RU2207950C1 - Method of manufacture of articles from foam material and device for realization of this method - Google Patents

Abstract

FIELD: manufacture of building blocks from foam materials. SUBSTANCE: proposed method includes pouring raw material in form, forming blocks, removal of forms, withdrawal of block and separation of it into separate articles. Prior to pouring raw material into form, sheet packing material is laid over its side surfaces; part of packing material is brought beyond internal volume of form at joint areas and is secured around vertical rod supports. After forming, packing material is cut, block is withdrawn together with elements of packing material and ends of these elements are connected in single envelope over perimeter of block. Separation of block is effected by cutting it together with envelope. Device proposed for realization of this method has base with side walls, flexible cloth and supporting members for locking it in required position; side walls are movable relative to one another and are coupled together in operating position; supporting members are made in form of vertical rods. Flexible cloth is laid on inner surfaces of side walls shifted by gap and is passed through gaps between walls and rod supports. EFFECT: improved quality of articles; avoidance of crushing of block. 16 cl, 6 dwg

Description

 The invention relates to the production of building products from various foams, including which it can be used for the manufacture of products from especially light materials - foam concrete grades below 300. penoizol and others.

State of the art
A known method of forming lightweight wall blocks (see application for invention 94018353, publ. 04/10/1996, IPC 28 V 1/50), including the preparation of molds, loading into the molds of a light porous aggregate, pouring foam concrete, holding time and smoothing the textured layer. Products are formed in cassette forms, the inner surface of the walls of which are made with high purity processing.

 The method is characterized by high performance obtained by manufacturing several products at the same time, and allows the manufacture of lightweight blocks with low thermal conductivity and with a processed textured layer. However, the method is directed to the manufacture of large wall products. which are ready for use and are not further divided into smaller products.

 The closest in essence to the claimed method, the solution chosen for the prototype, is a method of molding products from foam (see USSR author's certificate 1516369, IPC B 29 C 6 7/20, publ. 23.10.1989, Bull. 39). A method intended primarily for materials having sufficiently high visco-plastic characteristics includes pouring an expandable composition into a mold, densifying the molding material by horizontal movement of one of the side walls of the mold, lowering the separation walls and foaming the material. After the hardening of the material, the dividing walls containing at the base of the expansion with smooth transition lines are lifted, and the surface of the products is densified and smoothed out. The size of the extensions depends on the properties of the foam, its predisposition to deformation. Then the end wall is tilted and the products are pushed out of the mold. The dividing partitions are installed with a gap in relation to one of the walls of the mold, therefore, the molded products are interconnected at the ends by jumpers into a single unit, which protects the products from warping during formwork and allows you to store and transport products in blocks. For further use, it is enough to cut the jumpers, dividing the block into separate products. Thus, in the above method, the separation of the foam block into smaller products is carried out when forming the products directly in the form, leaving only small jumpers to maintain communication between the individual parts.

 This method allows to produce blocks of foam plates with a reinforced / hardened surface of the product obtained by compaction by means of dividing walls. However, when transporting products, damage to the outer surfaces, chips or breaks of the unit, especially in the places of jumpers, are possible. To preserve the integrity of the unit during transportation to the place of use of the products or their storage, i.e. in order to avoid breaking the jumpers between the products, in which, as a rule, there will be damage to the shape of the product, chips or chipping of the surface, it is necessary to additionally pack the unit or fix the products together in some other way.

 Known multi-seat form for the manufacture of products from concrete mixtures (see application for invention of the Russian Federation 93017067, IPC B 28 V 7/24, publ. 06/09/1995). The form contains a pallet, longitudinal and end sides and dividing partitions articulated on it. The dividing partitions are removable and mounted on the longitudinal sides. In the assembled state, the form is fixed by locks. The form is characterized by high productivity and allows you to immediately produce a batch of wall products from aerated concrete or aerated concrete.

 The presence of removable dividing walls makes it convenient to assemble and maintain the mold and makes it easy to remove formwork, eliminating product damage.

 However, in the process of molding products from foam materials, the adhesion of particles of foam to the walls of the mold is inevitable. To obtain high-quality products, it is necessary to clean the inner surfaces of the walls of the mold to a certain degree of purity of treatment, or to cover the inner surfaces of the walls of the mold with a special release agent. All this takes time to prepare the mold for forming products. The cost of labor and time resources can be reduced if large blocks are made with their subsequent sawing into individual products. However, this raises the problem of chipping the foam during sawing and the formation of chips at the ends of the products, which significantly impairs their quality.

 Closest to the design solution to the claimed device is a form for the manufacture of building products (see USSR author's certificate 1105315, IPC V 28 V 7/24, publ. 30.07.1984, Bull. 28). The form contains a pallet, longitudinal and end sides fixed to it, form-forming panels with clamps for their position and tension mechanisms. The form-forming panels are made of fiberglass and, after tensioning, form several compartments / cells into which the raw material mixture is placed to form building products. In the process of forming products, the mixture adheres to the forming surfaces. To prevent the removal of the forming elements together with the products during formwork, the position fixers of the forming panels are used. The mechanisms of tensioning the panels mounted on the end walls provide the possibility of a complete careful stripping by removing the tension of the panels and free extraction of products. The end walls are made reclining, which provides ease of assembly / disassembly of the form. Due to the implementation of the forming cloths from fiberglass, the adhesion of the particles of the raw mix to the forming surfaces of the cloths is reduced, and therefore, the cost of cleaning the latter and preparing the mold for work is reduced.

 Auto form testimonial. 1105315 allows you to simultaneously produce a batch of large construction products, which can be further divided into smaller ones. However, when they are separated, the surfaces of the products will undergo chipping. In addition, to ensure the safety of the surface of the products during further transportation to the places of use and during storage of the product must be packaged.

The essence of the claimed invention
The claimed invention solves the problem of developing a method for manufacturing products from foam, which allows not only to obtain high-quality products by the method of manufacturing simultaneously a block of products with subsequent division of the block into separate products, but also to ensure the safety of the quality of the shape and surface of the products during their further storage, transportation and use, as well as solves the problem of developing a device. allowing to implement this method. At the same time, the task of preventing chipping during separation (cutting or sawing) of the block into individual products is solved.

 The problem is solved in that in a method of manufacturing products from foam, including pouring raw materials into a mold, molding a block of products, stripping a mold and removing the block with subsequent separation of it into separate products, according to the claimed invention, before filling the raw materials into the mold along its lateral forming surfaces, sheet packaging material, while part of the sheet packaging material at the junction of the mold elements is taken outside the internal volume of the mold and fixed, after molding carry out the unlocking of the packaging material, take out the block of products with the elements of the packaging material and connect the ends of these elements into a single shell around the perimeter of the block, separation into separate products is carried out by cutting the resulting block together with the shell.

 In the inventive method, in contrast to the prototype, the separation of the block into individual products is carried out after molding and removing the finished block from the mold.

 Reinforcement / hardening of the surface in the proposed solution is due to the sheet packaging material, laid on the side forming surfaces of the form with fixing its position outside the forming volume. During the filling of the raw material and its subsequent hardening, particles of the material adhere to the forming surfaces of the packaging material, which allows, after molding, to remove the finished block of products with elements of packaging material previously cut near the fixation points, for example, at the locations of the rod supports. Then the corners of the elements of the packaging material are combined into a single shell around the perimeter of the block and a finished product block with a surface reinforced by the presence of a shell of packaging material is obtained. Subsequent separation of the block into separate products is carried out by cutting the resulting block together with the shell.

 The shell prevents the coloring of the material during the separation (cutting) of the block into individual products, the surface of the products is high-quality, shape accuracy is observed. In addition, the shell protects the product from damage during storage and transportation.

 It is most advisable to separate the block directly at the place of use of the products.

 In the study of known technical solutions in the art, no solutions were found that have similar distinctive features aimed at solving the problem, which allows us to conclude that the claimed invention meets the criteria of "novelty" and "inventive step".

 Sheet packaging material can be fixed around vertically located rod supports mounted near the joints of the mold elements, from its outer side.

 The release of the sheet packaging material is carried out by cutting the sheet packaging material at the locations of the rod supports.

 The manufacture of a unit of products at the same time, followed by its division into products, is aimed at increasing the productivity of the production process, saving time and labor resources, and packaging of products produced simultaneously with molding reduces the time required for this operation in a known production.

 To increase productivity, it is possible to carry out the simultaneous molding of several product blocks in a multi-layered form, while the sheet packaging material is located on the inner perimeter of each compartment of the form.

 In the case of a multi-seat form, it is advisable to pull the sheet packaging material with a single cloth through all the compartments of the form.

 As the sheet packaging material, polyethylene, laminate, paper or fabric can be used. The use of polyethylene as sheet packaging material makes it possible to obtain products with waterproofing for construction work.

 Preferably, after molding, seal the resulting block, applying a pressing force evenly along one of the side faces.

 In the particular case of the application of the method, it is possible to divide the resulting block in the shell into products by sawing.

 The problem is also solved due to the fact that in the device for forming a block of products from foam containing a base forming a volume and associated side walls, a flexible panel placed inside the said volume and supporting elements fixing its position, according to the claimed invention, the side walls are movable relative to each other and joined together in working condition, the supporting elements are made in the form of vertical rod supports placed outside the forming bemsya and near lines joining the side walls, the flexible cloth is designed as a packaging sheet material stacked on the inner surfaces of the side walls of the skip into the gaps between the walls and around the fixation rod supports.

 The device is characterized by a combination of distinctive features from the prototype features that allow you to implement the inventive method of forming a block of foam products.

 In contrast to the prototype, sheet packaging material is used as a flexible panel, which is laid on the inner surfaces of the side walls with the formation of a forming volume, passing into the gaps between the extended or completely folded side walls, and fix its position by means of vertical rod supports, enveloping the panel around the latter. Vertical rod supports are placed outside the forming volume near the docking lines of the side walls of the device. Vertical rod supports can be rigidly mounted on the base.

 In order to enable mounting, the side walls are made in the form of walls that are movable relative to each other, joined together and in working condition, i.e. in a state of readiness for pouring raw materials and molding. Fixing the position of the side walls in working condition can be carried out using various locking devices. The implementation of the side walls of the form movable takes place in the decision on the application for the invention, RF, 93017067, however, the claimed solution is characterized by a combination of distinctive features.

 The proposed device allows you to form a block of foam products, packaged in a shell of sheet packaging material, for subsequent separation into smaller products together with the shell, thereby preventing chipping of the surface of the products during sawing.

 The above confirms that the inventive method and device for molding a block of foam products are aimed at solving one problem and meet the criterion of "unity of invention".

 The above set of features allows you to get an additional technical result, namely to eliminate the problem of lubrication or cleaning of the inner forming surface, since the sheet packaging material protects the walls of the mold from sticking to them of particles of foam material.

 It is preferable to design pivotally fixed on the basis of the side movable walls (reclining walls). Other technical solutions for the execution of the walls are also possible.

 One of the side walls can be installed with the possibility of reciprocating horizontal movement inside the form and with control from the power drive.

 In the device for the simultaneous molding of several product blocks, two opposed side walls of the device are made up of several elements of the same type. The mentioned elements contain a lateral forming surface and are freely mounted on a single axis for each wall with the possibility of reciprocating movement along it. Such a solution allows you to push the elements of the walls to the formation of gaps between consecutively located elements necessary for laying a flexible panel. The device is additionally equipped with vertical rod supports installed outside the forming volume and near the joints of similar elements of the side walls in the working position. The sheet packaging material is additionally passed into the gaps between the similar elements of the side walls and fixed around the corresponding rod supports, alternating with the supports of the opposite sides so that the said material divides the forming volume into separate compartments. In this case, the sheet packaging material is located on the inner perimeter of each received compartment.

 The device can be equipped with removable partitions made in the form of plates and installed between the layers of sheet packaging material that form the walls of adjacent compartments.

 As a sheet of packaging material, it is possible to use polyethylene, laminate, paper, fabric.

The invention is illustrated by drawings, which depict:
figure 1 - General view of the device with one forming volume;
figure 2 is an extracted block of products with elements of packaging material, shows the line of separation of the block into products;
in FIG. 3 - a device for the simultaneous formation of several blocks of products;
figure 4 is a view aa from figure 3 on a device without a cover;
figure 5 presents a fragment of I view of figure 3, enlarged and rotated;
in FIG. 6 shows a diagram of the possible installation of sheet packaging material in the case of the simultaneous formation of several product blocks.

Information confirming the possibility of carrying out the invention
The inventive method of manufacturing products from foam was implemented using the inventive device.

 Example 1

 A device (see Fig. 1) for forming a block of foam products contains a base 1, associated side walls 2, 3, 4, 5, a flexible panel 6 and supporting elements 7.

 The side walls 2-5 are made in the form of walls movable relative to each other, fixed by means of hinges 8 on the base and joined together in the assembled state of the form. The supporting elements 7 are made in the form of vertical rod supports installed on the base 1 near the connecting lines of the side walls 2-5. As a flexible cloth use sheet packaging material, namely a plastic film.

 Preparation of the device for molding is as follows.

 The side walls 2-5 are apart or tilted. Lay the film 6, passing it into the gaps between the side walls 2-5, bending around the vertical rod supports 7. Close the side walls 2-5 and fix their position with locks (not shown in the drawing). Such a fixed position of the walls is working, i.e., at which molding is carried out. The device is ready to go.

 Foam is poured into the prepared form. During the hardening, the foam particles are set on the surface of the film 6. After collecting enough material, the film 6 is cut at the locations of the rod supports 7. The side walls 2-5 are folded and the finished block of products is removed together with the elements 9 of the packaging material, i.e. films. Glue the ends of these elements into a single shell around the perimeter of the block. The resulting block in a shell made of polyethylene is stored, transported to the place of use. The separation of the block into separate products is carried out by cutting the resulting block together with the shell directly at the place of use.

 Example 2

 Simultaneous molding of several product blocks.

 The device (see Fig. 3 and 4) contains a base 1, side walls 2, 3, 4, 5, a flexible panel 6 and supporting elements 7. The side wall 2 is fixed to the base 1 using hinges 8. The side wall 3 is connected with the power drive 9, has the ability to reciprocate horizontal movement within the mold and plays the role of a piston. The side walls 4 and 5 are made of composite elements of the same type 10, containing a lateral forming surface 11. Elements 10 are mounted on the axes 12 and 13 with the possibility of reciprocating movement along the axes (see figure 5).

 Preparation of the device for molding is as follows. Side wall 2 is open. The side wall 3 is in the extreme left position. Elements 10 of the side walls 4 and 5 are spaced apart from each other by a certain distance necessary for installing the flexible panel 6. Lay the film 6 on the inner lateral forming surfaces, passing it into the gaps formed between successive elements of the side walls, and bending around the vertical rod supports 7. Alternate supports 7 in such a way that the forming volume is divided into separate compartments, while the film 6 is located on the inner perimeter of each received compartment (see Fig.6 ) Between the lateral forming surfaces of adjacent mold compartments formed by a plastic film, plates 14 are installed, which act as reinforcing partitions. Close the side walls 2-5 and fix their position with locks (not shown in the drawing). The device is ready to go. Fill the foam into the compartments of the prepared form. After gaining some strength by material, the formed blocks are compacted by moving the side wall 3 with the power drive 9. Further stripping and removal of the finished blocks, as well as their separation into separate products, are carried out analogously to example 1.

Claims (16)

 1. A method of manufacturing products from foam, including pouring raw materials into a mold, molding a block of products, stripping a mold, removing the block and separating it into separate products, characterized in that before filling the raw materials into the mold, sheet packaging material is laid on its lateral forming surfaces, this part of the sheet packaging material at the junction of the mold elements is removed outside the internal volume of the mold and fixed, after molding, the packaging material is unlocked, the block is removed and dely of the packaging material elements, and connect the ends of these elements into a single unit by the shell perimeter, the separation into individual products is performed, the obtained cutting unit together with the shell.  2. The method according to claim 1, characterized in that the sheet packaging material is fixed by pulling it around vertically arranged rod supports mounted in the joints of the mold elements from its outer side.  3. The method according to p. 1 or 2, characterized in that the release of the sheet packaging material is carried out by cutting it in places of fixation.  4. The method according to any one of claims 1 to 3, characterized in that the simultaneous molding of several blocks of products in a multi-place form, while the sheet packaging material is located on the inner perimeter of each compartment of the form.  5. The method according to claim 4, characterized in that the sheet packaging material is pulled with a single panel through all the compartments of the form.  6. The method according to claim 4 or 5, characterized in that between the two layers of sheet packaging material forming the side surfaces of adjacent compartments, reinforcing partitions are installed.  7. The method according to any one of claims 1 to 6, characterized in that as a sheet packaging material use a material independently selected from the group of materials consisting of polyethylene, laminate, paper, fabric.  8. The method according to any one of claims 1 to 7, characterized in that, after molding, the resulting block is compacted by applying a pressing force uniformly along one of the side faces.  9. The method according to any one of claims 1 to 8, characterized in that the separation of the obtained block into products is carried out by the sawing method.  10. The method according to any one of claims 1 to 9, characterized in that the separation of the obtained block into products is carried out immediately before use.  11. A device for molding a block of foam products, comprising a base forming a volume and associated side walls, a flexible panel placed within the volume and supporting elements fixing its position, characterized in that the side walls are movable relative to each other and joined together in working condition, the supporting elements are made in the form of vertical rod supports placed outside the forming volume and near the lines of the side walls, the flexible panel ying a packaging sheet material stacked on the inner surfaces of the side walls of the skip into the gaps between the walls and around the fixation rod supports.  12. The device according to p. 11, characterized in that at least one side wall is made in the form of articulated on the basis of the flip side.  13. The device according to claim 11 or 12, characterized in that at least one of the side walls is mounted with the possibility of reciprocating horizontal movement controlled by a power drive.  14. The device according to any one of paragraphs.11-13, characterized in that the two opposite side walls are made up of several elements of the same type with a lateral forming surface, freely mounted on a single axis for each wall with the possibility of reciprocating movement along it with the formation of gaps between successive elements, the device is additionally equipped with vertical rod supports installed outside the forming volume and near the joints of the same type s side wall elements in the operating position, the packaging sheet material is passed into the gaps between the same elements of the side walls and around the corresponding rod bearings with alternating poles opposing sides and dividing the forming volume into separate compartments, the packaging sheet material is disposed around the inside perimeter of each resulting compartment.  15. The device according to p. 14, characterized in that it is equipped with removable partitions made in the form of plates and installed between the layers of sheet packaging material that form the walls of adjacent compartments.  16. The device according to any one of paragraphs.11-15, characterized in that as a sheet of packaging material use a material independently selected from the group of materials consisting of polyethylene, laminate, paper, fabric.

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