GB2623252A

GB2623252A - Method of manufacturing building blocks with precise dimensions

Info

Publication number: GB2623252A
Application number: GB2400912.8A
Authority: GB
Inventors: Savushkin Roman; Sokolov Alexey
Original assignee: Avvyland Ltd
Current assignee: Avvyland Ltd
Priority date: 2021-04-29
Filing date: 2021-08-03
Publication date: 2024-04-10
Also published as: GB202400912D0; WO2022229689A1

Abstract

This invention concerns the field of construction, namely, methods for manufacturing solid building blocks with various geometric characteristics using removable molds. Method for manufacturing building blocks consists in assembling the parts (1-3) of a mold, sealing the mold's internal cavity on all sides, setting the shape of the mold's internal surface, feeding into the mold a liquid mixture capable of solidifying inside the mold's internal cavity, and removing the resulting product from the mold after it has reached sufficient strength by separating the mold's parts. A liquid mixture capable of solidification is poured into the sealed cavity of the mold. A pressure of at least 9 kPa is applied to the liquid mixture capable of solidifying inside the mold by inserting at least one plunger (4) into the mold's cavity and fixing it in place until the product gains sufficient strength to extract.

Claims

1. Method for manufacturing building blocks with highly precise dimensions, which consists in assembling the parts of a mold, sealing the moldâ s internal cavity on all sides, setting the shape of the moldâ s internal surface, feeding into the mold a liquid mixture capable of solidifying inside the moldâ s internal cavity, and removing the resulting product from the mold after it has reached sufficient strength by separating the moldâ s parts, is distinct in that the mold consists of a bottom plate mounted on an assembly table, side plates installed on the bottom plate at right angles with their end surfaces positioned around its perimeter, as well as a top plate laid on top of the end surfaces of the side plates opposite the end surfaces in contact with the bottom plate, while at least one mold part contains at least one shaping surface; a liquid mixture capable of solidification is poured into the sealed mold cavity, with the volume of the poured mixture greater than the volume of the material of the final product in a range from 0.1 to 99 percent, preferably from 1 to 65 percent, more preferably from 5 to 15 percent, and most preferably 10 percent; a pressure of at least 9 kPa is applied to the liquid mixture capable of solidifying inside the mold by inserting at least one plunger into the mold and fixing it in place until the product gains sufficient strength to extract; the casting mold contains at least one channel, the shape of whose cross-section relative to its axis passing through the centers of the base of the channel in its central part is selected from a group consisting of a circle, oval, square, rectangle, triangle, trapezoid, or their combinations, which is intended for inserting a plunger whose immersion will subject the liquid mixture inside the moldâ s sealed cavity to a required pressure, after which the liquid mixture hardens and, after gaining sufficient strength to extract, the resulting product is removed by separating the parts of the mold.

2. Method of claim 1 wherein the plunger is made in the form of a threaded screw or smooth rod, and the shape of the plungerâ s cross- section relative to its axis passing through the centers of the base of the plunger in its central part is selected from a group consisting of a circle, oval, square, rectangle, triangle, trapezoid, or their combinations .

3. Method of claim 1 wherein the immersion depth, which is defined as the distance the plunger is inserted between the projection of a plane perpendicular to the axis of the channel passing through the centers of the channel base in its central part and the surface of the plunger in contact with the liquid mixture inside the closed cavity of the mold, is from 1 to 983 mm.

4. Method of claim 1 wherein the one of the forming surfaces is made with a complex pattern containing protruding elements.

5. Method of claim 1 wherein the moldâ s parts are designed in such a way that, when assembling them, it is possible to fix inserts inside the space formed by the mold, which are designed to fasten the resulting products to each other.

6. Method of claim 1 wherein the one of the casting moldâ s plates consists of two components, of which the first contains the form of the surface of the product and the second serves as a structural element, with the first component attached to the surface of the second by means of a detachable connection.

7. Method of claim 1 wherein the side plates standing between the surfaces of the bottom and top plates of the casting mold are prevented from moving by elements on their surfaces executed in the form of interacting protrusions on one surface and depressions on the other.

8. Method of claim 1 wherein the liquid mixture capable of solidification in the mold is kept under pressure until it has gained strength sufficient to be extracted under natural conditions, while heat is released as a result of the exothermic reaction of the mixtureâ s components with water.

9. Method of claim 1 wherein the product does not require further processing after removal from the mold.

10. Method of claim 1 wherein the temperature of the liquid mixture poured into the assembled mold is at least in a range from 1 to 90 degrees Centigrade.

11. Method for manufacturing building blocks with highly precise dimensions, which consists in assembling the parts of a mold, sealing the moldâ s internal cavity, setting the shape of the moldâ s internal surface, feeding into the mold a liquid mixture capable of solidifying inside the moldâ s internal cavity, and removing the resulting product from the mold after it has reached sufficient strength by separating the moldâ s parts, is distinctive in that the mold consists of a bottom plate mounted on an assembly table, side plates installed on the bottom plate at right angles with their end surfaces positioned around its perimeter, as well as a top plate laid on top of the end surfaces of the side plates opposite the end surfaces in contact with the bottom plate, while at least one mold part contains at least one shaping surface; a liquid mixture capable of solidification is poured into the sealed mold cavity, with the volume of the poured mixture greater than the volume of the material of the final product in a range from 0.1 to 99 percent, a pressure of at least 9 kPa is applied to the liquid mixture capable of solidifying inside the mold by inserting at least one plunger into the mold and fixing it in place until the product gains sufficient strength to extract; the casting mold contains at least one channel, whose cross-section relative to its axis passing through the centers of the base of the channel in its central part is selected from a group of shapes consisting of a circle, oval, square, rectangle, triangle, trapezoid, or their combinations, which is intended for inserting a plunger whose immersion will subject the liquid mixture inside the moldâ s sealed cavity to a required pressure, after which the liquid mixture hardens and, after gaining sufficient strength to extract, the resulting product is removed by separating the parts of the mold.