US2366435A

US2366435A - Method of forming complementary concrete dies

Info

Publication number: US2366435A
Application number: US441415A
Authority: US
Inventors: Brown James Hugh
Original assignee: Individual
Current assignee: Individual
Priority date: 1942-05-01
Filing date: 1942-05-01
Publication date: 1945-01-02
Anticipated expiration: 1962-01-02

Description

Jan. 2, 1945. J. H. BROWN 2,366,435

METHOD .OF FORMING COMPLEMENTARY CONCRETE DIES- ATTE! RN EYB Jan. 2, 1945. 1 H BROWN METHOD 0F EORMING GOMPLEMENTARY CONCRETE DIES Filed May 1, 1942 6 Sheets-Sheet 2 /7/ 1z/.// ////////w/.//././l

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f ,uuu-ED CONCRETE DIES James Hugh Brown, Seattle, Wash. Application May ll, 1942, Serial No. 441,415 k 4 claims. (Cms- 155) My invention relates to the shaping and contouring of laminated wood, ply wood or veneer,

and the molding of plastic materials, and has among its objects and advantages the provision of an improved mold and a method of making the same. i

Considerable difficulty has been experiencedy in the construction of iron and steel molds in.

the nature of a shoe and a die for bending and shaping structural materials, particularly in cases where the shapes are in the nature of bends or geometrical curves in both single and compound curvatures. In the case of iron or steel., each mold part has to be separately cast from a separate pattern.H This method does not insure, in the molding of each part, a perfect conformity and contour. Such methods require much expensive machine work on both the die and the shoe in order that they shall closely conform to and contour with each other. Then, too, there is the further problem of warping and shrinking peculiar to metallic shoes and dies.

Accordingly, an object of my invention is to provide a novel shoe and die combination wherein the two parts may be accurately shaped .to closely conform to and contour one with the other, and in which the parts are`constructed of material which entirely eliminates objectionable warpage and shrinkage.

A further object is to provide a mold `cornprising coacting die and shoe units formed of concrete or other initially plastic material wherein the shoe and the die are provided with internal and external reinforcing means, and in which the die and the shoe are provided with means for circulating aheating and drying or cooling medium therethrough for subjecting the work being bent or shaped to the required teml perature conditions.

shaped coacting fa'ce on the second unit, to-

gether with the use yof a thin -separator between the two units to facilitate separation thereof upon hardening of the second unit.

Another object is to provide a novel mold wherein a ilexible pressure or suction responsive means may be employed in' connection with a rigid mold member to bend or shape construction materials to the contour of Ithe rigid mold member.

In the accompanying drawings: Figure l is a perspective view of a mold in accordance with my invention;

Figure 1a is a sectional detail view vof a portion of one of the mo'ld clamps:

Figure 1b ,is a perspective view of a form for pouring the concrete;

Figure 2'ls a transverse sectional view of a shoe and die mold contoured in accordance` with Figure lbut in which the shoe and die are provided with internal and external reinforcement;

Figure 3 is a longitudinal sectional` view of the structure of Figure 2;

Figure 4 is a top plan view;

Figure 5 is a detail view of one of the work or material guides; I

Figure 6 is a view similar to Figure 5 but illustrating fingers attached to the guide for holding the elements of a laminated assembly in olset relationship one with the other;

Figure '7 is a view illustrating a shoe member in association with a suction responsive wall for shaping and bending construction material;

Figure 8 is a sectional view of the shoe in association with a pressure envelope for bending and shaping construction material;

Figure 9 is a sectional view of a shoe illustrating the manner in which a shoe facing of different contour may be mounted' thereon;

Figure 10 is a sectional view of a die illustrating internal and external reinforcement therefor;

Figure 11 is a perspective view of a series of shoe and die sections assembled upon a common base for coaction on a single piece of construction material together with means for circulating a heating or cooling medium through the respective shoe and die sections;

Figure l2 is an end view of a shoe and die unit wherein the shaping and bending faces are of different radii to bend and shape work having a curved contour of uniform thickness throughout.

its entire body;

Figure 13 illustrates a`further modication in the work or material guide means;

Figure 14 is a top view of one end of the structure of Figure 13;

Figure l5 is a view of one guide member; Figure 16 is a. view of a companion guide mtmbel', and.

In the embodiment selected for illustration, I ,i

make use of a concrete shoe I and a concrete die I2. The shoe I0 is provided with a shaping and bending face I4 and the die I2 is provided with a correspondingly shaped face I6. Figure 1 illustrates sheets I8 of ply wood arranged between the faces I4 and I6 to be bent to the contour of the faces and united into a unitary structure by grooved joints between the respective ply 4wood sheets. A sheet 20 of pliable material, such as rubber, is positioned between the face I4 and the lowermost ply wood sheet I3. A similar pliable sheet 22 is placed'between the face I6 and the uppermost ply wood sheet I8. I'he sheets 20 and 22 are employed only in such cases as where the materials being fabricated are characterized by slight or pronounced irregularities which, prevent eil'ective pressure from being applied throughout the entire area jof the assembly. In most cases tlf@ pliable sheets may be dispensed with and thestructural materials arranged for direct engagement with the two forming faces I4 and I6.

After application of glue to the engaging faces of the sheets I8, pressure is brought to bear on the assembly through tightening of nuts 24 on Arods 26 passing through openings in lugs 28 partially embedded in the concrete of the respective shoe and die I0 and I2. This'pressure condition serves as a holding means until such time as the required pressure is applied by means of hydraulic or other external means of like force and strength. The assembled" sheets are maintained K under pressure until the glue has dried thoroughly. When the glue has been properly dried, the sheets I8 are secured firmly one to the other and the assembly has a contour conforming to the faces I4 and I6.

In order to position and retain the die I2 in true vertical relationship with the shoe I0, guide rods 30 are slipped through eyes 32 in both the shoe and the die, which rods are preferably hooked at 34 to engage the upper face of the die I2 to be restrainedy from downward longitudinal movement. The eyes 32 are also partly embedded in the concrete of the shoe and the die.

In securing the sheets I8 into a unitary struc-` ture by means of glue, the glue frequently acts as a lubricant which causes the sheets to shift laterally when pressure is applied to the assembly. In cases where it is desirable tol restrain the sheets from such relativerlateral displacement, aligning bars 36 are brought into engageing and shaping materials of different total thick- IIESSBS.

In cases where it is desirable to arrange theedges of the sheets I8 in offset relationship, spacing fingers 50, see Figure 6, may be employed. Each group of fingers 50 is carried by a bar 52 corresponding to one of the bars 38, and the bars 50 are adjustable horizontally and vertically through the medium of'bolts 54 which pass through a slot 56 in the bar 52 and through slots 58 in the respective fingers. The bars 52 may be substituted for the bars 36 in the eyes 40.

assunse u The loffset arrangement of the sheets I8 in Figure 6 provides an edge contour wli'ereinlthe respective sheets of one assembly may be joined in overlapping relationship with the sheets in another such assembly to provide a strong joint.

Frequently it is desirable to heat the shoel and the die for work drying purposes. Figures 1 and 4 illustrate the shoe andthe die as being provided withv steam pipes 60 embedded in the material of the respective bodies. Oneor more such pipes may be embedded in each unit, as the particular situation may demand or require, with the pipes bent to zigzag contour, and with the ends of the" pipes projecting sufciently far from the units to provide connections for steam conduits. A cooling medium may be circulated through the pipes if a low temperature condition is desired. To facilitate handling of the shoe and the die, each is provided with two pipes 82 embedded therein and extending the full width thereof so that lifting rods may be inserted in the pipes for connection with a lifting hoist. The lifting rods are indicated at 64 in dotted lines in Figure 4.

Figure 1b illustrates a box or form 66 which may be placed on a floor or table 68. The upper faces 'I0 of the side Wallsy 12 are contoured to produce the curvature, single or compound, desired. The concrete is poured into the box 66 and the face of the shoe shaped to the desired contour, with the faces 10 acting as a guide or aid \\in shaping the shoe face. When the shoe is solidified, the box 66 is removedfrom the shoe by unloosening the tie rods 14. 'Ihe tie rods are again tightened .afterthe removal of the box from the shoe, and the box is reversed and placed directly over the shoe, with a sheet of oiled paper on the face of the shoe as a separating means. Concrete is then poured into the box to produce a die having a contour conforming exactly to the face of the shoe, since the shoe then constitutes the bottom of the box.

Figures 2 and 3 illustrates a shoe 16 and a die 'I8 of the same contours as the shoe I0 and the die I2. In the construction of Figures 2 and 3, both the shoe and the die are provided with a plurality of parallel reinforcing members 80 in the nature of I beams embedded in the concrete of the respective bodies. Additional reinforcing rods 82 are also embedded in the shoe and the die in right angular relationship with the I beams 80.

The shoe 16 and the die 'I8 are provided with means to resist chipping and cracking of the concrete about the respective bending and shaping faces 84 and 86, respectively. This reinforcementl comprises steel frames 88 engaging the four faces 90 on the respective shoe and die bodies. The frames 88 terminate slightly short of the respective faces 84 and 86, and each frame includes a narrow ange 82 lying in engagement with the rear face of its respective concrete body. Key flanges 94 are formed on each of the frames 88 to be embedded in the concrete for rmly anchoring the frame. The lugs 96 corresponding ,to the lugs 28 are carried by the frames 88. y, .Y

Both the shoe and the die of Figures 2 and 3 are provided with steam pipes 98. The frames are also provided with eyes I00 corresponding to the

eyes

32 and 46 for supporting aligning rods |02 and guide rodsy I 04 of the type illustrated at 30 and 44, respectively, in. Figure 1. Lift pipes |06 are also embedded in the concrete of the shoe and the die.

Figure '1 illustrates a concrete shoe |08 lying assaut l l in a steel pan provided with a flange ||2 about its open end. Enclosing the upper portion of the shoe |08 is a flexible or rubber cap ||4 secured between the flanges 2 and bars ||8 by bolts ||8L The work to be shaped is indicated at as lying on the contour face 22 of the shoe |08 and inside the cap ||4. A pipe |24 is attached to the cap ||4 and has communication with the jspace between the cap and the shoe. This pipe is connected with a vacuum Ipump (not shown) for bringing the cap |4 into pressure engagement with the work to bend it to the contour face |22 through evacuation of the air in the work space.

Figure 9 illustrates means for shaping a shoe having such extreme contours as to necessitate the formation of a patternrto mold the face of the shoe. In the form |42 is placed a .pattern |44 having a shoe-shaping face |46 characterized by sharp curves |48. The face |46 is treated with wax, grease or the like and the concrete is poured into the form and over the pattern |44, which side edges and face |54 opposite the contour face |56. Reinforcing ribs |58 are formed on the .inner faces of the jacket |52 for strengthening the body-|50. I

In Figure 11, a series of shoes |60 and a series of dies |62 are arranged in abutting relationship upon a common base |64 for shaping a relatively large piece of work |66. The shoes and dies may` ybe identical with those of Figure 1 with respect to clamps, aligning means, guides and.heating or cooling means, with the exception that these devices should be so arranged as to permit end to end engagement between the respective shoe and die elements in the series, thereby providing continuous pressure faces.

'I'he mold of Figure 12 comprises a shoev |68 having a face contour |10 and a die |12 having a,

face contour |14 coacting with the face |10 to bend plywood y|16 or the like for the construction of tank walls and similar structures. The face |14 is characterized Y.by a smaller diameter than the face |10 so as to provide uniform spacing between the two faces. In the form of Figure 12 the two faces |10 and |14 are independently shaped to size and contour, since one face can not be shaped by pouring concrete over the other face because oi.' the difference in diameters of the respective faces. Both the die and the shoe may be provided with conduits for a heating or cooling medium, as well as the clamps," guides and the aligning means of Figure ,1.

Figures 13 through 16 illustrate a further modification in the work guiding means. Figure 13 illu'stratesa plurality of sheets |16 arranged in overlapping relationship between the shoe sec: tion |18 and the die section'l80, as when being glued or cemented into -a unitary structure. To the shoe-` section |18 are connected two gage brackets |82, which brackets are located on opposite faces of the shoe and secured thereto by bolts |84 embedded in the material of the shoe. Two similar gage brackets |88 are attached to the die by bolts |88. .The brackets |86 are located vertically above the brackets |02. Each bracket is provided with two bores [90,l the bores in the brackets |82 being respectively co-axially arranged with the bores in the brackets |86. Gage guide rods |92 are slipped through the aligned bores and preferably made secure to the brackets |82 by set screws |94. f

Each of the bodies |96 is provided with a trans-A verse rectangularly-shaped opening 200.

A tongue-forming guide 202 is inserted in the-slot 200 in one body 96 and made secure by a set screw 204. This guide is provided with shoulders 206 so spaced and arranged as to abut the sheets |16 in the laterally offset relationship of Figure 13 to provide'a tongue formation 208. Guide 200 extends to a position between the shoe 18 and the die |80 and its vertical dimension is narrower than the spacing between the shoe and the die to provide clearance in the closest spacing of the shoe and the die.

A work guide 2|0 is inserted in the other body |96 and may be made secure by a set screw 2| 2. This work guide is provided with shoulders 2|4 so arranged as to engage the opposite edges of the sheets |16 when the latter are relatively laterally offset in the manner of Figure 13 and in conformity with the work guide 202. I'he work guide 2 I0 is also narrower than the-closest spacing between the shoe and the die, and either work guide 202 or 2|0 may be adjusted to bring the edgesl of the sheets 18 into desired holding engagement with the respective shoulders 206 and 2|4 to restrain the sheets |16 from relative lateral shifting when pressure is applied to the assembly. While the set screws |94 firmly secure the rods |92 against vertical movement, the brackets |86 are free to move longitudinally on the rods |92, as when the die |80 is moved vertically relatively to the shoe |18. When the sheets |16 have been thoroughly secured into a unitary assembly, the assembly is characterized by a tongue 208 along one edge and a groove formation 2|6 along its opposite edge for receiving the tongue formation 208 on another assembly. Thus sections 0f assemblies may be effectively joined one to the other and with the respective sheets of the assemblies overlapping one with the other.

While I have employed specic designs to illustrate the purpose, scope and function of my invention, I am not to be restricted to these, provided always, of course, that I confine such other designs as I may employ within the scope and principle of my invention.

Without further elaboration, the foregoing will so fully illustrate my invention, that others may,

` quently separating the die from the shoe at their same for use under various conditions of service.

I claim:l

l. The methodA of forming a shaping mold comprising a concrete shoe inthe nature of a monolith and having sides and ends, and a top and bottom face, thewhole of the top face constituting a work-shaping face and a concrete die in the nature oi' a monolith and havingJ sides and ends, and a top and bottom, the whole of the bottom. face of which constituting a work-shaping face which consists in preparing a form having an edge contour conforming to the predetermined perimetrical contour of the work-shaping face ofthe shoe, pouring concrete into said form and shaping the face of the concrete to said edge contour and the predetermined face contour of the shoe and allowing the concrete to set, remov-` ing the form from the hardened shoe, applying a separator medium upon the work-shaping 'face of the shoe, arranging the form upon the shoe, pouring concrete into the form to form the die with a work-shaping face' the whole of which contoured from the work-shaping face of the shoe, allowing the die to harden. and subsequently L separating the die from the shoe at their juncture with said separator medium.

2. 'I'he method of forming a shaping mold juncture with said separator medium.

3. The method of forming a lshaping` mold comprising a concrete shoe in the nature yof a monolith having a work-shaping face and a concrete die in the nature oi' a monolith having an identical work-shaping face which comprises forming a pattern contoured to the work-shaping face of the shoe, applying a separating medium on the pattern, placing the pattern in a form and pouring the concrete upon the pattern to contour the work-shapingy face of the shoe, allowing the concrete to set, removing the shoe from the patl tern and applying la separator medium to the work-shaping Aface of the shoe, pouring the concrete of the die upon the work-shaping face of the shoe to shape the work-shaping face of the die in conformity with the work-shaping face of the shoe, allowing the concrete of the die to set, and subsequently separating the die from the shoe at their juncture with said separator medium.

4. The method of forming complementary shoe and die sections each having a monolithic char-y acter' of/a plastic shaping mold having co-acting work-shaping faces which comprises molding' one section as a unit in a form having the top edges conforming to the edge contour of a. selected work-shaping face, placing a separator medium on the uppermost work-shaping face of the section, removing the said form from the molded section, and mounting said form in reversed position for molding the complementarysection as a unit on the first section and the separator thereon so that the lowermost work-shaping face of the upper section will accurately conform'to the work-shaping face of the bottom section.

JAMES HUGH BROWN.