EP4257315A1 - Method and device for producing concrete blocks - Google Patents

Abstract

A method is described for producing concrete blocks (1), in particular concrete blocks (1) for creating a surface covering, wherein each concrete block (1) has a multi-layered concrete block body (2) with at least one flat concrete block underside (2.1) and a substantially flat one opposite it Concrete block top (2.2) and wherein the concrete block body (2) has at least one first concrete block layer (2a) designed as a facing concrete layer and forming the concrete block top (2.2), at least one second concrete block layer (2b) designed as a core concrete layer and at least one forming the concrete block underside (2.1). third concrete block layer (2c). In the method, at least one formwork form (4) is provided. In a step for producing the second concrete block layer (2b) designed as a core concrete layer, a core concrete is introduced into the formwork mold (4) by means of a first filling device (11). After the core concrete has been introduced, a facing concrete is refilled into the formwork mold (4) in a further step to produce the first concrete block layer (2a) designed as a facing concrete layer. The concrete material placed in the formwork form (4) is then compacted and hardened. According to a special aspect of the present method, before the core concrete is introduced, in an initial step of the method for producing the third concrete block layer (2c), a concrete material for the third concrete block layer (2c) is introduced into the formwork mold (4) by means of a first metering device (13). becomes.

Description

Technical area

The invention relates to a method and a device for producing concrete blocks, in particular concrete blocks that are suitable for creating a surface covering.

State of the art

Concrete blocks, in particular surface covering elements, paving stones, steps, wall and boundary stones made of concrete are well known from the prior art. Such concrete blocks are very often used in road, traffic route and landscaping construction to produce surface coverings, so that concrete blocks for creating surface coverings are widespread and well known.

Particularly in urban areas, large areas of the surface are designed as walkable or drivable traffic areas such as streets, paths, squares or parking lots and are covered with surface coverings. The surface coverings are often produced by laying individual concrete blocks on a bedding layer of the subsurface in a composite manner, for example by paving. As a rule, joints remain between adjacent concrete blocks or shaped stones, in particular concrete paving stones, which are filled with suitable, usually sand-like or gravel-like joint materials.

It is also known to use multi-layered concrete blocks or concrete paving stones to create such a surface covering. These multi-layered concrete blocks generally have at least one core layer and one facing layer, with the core layer usually being made from a core concrete and forming a core of the concrete block and the facing layer generally being made from a facing concrete and the top side being accessible or driveable of the concrete block, namely its visible surface.

The production of the concrete blocks is usually done with the help of formwork molds and is carried out, for example, by machine, with concrete paving stones being known for this purpose in so-called paving stone machines or systems specifically designed for this purpose. As a rule, the concrete paving stones are manufactured in the desired stone formats using appropriate formwork shapes.

It is also known that the multilayer concrete blocks of the type mentioned are designed in such a way that they have a certain or desired water permeability due to their structure and the nature of the individual layers, in particular also due to the nature of the concrete used to produce the individual layers or water permeability and/or also have a specific or desired water storage capacity.

This is what this reveals DE 10 2012 100 616 B4 a surface covering made of two-layer shaped stones, which have a water-absorbing, water-permeable layer below a substantially water-impermeable layer on the surface, so that the impinging rainwater flows both over the joints and over the water-permeable layer of the shaped stones, thus via a seepage path through the concrete blocks itself, can flow downwards.

If necessary, rainwater can also be stored, which means that increased water evaporation can counteract a so-called urban "heat island effect", since evaporation cold occurs when water evaporates. Such a water-storing concrete block is made, for example EP 3 153 625 A1 known.

When producing multi-layer concrete blocks, it often proves to be difficult and problematic to obtain a desired layer structure in the concrete block in a defined manner using the methods known from the prior art, especially if layers with a small layer thickness are to be formed. Therefore, there remains a need for improved manufacturing processes.

Presentation of the invention

The object of the present invention is therefore to provide a method for producing multi-layer concrete blocks, which enables mechanical and at the same time flexible and rapid production of concrete blocks with a particular defined layer structure and at the same time enables the creation of thin layers of concrete blocks. This object is achieved by the method for producing concrete blocks according to patent claim 1. Furthermore, the object is solved by a device for producing floor covering elements according to patent claim 13. Further advantageous aspects, details and refinements of the invention result from the dependent claims, the description and the drawings.

The present invention provides a method for producing concrete blocks, in particular for producing concrete blocks to create a surface covering. The method according to the invention is intended for the corresponding operation of a paving stone machine. Each concrete block, in particular concrete paving stone, produced using the present method comprises a multi-layer concrete block body with at least one flat concrete block underside and a substantially flat concrete block upper side opposite this. The concrete block body has at least one first concrete block layer designed as a facing concrete layer and forming the top of the concrete block, at least one second concrete block layer designed as a core concrete layer and at least one third concrete block layer forming the underside of the concrete block. In the process, at least one formwork form is initially provided. In a step for producing the second concrete block layer designed as a core concrete layer, a core concrete is introduced into the formwork mold by means of a first filling device. After the core concrete has been introduced, a facing concrete is then refilled into the formwork form in a further step to produce the first concrete block layer designed as a facing concrete layer. The concrete material placed in the formwork form is then compacted and hardened. A special aspect of the method according to the invention can be seen in the fact that in an initial step of the method, namely before the core concrete is introduced into the formwork form, a concrete material for the third concrete block layer is introduced into the formwork form by means of a first metering device to produce the third concrete block layer .

In other words, after the formwork form has been prepared, the third layer of concrete blocks is first produced in the initial process step, then the second layer of concrete blocks and then again the first layer of concrete blocks.

The concrete block layers adjoin one another in the direction along a vertical axis of the concrete block body, with the second concrete block layer adjoining the The first concrete block layer forming the top of the concrete block is connected and the third concrete block layer in turn is connected to which the second concrete block layer is connected. In this context, the term "connect" is to be understood in the present case to mean that the adjoining concrete block layers follow one another directly and directly, that is to say without intermediate layers, and are connected to one another, or that additional intermediate layers are provided and the adjoining concrete block layers are thereby indirectly or indirectly connected to one another are connected. The second concrete block layer, designed as a core concrete layer, is in any case arranged between the first and third concrete block layers.

In the method, the facing concrete for producing the first concrete block layer can be refilled by means of a filling device or, if necessary, by means of a metering device, with the facing concrete preferably being refilled by means of a second filling device. A filling device in the sense of the present invention can, for example, be a filling carriage, in particular a movable, controlled-driven filling carriage which is movable, namely movable, relative to the formwork shape.

With the method according to the invention, the mechanical or automated production of multi-layer concrete blocks, which are also understood here as layered concrete blocks, is possible in a particularly defined manner and with a precise layer structure. Very special advantages result from the method according to the invention in that the concrete block layers, in particular the third concrete block layer forming the underside of the concrete block, can be produced in the desired, precisely defined and in particular uniform layer thickness, regardless of the concrete material used for production and also in a particularly small layer thickness.

This means that the concrete material for the third concrete block layer can be selected for the specific application and can, for example, also be a tough or coarse or water-poor or granular concrete material, while at the same time the layer thickness of the third concrete block layer can be kept very small and this thin concrete block layer can be defined and produced evenly.

With the present method, a layered concrete block can be produced which is equipped with at least the "third concrete block layer", which can also be referred to here as the "functional layer". The functional layer can vary depending on the type and planned use of the concrete block fulfill functions and can be provided, for example, as a layer to regulate water permeability or water storage or as a high-strength layer to increase the compressive or tensile strength of the concrete block or as a layer to prevent the concrete block from shifting or to interlock with the subsurface, for example with the bedding layer .

In the present case, the third concrete block layer can therefore be, for example, a water-storing or water-permeable or water-impermeable concrete block layer, a displacement protection or interlocking layer or a stability or strength layer, in particular a compressive strength or tensile strength layer or the like.

The present concrete blocks can also be referred to as surface covering elements made of concrete and are in particular, for example, plate-shaped or stone-shaped. The production of the concrete block, which in the present case can also be designed as a concrete paving stone and is preferably a "paving stone made of concrete" according to DIN EN 1338, is carried out mechanically using the method according to the invention in a device for the production of concrete blocks, which is advantageous for automated, preferably controlled, in particular program-controlled production and includes, for example, a paving stone machine. The method for producing the concrete blocks is therefore particularly automated, preferably controlled, in particular program-controlled.

The "formwork mold" used to carry out the method is preferably a mold that is configured for a single or for several concrete blocks, that is, one or more concrete blocks can be formed in a formwork mold, in which case in the latter case several mold recesses are formed in the formwork mold , each of which can also be understood as an individual form. The concrete blocks are preferably manufactured in a desired format or final format, which in this case can also be referred to as a nominal format or nominal size or nominal dimension.

The concrete material for the third concrete block layer is preferably introduced into the formwork in volumetric doses. As a result, the concrete material is metered into the formwork form with precise volume, which enables precise and uniform adherence to the layer structure, as well as in particular the thin and uniform layer thickness of the third concrete block layer.

The volumetric dosing is based on volume and therefore quantity, that is, the dosing device does not determine or measure the mass of the material to be dosed, but rather the volume, which is why the volumetric dosing here also depends on the "concrete material specification", for example. For a high level of accuracy, the metering device is therefore preferably calibrated before use to the respective concrete material used for the production of the third concrete block layer, in particular when changing between different concrete materials.

Particular advantages arise when the concrete material for the third concrete block layer is introduced into the formwork mold by means of a metering device designed as a rotary valve or having a rotary valve. Rotary valves, which are also referred to as devices for metering or feeding materials, in particular granular materials, are known to those skilled in the art in various designs. Advantageously, a very high metering accuracy can be achieved with such rotary valves, so that the concrete material is metered very precisely via the rotary valve, i.e. H. with high dosing accuracy, is introduced into the formwork. The concrete material is dosed volumetrically and the exact and volume-specific amount of concrete material can be dosed and introduced into the formwork.

The cellular wheel sluice preferably used here has, for example, a controlled, rotating cellular wheel and a metering aid that interacts with the cellular wheel, the metering aid being, for example, a metering plate designed in the form of a perforated plate.

In particular, in the present method, the dosing aid for dosing or volumetric introduction of the concrete material into the formwork mold is adapted depending on the concrete material used to be dosed. For example, a hole size in the metering plate is selected or set depending on the grain size of the concrete material. The hole size of the metering plate is preferably chosen so that it is in a range of approximately 2 times to 2.5 times the grain size.

Depending on the design of the dosing device, which is designed as a rotary valve or has a rotary valve, the concrete material can also be fed evenly into the formwork when it is introduced or filled into the formwork of the formwork form, in particular distributed over the surface of the formwork form, which promotes and supports uniform layer formation and layer thickness.

For the volumetric metered introduction of the concrete material for the third concrete block layer, a rotating cellular wheel of the cellular wheel lock is preferably driven in a controlled manner. The rotational speed of the cellular wheel can be set in a controlled manner, in particular in a frequency-controlled manner, for example by means of a frequency-controlled gear unit. By adjusting the rotation speed of the rotating cellular wheel, the dosing accuracy and the dosing behavior can be adapted to the respective concrete material for the third concrete block layer, thereby improving the overall dosing accuracy and the dosing behavior. Since, among other things, the rotation speed of the cellular wheel, namely its speed, influences the amount of concrete material conveyed or discharged and thus metered, the rotation speed can also be adjusted depending on the desired layer thickness to be produced.

Preferably, during the introduction of the concrete material for the third concrete block layer, the metering device is moved in at least one first direction of travel running along a longitudinal axis of the formwork form at a controlled predetermined or controlled speed, which is also referred to as a feed speed. In this case, the metering device is movably mounted, for example mounted movably on a corresponding frame, or by means of a guide provided for this purpose, for example a slide guide, and can preferably be moved above the formwork form in the direction of its longitudinal axis over the formwork form. As a result, the concrete material is supplied evenly, in particular at least in relation to a longitudinal direction of the formwork form, namely along its length.

The movement or movement of the metering device in the first direction of travel is driven, for example by means of a controlled drive device. The controlled drive device includes, for example, a controlled gear unit, in particular a frequency-controlled gear unit. In the present method, the dosing device is moved in a controlled manner in the first direction of travel, whereby the feed speed can be adjusted in a controlled manner or kept constant in a controlled manner along the movement path of the dosing device, that is to say over the feed path.

Likewise, the filling device is preferably a filling carriage that can be moved in a controlled manner at least in the first direction of travel. The functionality or method of operation of the filling device and metering device can be independent of one another or coupled.

For example, according to a first operating variant, the filling device and metering device can be coupled in such a way that in one operation both the concrete material for the third layer of concrete blocks is volumetrically metered into the formwork mold and the core concrete material is filled in by the metering device and the filling device together in the first Direction of travel above the formwork form can be moved or moved over it. The formwork form is filled sequentially, since in this first direction of travel the dosing device runs ahead of the filling device, so that at every point on the formwork form that is being filled, the concrete material for the third concrete block layer is always introduced in volumetric doses first and then the core concrete is filled. An operation is understood here as a single feed event in the first direction of travel. With this first operating variant, two layers of concrete blocks can be created in a single operation, which advantageously results in time savings.

In this first operating variant, the filling device and metering device can be moved back to their starting position after one operation in a return movement oriented opposite to the first direction of travel. The return journey or reset can take place in an idle state, that is, without releasing concrete material into the formwork form. Alternatively, however, for example, the metering device can be retracted or reset during the work run, so that additional concrete material is metered in during reset to produce a further concrete block layer above the core concrete layer.

According to a second operating variant, the metering device and the filling device are moved independently or separately from one another, that is to say in two operations, in the first direction of travel in order to introduce the concrete into the formwork form. Here, for example, in the first operation, the metering device can move in the first direction of travel and then be reset while idling. In the second operation, the filling device can finally move in the first direction of travel and then be reset while idling. In this second operating variant It proves to be advantageous that a compression and/or distribution step can be carried out between the two operations, for example by shaking, stamping, pressing, cutting or the like.

In the case of a formwork mold with several mold recesses, it is achieved that the mold recesses adjoining one another in the direction of the longitudinal axis are all reached by the metering device and are accordingly "equipped" with the concrete material in the desired manner. According to particularly preferred variants, it is also conceivable that the metering device is additionally moved over the formwork in a direction transverse to the longitudinal axis of the formwork form, namely in the direction of a width of the formwork form, in order to distribute the concrete material also in the direction oriented transversely to the longitudinal axis , namely to ensure the width of the formwork form.

In embodiments with a rotary valve, for example, the rotary valve has a working width that corresponds to the width of the formwork mold, so that when the metering device moves in the direction of travel, namely in the direction along the longitudinal axis of the formwork mold, which runs essentially perpendicular to the working width, all mold recesses are equal can be filled. The working width of the rotary valve is here to be understood as the width, or as that section of width or extension area, along which the concrete material is dispensed or dispensed in a metered manner by the rotary valve, that is, the section of width over which the rotating rotary wheel in cooperation with an outlet and/or discharges or dispenses the concrete material with a discharge device provided at the outlet.

In the present case, the rotating cellular wheel of the cellular wheel lock is an elongated or elongated rotor or rotor body, which extends along its length along the axis of rotation, with elongated or elongated rotor blades, which also extend along their length in the direction of the axis of rotation. Since the working width is determined, among other things, by the longitudinal extent of the cellular wheel and the longitudinal extent of the outlet interacting with the cellular wheel or the discharge device provided at the outlet, the working width in the preferred embodiment described corresponds to the length of the cellular wheel, which in turn preferably essentially corresponds to the width of the corresponds to the formwork used.

In the present method, the feed speed of the metering device moving in the direction of travel and the rotation speed of the cellular wheel are preferably coordinated with one another in a controlled manner and are adapted and coordinated in particular depending on the type of concrete material used for the third concrete block layer and / or a desired layer thickness of the third concrete block layer. This can ensure an application-related, optimized and effective allocation of the concrete material into the formwork mold or into the individual mold recesses. The layer thickness of the third concrete block layer can therefore be determined in the present method by a suitable combination or by coordinating the selected, controlled feed speed and rotation speed.

By advantageously providing a formwork mold equipped with a large number of mold recesses, a number of concrete blocks corresponding to the number of mold recesses can be produced simultaneously in one process run. Particularly advantageously, the concrete material for the third concrete block layer is introduced into each of the mold recesses of the formwork in a volumetric metered manner, so that the concrete blocks of a desired type or "variety" can be reliably produced in layers, namely as entire layers of the same concrete blocks with correspondingly similar and equally dimensioned Concrete stone layers.

Advantageously, at least the feed speed of the metering device, preferably also the rotation speed of the cellular wheel, is controlled depending on the design of the formwork shape. This shape-dependent control can also be understood as an adaptation of the feed and/or the feed speed to the formwork shape, with the terms “recipe control” or “recipe-controlled feed speed” also being used synonymously in the present sense.

For example, the feed speed can be controlled in such a way that a height of the speed along the travel path, namely along the feed path, changes in a sinusoidal manner or the speed values take a sinusoidal curve. In particular, the respective feed speed is at a minimum in the respective areas of a transition between two adjacent mold recesses of the formwork mold. This makes it particularly advantageous to achieve a particularly uniform distribution of the Concrete material can be achieved, since this effectively reduces such "shadowing" or "shading effects" caused by the intermediate walls of the formwork separating the mold recesses, which can have a negative effect on the uniform introduction of the concrete material.

Particularly preferably, before filling in the core concrete and/or before refilling the facing concrete, at least one further concrete material is filled into the formwork form, thereby producing at least one further concrete block layer. Depending on the planned application and intended use of the concrete block, this further concrete block layer can be arranged between the second and third concrete block layers or between the first and second concrete block layers. With this process variant, four-layer concrete blocks or even concrete blocks with more than four layers of concrete blocks can be produced easily, quickly and safely.

In those cases in which three layers of concrete blocks, namely the first, second and third layers of concrete blocks, are produced, the second layer of concrete blocks arranged between the first and third layers of concrete blocks is directly and immediately connected to the first or third layer of concrete blocks. In the equally possible cases in which four or more concrete block layers are produced, the second concrete block layer does not adjoin at least one of the first or third concrete block layers directly and directly, but indirectly or indirectly via the further concrete block layer.

In the preferred method variant with the production of at least one further concrete block layer, the further concrete material for the further concrete block layer is preferably introduced into the formwork in a volumetric metered manner, in particular also by means of the first metering device or by means of a second metering device designed as a rotary valve or having a rotary valve. As a result, the further concrete block layer can also be produced in the same advantageous manner as described above for the third concrete block layer.

In the event that the further concrete material for the further concrete block layer is introduced via a second metering device, the first and second metering devices can work independently of one another, that is to say can be operated independently of one another and controlled independently of one another, can be driven and moved. Alternatively, however, the metering devices can also work and be operated in a coupled mode of operation.

For example, with the present method, a large number of additional concrete block layers can also be integrated into the concrete block body, each of the many additional concrete block layers preferably being very thin and having a small layer thickness. Through this corresponding "multi-layered arrangement" of the thin concrete block layers or through this mutual "overlaying" of the large number of thin concrete block layers, for example, transition layers or graduation layers or mixed layers can be created.

For the production of such a large number of additional concrete block layers, a first and a second metering device with a respective rotary valve is preferably used, the two rotary valves working alternately, for example, and each successively introducing a respective concrete material into the formwork form in a volumetric metered manner. Between the respective dosing steps, additional intermediate steps for compacting or shaking or stamping the concrete material introduced in a respective dosing step can also be carried out. As already mentioned, a coupled mode of operation is alternatively possible, in which the metering devices are connected in series in such a way that they meter the respective concrete material into the formwork form in a common operation, that is to say in a common feed.

According to a particularly preferred embodiment, the concrete material introduced into the formwork form for the third concrete block layer and/or the core concrete introduced and/or the facing concrete introduced is evenly distributed over the area using concrete distribution means after the respective introduction. The respective concrete can be distributed, for example, using distribution means provided for this purpose. This distribution step allows particularly uniform layers of concrete blocks to be created. In particular, the concrete block layers therefore have a consistent layer thickness with small deviations based on the surface.

It is also preferred that the concrete material introduced into the formwork form for the third concrete block layer is pre-compacted in an intermediate step before the core concrete is introduced. Compaction can be done, for example, by pressing or shaking done, for example with a stamp of a press or with a vibrating system. Alternatively or additionally, the core concrete introduced into the formwork form is also pre-compacted in an intermediate step before the facing concrete is introduced. Here too, compaction can be done using a stamp in a press or by vibration or shaking.

Particularly preferably, the third concrete block layer is produced with a layer thickness which is between 1% and 20% of a total height of the concrete block body, preferably between 2% and 15% of a total height of the concrete block body and particularly preferably between 4% and 12% and particularly preferably between 5% and 10 % of a total height of the concrete block body.

For example, a concrete rich in grit and/or sand can be used as the concrete material for producing the third layer of concrete blocks. In particular, dry concrete can be used. The concrete material may be a coarse or fine concrete material and comprise a coarse or fine aggregate, the grain size of which may be, for example, in a range of 0 to 4 mm or 2 to 8 mm or 4 to 8 mm or 8 to 22 mm . A high-strength concrete can also be used as the concrete material for producing the third layer of concrete blocks.

Very particularly preferably, an earth-moist concrete can be used as the concrete material for producing the third layer of concrete blocks. “Earth-moist concrete” is understood to mean a concrete of stiff consistency that has a water-cement ratio (w/c ratio for short) of less than or equal to 0.4. In the present case, a concrete with a w/c ratio in the range from 0.25 to 0.4 is preferably used, particularly preferably in a range from 0.28 to 0.38.

A porous concrete is preferably used as the core concrete for producing the second concrete block layer. In this way, a concrete block with a desired water permeability or with water-storing properties can be produced. Such concrete blocks, for example, benefit the inner-city climate by increasing water evaporation when exposed to sunlight and can counteract a so-called heat island effect. Such water-permeable concrete blocks also contribute in an ecologically effective way to ensuring that surface coverings created from them do not result in complete surface sealing.

The present invention also relates to a device for producing concrete blocks. The device comprises at least one formwork mold with at least one or more mold recesses and at least one first filling device for introducing concrete into the formwork mold. The device is characterized in particular by a first metering device, wherein the first metering device is designed for the volumetric metered introduction of concrete material into the formwork mold.

With regard to the design of the present device, reference is made to the description above, where the device has already been described in more detail in connection with the method.

The device preferably also has a second filling device. Each of the filling devices can be designed, for example, as a filling cart. A second metering device can also preferably be provided.

Particular advantages arise from the fact that the first metering device and preferably also the second metering device can be coupled to the first filling device and can be coupled in such a way that the filling device and the metering device (s) can be operated in a coupled manner and in one operation both the volumetric metered introduction of concrete material through the metering device(s) as well as the filling of the core concrete can take place. Alternatively or additionally, the filling devices and metering devices can also be designed for independent operation.

Preferably, the at least one first metering device is formed by a rotary valve or comprises at least one rotary valve. Furthermore, the at least one first metering device is preferably mounted in a movable manner and can be moved, in particular in a controlled manner, in at least one first direction of travel running in the direction along a longitudinal axis of the formwork form.

At least the first filling device is preferably designed in the form of a filling carriage which can be driven and moved at least in the direction along a longitudinal axis of the formwork form. Furthermore, the second filling device can optionally also be designed as a filling carriage which can be driven and moved at least in the direction along the longitudinal axis of the formwork mold.

In the device, a control and/or regulating unit which communicates with the first and possibly the second filling device as well as with the first and possibly the second metering device is also provided. The introduction of concrete material into the formwork form can be adjusted in a controlled manner, in particular programmatically via at least one control routine carried out in the control and/or regulating unit.

Further developments, advantages and possible applications of the invention also emerge from the following description of exemplary embodiments and from the figures. All described and/or illustrated features, individually or in any combination, are fundamentally the subject of the invention, regardless of their summary in the claims or their relationship. The content of the claims is also made part of the description.

Brief description of the drawings

Fig. 1

in einer grob schematischen und stark vereinfachten Ansicht einen Ausschnitt einer Ausführungsform einer Vorrichtung zur Herstellung eines Betonsteins, in einem Zustand während des Einbringens von Betonmaterial in eine Schalungsform;

Fig. 2

in einer grob schematischen und stark vereinfachten Ansicht einen Ausschnitt einer Ausführungsform der Vorrichtung zur Herstellung des Betonsteins, in einem Zustand während des Einbringens von Kernbeton in die Schalungsform;

Fig. 3

in einer grob schematischen und stark vereinfachten Ansicht einen Ausschnitt einer Ausführungsform der Vorrichtung zur Herstellung des Betonsteins, in einem Zustand während des Einbringens von Vorsatzbeton in die Schalungsform;

Fig. 4

in einer grob schematischen und stark vereinfachten Ansicht einen Ausschnitt einer Ausführungsform der Vorrichtung zur Herstellung des Betonsteins, in einem Zustand während des Verdichtens des Betons;

Fig. 5

sehr vereinfacht und grob schematisch skizziert in perspektivischer Ansicht eine Ausführungsform einer Dosiervorrichtung und einer zu füllenden Schalungsform,

Fig. 6

die Dosiervorrichtung aus Figur 5 mit teilweise geöffnetem Gehäuse;

Fig. 7

sehr vereinfacht und grob schematisch dargestellt eine perspektivische Ansicht einer Ausführungsform eines dreischichtigen Betonsteins;

Fig.8

sehr vereinfacht und grob schematisch dargestellt eine perspektivische Ansicht einer Ausführungsform eines vierschichtigen Betonsteins und

Fig.9

in einer seitlichen Ansicht sehr vereinfacht und grob schematisch dargestellt eine Ausführungsform eines vielschichtigen Betonsteins.

The invention will be explained in more detail below using exemplary embodiments in connection with the drawings. Show it

Fig. 1

in a roughly schematic and highly simplified view a section of an embodiment of a device for producing a concrete block, in a state during the introduction of concrete material into a formwork form;

Fig. 2

in a roughly schematic and highly simplified view a section of an embodiment of the device for producing the concrete block, in a state during the introduction of core concrete into the formwork form;

Fig. 3

in a roughly schematic and highly simplified view a section of an embodiment of the device for producing the concrete block, in a state during the introduction of facing concrete into the formwork form;

Fig. 4

in a roughly schematic and highly simplified view a section of an embodiment of the device for producing the concrete block, in a state during the compaction of the concrete;

Fig. 5

Very simplified and roughly schematically sketched in a perspective view of an embodiment of a dosing device and a formwork form to be filled,

Fig. 6

the dosing device Figure 5 with partially opened housing;

Fig. 7

very simplified and roughly schematically shown a perspective view of an embodiment of a three-layer concrete block;

Fig.8

Very simplified and roughly schematically shown is a perspective view of an embodiment of a four-layer concrete block and

Fig.9

In a side view, a very simplified and roughly schematic representation of an embodiment of a multi-layered concrete block.

Ways of carrying out the invention

Identical reference numbers are used in the figures for elements of the invention that are the same or have the same effect. Furthermore, for the sake of clarity, only reference numbers that are necessary for the description of the respective figure are shown in the individual figures.

With reference to the Figures 1 to 4 The present process for the production of multi-layer concrete blocks 1 (in the Figures 1 to 4 not clearly seen; see also Figures 7 to 9 ) described as an example. The Figures 1 to 4 outline individual, selected process steps purely by way of example and show, in each case greatly simplified and only shown roughly schematically, views or partial views of respective sections of a device 10 for producing the concrete blocks 1, as they can be used to carry out the process. In the figures Shown here are individual units or devices included in the device selected for the respective figure.

With the present method, the concrete blocks 1 are produced as multi-layer concrete blocks 1, each with a multi-layer concrete block body 2, which in each case has at least one first concrete block layer 2a made from a facing concrete and designed as a facing concrete layer, a second concrete block layer 2b made from a core concrete and designed as a core concrete layer, and has at least a third concrete block layer 2c. The first concrete block layer 2a, designed as a facing concrete layer, forms a concrete block top 2.1 of the concrete block body 2 and thus also the surface of the concrete block 1, namely the surface in the state of use, in which several concrete blocks 1 laid in a composite form a surface covering, the visible and walkable or drivable surface or Traffic area. The third concrete block layer 2c forms a concrete block underside 2.1 opposite the concrete block top 2.1, which is intended to rest on a bedding layer.

In order to produce the concrete blocks 1, in the present method a formwork mold 4 is first provided, which in the examples of Figures 1 to 4 only for reasons of simplified representation is shown as a single mold for a floor covering element 1, that is to say as a formwork mold 4 with only one mold recess 4a for receiving the concrete material. However, it is understood that the formwork mold 4 can of course also be a formwork mold 4 for the simultaneous, in particular layered, production of several concrete blocks 1, which then correspondingly has several mold recesses 4a and each of the mold recesses 4a is designed to form one concrete block 1.

In the present method, in an initial, in Figure 1 outlined method step, which is essentially the first step for producing the concrete block layers 2a, 2b, 2c of the multi-layer concrete block body 2, a concrete material for the third concrete block layer 2c is introduced into the formwork mold 4 and thereby produces the third concrete block layer 2c. The concrete material for the third concrete block layer 2c is thus introduced before the core concrete and the facing concrete are introduced.

In the process, the concrete material for the third concrete block layer 2c is volumetrically metered into the formwork mold 4 by means of a first metering device 13. The first metering device 13 includes in the example shown a rotary valve 14 for volume-related dosing of the concrete material. The metering device 13 with the rotary valve 14 is arranged above the formwork mold 4 and is preferably mounted movably relative to the formwork mold 4.

This step of introducing the concrete material for the third concrete block layer 2c into the formwork mold 4, namely the allocation of the concrete material into the mold recess 4a or the metering or metering in, is described further below in the text with reference to Figures 5 and 6 described in more detail.

In the example of the Figure 1 the concrete material for the third concrete block layer 2c is introduced into the mold recess 4a in such an amount that a continuous, complete and uniform third concrete block layer 2c is formed. In the example shown, the concrete material for the third concrete block layer 2c is a coarse concrete rich in grit and/or sand, which is at least partially permeable to water.

For example, the concrete material for the third concrete block layer 2c is selected such that the third concrete block layer 2c is configured to capillary suck water upwards from the bedding layer in order to increase the evaporation of water over the surface of the concrete block 1.

After the step of forming the third concrete block layer 2c, according to the present method, as exemplified in Figure 2 shown, the core concrete is introduced into the formwork form 4 to produce the second concrete block layer 2b. The core concrete is replenished onto the concrete material of the previously formed third concrete block layer 2c and the core concrete layer is formed.

The step of filling the core concrete into the formwork mold 4, which can also be understood as pouring or pouring the core concrete, takes place by means of a first filling device 11, via which the core concrete is removed from a corresponding storage container and fed to the formwork mold 4, for example using suitable pumps or through other suitable funding means known to those skilled in the art. In the example shown, the first filling device 11 is designed as a filling carriage, which is movable relative to the formwork mold 4, preferably height-adjustable and also movable, in particular movable in both an x-direction and y-direction relative to one Formwork form 4 receiving level, so that uniform filling of the formwork form 4 can be facilitated or ensured.

The first filling device 11 can preferably include a filler neck which extends into the formwork mold 4 so that the core concrete can be filled as cleanly and as splash-free as possible. The filling device 11 can, for example, comprise a funnel-like filling vessel which carries the filler neck. The filling vessel and/or the filler neck can, for example, be connected to further units of the filling device 11 via a flexible connecting piece, for example via a hose, and/or in particular connected to a concrete supply.

In a next step of the process, which is in the highly simplified representation of Figure 3 is sketched, a facing concrete is refilled onto the core concrete, namely onto the prepared second concrete block layer 2b, thereby producing a first concrete block layer 2a forming the facing concrete layer. The facing concrete is introduced into the formwork form 4 by means of a second filling device 12, which can be designed similarly to the first filling device 11 and is preferably also movable and therefore movable relative to the formwork form 4.

In a next step of the manufacturing process, the concrete filled into the formwork mold 4 is compacted, as in Figure 4 roughly schematically sketched. For this purpose, for example, a compression device is used, which in particular has a press or a stamp 15. Alternatively or additionally, the concrete can be compacted by shaking and/or vibration. After compacting, the concrete is finally hardened, whereby the concrete block bodies 2 are completed.

With reference to the Figures 5 and 6 The volumetric metered introduction of the concrete material for the third concrete block layer 2c by means of the first metering device 13 will now be described in more detail. As above in connection with Figure 1 already mentioned, the metering device 13 in the example shown as an example includes a rotary valve 14, which is only partially and very roughly shown schematically in the figures.

The exemplary rotary valve 14 is designed and set up in such a way that the introduction of concrete material into a formwork mold 4 equipped with several mold recesses 4a can be carried out in an optimal and effective manner the concrete material is introduced into each of the mold recesses 4a in a volumetric dosage.

The formwork shape 4, which extends along its length along a longitudinal axis LA and has a shape width BF in the direction transverse to the longitudinal axis LA, has a shape width BF in the example shown Figure 5 over nine mold recesses 4a, whereby it is expressly emphasized here that the number and arrangement of the mold recesses 4a shown is only an example and of course various numbers and arrangements deviating from this are conceivable without departing from the idea of the invention.

The rotary valve 14, which in Figure 6 For reasons of clarity, shown again isolated from the formwork form 4 and in a partially covered state, has a working width AB which corresponds or approximately corresponds to the form width BF of the formwork form 4, so that concrete material is delivered or delivered over the entire form width BF of the formwork form 4 . is issued.

The rotary valve 14 is fed with concrete material on the inlet side in the area of an inlet 14.1 via a feed or feed not shown in the figures. Likewise, the rotary valve 14 has a buffer, not shown in the figures, which is provided in the area of an inlet 14.1 and is connected to it, so that concrete material stored in the buffer can be fed to a lock or metering space 14a of the rotary valve 14. The concrete material thus enters the lock or dosing chamber 14a, which can also be called a lock or dosing chamber and is delimited at least in sections by a housing wall or chamber wall.

In the lock or metering space 14a, the driven cellular wheel 16, which is provided with a drive (not shown), is designed as a rotor and rotates about a rotor axis RA in the direction of rotation DR. The cellular wheel 16 comprises an elongated or elongated axle body or rotor body 17, which extends along its length along the axis of rotation RA, on which several rotor blades 18, which are also elongated or elongated and in turn extend along their respective lengths in the direction of the axis of rotation RA, are arranged . The cellular wheel 16 has a cellular wheel length LZ that approximately corresponds to the working width AB.

The rotor blades 18, the number of which is four in the example shown, but can also differ, protrude essentially radially outwards from the rotor body 17. The cellular wheel 16, in particular an outer circumference of the cellular wheel 16, is dimensioned such that the cellular wheel 16 is accommodated in a fitting manner, in particular with a precise fit, in the housing of the lock or metering space 14a and can rotate freely. The rotor blades 18 are arranged with their respective outward-facing, free longitudinal sides as close as possible to the housing walls, but at the same time at a sufficient distance that clogging or clogging or caking with concrete material is prevented.

The rotor blades 18 are evenly distributed around the circumference of the rotor body 17, with a cell being formed between respective adjacent rotor blades 18. The same angular distance is always maintained between adjacent rotor blades 18, so that all cells of the cellular wheel 16 have essentially the same size. When the cellular wheel 16 rotates about the axis of rotation RA, each cell in the area of the inlet 14.1 of the cellular wheel sluice 14 absorbs a defined amount of concrete material and releases it again in the area of an outlet 14.2, from where the concrete material falls into the formwork mold 4 arranged below or . is introduced.

In the exemplary rotary valve 14, a metering aid 19 is provided in the area of the outlet 14.2, which can also be referred to as a distribution and/or dispensing aid and in the example shown is designed as a metering plate, which in turn can also be referred to as a distributor plate. The metering plate 19 of the example shown is a curved plate with several openings, for example a curved perforated plate or a curved perforated plate. The metering plate 19 of the example shown is a substantially shell-shaped or partially cylindrical shell-shaped perforated plate. When the concrete material is dispensed at the outlet 14.2, the concrete material passes through the holes in the perforated plate from the respective cells of the cellular wheel 16 to the outside and into the formwork form 4. With the help of the metering plate 19, the concrete material is distributed evenly, namely in relation to the surface of the formwork form 4 .

The exemplary metering device 13 with rotary valve 14 is movably mounted, for example movable on a frame not shown in the figures, and has a drive, also not shown in the figures, so that the metering device 13 with rotary valve 14 can be driven, in particular moved, in a travel direction FR along the longitudinal axis LA of the formwork mold 4. The direction of travel FR runs essentially perpendicular to the working width AB of the rotary valve 14.

To introduce the concrete material into the formwork form 4, the rotary valve 14 is started from a starting position (as in Figure 5 indicated) moves relative to the formwork form 4 and above it in the direction of travel FR, with the cellular wheel 16 rotating at the same time. The rotary valve 14 moves over the formwork mold 4 when the rotary wheel 16 is in operation. As a result, all mold recesses 4a can be filled equally. It is understood that the metering device 13 with rotary valve 14 can be moved back into its starting position via a restoring movement running counter to the direction of travel FR.

With reference to the Figures 7 to 9 Various embodiments of exemplary concrete blocks 1, which are produced using the present method, will now be described. The Figures 7 and 8 each show a perspective view and the Figure 9 a side view of a respective concrete block 1 in a very simplified and roughly schematic representation.

As already explained above in connection with the manufacturing process, the concrete blocks 1 are multi-layered, namely at least three-layered, and each have a multi-layered, essentially cuboid-shaped concrete block body 2 in the example of the figures with at least a first, second and third concrete block layer 2a, 2b , 2c on. Figure 7 shows such a three-layer concrete block 1. Figure 8 shows an alternative, four-layer variant, the concrete block body 2 of which includes a further concrete block layer 2n in addition to the first to third concrete block layers 2a, 2b, 2c and Figure 9 shows a multi-layered variant.

Each concrete block 1 or the concrete block body 2 has a predetermined format with a stone length SL and a stone width SB and has at least one concrete block underside 2.1 suitable for laying on a bedding layer of a subsurface and an opposite concrete block upper side 2.2, along which there is an upper surface of the concrete block 1 extends.

On the side surfaces of the concrete block 1, projections 3, for example rib- or nose-like projections 3, can be provided, which serve as spacers or spacer lugs and, when laying the concrete blocks 1 in a composite, ensure that a minimum distance between the respective adjacent concrete blocks 1 is maintained in the laid surface structure and thereby joints with a specified minimum width are created.

The first concrete block layer 2a, which defines the upper surface and is designed as a facing concrete layer, is made from a facing concrete, which is, for example, a structurally dense concrete. Depending on the intended use, the first concrete block layer 2a can be designed as an at least partially water-permeable or water-permeable layer or as a water-impermeable layer.

Following the first concrete block layer 2a, the second concrete block layer 2b is formed, which in the examples shown directly or immediately adjoins the first concrete block layer 2a. The second concrete block layer 2b is made from a porous core concrete with a large proportion of fine and micropores. This heap-porous concrete block layer 2b supports the absorption and storage of water and thus allows water to penetrate via the side surfaces of the concrete blocks into the second concrete block layer 2b. Under thermal conditions that promote evaporation of water, the water temporarily stored in the second concrete block layer 2b can be released back to the outside, in vapor form again via the side surfaces and / or, if the first concrete block layer 2a is water-permeable, via this from the concrete block 1 escape or are released into the environment.

Those in the example of Figure 7 The third concrete block layer 2c, which immediately adjoins the second concrete block layer 2b, is water-permeable and made from a concrete material rich in grit and/or sand, which has at least moderate water permeability. The grit and/or sand content can be fine or coarse, or a mixture of fine-grained sand and coarse-grained grit can also be added. Due to the capillary effect generated in the third concrete block layer 2c, it is also possible to supply moisture from the bedding layer or the subsurface into the second concrete block layer 2b, whereby the evaporation properties of the concrete block 1 are additionally improved and in particular the evaporation rate is increased.

At the in Figure 8 In the example shown, an additional concrete block layer 2n is formed between the second and third concrete block layers 2b, 2c, whereby the concrete block 1 can be even better adapted to the desired uses. For example, the third concrete block layer 2c is designed here as a stabilization layer or strengthening layer, which gives the concrete block 1 greater stability and strength. The further concrete block layer 2n is designed as a water-permeable layer, for example to support controlled water permeability and/or water storage.

When producing the in Figure 8 Concrete block 1 shown, both the concrete material for the third concrete block layer 2c, as well as the further concrete material for the further concrete block layer 2n, are introduced into the formwork mold 4 in volumetric doses, with a second metering device being provided for introducing the further concrete material for the further concrete block layer 2n. The second dosing device is both structurally and functionally similar to the first dosing device 13 or is identical to it.

In Figure 9 a further, alternative embodiment of the concrete block 1 is shown in a side view. The concrete block body 2 comprises, between the third concrete block layer 2c and the second concrete block layer 2b, a large number of further concrete block layers 2n with a total layer thickness Dn. The large number of additional concrete block layers 2n is composed of many individual additional concrete block layers 2n, each of which is very thin and has very small layer thicknesses. This allows, for example, layers of different concrete material to be combined in a particularly precise and defined manner in such a way that a specifically desired property, such as the desired water permeability, certain density or strength values or the like, is set in the concrete block body 2 in a predetermined, defined manner .

For example, it is also possible to vary the mentioned properties based on a height of the concrete block body 2 in a progression and, for example, to change them gradually. Here, one of the properties mentioned - such as water permeability, water storage, strength or density - can also define a "transition", for example, so that the large number of additional concrete block layers 2n can also be understood here as a common transition layer. Alternatively, it would also be conceivable to alternate the individual thin, additional layers of concrete blocks 2n one after the other, so that, for example alternating water-permeable and water-impermeable layers of concrete blocks and/or dense and less dense layers of concrete blocks and/or coarse and fine layers of concrete blocks are stacked on top of each other.

For making a like in Figure 9 In the embodiment variant of the concrete block 1 shown as an example, a first metering device 13 and a second metering device, in particular each with a rotary valve 14, are preferably used, the two rotary valves 14 working alternately and each successively introducing a respective concrete material into the formwork mold 4 in a volumetric metered manner. Between the respective metering steps using the two rotary valves 14, for example, intermediate steps for compacting or stamping the concrete material introduced in a respective metering step can also be carried out.

Reference number list

1

Concrete block

2

Concrete block body

2.1

Concrete block underside

2.2

Concrete block top

2a

first layer of concrete blocks

2 B

second layer of concrete blocks

2c

third layer of concrete blocks

2n

another layer of concrete blocks

3

head Start

4

formwork shape

4a

Deepening of the shape

10

Device for producing concrete blocks

11

first filling device

12

second filling device

13

first dosing device

14

Rotary valve

14.1

enema

14.2

outlet

14a

Lock or dosing room

15

Press or stamp

16

cell wheel

17

Axle or rotor body

18

Rotor blades

19

Dosing aid

AWAY

Working width

BF

Shape width

DR

Direction of rotation

DC

Layer thickness of the third concrete block layer

Dn

Total layer thickness of the additional concrete block layers

FR

Direction of travel

LA

Longitudinal axis of the formwork

LZ

Cell wheel length

R.A

Axis of rotation

SB

Width of the concrete block

SL

Length of the concrete block

Claims (15)

Method for producing concrete blocks (1), each concrete block (1) comprising a multi-layer concrete block body (2) with at least one flat concrete block underside (2.1) and a substantially flat concrete block upper side (2.2) opposite it, the concrete block body (2) having at least one formed as a facing concrete layer and forming the concrete block top (2.2), a first concrete block layer (2a), at least one second concrete block layer (2b) designed as a core concrete layer and at least one third concrete block layer (2c) forming the concrete block underside (2.1), wherein in the method at least one formwork form (4) is provided and in a step for producing the second concrete block layer (2b) designed as a core concrete layer, a core concrete is introduced into the formwork mold (4) by means of a first filling device (11), wherein after the core concrete has been introduced in a further step for production the first concrete block layer (2a) designed as a facing concrete layer is filled with facing concrete into the formwork mold (4) and the concrete material introduced into the formwork mold (4) is then compacted and hardened, characterized in that before the core concrete is introduced in an initial step of Method for producing the third concrete block layer (2c), a concrete material for the third concrete block layer (2c) is introduced into the formwork mold (4) by means of a first metering device (13). Method according to claim 1, characterized in that the concrete material for the third concrete block layer (2c) is introduced into the formwork mold (4) in volumetric doses. Method according to claim 1 or 2, characterized in that the concrete material for the third concrete block layer (2c) is introduced into the formwork mold (4) by means of a metering device (13) designed as a rotary valve (14) or having a rotary valve (14). Method according to claim 3, characterized in that for the volumetric metered introduction of the concrete material for the third concrete block layer (2c), a rotating cellular wheel (16) of the cellular wheel sluice (14) is driven in a controlled manner and a rotation speed of the cellular wheel (16) is set in a controlled manner. Method according to one of the preceding claims, characterized in that the metering device (13) during the introduction of the concrete material for the third concrete block layer (2c) in at least one first direction of travel (FR) running in the direction along a longitudinal axis (LA) of the formwork form (4). is moved with a controlled feed speed and the concrete material is thereby fed evenly, in particular at least in relation to a longitudinal direction of the formwork form (4). Method according to claims 4 and 5, characterized in that the feed speed of the metering device (13) moved in the direction of travel (FR) and the rotation speed of the cellular wheel (16) are coordinated with one another in a controlled manner and in particular depending on the type of concrete block layer (2c) for the third layer. Concrete material used and / or a desired layer thickness (Dc) of the third concrete block layer (2c) can be adjusted and coordinated. Method according to one of the preceding claims, characterized in that at least the feed speed of the metering device (13) moved in the direction of travel (FR) is controlled depending on the design of the formwork mold (4), in particular depending on the shape and/or that one with a plurality of mold recesses ( 4a) equipped formwork mold (4) is provided and a number of concrete blocks (1) corresponding to the number of mold recesses (4a) is produced simultaneously, the concrete material for the third concrete block layer (2c) preferably being placed in each of the mold recesses (4a) of the formwork mold (4 ) is introduced volumetrically dosed. Method according to one of the preceding claims, characterized in that before filling the core concrete and / or before refilling the facing concrete, at least one further concrete material is filled into the formwork mold (4) and thereby at least one further concrete block layer (2n) is produced, the Another concrete block layer (2n) is arranged between the second and third concrete block layers (2b, 2c) or between the first and second concrete block layers (2a, 2b). Method according to claim 8, characterized in that the further concrete material for the further concrete block layer (2n) is introduced into the formwork form (4) in a volumetric metered manner, in particular by means of the first Metering device (13) or by means of a second metering device designed as a rotary valve or having a rotary valve. Method according to one of the preceding claims, characterized in that the concrete material introduced into the formwork mold (4) for the third concrete block layer (2c) and/or the core concrete introduced and/or the facing concrete introduced is evenly distributed over the area using concrete distribution means after the respective introduction . Method according to one of the preceding claims, characterized in that the concrete material introduced into the formwork form (4) for the third concrete block layer (2c) is pre-compacted in an intermediate step before the core concrete is introduced and/or that the core concrete introduced into the formwork form (4). is pre-compacted in an intermediate step before the facing concrete is placed and/or that the third concrete block layer (2c) is produced with a layer thickness (Dc) which is between 2% and 20% of a total height (H) of the concrete block body (2), preferably between 4% and 15% of a total height (H) of the concrete block body (2) and particularly preferably between 5% and 10% of a total height (H) of the concrete block body (2). Method according to one of the preceding claims, characterized in that a concrete rich in chippings and/or sand is used as the concrete material for producing the third concrete block layer (2c) and/or that a heap-porous concrete is used as the core concrete for producing the second concrete block layer (2b). and/or that a concrete with a water-cement ratio in a range of 0.25 to 0.4 is used as the concrete material for producing the third concrete block layer (2c), in particular with a water-cement ratio in a range of 0.28 to 0.38. Device (10) for producing concrete blocks (1), comprising at least one formwork mold (4) with at least one or more mold recesses (4a) and at least one first filling device (11) for introducing concrete into the formwork mold (4), characterized in that in that the device (10) further has at least one first metering device (13), the first metering device (13) being designed for the volumetric metered introduction of concrete material into the formwork mold (4). Device (10) according to claim 13, characterized in that the at least one first metering device (13) is formed by a rotary valve (14) or comprises at least one rotary valve (14) and / or that the at least one first metering device (13) is movably mounted and can be moved in a driven manner in at least one first direction of travel (FR) running in the direction along a longitudinal axis (LA) of the formwork mold (4), in particular in a controlled driven manner. Device according to claim 13 or 14, characterized in that at least the first filling device (11) is designed in the form of a filling carriage which can be moved in the direction along a longitudinal axis (LA) of the formwork mold (4) and/or that furthermore a filling device connected to the first filling device (11 ) and the first metering device (13) communicating control and / or regulating unit is provided and the introduction of concrete material into the formwork form (4) can be adjusted in a controlled manner, in particular program-controlled via at least one control routine carried out in the control and / regulating unit.

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