ES2331036A1 - Prefabricated slab and mold for its manufacture (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Prefabricated slab and mold for its manufacture. It is of the type of those formed preferably by two layers of different materials which respectively constitute the upper layer seen of natural stone or similar and another lower resistant layer of concrete, extruded polystyrene, foam or the like. The upper layer or view is materialized according to the invention by a plate or tablet (2) made of natural stone or similar, which can be provided with a plurality of grooves (5) in two perpendicular directions to configure tiles (6) of small size or well, formed by several independent cobblestones (22). The tablet (2) is joined to the resistant lower layer (3) in the same molding phase, and a reinforcement element (4, 4 ") is also placed. The lower layer (3) may include holes (8) to lighten the weight. The mold (12) includes a perimeter wall (13) with holes (14) at different heights in its longitudinal walls to place two support rods (15) of the tablet (2) made of natural stone or paving stones (22) on a board (25) (Machine-translation by Google Translate, not legally binding)

Description

Prefabricated slab and mold for your manufacturing.

Object of the invention

The present invention, as expressed by the set forth in this specification, refers to a slab prefabricated and mold for manufacturing, providing notable advantageous features compared to other slabs and molds for your manufacturing that exist today.

This type of slabs is formed by two layers of  different materials: a superior that constitutes the face of the slab and whose nature is preferably natural stone or similar, and another resistant bottom that is achieved by concrete and advantageously reinforced with an additional element (mesh, fibers or any known element used for this purpose), or either of extruded polystyrene or any type of foam, resins and Similar.

These slabs are built for the purpose of get a very resistant pavement and yet use a Natural stone tablet or similar of thin thickness. The assembly of the prefabricated slabs are made by gluing them directly on the ground.

Background of the invention

In utility model U 200202869 it was given to get to know a precast reinforced concrete panel with face view of natural stone, where these stones were loose and fixed with the concrete that was poured into a mold in which they were placed Whimsical form irregular pieces. The possibility of placing regular and well distributed pieces using a tool as a distributor grid. In this case the surface view of the panel was on top of the mold and a flat surface was not achieved, especially if the pieces They were irregular.

On the other hand we can quote that it is known make total or partial cuts in two directions perpendicular on the surface of a piece, as is the case of utility model No. 259,987 of the year 1981 in which it is also it contemplates a motherboard larger than a superior one for allow the mounting of a false frame so that it does not mount on the decorative plate that constituted the face seen from the mosaic formed. The larger motherboard forms the base resistant to assemble the frame thus formed.

Description of the invention

In general, the prefabricated slab object of the invention, as well as the mold for its manufacture, allow get a perfect finish in addition to a highly product resistant, which is materialized by a lower layer preferably concrete with reinforcement elements (mesh, fibers ...), joining it in the same molding phase and before setting of the concrete, the top layer or view of the slab, defined by a natural stone tablet or similar that has the particularity that it can include a plurality of stretch marks in two perpendicular directions imitating tiles or cobblestones small size and also offering a perimeter machining that eliminates the upper edge, this machining being of an amplitude which corresponds to half the width of the stretch marks to so that when joining the slabs in the assembly of the pavement, they are formed stretch marks or joints of the same width as the rest. The face seen of the slab could also have other types of marks or reliefs, such as means of warning to blind people.

The sturdy bottom layer of reinforced concrete, It is also contemplated that it may include gaps or recesses that lighten your weight, getting these holes by blocks or Expanded polyethylene studs, porexpan, or similar by way of males in the molding process. Instead of using concrete it is possible to use extruded polystyrene or any type of foams or resins.

Moreover, for the manufacture of this slab  prefabricated, the invention provides a mold consisting of a perimeter wall of rectangular contour, having the walls longitudinal holes at different heights to enable the selective mounting of two rods on which it will be deposited in inverted position the natural stone tablet, that is, with the stretch marks and perimeter machining arranged face down supporting on said rods. The holes located at the desired height depending on the thickness of the slab prefabricated, since as we will see later concrete will be poured on the tablet until the mold is filled, after having made the pouring of a first layer to then place the mesh of armed, which will include in a known way some small spacers to support directly on the tablet and so the mesh is located at the appropriate preset height. Later already the concrete mold is filled and scratched.

To facilitate the demoulding, the impregnate the walls of the mold with a substance suitable for this function, or use a plastic film that avoids contact Direct with the mold.

If you want to manufacture slabs of smaller size than the mold, for example shorter but of the same dimension in width, including those of square shape or even shorter, is employs a separator defined by a transverse plate that available vertically as a partition to shorten the length of the mold to the desired extent.

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It is also planned that if the width were minor supplements are used until the difference of measures and thus the wall of the mold is fixed and stable.

In order to lighten the final product, it induce some gaps in the concrete layer by using Males of material with very low density (foams, poliexpan ...). So that these males or blocks are perfectly placed and correctly distributed on the surface of the mold, a tool defined by a rectangular frame independent of the mold and whose stringers are arranged transversely on the wall perimeter of the same, so that the crossbars contact by the  exterior of said wall to center the position of the tool. The stringers of this rectangular frame include spikes or nails that they are nailed in the block or block of poliexpan also fixing the position of these. When it comes to demolding, it is removed It is useful so that the blocks or blocks remain within the concrete, thoroughly lost.

It is also contemplated that the stone tablet natural or similar instead of having stretch marks that mimic the joints between tiles or small cobblestones, formed by independent pavers separated precisely in that same distance and being perfectly distributed on the surface with the help of a grill or placement tool.

The manufacturing mold of these slabs with independent pavers is the same as used in the case previous full tablet, but you have to complement it first place with a board that is placed instead of that one so that the independent pieces or pavers are also placed upside down and each in its respective grid grid grid that occupies exactly the bottom of the mold and that is located directly on the board.

Instead of pouring the first concrete layer directly on the independent pavers and then place the reinforcement mesh to finally fill in the concrete mold, it is planned that before placing the independent pavers a film is placed on the grill plastic so that when you are placing the latter, it will stick to the grill walls while protecting the face view of the slab. In addition it is possible to facilitate the demoulding since the film of plastic stands between the mold and the slab and also the grill recovers perfectly.

Another added advantage when using the film plastic is that its thickness and tension when placed independent pavers achieve a perfect fit in the grill and remain self-centered as we will see later in Relationship with the figures.

To facilitate the understanding of characteristics of the invention and forming an integral part of this Descriptive report, accompanying some sheets of plans in whose figures, with an illustrative and non-limiting nature represented the following:

Brief description of the drawings

Figure 1.- It is a perspective view of a prefabricated slab constructed in accordance with the invention and whose face Vista has a striatum imitating a cobblestone.

Figure 2.-It is a perspective view by the back side of the same slab of figure 1.

Figure 3.- It is a plan view of what is shown in figure 1.

Figure 4.- It is an elevation view of it. Slab with an expanded detail.

Figure 5.- It is a perspective view of the union of two slabs, with an enlarged detail of the area of Union.

Figure 6.- It is a perspective view of a lightened slab (with holes), according to the invention, on the face lower.

Figure 7.- It is a perspective view exploded mold for manufacturing precast slabs of the previous figures.

Figure 8.- It is a sequence of phases of manufacture of the slabs of figures 1 and 2 with the object mold of the invention, in six positions a) to f).

Figure 9.- Sample in two positions d ') and e') the final stages of manufacturing lightened or hollow slabs, from position c) of figure 8.

Figure 10.- It is a perspective view by the underside of a tool for placing the blocks of porexpan of figure 9.

Figure 11.- It is a perspective view of the same tool of figure 10, in the mounting position and with the Porexpan blocks or blocks attached to it.

Figure 12.- It is a perspective view of the shown in figure 11 but arranged on the mold.

Figure 13.- It is a view similar to figure 4 but of a prefabricated slab whose visible face is formed by independent pavers that are placed in the mold prior to concrete pouring

Figure 14.- It is a perspective view exploded mold and other elements involved in the manufacture of the prefabricated slabs of figure 13.

Figure 15.- They are different perspective views of as many manufacturing phases of prefabricated slabs according Figures 13 and 14, in four positions a) to f).

Figure 16.- It is a cross section of the prefabricated slab of figure 13 to observe the situation of plastic film covering the grill and the board and separating them from the slab.

Figure 17.- It is a view similar to figure 16 to observe how cobble tolerances are absorbed placed on the grill of the mold.

Description of the preferred embodiment

Referring to the numbering adopted in the figures and specifically in relation to figures 1 to 5, in they can see the structure that presents the prefabricated slab object of the invention, generally referenced with the number 1 and consisting of a tablet 2 of natural stone or similar, joined by molding to a base of reinforced concrete, extruded polystyrene, foams or resins, constituting the bottom layer 3 resistant.

The mesh represented in its armor shape crosslinked armed is referenced with number 4 and observed partially in figure 2.

The tablet 2 that constitutes the exposed face of the prefabricated slab 1, in its version with paving finish, it has practiced a mechanized in his surface seen, that configure two parallel 5 stretch beams in directions perpendicular imitating joints between tiles or pavers 6 of smaller size

The perimeter edge of this upper face seen is affected by a machining 7 that eliminates the edge and whose amplitude equals half the width of stretch marks 5 for that when placing the slabs next to each other simulate a joint normal, as shown in figure 5.

In the lightened version of the slab, as see in figure 6 referenced with 1 ', the underside It presents the holes 8 that lighten the total weight of the slab 1 '. In In this case, the reinforcement or reinforced concrete mesh is referenced with 4 'and defined by a perimeter rod 9 tucked into the slab contour, with two crossbars 10 perpendicular, so that larger reticles are determined dimension than the gaps, these corresponding to the volume of the tacos or blocks 11 of porexpan or similar (see figure 9) that they leave thoroughly lost or are subsequently extracted as we will see more forward in relation to figures 9 to 12.

In figure 7 the mold 12 can be seen for manufacture of slabs 1, materialized by the hollow frame of perimeter wall 13 of rectangular contour whose walls longitudinal have holes 14 at different heights and in different longitudinal areas facing for assembly selective of two rods 15 as seen in position a) of the Figure 8. Reference 16 designates a separator to shorten the mold length, and be able to manufacture slabs of dimensions smaller than those of the mold, as referenced with 2 in this figure 7.

Figure 8 shows the sequence of operations to manufacture the slab using mold 12. In the position a) the two rods 15 are mounted in the holes 14 selected both for the height due to the thickness of the slab to form, as per its dimension shorter than the mold 12. A then, position b), separator 16 is mounted and then, position c), the tablet 2 in an inverted position since its face view with stretch marks 5 must be below.

Then we proceed to pour a layer of concrete 17 to place the mesh 4 (position e) on top and finally complete the pouring until filling the mold 12, thus forming the heavy duty layer 3 of slab 1.

To manufacture slabs as represented in the Figure 6 that has the holes 8 that make it lighter, just place the blocks or blocks 11 on the tablet 2 as shown in position d ') of Figure 9, since it is an operation after position c ') of Figure 8. The following is pour the concrete placing the 4 'mesh (as we saw previously its wide cross-linking of rods 9 and 10 allows), according to position e ') of this figure 9.

So that the tacos or blocks 11 of porexpan or similar are well located and centered, the mold 12 is complements the tool 18 shown in figures 10 a 12.

This tool 18 is formed by two stringers 19 and two crossbars 20 fixed to its lower face. The stringers 19 they include pairs of nails 21 to nail in the blocks or tacos 11 as seen in figure 11.

Figure 12 shows the position of the tool 18 with studs 11, arranged on the mold, centering perfectly the position of the studs 11. Previously the 4 'mesh slightly separated from tablet 2 with the help of timely spacers and concrete pouring is done until make up with the edge of the mold.

Making special reference to the figures now 13 to 17, in them the structure of the slab can be seen prefabricated composed of small cobblestones 22, referenced in this case with the number 23 and whose manufacture is done with help of the grill 24 previously arranged on the board 25 of the bottom of the mold 12, since being independent pieces the pavers 22, it is necessary to place board 25 on the  rods 15. Next is the grill 24 and the separator 16 'on it, then placing the plastic film 26 and the cobblestones 22 (see figure 16). This provision corresponds to shown in figure 15 position a).

The separator has been referenced with 16 ' (adding the apostrophe) because it has a lower height than the referenced with 16 in figure 7 as its vertical wing or partition of concrete containment must have its free edge flush with mold 12 as in the previous case, but nevertheless it is necessary to discount the thickness of the board 25 that did not exist in the case previous.

In position b) of figure 15 it has been poured the first layer 17 of concrete and then the mesh 4 is placed (position c) and finally the mold is completed with the concrete as It is shown by position d).

Figure 16 shows the prefabricated slab 23 removed from mold 12 and in the inverted position as it has been molded Plastic film 26 wraps the walls of the grill 24 and cover the board 25 with the slab 23 being isolated. When dismantling the board and then remove the grill is obtained without difficulty the slab 23.

Comparing this figure 16 with figure 17 is you can check that if the cobblestones 22 are of different sizes due to manufacturing tolerances, the plastic film 26 itself absorbs part of the slack in relation to grid crosslinking 24 and center the cobblestones 22.

Claims (11)

1. Prefabricated slab, of the type formed by at least one top layer seen and which can be complemented with another resistant bottom one, characterized in that the top layer or view is defined by a tablet (2) of natural or similar stone that is capable of being provided of marks or reliefs as means of warning to blind people, or of stretch marks (5) in two perpendicular directions imitating tiles (6) or cobblestones (22) of smaller size and a recess (7) in its perimeter edge of amplitude corresponding to half of the width of the stretch marks (5). 2. Prefabricated slab according to claim 1, characterized in that the resistant bottom layer (3) is made of concrete in which a reinforcing element can be accommodated as a mesh (4, 4 ') conveniently placed, or as fibers dispersed throughout its volume. 3. Prefabricated slab according to claim 1, characterized in that the resistant bottom layer (3) is made of extruded polystyrene or any type of foam or resins. 4. Prefabricated slab, according to claims 1, 2 and 3, characterized in that the tablet (2) of natural stone or the like is formed by a plurality of independent pieces or pavers (22), separated at the distance corresponding to the amplitude of the stretch marks (5) and with a separation from the contour equivalent to half of it, joining the lower layer (3) in the same molding phase. 5. Prefabricated slab according to claim 2, characterized in that the lower layer (3) of concrete includes recesses or gaps (8) that lighten its weight. 6. Prefabricated slab, according to claim 5, characterized in that the reinforcing mesh (4 ') is defined by a perimeter rod near the contour and rods in two perpendicular directions defining reticles larger than the gaps (8) to be formed and in correspondence with them. 7. Mold for manufacturing prefabricated slabs, characterized in that it is constituted by a perimeter wall (13) of rectangular contour, with a plurality of holes (14) or projections in its longitudinal walls, at different heights for the selective mounting of two rods ( 15) positioned at the desired height of the tablet itself (2) of natural or similar stone, or by interposing a support board (25) of the pavers and (22) arranged in an inverted position, on which a concrete layer in which the reinforcement elements are housed. 8. Mold for manufacturing prefabricated slabs, according to claim 7, characterized in that it includes a grill (24) arranged on the board (25), with a reticulate for uniform distribution of the pavers (22). 9. Mold for manufacturing prefabricated slabs, according to claim 8, characterized in that it includes a plastic film (26) arranged on the grill (24) prior to positioning the pavers (22). 10. Mold for manufacturing prefabricated slabs, according to claims 7 to 9, characterized in that it includes a separator (16, 16 ') defined by a transverse plate that is arranged vertically as a partition to shorten the length of the mold (12) in the desired measure. 11. Mold for manufacturing prefabricated slabs, according to claim 7, characterized in that it includes an independent rectangular frame whose stringers (19) are arranged transversely to the perimeter wall (13) resting on it and with two crossbars (20) arranged below and which are they adjust on the outside of said perimeter wall (13) centering the position of some plugs (11) for the evacuation of the poured concrete to form two holes (8) that lighten the weight, plugs (11) that are previously nailed to the lower face of said stringers (19).