pump 16, the pressure nevertheless tends to increase slowly in the casing 12 due to leaks. However, the depression remains in the envelope 12 long enough to maintain the mold 14 by the envelope 12.
• the shutter 18 can be integrated with the vacuum pump 16. In this case, the shutter 18 can be triggered automatically to close one end of the connecting element 17 when the operation of the vacuum pump 16 is interrupted. To the FIGS. 1 and 2, the shutter 18 is schematically delimited by a dashed line at the level of the vacuum pump 16.
• the device 10 may also include at least one thin drainage element 20 in the envelope 12, in the form of a membrane or sheet, etc.
• the drainage element 20 promotes the creation of the depression. Indeed, the drainage element 20 prevents the local adhesion of the envelope 12 to the mold 14, under the effect of the depression created within the envelope 12, which could lead to the imprisonment of bubbles. air and hinder the further creation of depression.
• the drainage element 20 is of woven or non-woven material. Such a material is not hermetic but allows the passage of air. While the depression is in progress, the drainage element 20 promotes the flow of air towards the vacuum outlet 15.
• the drainage element 20 is for example located between the upper portion 121 of the envelope 12 and the upper shell 141 of the mold 14.
• the drainage element 20 then promotes the flow of air between the upper portion 121 and the upper shell 141.
• the drainage element 20 can be located between the part lower part 122 of the casing 12 and the lower shell 142 of the mold 14.
• the drainage element 20 then facilitates the circulation of air between the lower shell 142 of the mold 14 and the lower part 122 of the casing 12.
• air circulation is all the more favored that, because of gravity, the lower shell 142 rests against the lower part 122 and the depression could be difficult to achieve in this area of the casing 12 in the absence of the element of drai 20 because air bubbles could be trapped between the mold 14 and the envelope 12.
• the drainage element 20 forms a buffer zone between the mold 14 and the envelope 12.
• the device 10 comprises two drainage elements 20 in the casing 12, one of the drainage elements 20 being disposed between the upper portion 121 and the upper shell 141 and the other of the drainage elements 20 being disposed between the lower portion 122 and the lower shell 142.
• the presence of two drainage elements 20 promotes the creation of vacuum throughout the casing 12.
• a drainage element 22 may be provided in the mold 14. The drainage element 22 then promotes the formation of the depression in the mold 14. Indeed, the depression created in the casing 12 also propagates in the mold 14, through the edges of the shells 141 and 142. However, the depression in the mold 14 is less important than that present in the mold 14. 12, so that the material to be molded is not at the same time sucked.
• the drainage element 22 in the mold 14 also promotes the circulation and suction of the air contained in the mold 14.
• the air contained in the mold 14 is mainly between the molding material and the upper shell 141 of the mold 14.
• the drainage element 22 is therefore preferably located in this area. It is thus avoided that the shell 141 is plated with the material by allowing air to circulate between the shell 141 and the material during the creation of the vacuum within the envelope 12.
• the drainage element 22 may be of the same material as the drainage element 20 and circulating the air.
• An insert guide member may be provided in the mold 14.
• This guide member corresponds, for example, to a flexible plate disposed between the shell 141 and the molding material and covering the molding material.
• the guide element comprises, for example, openings for the passage of parts or inserts penetrating partially or completely into the molding material. Proper positioning of the inserts is thus obtained.
• the device 10 comprises at least one deformation member 19 (two distinct deformation members 19 being shown in FIGS. 1 and 2) adapted to form the mold 14 in a desired shape so as to mold the material into a particular shape.
• the envelope 12 and the mold 14 being flexible, they can deform under the action of the deformation member 19.
• a single deformation member 19 may be sufficient to conform the mold 14, for example by deforming a central zone of the mold 14.
• several deformation members may be provided, so as to deform the mold 14 into several areas. In the rest of the text, the device will be described with several deformation members but the same remarks apply when a single deformation member is provided.
• the deformation members 19 of the mold 14 are in the mold 14. At rest, the mold 14 rests flat, and when the deformation members 19 are activated, they deform the mold 14 against gravity.
• the advantage is that the practical embodiment of the deformation is simpler to achieve than if the mold was held vertically and the members 19 laterally deformed the mold. Indeed, a problem would arise to happen to keep in place the material in the mold if the mold was held vertically. There is a risk that the material will flow into the mold and the thickness of the material will vary.
• the deformation members 19 bias the envelope 12.
• the members 19 are in contact with the envelope 12. By biasing the envelope 12, the mold 14 is deformed.
• the advantage is that the risks of drilling the mold 14 are reduced, since double protection is provided by the casing 12 and the mold 14.
• the deformation members 19 are therefore also located under the casing 12. Stressing of the envelope 12 and the deformation of the mold 14 are made against the gravity, by lifting or supporting the envelope 12 and the mold 14.
• the deformation members 19 are for example cylinders.
• the deformation members 19 may also be more simply metal rods whose height is adjusted by interposing shims between the base of the rod and the ground.
• the advantage of using jacks is that the shapes that can be obtained are infinite, since the jacks can occupy various positions.
• the axes of the cylinders or metal rods are oriented vertically.
• the device 10 may further comprise ball joints 31 (visible in FIG. 2) between each deformation member 19 and the envelope 12.
• the ball joints 31 improve the connection between the deformation members 19 and the deformed envelope 12 under the yoke. 19.
• the ball joint 31 allows the rotation around three orthogonal axes of the surface element of the casing 12 facing the corresponding deformation member 19.
• the device 10 may comprise a disc 32 (visible in Figure 2) between the ball joint 31 and the envelope 12.
• the ball 31 then allows the rotation of the disc 32 around three axes.
• the disc 32 also locally reinforces the envelope 12 so as to further reduce the risk of tearing the envelope 12 and therefore the mold 14.
• the disc 32 may be molded in the envelope 12, in particular in the lower part 121 of the envelope 12. The disc 32 is thus secured to the envelope 12.
• the disc 32 can also simply be inserted between the ball 31 and the envelope 12. An adaptation to a more random disposition of the deformation members 19 is thus facilitated.
• the ball 31 may correspond to a pad made of a deformable material, for example rubber.
• the deformation of parts which, at rest, can measure about 5 m 2 (for example) can be obtained by the device 10.
• the deformation members 19 are evenly distributed or not under the surface of the envelope 12. Preferably, the members 19 are regularly distributed in a grid. The deformation of the mold 14 can thus be better controlled.
• the device 10 further comprises an additional means 30, in addition to the envelope 12, allowing the application of a pressure on the mold 14, at least after the mold 14 has been deformed.
• the additional means 30 corresponds to a load 30 which is adapted to be disposed on the casing 12, when the mold 14 is placed in the casing 12 during the process for manufacturing molded parts like this. will be described in more detail later.
• the load 30 corresponds to one or more massive elements, for example weights.
• the load 30 consists of three solid elements, weighing, for example, several kilograms each.
• a pressure is applied to the major part of the mold 14 by the load 30 through the envelope 12.
• the pressure applied by the load 30 is distributed substantially uniformly over the majority of the mold 14 at the 12.
• the load 30 may correspond to several sandbags distributed over the mold 14 with the interposition of the envelope 12.
• the load 30 may correspond to a pocket in which are provided juxtaposed compartments, each compartment containing sand and / or water. The pocket can then be arranged so as to cover the mold 14, with the interposition of the envelope 12. The compartments filled with sand and / or water are thus distributed over most of the mold 14 and ensure the application of a uniform pressure on the mold 14.
• the invention also relates to a method for manufacturing parts.
• the parts may be concrete, preferably high performance fiber concrete. Thin pieces a few millimeters thick can be made with this type of concrete.
• the manufacturing method comprises a step of introducing a material to be molded into the mold 14.
• the method then comprises a step of placing the mold 14 in the envelope 12.
• the envelope 12 is closed and a vacuum is created in the casing 12 by forming a gaseous flow by taking vacuum 15.
• the vacuum in the casing 12 can even propagate in the mold 14, attention being drawn to the fact that the molding material does not
• the method then comprises a step of deformation of the mold 14.
• the method further comprises a step of stopping the gas flow after forming the vacuum in the envelope 12, this step which can be carried out before or after deformation of the mold 14.
• the method then comprises a step of applying a pressure, by the different means 30 of the envelope and deformation members, on at least a portion of the mold 14, at least after stopping the gas flow.
• the material dries (or sets) even as the mold 14 is kept deformed.
• a piece of a particular form which can give an aesthetic character to a work.
• the method is repeated, so as to obtain a plurality of pieces of particular shape.
• the pieces can then be assembled so that the resulting puzzle gives an aesthetic impression.
• Parts having a small thickness may in particular be molded by the method according to the invention. Indeed, the thickness of the material is controlled, and this, throughout the duration of the process.
• Figures 3 to 6 show the molding device 10 according to the first embodiment of the invention at successive stages of an exemplary method of manufacturing a molded part.
• FIG. 3 shows the device 10 after the molding material has been put into place in the mold 14 and the mold 14 has been placed in the envelope 12.
• the mold 14 is shown in dotted lines in FIG. 15 of the casing 12 is connected to the vacuum pump 16 which is not in operation in FIG. 3.
• the lower part 122 of the casing 12 may in the first place be arranged on the table 24 (not shown in FIG. 3).
• the mold 14 is placed in the envelope 12 in the sense that, at first, only the lower shell 142 is disposed on the lower portion 122 of the envelope 12.
• the lower portion 122 and the lower shell 142 lie flat . This arrangement facilitates the step of introducing the material to be molded into the mold 14, and the display of the material over the entire surface of the mold 14.
• the thickness of the material is thus better controlled.
• the mold 14 and the casing 12 being arranged horizontally, the molding material does not flow inside the mold 14.
• the drainage element 20 can be arranged on the lower part 122, before the setting place of the lower shell 142. This promotes the creation of the depression within the envelope 12.
• the mold 14 is closed by placing the upper shell 141 on the hull 142.
• the drainage element 22 is disposed between the material and the upper shell 141. The drainage element 22 promotes the propagation of the depression within the mold 14.
• the drainage element 22 also gives a better aspect to the material once the process is complete.
• the drainage element 22 reduces the risk of entrapment of air bubbles in the mold 14, which would give a cracked appearance to the surface of the molding.
• the insert guide member is disposed between the material and the upper shell 141. Inserts are then introduced completely or partially in the molding material using the openings of the guide member as a guide to penetrate the inserts into the molding material. Then the envelope 12 is closed on the mold 14, by arrangement of the upper portion 121 of the envelope 12 on the upper shell 141.
• a drainage element 20 may also be disposed between the upper portion 121 and the upper shell 141. This drainage element 20 promotes the creation of the depression and also reduces the risk of entrapment of air bubbles in the envelope 12, these air bubbles having the adverse effects described above.
• FIG. 4 shows the device 10 after having made a depression in the envelope 12.
• the depression is obtained by starting up the vacuum pump 16.
• the envelope 12 then conforms to the shape of the mold 14 containing the material to be molded .
• the casing 12 is pressed against the mold 14 (possibly via the drainage elements 20, where appropriate).
• This depression can propagate within the mold 14.
• This depression results in obtaining a wafer, composed of the envelope 12 and the mold 14 enclosing the molding material, which is rigid enough for the material to flow. not in the mold 14, but which is also flexible enough to undergo deformation by the deformation members 19.
• Another advantage is that the material confined in the mold 14 remains substantially constant thickness during the manufacturing process. A molded part of substantially constant thickness is thus obtained.
• the assembly consisting of the envelope 12 and the mold 14, the mold 14 being disposed in the envelope 12 and a depression being formed in the envelope 12, is called the envelope 12-mold assembly 14 .
• FIG. 5 shows the device 10 after applying the envelope 12-mold assembly 14 to the table 24 and after having actuated the deformation members 19, that is to say the jacks (shown in dotted lines) in the first example of realization.
• the deformation of the mold 14 can be effected by biasing the envelope 12 by the deformation members 19.
• the deformation members 19 are set independently of one another.
• the members 19 more or less solicit the envelope 12. To do this, the members 19 raise more or less the envelope 12, independently of each other.
• FIG. 6 shows the device 10 after carrying out the following steps: placing the load 30 on the envelope 12-mold assembly 14; blocking the flow of air passing through the vacuum tap 15; and interrupting the operation of the vacuum pump 16.
• the interruption of the operation of the vacuum pump 16 may automatically cause the blockage of the air flow. by the intake of vacuum 15.
• the interruption of the operation of the vacuum pump 16 can be performed before or after the disposition of the load 30, or even before the deformation of the assembly 12-mold envelope 14 by the deformation members 19
• the pressure in the envelope 12 increases slowly, in particular because of leakage at the envelope 12.
• the presence of the load 30 prevents the displacement of the mold 14, and in particular the displacement of the upper shell 141 relative to the lower shell 142.
• the mold 14 can be removed from the envelope 12.
• the piece obtained is a surface that may include asperities and depressions.
• the piece obtained is a three-dimensional object with a locally variable curvature.
• the curvature may be locally positive or negative sign. Preferably, there is no singularity or discontinuity.
• the surface may comprise a single hump. If several members 19 are used, then the surface may comprise a plurality of bumps more or less high and separated by recesses. The bumps may then correspond to the locations of the members 19 urging the envelope 12, while the recesses may correspond to the locations where there are no deformation members 19.
• a part may be made by molding by the method described above. It is conceivable that the process is repeated so as to manufacture several parts by molding, and to assemble these parts together. The parts to be assembled are then modules.
• the surface thus manufactured is itself a three-dimensional object with a locally variable curvature.
• the curvature may be locally positive or negative sign. Preferably, there is no singularity or discontinuity.
• a larger area (for example 8000 m 2 ) can then be obtained by manufacturing smaller pieces (for example up to 20 m 2 , preferably 5 m 2 , even more preferably 2 m 2 , even more preferential way of 1 m 2 ).
• the deformation members likewise urge the edges of two parts intended to be contiguous in the assembly, so as to be able to join the parts together by their edges and that the assembly obtained be continuous with a room to another.
• the advantage of the device and the method is that the parts obtained and assembled are thin and therefore relatively less heavy.
• FIG. 7 shows a molding device 40 according to a second embodiment of the invention.
• the deformation member 19 corresponds to a template.
• the advantage is that the deformation applied to the 12-mold envelope assembly 14 can be performed reproducibly easily and at a reduced cost.
• the jig 19 comprises a face 42 against which is applied the envelope 12-mold assembly 14, once the depression formed in the mold 14.
• the template 19 urges the envelope 12 so as to deform the mold 14.
• the template 19 has for example the shape of a saddle horse, a spherical portion, a cylindrical portion (as shown in Figure 7) and, generally, a curved surface in three dimensions.
• the load 30 is represented by three solid elements.
• the load 30 may correspond to a counter-jig, having a face whose shape is complementary to the shape of the jig 19, and which is adapted to cover the entire envelope 12-mold 14.
• the counter-jig is made of a sufficiently heavy material to cause the application of a sufficient pressure on the mold 14 through the envelope 12.
• Figures 8 and 9 show the molding device 40 according to the second embodiment in successive steps of an exemplary method of manufacturing a molded part.
• Figure 8 shows the device 40 after having applied the assembly 12-mold envelope 14 against the deformation member 19, that is to say a template in the second embodiment.
• the 12-mold envelope assembly 14 deforms to conform to the shape of the face 42 of the template 19.
• FIG. 9 shows the device 40 after having performed the following steps: placing the load 30 on the envelope 12-mold assembly 14 ; blocking the flow of air passing through the vacuum tap 15; and interrupting the operation of the vacuum pump 16.
• the interruption of the operation of the vacuum pump 16 may automatically cause the airflow to be blocked by the vacuum tap 15.
• the interruption of the operation of the vacuum pump 16 may be performed before or after the arrangement of the load 30, or even before the application of the envelope 12-mold assembly 14 on the jig 19.
• the pressure present in the envelope 12 then increases slowly, in particular because of leaks at the level of the casing 12.
• the presence of the load 30 prevents the displacement of the mold 14, and in particular the displacement of the upper shell 141 relative to the lower shell 142.
• the mold 14 can be removed from the envelope 12 and the molding material can be demolded.
• the additional means 30, in addition to the envelope 12, allowing the application of a pressure on the mold 14 corresponds to a load placed on the mold 14 with the interposition of the envelope 12.
• the additional means 30 can correspond to any type of system that allows the mold to be maintained.
• the additional means 30 may correspond to a fixing system of the mold 14 to the template 19, for example a set of straps or jaws holding the mold 14 against the jig 19
• the additional means 30 allow the application of a pressure on the mold 14 as uniformly as possible over the largest possible part of the mold 14 opposite the template 19.
• the material used to make the part by the method and the device is preferably ultra-high performance fiber concrete (abbreviated as UHPCF).
• UHPCF ultra-high performance fiber concrete
• This piece has, for example, a thickness of 5 to 50 mm. Very thin pieces can thus be obtained. Preferably the piece has a thickness of about 15 mm.
• Ultra-high performance fiber concretes are concretes having a cement matrix containing fibers. It is referred to the document entitled "Ultra High Performance Fiber Concretes” of the Technical Service of Roads and Highways (Serra) and the French Association of Civil Engineering (AFGC). The resistance of these concretes to compression is generally greater than 150 MPa, or even greater than 250 MPa.
• the fibers may be metallic, organic, or a mixture of organic and metallic fibers.
• the binder dosage is high (the E / C ratio is low, generally the E / C ratio is at most about 0.3).
• the cementitious matrix generally comprises cement (Portland), a pozzolanic reaction element (in particular fumed silica) and a fine sand.
• cement Portableland
• pozzolanic reaction element in particular fumed silica
• fine sand a fine sand.
• cement matrixes By way of example of cement matrixes, mention may be made of the matrices described in patent applications EP-A-518777, EP-A-934915, WO-A-9501316, WO-A-9501317, WO-A-9928267, WO-A-9958468, WO-A-9923046, WO-A-0158826, and WO2008 / 056065 to which it is referred for more details.

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• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)
• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
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• Molds, Cores, And Manufacturing Methods Thereof (AREA)

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• 2009
  • 2009-05-11 FR FR0902246A patent/FR2945234B1/fr not_active Expired - Fee Related
• 2010
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• 2014
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