FI130168B - Mould surface, casting mould and method for casting an inclined floor element - Google Patents

Abstract

A mold surface, a casting mold and a method for casting a sloped floor element. The form surface (9) has a well site (16) for a floor well (2) and inclined surfaces that delimit the well site and which have a slope from the well site in the direction of the edges of the form surface. Furthermore, the mold surface is one piece with several parts including at least one well part (17) and one edge part (18) which are separate. Said well part is designed to surround the well site and the edge part is designed to delimit the well part on at least two sides.

Description

Mold surface, casting mold and method for casting a poured floor element

Background of the invention

The invention concerns the mold surface of a casting mold for casting a screed floor element.

Furthermore, the invention concerns a casting mold and a method for casting a poured floor.

The object of the invention is described in more detail in the introductions of the independent patent claims of the application.

In construction, prefabricated elements with a poured floor surface can be used for wet rooms. Such poured floor elements can be equipped with a floor well and a floor surface leading towards it.

Poured floor elements can be produced in an element factory by casting concrete. Cast elements are delivered to the construction site as ready-to-install components.

In the publication FI-20196065-A1, an arrangement for the production of such a poured floor element is presented. Some defects have been observed in the production of current sloping floor elements.

Brief description of the invention

The idea of the invention is to create a new and improved solution for the production of floors in wet areas of buildings.

N 25 For the mold surface according to the invention, the

N these features are presented in the distinguishing mark part of the first independent device requirement. o Characteristic = features for the casting mold according to the invention are presented in the characteristic part of the second independent device claim * 30. the characteristic features a of the method according to the invention have already been presented in the independent method requirement

Q in the number part.

The idea of the presented solution is that for casting the screed floor element, the casting mold has a mold surface that gives the screed floor element the desired screed floor surface for use in a bathroom, utility room or other wet space. The formwork surface comprises a well point for the floor well and the sloped surfaces delimiting the well point, which have a slope from the well point towards the edges of the formwork surface. The mold surface is still a multi-part body, comprising at least a separate well part and an edge part. Said well part is adapted to surround the well point and the edge part is adapted to delimit the well part from at least two sides. In other words, the mold surface is not one solid piece, but consists of at least two pieces connected to each other at least for the duration of casting. The well part and the edge part can thus be manufactured in separate steps and they can be either the same or different material. The mold surface is suitable for use in casting molds where the cast mass is poured from above onto the mold surface. In addition, the well part has a 3-dimensional surface made up of curved surfaces, which forms part of the mold surface and has a slope away from the well point. In other words, the well part has a pouring surface with a uniform curved shape from the well opening towards the edges. The sump part is thus adapted to form a sump cup with a 3D shape in the pouring floor, which directs the water to the floor sump.

The geometry of the well part is therefore the negation of the finished well cup.

One advantage of the proposed solution is e.g. that

N mold surfaces can be used numerous times as well as other

N nella, as needed, its replaceable components

In that way. The solution also frees the direction of the poured floor element

N nitling and gives the possibility to place a floor drain

O 30 places free. In addition, the cost of casting can

E lowers. — The idea of one application is that the edge part

A surrounds the well section. In this case, the edge part borders the well part

N on each side.

N 35 The idea of one application is that the well part is placed on the edge of the mold surface, in which case the edge part borders it on three sides, or alternatively in a corner, in which case the edge part borders it on two sides.

The idea of one form of application is that the curvatures of the well part are formed in response to the location of the well site and the shape and dimensions of the well part.

The idea of one form of application is that the edge part comprises several interconnected planar surfaces, each of which has a bevel angle from the center of the mold surface towards the edge. In other words, the edge part consists of straight flat surfaces that lead away from the well part.

The idea of one form of application is that the planar surfaces forming the edge part are connected to each other by means of joint seams. Joints can comprise a sealing element, such as sealing tape, or sealing compound.

The idea of one embodiment is that at least one of the mentioned parts of the mold surface, the well part and the edge part, is formed from at least two separate components connected to each other. In other words, the well part and the edge part can each be formed from two or more components, in which case they are smaller in size and thus easier to manufacture and handle. In addition, the solution enables the modular structure and different components to be connected to each other to form mold surfaces with different geometries.

The idea of one form of application is that reu-

N parts are formed from at least three separate components

N tis, each of which are disc-like pieces. Otherwise sa-

N noe, the edge part can be assembled either in shape and mi-

N of similar or different plates

O 30 pieces, depending of course on the mold surface and well part

E about shapes and dimensions. — The idea of one form of application is that

A well part is located at the edge of the mold surface, so the edge part

N is formed from three plate-like pieces.

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The idea of one form of application is that the well part is located in the corner of the mold surface, in which case the edge part is formed from two plate-like pieces.

The idea of one form of application is that the well part is located surrounded by the edge part, in which case the edge part is formed from four plate-like pieces.

The idea of one form of application is that the well part is formed from four separate components, each of which has a curved 3-dimensional partial surface of the mold surface. In other words, the well part can be assembled from either similar or different components in terms of shape and dimensions.

The idea of one embodiment is that the components of the well part are rectangular in shape. They can be square or rectangular.

The idea of one form of application is that the well part is formed from several different separate components. In other words, the well part is formed from interconnected components that can have different external shapes and 3-dimensional parts of the mold surface.

The idea of one form of application is that the components of the well part can have a rectangular outer shape, i.e. they can be squares or rectangles when viewed perpendicularly to the mold surface.

N The idea of one embodiment is that

Each component of an N well section is different.

N The idea of one embodiment is that

The curved mold surface part of each component of the N well part

O 30 has several different radii of curvature.

E The idea of one form of application is that — between the components of the well part there are quick-connect elements, such as

A ten pin-hole members or other connectors.

N The idea of one form of application is that the

The tip of N 35 is made of fiber material. The fiber material can be, for example, wood fiber or other plant-based material.

The idea of one form of application is that the mold surface is made of plywood sheets. The components of the edge part can be, for example, molded plywood or film plywood.

The well part and its components can be either the same or different plywood than the components of the edge parts.

The idea of one form of application is that the mold surface is made of some other wood fiber board than plywood. If necessary, the mold surface can be treated with a coating, for example paint.

The idea of one form of application is that the mold surface or at least one of the components of the mold surface belonging to it is alternatively made of plastic material or composite material.

The idea of one embodiment is that the well part or at least one of its components is alternatively made of metal, such as for example steel or aluminum.

The idea of one form of application is that the well part has a 3-dimensional mold surface, which is made with a cutting tool. In other words, the part of the mold surface on the well part is formed using a material-removing machining technique.

The idea of one embodiment is that

The mold surface of N well part or the mold surface of its components is

N formed using multi-axis milling.

N The idea of one embodiment is that

The N well part has a 3-dimensional mold surface, which is ready-

O 30 made with additive manufacturing technology (AM).

E The idea of one form of application is that — the mold surface of the well part can be formed from a 3D print-

A malla. The material can be plastic material or any other

N hansa other hardening mass.

No. 35

The idea of one form of application is that the mold surface of the well part is formed on top of the bottom part made of fiber material or plastic using AM technology.

The idea of one form of application is that the target of the solution is a casting mold for casting the building's sloped floor element. The casting mold comprises: a body; and the mold surface, which is a separate piece in relation to the frame and is fitted on top of the frame. The mold surface is a multi-part piece like the one shown in this document, which is assembled on top of the frame.

The idea of one embodiment is that the body of the casting mold is made of steel. In addition, the parts or components of the mold surface are equipped with magnets, in which case they can be fixed in place on the frame with the help of magnets.

The idea of one form of application is that the casting mold comprises separate edge moldings or beams that can be attached to the frame. The attachment can be based on magnets, for example. Alternatively, there can be, for example, a pin or screw fastening.

The idea of one embodiment is that the casting mold comprises adjustment elements for adjusting the height of parts or components of the mold surface in relation to the body of the casting mold.

In this case, for example, the edges of the edges can be adjusted. The control elements can comprise, for example, screw elements. Still

N possible to use fixed-altitude non-weather

Adjustable spacers or platforms.

N The idea of one form of application is that rat-

The application focuses on the method of pouring the poured floor element

O for 30 The method comprises: pouring a poured floor element

E mold casting at the prefab factory; a casting mold is used, — with an upward-facing mold surface that is equipped

A at the point of the floor well and on sloping surfaces, the wet area

N according to the floor; hardening casting compound is cast to form

N 35 on top of the tip surface, in which case a downward-directed cast floor surface is formed against the mold surface; and after the casting has hardened, turn the sloping floor element upside down so that the sloping floor is in the operating position pointing upwards. In addition to this, a mold surface is used which has a multi-part structure comprising at least a separate well part and an edge part; and the configuration of the well part and the edge part of the mold surface is selected according to the dimensioning of the poured floor element to be cast and the location of the floor well point.

The idea of one form of application is that, in the method, the components of the well part and the components of the edge part are selected from the preformed mold library based on the design data of the poured floor. In other words, for the production of the sloped floor element, a large number of well-part Components of different shapes, dimensions and surface geometry, as well as edge-part components of different shapes and dimensions, have been planned in advance. In this case, the well part and the edge part can be formed using the modular components of the mold library. There is thus a very large number of different combinations of components and mold surfaces that can be achieved, even if the number of components used is considered reasonable.

Alternatively, the term component library can be used for mold library.

The idea of one form of application is that a computer program or algorithm is used to select the components

N rhythm. For a computer or electronic terminal

N is entered in the design-

N data, in which case the device's processor determines the planning

With the N calculation program, the mold surface com-

O 30 ponents. Alternatively, product or manufacturing directions can

The user can select the components manually, for example — with the help of a graphical user interface.

A The idea of one form of application is that va-

N roughen the upper surface of the casting mold with one or more

N 35 with rough additional components: floor drain, drain pipe, flat

duct heating element, stiffeners and lifting eyes; and is poured onto the upper surface of the casting mold in a casting that at least partially covers the mentioned one or more additional components.

The idea of one form of application is that the floor heating element can be a floor heating pipeline or an electric resistance element.

The idea of one form of application is that the floor well point of the mold surface comprises a pre-planned reservation or place for the floor well.

The idea of one form of application is that the floor well point of the mold surface is a flat surface in the well part, to which the floor well can be fitted for casting. The floor well point can also be equipped with an adapter and other connecting means for casting.

The idea of yet another form of application is that the mold surface presented in this document can also be used in some cases, deviating from the patterns in this document, so that the 3-dimensional mold surface points downwards. In this case, the hardening mass can be fed below the mold surface, for example by pumping or other pressure casting techniques. Therefore, it can be stated that the presented mold surface solution is versatile for different cases.

It should be mentioned that the sloping floor refers to the sloping upper surface of the floor, which leads towards the floor well and

N leads the water to the floor well. A floor drain can be located in

N on the edge of the hand space, in the middle or anywhere, as long as it is

The water that got on the floor of the N wet room is removed by gravity

N led away from the wet area.

O 30 The above-mentioned forms of application and in them pre-

These features can be combined to achieve the desired solutions.

S

N Brief description of the patterns

N Some applications of the presented solution are shown in more detail in the following figures, in which figure 1 shows a schematic view of a sloped floor element, figure 2 shows a schematic view from above of another sloped floor element with installations cast inside it, figure 3 schematically shows a prefabricated section auxiliary slab after casting and before it has been turned into its operating position, figures 3-5 schematically show the stages of manufacturing a cast floor element, figures 6 and 7 show schematically and seen from above some of the mold surfaces of the casting mold, figure 8 shows schematically and seen from above one of the mold surfaces, which is formed from a total of eight interconnected components, figures 9-12 show schematically and seen from above some components of the well part of the mold surface, figure 13 shows schematically and seen from above a mold surface with a beveled side surface, figure 14 shows schematically and seen from above, the mold surface, where the well part is located at the edge of the mold surface, and Figure 15 shows schematically and seen from above the mold surface, where the well part is located in the corner of the mold surface.

N For the sake of clarity, some of the presented solutions

N implementation forms are shown in the figures as simplified.

N The figures use the same reference numbers to refer to the

N to these elements and features. oO = 30 Detailed description of some forms of application = Figure 1 shows a sloping floor element 1, which

S includes the floor well 2 and the sloping K pouring surfaces a 3a - 3d to lead the water to the floor well 2 and further

NN out along drain 4. Poured floor element 1 is cast from a hardening mass, such as, for example, concrete or copper

from concrete non-cement based mass. Slab floor element 1 is a load-bearing structure that comprises a reinforcing structure, such as reinforcement. Poured floor element 1 is suitable for use, for example, on the floor of a bathroom, toilet, utility room or similar wet room. Poured floor element 1 can be cast in good factory conditions and efficiently on the casting line of the prefab factory.

Figure 2 shows that floor heating elements 5, such as circulating fluid piping or heating cables, can be integrated into the structure of the poured floor element 1. Furthermore, it can comprise one or more drains 6 for sinks, toilet seats or the like. In addition, other necessary installations can be integrated into the structure, such as lifting links, fastening elements and other components belonging to the pipeline or electrical system.

Figures 3-5 show the manufacturing steps of the sloped floor element 1 as simplified figures. For the sake of clarity, the well part and the edge part of the mold surface are not shown separately in Figures 3-5.

In Figure 3, the casting mold 7 is assembled for casting.

The casting mold 7 comprises a body 8 and a mold surface 9, which is a separate body in relation to the body 8 and is fitted on top of the body 8. The frame 8 can be a steel plate or base, to which the edge parts 10 can be attached, for example with magnets 11 or screws. Mold surface 9 can be supported at an angle

N on top of the frame 8, for example, the adjustment element 12 or the intermediate

N lein. The upper surface of the formwork surface 9 gives the roof floor element

N desired three-dimensional surface with roofs. 9 of the mold surface

The necessary fittings can be fitted above N or

O 30 corresponding stiffeners, such as mesh 13 and brush steels 14.

For E F, a floor drain 2 can be attached to the mold surface 9 — and the drain 4 can be supported so that they come inte-

A to become part of the structure.

N In Figure 4, the hardening casting compound is poured into a casting mold

N 35 was removed from the casting equipment 15. When the casting mass has hardened, the hardened cast floor element 1 is removed from the casting mold 7 and turned T upside down to its operating position shown in Figure 5.

Figure 6 shows the mold surface 9, which has a multi-part structure. The mold surface 9 comprises a well point 16 for a floor well. The well point 16 is surrounded by the well part 17, which in turn is bounded by the edge part 18. The well part 17 and the edge part 18 are separate pieces that can be connected to each other to form the mold surface 9. The well part 17 can be one continuous piece or it can consist of several components. The edge part 18 delimits the well part 17 from several sides, and in the solution of Figure 6 it consists of four components 18a-18d, each of which has a different shape. The components 18a-18d of the edge part 18 are set to extend obliquely towards the edges of the well part 17. The well part 17 is also shaped as a 3-dimensional surface so that the highest point of the mold surface 9 is the well point 16 and the other surfaces lead away from it. In this case, the mold surface 9 has a negation with respect to the working surface of the poured floor element to be cast. The edges of the mold surface 9 can be shaped as needed. In the solution according to the pattern, as an example, 19 are recessed for flues or the like.

Figure 7 shows the configuration of another mold surface 9.

Figure 8 illustrates the mold surface 9, where the well part 17 consists of four interconnected

N view of components 17a-17d.

N Figures 9-12 show the components of the well part

N 17e-17h possible shapes and 3-dimensional shapes. This

By combining N kinds of different components

O 30 can be formed into many different well parts.

E It can be seen from Figure 13 that the components 8a-18d of the edge part 18 can be easily shaped into the desired shape.

A An example of this is a compo-

N nent 18b. Components 18a-18d can be fiberboard,

N 35, from which it is easy to saw the components of the required shape at any given time. The components 17a-17d of the well part 17 can also be selected on a case-by-case basis.

In Figure 14, the well part 17 is placed at the edge of the mold surface 9, whereby the edge part 18 comprises three components 18a-18c.

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Claims (14)

Patent requirements 1. A mold surface (9) for a mold (7) for a sloped floor element (1) in a building, which mold surface (9) has a well location (16) for a floor well (2); and inclined surfaces which delimit the well site (16) and which have a slope from the well site (16) in the direction of the edges of the mold surface (9); characterized in that the mold surface (9) is a piece with several parts including at least a well part (17) and an edge part (18) which are separate; the well part (17) is arranged to surround the well site (16); the well part (17) has a 3-dimensional surface which consists of curved surfaces and which forms part of the mold surface (9) and which has a slope in the direction away from the well site (16); and whereby the edge part (18) is arranged to delimit the well part (17) on at least two sides. 2. Form surface according to patent claim 1, characterized in that the edge part (18) comprises several connected flat surfaces, each of which has an angle of inclination from the center of the form surface (9) in the direction of the edge. N 3. Mold surface according to patent claim 1 or 2, characterized in that at least one of the said parts of the mold surface (9), the well part (17) and the edge part (18), consists of at least two connected separate components . A 4. Form surface according to patent claim 3, characterized N in that the N edge part (18) consists of at least three separate components (18a-18d), each of which is a disc-shaped piece. 5. Mold surface according to patent claim 3 or 4, characterized in that the well part (17) consists of four separate components (17a-17d) each of which has a curved 3-dimensional partial surface of the mold surface (9). 6. Form surface according to one of the preceding patent claims 3 - 5, characterized in that the well part (17) consists of several separate components (17a-17d) which are different from each other. 7. Mold surface according to any of the preceding patent claims 1 - 6, characterized in that the mold surface (9) is made of fiber material. 8. Form surface according to any of the preceding patent claims 1 - 7, characterized in that the well part (17) has a 3-dimensional form surface that has been created with a flexible cutting tool. 9. Mold surface according to one of the preceding patent claims 1 - 8, characterized in that the N well part (17) has a 3-dimensional mold surface which N has been created by additive manufacturing (AM). Oh 30 10. A mold (7) for casting a sloped floor element (1) for a building, which mold (7) has — a frame (8); and A a mold surface (9) which is a separate piece in relation to the frame (8) and arranged on the frame (8); N 35 characterized in that the mold surface (9) is a piece with several parts according to one of the previous patent claims 1 - 9 which is assembled on the frame (8). 11. Mold according to patent claim 10, characterized in that the frame (8) consists of steel; and the parts of the mold surface (9) are fitted with magnets, whereby they can be fixed in place on the frame (8) with the help of the magnets. 12. A method for casting a sloped floor element (1), which method includes casting a sloped floor element (1) by mold casting at an element factory; a casting mold (7) is used which has an upwardly directed mold surface (9) with a well place (16) and inclined surfaces according to a sloping floor in a wet room; a hardenable casting compound is poured onto the mold surface (9), whereby a downward sloping floor surface is created against the mold surface (9); and the inclined floor element (1) is turned upside down (T) after the cast material has hardened so that the inclined floor is in its use position and directed upwards; characterized in that N a mold surface (9) of multi-part construction N comprising at least a well part (17) and an edge part (18) N which are separate is used; N it chooses a configuration for the mold surface (9) well part (17) and edge part (18) according to the dimensions of the slope E floor element (1) to be cast and according to the location of the floor well — (12); and A well part (17) is used which has a 3-dimensional N ional surface consisting of curved surfaces and which forms part of the N 35 mold surface (9) and which has a slope in the direction away from the well site (16). 13. Method according to patent claim 12, characterized in that at least the components (17a-17d) of the well part (17) are selected from a shape library, which has been created in advance, based on the design data of the sloping floor. 14. Method according to patent claim 12 or 13, characterized in that the upper surface of the mold (7) is provided with one or more of the following additional components: a floor well (2), a drain pipe (4), a floor heating element (5), stiffeners (13, 14) and lifting eyes; a molding compound is cast on the upper surface of the mold (7) to at least partially cover said one or more additional components. N N O N N = I jam a LO N LO N N O N