EP4157601A1

EP4157601A1 - Mold part

Info

Publication number: EP4157601A1
Application number: EP21729476.8A
Authority: EP
Inventors: Jonas Jacob
Original assignee: Hs 3d Performance GmbH
Current assignee: Hs 3d Performance GmbH
Priority date: 2020-06-02
Filing date: 2021-05-27
Publication date: 2023-04-05
Also published as: DE102020114658A1; CA3185716A1; WO2021244929A1; US20230191657A1

Abstract

The invention relates to a mold part (7, 9, 10, 11, 31, 32, 35) of a modular concrete block mold, said mold part having a generatively manufactured region (17, 19, 21) or being a generatively manufactured mold part (7, 9, 10, 11, 31, 32, 35).

Description

Mold part

The invention relates to a molded part of a modular concrete block mold. Such a concrete block mold is assembled from several mold parts.

Concrete block molds are used to set shaped blocks. An amount of concrete is poured into the concrete block form, and the concrete amount is compacted in the concrete block form by means of a block maker to create a concrete block. The concrete block mold comprises a lower part of the mold, in whose one or more cavities the amount of concrete is filled, and an upper part of the mold with a stamp unit for compacting the amount of concrete in the cavities. The stamp unit comprises pressure plates which can engage in the mold cavities of the lower part of the mold. The lower part of the mold is open at the top and bottom, with the underside being closed by a horizontal pad. The amount of concrete is poured through the upper openings of the mold cavities and then pressed through the pressure plates by being sunk into the mold cavities through the upper openings with a load unit. By shaking the base, the concrete mix solidifies to form stable molded concrete parts. In a final step, the molded concrete parts are removed from the mold through the lower openings in the mold cavities.

Flohlsteine are made using a concrete block mold in which cores are also placed in the recesses so that the amount of concrete is pushed into the space between the recess wall and the core. The pressure plates used in the manufacture of fleas have cutouts whose shape corresponds to the core shape, so that the pressure plates can be pressed down along the upper core area during pressing.

A concrete block mold in modular construction comprises several mold parts that are detachably connected to one another to form the concrete block form. The modular design allows the replacement of individual mold parts, so that when individual mold parts wear out, the entire concrete block mold does not have to be replaced and, in contrast to concrete block molds with permanently welded mold parts, the concrete block mold can be used more economically and sustainably. The replacement mold parts, like the mold parts of the concrete block mold, are made by conventional machining processes and / or casting processes.

The task is to provide an alternative mold part for a modular concrete block form.

The mold part of a modular concrete block mold for solving the task has an additively manufactured area or is an additively manufactured form part. In other words: such a molded part is generatively manufactured at least in some areas. Another area of the molded part, if not entirely generatively manufactured, is manufactured conventionally, for example milled or cast. The connection between generatively and conventionally manufactured Be rich can be made by suitable connecting means, for example welded connection, adhesive connection, fastening means such as screws or by printing the generatively manufactured area onto the conventionally manufactured area. Depending on the connection between the areas, the molded part is made in one piece or in several parts.

Generative manufacturing, also known as additive manufacturing, of mold parts has so far been unknown in mold making for block making machines. Automated processes that produce three-dimensional physical objects from a data set are called generative manufacturing processes. For this purpose, volume elements are stacked or joined in layers so that no mold-dependent tools are required. Generative manufacturing processes are also known as 3-D printing. Given the loads to which the concrete block mold is exposed, the mold part or at least its generatively manufactured area is advantageously manufactured from metal by means of a 3-D metal printing process. With 3-D metal printing, an energy source, such as a laser, sinks or melts a metal powder, usually in order to create the object to be manufactured in layers. The powder can be in a powder bed or projected using a nozzle. In this way, a metal additively manufactured area, that is to say a 3-D metal printing area, or a metal additively manufactured mold part, that is to say a 3-D metal printing mold part, can be manufactured.

A person skilled in the art can distinguish additively manufactured areas and molded parts from conventionally manufactured ones. Generatively manufactured areas and molded parts, especially if they are metal, can be identified as such based on their basic structure because of their manufacture from powder. Furthermore, they can be recognized as generatively manufactured by means of layers, in particular when combining different materia. In addition, the shape of generatively manufactured areas or mold parts also allows them to be recognized as such if such a shape could not be manufactured in a conventional manner.

The use of at least regionally generatively manufactured mold parts in concrete block molds has several advantages. Additive manufacturing, especially 3-D metal printing, allows great freedom in the design of the molded part. 3-D metal printing can be used to produce shapes that could not be produced using conventional methods, such as undercuts. Tool-related limitations of conventional manufacturing processes, for example a limited selection of milling tools that would be associated with limited radii, do not apply to 3-D metal printing. Through additive manufacturing, for example, protruding embossments can be formed without milling radii. In addition, many shapes can also be produced in a simpler way than with conventional production, for example Cavities. Complex groups of mold parts, which are composed of several mold parts, can be printed in one piece, so that the number of mold parts can be reduced in the case of the concrete block mold. The topology optimization for the mold parts can be done with the support of the finite element method (FEM).

The generatively manufactured mold parts offer increased functionality compared to conventionally manufactured ones. Geometry contours that cannot be produced conventionally can be easily produced using 3-D printing. Genera tively manufactured cavities result in a weight saving and an increase in the dynamic strength value. Furthermore, embedded additional functions can be provided by additive manufacturing in order to form heatable molded parts in this way. The molded part can be designed to receive a heating element and / or has a heating channel. By means of heated mold parts, in particular pressure plates, the sticking of the concrete mixture to the surface of the mold part is reduced and the concrete mixture becomes easier to detach. Overall, through additive manufacturing, not only shapes and contours, but also surface structures can be created in a simpler way than with conventionally manufactured molded parts. For example, scanned natural stone surfaces can be reproduced almost exactly. Structural surfaces with a high level of detail and particularly fine contouring, which conventionally could only be milled with micro tools, can also be created in this way.

Another advantage is that the molded part with an additively manufactured area or the additively manufactured molded part saves material in production, waste is minimized and there is no need to cut.

In one embodiment, the molded part can have a conventionally manufactured milled or cast area as well as the additively manufactured area have, which can be associated with a combination of different materials.

In one embodiment, the at least regionally generatively manufactured molded part has a first region made of a first material and a second region made of a second material. At least one of the two areas is produced generatively. Advantageously, both areas are produced generatively so that the additively produced area can include the first and the second area. These versions offer the possibility of combining different materials in one mold, for example to print areas with harder materials that are particularly exposed to abrasion.

The use of a harder, more stable material comes in particular for areas on the top of the lower mold part, in which the pressure plates engage, and on the underside of the lower mold part and the upper mold part, which rests on the base or which engages in the mold cavities, in question . Molded parts that are less stressed by frictional wear are printed using a material that has a high tensile strength, for example the molded parts of the frame.

The selection of the first and the second material is made with regard to the function and load of the corresponding areas. For example, the first material can be one from the group comprising covering material, filler material and support material, and the second material can be another material from the group comprising covering material, filler material and support material. Of course, more than two different materials can also be combined. The shell material is used on the functional surface of the molded part. It is advantageously wear-resistant. The formation of a non-stick area is also conceivable. The filling material fills free volumes of the molded part. It's usually easy and good printable. The support material is used for areas subject to higher forces, such as stiffeners. It should have high strength.

The use of the mold part with a generatively manufactured area in a concrete block mold has another advantage in the event of wear, whereby wear not only means material wear and tear due to the running time, but also defects of all kinds. It is not necessary to replace the entire mold part if it is only worn in areas . Rather, it is sufficient to simply replace the worn area that has been manufactured using generative methods and, for example, to rebuild it by means of additive manufacturing. The generatively manufactured area can therefore also be referred to as an exchangeable wear volume. Mold parts with a wear volume enable groups of mold parts that are subject to wear to be further modularized beyond their individual mold parts, so that the corresponding concrete block mold can be viewed as a further modularized mold.

Generatively manufactured areas that are interchangeable are directly engaging areas of the mold parts, in particular the upper edge of the lower part of the mold in the main compression area, core tops, printing plate mirror and printing plate bevel as well as sword mirror and sword tip. The printing plate mirror is the side of the printing plate facing the nest. Their bevel is the beveled edge area, which is particularly stressed during lowering into the nest and by shaking. The bevels of the nest edges, in order to prevent or mitigate the impacts of the pressure plates, are also exposed to loads. A sword is a pressure plate, one edge area of which extends to a point along the nest wall when the pressure plate is lowered, in order to form a shaped stone with an inclined side.

With regard to the expected wear and tear and the expected service life, the choice of material for the concrete block mold and its at least Generatively manufactured molded parts are made in abundance. The choice of material can depend on the wear-dependent pressure parameters and raw materials. Concrete block molds, which are only expected to be used for a few cycles, can be made of a different material or a different combination of materials than standard molds that are designed for a high cycle rate, or even concrete block molds for special applications. If the concrete block mold is planned to be used for only a few cycles, an inexpensive, easy-to-use material can be selected that is accompanied by a simple 3-D printing process. However, the mold part of such a concrete block mold is not as strong as that described below. In the case of a standard mold for a high number of cycles, the powder selection for the 3-D printing of the mold parts is optimized with regard to the highest strength and service life values. Additional strengthening measures, such as heat treatment and coating, can be carried out during manufacture in order to achieve a longer service life for the concrete block mold. In the case of special applications, the choice of material is based on the specific application. For example, higher-quality types of metal can be selected for particularly abrasive types of concrete, even if 3-D metal printing is more difficult and complex for such types of metal.

Some exemplary embodiments are explained in more detail below with reference to the drawing.

Figure 1 shows an embodiment of a modular concrete block mold in an exploded view.

FIGS. 2A, 2B and 2C show an exemplary embodiment of a molded part in a three-dimensional representation, in a side view and in a detailed representation of the side view. Figure 3 shows a further embodiment of a molded part in a three-dimensional representation.

FIG. 4 shows a section through a further exemplary embodiment of a component part.

Figure 5 shows a further embodiment of a molded part in a side view.

In the figures, identical or functionally identical components are provided with the same reference symbols.

Figure 1 shows an embodiment of a modular concrete block mold in an exploded view. The concrete block mold comprises a lower mold part and an upper mold part. For the sake of clarity, the lower part of the mold and only parts of the upper part of the mold that come into contact with the concrete mixture during the production of concrete blocks are shown. With the concrete block form shown, several fleas can be formed at the same time.

The lower mold part has a frame 1 made up of several mold parts 10. The frame 1 surrounds an insert 3, which is composed of several molded parts 31, 32. The insert 3 has several recesses 5, which are designed as cavities in the form, also referred to as stone cavities. In this exemplary embodiment, the concrete block form has twelve nests in two rows. The molded parts 31, 32 of the insert 3 comprise longitudinal walls 32 which extend along the length of the insert. Transverse walls 31 are inserted between the longitudinal walls 32. Cores 7 in the recesses 5 are used to form the hollow spaces in the hollow stones to be manufactured. In this exemplary embodiment, two cores 7 are provided for a recess 5. The cores 7 are fastened line by line to a core holding bar 11, which in turn is attached to the frame 1 is consolidated. The cores 7 and the core holding strips 11 are also molded parts. The mold parts 7, 11, 10, 31, 32 can be connected to one another, for example, by tongue and groove connections and / or plug connections and / or screw connections in order to form the lower part of the modular concrete block mold.

The upper mold part (not shown in its entirety), which comprises a plurality of pressure plates 9, is arranged opposite the recesses 5. The pressure plates 9 correspond in size and shape to the area between Aussparungskon structure and core contour and can be lowered into the recess 5 so that they move past the top of the core. The printing plates 9 as compo th of the upper part of the mold are connected via stamps and a plate to form a unit (not shown). The pressure plates 9, like the other parts, e.g. stamp and plate, which are mounted to the mold upper part of the concrete block mold, are also mold parts.

During the stone production, a quantity of concrete is poured into the recesses 5. The amount of concrete is compacted by shaking, during which the filling level of the amount of concrete is reduced and the pressure plates 9 press the concrete mixture and so on are lowered. The area between the volume level in insert 3 before and after compaction is also referred to as the main compaction area. The main compression area is in the upper area of the lower part of the mold. Due to the combination of shaking and a lowering of the pressure plates 9 during compression, the mechanical loading of the molded parts 31, 32 of the insert 3 in the main compression area is particularly high. This also applies to the upper area of the cores 7.

The concrete block mold has molded parts 7, 9, 10, 11, 31, 32 which have been produced generatively at least in some areas. The corresponding molded parts 7, 9, 10, 11, 31, 32 can be produced generatively entirely or only in certain areas are. The concrete block mold can also have mold parts 7, 9, 10, 11, 31, 32 made entirely conventionally.

The modular construction of the concrete block mold makes it possible to replace a mold part 7, 9, 10, 11, 31, 32, even if it is manufactured entirely conventionally, with a generatively manufactured mold part 7, 9, 10, 11, 31, 32 . In this way, a replacement mold part can be produced in a simple manner by means of 3-D metal printing. Of course, the replacement mold part can also be produced generatively only in certain areas. In the case of only local wear of a molded part 7, 9, 10, 11, 31, 32, the affected molded part 7, 9, 10, 11, 31, 32 can be adapted, that is, it is refurbished and reused. During adaptation, additive manufacturing is used to restore the shape in the non-worn state, i.e. the original shape of the molded part, by means of 3-D metal printing. In the case of a molded part 7, 9, 10, 11, 31, 32 whose generatively manufactured area is worn out, the adaptation can take place by exchanging the additively manufactured area.

In general, the upper areas of the mold parts 7, 10, 11, 31, 32 in the lower part of the mold and the underside, which is also referred to as a mirror, and side areas of the pressure plates 9 wear out in the concrete block mold upper area of the insert 3 abuts. A concrete block mold has a specific mold height, for example 88 mm, in order to produce a desired block height, following the example above this would be 80 mm. During block production, the complete concrete block form is filled with concrete up to the form height, 88 mm. The pressure plates 9 then begin to dip into the recesses 5 under pressure and to compress the mixture. At the same time, there is strong shaking from below, which is also known as shock vibration. The amount of concrete only reaches its necessary strength when the pressure plates 9 have reached the stone height, 80 mm. This means that the upper area of the concrete block form is between the form height and the stone height, which is 8 mm wide and is also referred to as the main compression area, is the most stressed and therefore also the fastest to wear. In Figures 2A, 2B, 2C and 3 mold parts 31, 7 from the concrete block form are shown in which exactly these areas are armored by generatively manufactured areas against the load described above.

FIGS. 2A, 2B and 2C show an exemplary embodiment of a molded part 31, which has generatively manufactured areas, in a three-dimensional representation, in a side view and as a detailed representation of the upper region of the side view. The mold part 31 is a transverse wall of the insert 3 of the concrete block form.

The metal mold part 31, which is designed as a transverse wall, has a rectangular base area with laterally extending fastening means 13 for engaging the adjacent, transversely extending longitudinal walls 32. At an upper part of the mold part 31, which faces the mold upper part of the concrete mold in the assembled state, has the molded part 31 bevels 15 as obliquely ver running upper edges on the front and back.

In the upper area, the molded part 31 has strip-shaped, generatively manufactured first areas 17 on the front and rear. The generatively manufactured first areas 17 are 3-D metal printing areas and also form the bevels 15. The strip-shaped first areas 17 extend over the entire length of the transverse wall and at least along the main compression area in which the molded part 31 is exposed to particular loads. The second region 19 of the molded part 31 beyond the first regions 17 can be conventionally manufactured, for example milled or cast. In an alternative exemplary embodiment, the second area 19 is likewise a generatively manufactured 3-D metal printing area, the material of which, however, differs from that of the first area 17. The connection between the areas 17, 19 can done by suitable means, for example welded joint, adhesive bond, fasteners such as screws or preferably by one of the areas 17, 19 has been printed on the other.

The at least regional generative production of the molded part 31 allows different materials to be used for the different areas 17, 19 of the molded part 31, the materials being optimized with regard to the various requirements of the areas 17, 19. The abrasively stressed first areas 17 are made of a more resistant, more stable material than the second area 19.

If the first areas 17 wear out, it is not necessary to replace the entire form part 31, but rather it is sufficient to merely adapt the form part 31 by replacing only the generatively manufactured first areas 17 with new generatively manufactured areas and / or with 3-D -Metal pressure to be rebuilt.

FIG. 3 shows an exemplary embodiment of a molded part 7, which has generatively manufactured areas, in a three-dimensional representation. The mold part is a core 7 of the concrete block mold. On its upper side there is a gap 21 in which the core holding strip 11 engages. The edges of the upper side of the core facing away from the gap 21 are rounded in order to facilitate the lowering of the pressure plate 9 along the core 7 and to prevent the pressure plates 9 from striking.

The upper side of the core has generatively manufactured first regions 13 on both sides of the gap 21, which extend beyond the rounded edges.

The upper side of the core 7 is exposed to great loads due to the pressure plates 9, which lower over it and possibly hit it, in combination with the shaking. The generatively manufactured first areas 17 are made of a harder material than the second area 19, which forms the core body. det. The second area 19 can be manufactured conventionally or generatively, and different materials can be combined for the body and top, as has already been described in connection with the previous exemplary embodiment.

When the first areas 17 wear out, it is not necessary to replace the entire Formenteil 7, but it is sufficient to merely adapt the molded part 7 by replacing and / or rebuilding only the generatively manufactured first areas 17 by generatively manufactured areas.

FIG. 4 shows a section through an exemplary embodiment of a pressure plate 9 with a rectangular base area, as can be used for printing paving stones.

The pressure plate 9 has a negative bevel 16 on the edge, which is designed as a protruding area with a triangular contour in order to form a beveled edge of the stone. The bevel 16 is a generatively manufactured first area 17 on a second area 19 extending over the entire mirror 27. The first area 17 is made of a harder material than the second area 19. The material of the second area 19 is a non-stick covering material. On the side of the second area 19 facing away from the first area 13, a third area 21, which is manufactured using an alternative method and has a flat recess 23, is applied. A component for an additional function, for example a flat fleece element 25, can be introduced into the recess so that the pressure plate 9 can be heated. The third area 21 has a flint cut 29 which can engage in another molded part. The fleece element 25 supports the non-stick properties of the pressure level 27, since the amount of concrete, which has slightly dried on the surface as a result, comes off more easily. Figure 5 shows a further embodiment of a molded part, which is designed as a sword 35, in a side view. The sword 35 is a characteristically shaped pressure plate which has an edge area which, when the sword is sunk in the nest, extends tapering to a point along the wall of the cavity in order to form a stone with a sloping side, for example a curb. The mirror 27 of the sword 29 faces the mold cavity. A first region 13, which is manufactured using generative methods, forms the sword tip 37, which is made of a harder, more stable material than the second region 19, which forms the sword body with the mirror 27. The first area is an exchangeable wear volume.

The features indicated above and in the claims as well as the features which can be inferred from the illustrations can advantageously be implemented both individually and in various combinations. The invention is not restricted to the exemplary embodiments described, but can be modified in many ways within the scope of the skilled person.

Reference number

I frame

3 insert 5 recess

7 core

9 pressure plate

10 mold part

I I core retaining strip 13 fasteners 15 chamfer

17 first area

19 second area

21 third area 23 recess

25 meat element

27 mirrors

29 undercut

31 mold part 32 mold part

35 sword

37 tip

Claims

Expectations:

1. Mold part (7, 9, 10, 11, 31, 32, 35) of a modular concrete block mold, which has a generatively manufactured area (17, 19, 21) or a generatively manufactured mold part (7, 9, 10, 11 , 31, 32, 35) is.

2. Mold part (7, 9, 10, 11, 31, 32, 35) according to claim 1, wherein the additively manufactured area (17, 19, 21) is a 3-D metal printing area or the additively manufactured mold part (7, 9 , 10, 11, 31, 32, 35) is a 3-D metal printing mold part.

3. mold part (7, 9, 10, 11, 31, 32, 35) according to claim 1 or 2, which has a milled or cast area (19) and the generatively manufactured th area (17).

4. Mold part (7, 9, 10, 11, 31, 32, 35) according to one of the preceding claims, which has a first area (17) made of a first material and a second area (19) made of a second material, wherein at least the first area (17) is produced generatively.

5. molded part (7, 9, 10, 11, 31, 32, 35) according to claim 4, wherein the first material is one from the group with envelope material, filler material and support material and the second material is another from the group with envelope material, filler material and support material is.

6. Mold part (7, 9, 10, 11, 31, 32, 35) according to one of the preceding claims, wherein the generatively manufactured area (17, 19, 21) or the generatively manufactured mold part (7, 9, 10, 11 , 31, 32, 35) is at least partially non-stick.

7. Mold part (7, 9, 10, 11, 31, 32, 35) according to one of the preceding claims, which has an undercut (29).

8. Mold part (7, 9, 10, 11, 31, 32, 35) according to one of the preceding claims, which has a flea space. 9. Mold part (7,

9, 10, 11, 31, 32, 35) according to one of the preceding claims, which is heatable.

10. Mold part (7, 9, 10, 11, 31, 32, 35) according to one of the preceding claims, wherein the generatively manufactured region (17, 19, 21) is an edge region of the mold part (7, 9, 10, 11 , 31, 32, 35) is.

11. mold part (7, 9, 10, 11, 31, 32, 35) according to one of claims 1 to 10, wherein the first region (17) is an edge region of the mold part.

12. Mold part (9, 35) according to one of the preceding claims, which is a pressure plate (9) or a sword (35).

13. Mold part (9, 35) according to claim 12, wherein the generatively manufactured area (17, 19) forms a printing plate mirror (27) or a bevel (15, 16) or a sword mirror (27) or a sword tip (37).

14. mold part (9, 35) according to claim 12, wherein the generatively manufactured area (17, 19) forms a printing plate mirror (27) or a bevel (15, 16) or a sword mirror (27) or a sword tip (37).