WO2003092974A1 - Plate-shaped molded block and method for the production thereof - Google Patents

Plate-shaped molded block and method for the production thereof Download PDF

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Publication number
WO2003092974A1
WO2003092974A1 PCT/DE2003/001300 DE0301300W WO03092974A1 WO 2003092974 A1 WO2003092974 A1 WO 2003092974A1 DE 0301300 W DE0301300 W DE 0301300W WO 03092974 A1 WO03092974 A1 WO 03092974A1
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WO
WIPO (PCT)
Prior art keywords
shaped
less
mixture
mold
cement
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Application number
PCT/DE2003/001300
Other languages
German (de)
French (fr)
Inventor
Dieter KÄNNER
Original Assignee
Quartz Technologies Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Quartz Technologies Gmbh filed Critical Quartz Technologies Gmbh
Priority to AU2003223920A priority Critical patent/AU2003223920A1/en
Priority to DE10392005T priority patent/DE10392005D2/en
Publication of WO2003092974A1 publication Critical patent/WO2003092974A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/40—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material
    • B28B7/44—Moulds; Cores; Mandrels characterised by means for modifying the properties of the moulding material for treating with gases or degassing, e.g. for de-aerating
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00103—Self-compacting mixtures

Definitions

  • the present invention relates to a plate-shaped shaped block and a method for its production.
  • Slab-shaped shaped blocks are essentially produced using three different processes: First, there are ceramic-made products in which the slabs are formed from a ceramic mass and then fired. The molded parts must be oversized due to the shrinkage when burning. These shaped stones are very stable and allow for many different designs, including color and shape. However, their production is economically unfavorable and expensive, for example because of the varying shrinkage and the high energy expenditure during burning. Secondly, shaped stones are known that are bound by synthetic resins. However, their production is expensive because of the high cost of synthetic resins. Because of their high UV sensitivity, these shaped stones are not suitable as facade materials. Heat sensitivity and flammability are further disadvantages of these stones for house and furniture construction.
  • slab-shaped shaped stones are also produced in an inorganic bond.
  • so-called "washed concrete slabs” are known.
  • these known shaped stones are raw in appearance and comparatively sensitive to breakage, in particular due to air pores. Therefore, such slabs have so far almost exclusively been shown to be suitable as “walkway slabs,” wherever a comparatively low demand is made on aesthetic demands.
  • the present invention has for its object to provide a plate-shaped molded block which is inexpensive, fire-resistant and UV-resistant and aesthetically high quality, and a method for its production.
  • a plate-shaped shaped block is produced by self-compacting a mixture of at least cement, minerals and water into one
  • the mixture is so thin that it can flow in the mold without additional pressure and compress itself.
  • gas bubbles contained in the poured mixture are removed from the poured liquid by shaking the mold, by negative pressure with which the mold is applied and / or by penetrating the poured liquid with the spikes of a spiked roller.
  • the degassing can be supported by a degassing agent as an additional component of the mixture.
  • the shape in the form of a flat container with a flat bottom is particularly preferred. It then has edges corresponding to the outer contour of the plate-shaped shaped block produced. For example, it is rectangular and, for example, made of a light metal frame with a coated light metal frame and a formwork board as the floor.
  • the liquid mixture is then poured into the mold which is open at the top, which can be favored by an additional liquefier as a component of the mixture.
  • the filling height of the mold is preferably less than 40 mm or even less than 20 mm, so that particularly thin-walled plates are produced. Due to the fact that they are made from the liquid mixture, they are non-breakable due to the low proportion of pores.
  • the method according to the invention permits the production of panels with an edge length of greater than 1 m ⁇ 1 m, even greater than 1.4 m ⁇ 2.8 m, with a wall thickness of up to approximately only 12 mm.
  • the low proportion of pores allows grinding and / or polishing of the plate surface to result in a very high-quality appearance of the plate-shaped artificial stone. This means that slabs that are hard to distinguish from natural stones can be produced in a size in which natural stones are hardly available. This is particularly advantageous for use in architecture as a facade material.
  • sand and / or additives can also be added to the liquid casting mixture in order to produce different appearances of the plate surface: sand and / or grit with more than 90% quartz content are preferred - preferably with a grain size of more than 0.3 mm. Quartzite, granite, basalt and / or other natural stones and / or glass and / or metal such as, for example, aluminum, copper and / or (stainless steel), for example as grain and / or chips, can also be additives. In particular with a polished surface of the shaped stone according to the invention, an image is formed which is shaped by these materials and their shapes.
  • the liquid mixture can also have color pigments, so that the molded block is completely colored. Particularly when using white cement, a strong luminosity and color effect is advantageously obtained even with a small amount of pigments.
  • Another advantage of the shaped blocks produced according to the invention is to fill joints between the shaped blocks on site with the same liquid mixture. After a suitable surface treatment of the joint, it can then adapt to the appearance of the grouted molded blocks.
  • L-shaped shaped stones laid in a corner can be connected to form a seamless worktop with a continuously polished surface, for example by mitred shaped stones that are cut to fit each other and placed in an L-shaped manner, the miter joint with liquid
  • the mixture is filled in and polished after hardening, just like the surface of the molded stones.
  • the cement portion of the mixture of high-performance mortar with Portland cement and fine binder is formed. This can have a grain size smaller than 0.5 mm and / or a water / cement value smaller than 0.35.
  • shaped stones can be produced whose gas pores have a diameter of less than 1 mm or even less than 0.1 mm.
  • the gas pore volume fraction can be less than 0.1% or even less than 0.01%.
  • Figures 1 to 8 show schematic sectional views of the steps of an embodiment of the manufacturing method of a plate-shaped shaped block according to the invention.
  • Figure 1 shows a liquid mixture 2 of cement, minerals and water, which falls from a funnel 4 solely by its own weight and by opening one Slider 6 is poured into a mold 8.
  • the shape 8 is a flat container with a flat bottom 10 and a frame-shaped edge contour 12 which is rectangular in plan view (not shown).
  • the floor 10 is made of a formwork board - a board made of wood-based material, which is coated for easier demolding - and the frame 12 made of aluminum sheet coated with Teflon on the inside for easier demolding is screwed onto the top of the formwork board 10.
  • the frame 12 tapers in the direction of the base 10 for better demolding of the plate 14 which later hardened according to FIG. 4.
  • Mixture 2 flows self-compacting into mold 8 and is distributed evenly there.
  • the funnel 4 can be moved in a horizontal plane parallel to the bottom 10 of the mold 8.
  • there is a large-volume silo which is filled with the mixture 2 and from which a tubular connecting piece leads out on the underside.
  • the hose connector can then advantageously be moved in the horizontal plane parallel above the bottom 10 of the mold 8 for pouring the mixture 2 into the mold 8.
  • edge lengths of the cross section of the shaped slab shown are not shown proportionally.
  • an extreme relationship between the filling height of the mold 8 - that is to say the thickness of the plate (preferably smaller than shown) - and the edge dimension of the plate (preferably larger than shown) is preferred.
  • An edge dimension of approximately 1.9 m ⁇ 3.8 m with a filling height between 12 mm and 40 mm in the step according to FIG. 1 is particularly preferred.
  • This degassing is additionally supported by shaking the table 20 on which the mold 8 is supported.
  • a spike roller 22 can be used to drive through the liquid mixture 2 in the mold 8 according to FIG. 2b, which is a particularly simple method for supporting the degassing.
  • the free upper side of the mold 8 is covered in order to prevent rapid drying and / or premature hardening on the free upper side of the blank 14.
  • a second mixture (not shown) can be poured into the mold to the first mixture, with a different color and to control how much the two mixtures flow into one another after the first mixture and has set / or with an organic binding component of the second mixture.
  • the surface of the mass poured into the mold can also be covered in direct contact with a structured cover, so that the structure, for example in the form of a hewn stone surface, is reproduced on the later hardened form. In this case, the surface covered in this way is not machined further in accordance with FIGS. 6 and / or 8.
  • the plate 14 hardened in the mold 8 can be seen in FIG.
  • a layer 24 with excessive concentration of binder has formed under the free upper surface and, as a boundary layer with the bottom 10 of the mold 8, a layer 26, the consistency of which is influenced, for example, by release agent applied to the mold surface.
  • the same layer consistency 26 is also found in the edge area of the frame 12 of the shape 8.
  • FIG. 5 shows the blank 14 of the slab molded from the shape 8. After the hardening according to FIG. 4, it was lifted out of the mold 8, for example by means of vacuum suction devices (not shown) which gripped the top side of the blank 14.
  • the respective layers 24, 26 are removed by grinding, milling and / or sawing using suitable tools 28 according to FIG.
  • the edges of the blank 14 that have been in contact with the frame 12 of the mold 8 are then trimmed using suitable tools (not shown).
  • the molded block 14 is now allowed to harden further, which can be carried out in an air-conditioned atmosphere.
  • at least the surface of the shaped stone 14, which is provided as the visible upper side, is preferably polished with grit 800 using suitable tools 30.
  • the plate of the mentioned edge dimensions can now have a thickness of only 10 mm.

Abstract

Disclosed is a method for producing plate-shaped molded blocks, according to which a liquid mixture which is made at least of cement, minerals, and water is cast into a form in a self-compacting manner and is allowed to harden in an inorganically bonded manner. The invention also relates to a plate-shaped molded block which is characterized by being cast from a mixture of cement, minerals, and water and being inorganically bonded.

Description

Plattenförmig gegossener Formstein und Verfahren zu seiner HerstellungMolded slab and method of making it
Die vorliegende Erfindung betrifft einen plattenförmigen Formstein und ein Verfahren zu seiner Herstellung.The present invention relates to a plate-shaped shaped block and a method for its production.
Plattenförmige Formsteine werden im Wesentlichen nach drei unterschiedlichen Verfahren hergestellt: Erstens gibt es keramisch erstellte Erzeugnisse, bei denen die Platten aus einer Keramikmasse geformt und danach gebrannt werden. Die Formteile müssen wegen des Schwundes beim Brennen Übermaß haben. Diese Formsteine sind sehr beständig und lassen sehr viele verschiedene Ausgestaltungen auch bezüglich Farbe und Form zu. Ihre Herstellung ist jedoch wirtschaftlich ungünstig und teuer zum Beispiel wegen des variierenden Schwundes und des hohen Energieaufwandes beim Brennen. Zweitens sind Formsteine bekannt, die von Kunstharzen gebunden sind. Deren Herstellung ist jedoch wegen der hohen Kosten der Kunstharze teuer. Wegen hoher UV-Empfindlichkeit eignen sich diese Formsteine nicht als Fassadenmaterial. Hitzeempfindlichkeit und Brennbarkeit sind weitere Nachteile dieser Steine für den Haus- und Möbelbau.Slab-shaped shaped blocks are essentially produced using three different processes: First, there are ceramic-made products in which the slabs are formed from a ceramic mass and then fired. The molded parts must be oversized due to the shrinkage when burning. These shaped stones are very stable and allow for many different designs, including color and shape. However, their production is economically unfavorable and expensive, for example because of the varying shrinkage and the high energy expenditure during burning. Secondly, shaped stones are known that are bound by synthetic resins. However, their production is expensive because of the high cost of synthetic resins. Because of their high UV sensitivity, these shaped stones are not suitable as facade materials. Heat sensitivity and flammability are further disadvantages of these stones for house and furniture construction.
Drittens werden plattenförmige Formsteine auch anorganisch gebunden hergestellt. So sind zum Beispiel sogenannte „Waschbetonplatten,, bekannt. Diese bekannten Formsteine sind aber in ihrer Erscheinung roh und insbesondere aufgrund von Luftporen vergleichsweise bruchempfindlich. Daher haben sich derartige Platten bislang beinahe ausschließlich als „Gehwegplatten,, geeignet gezeigt, dort wo an ästhetische Ansprüche ein vergleichsweise geringer Anspruch gestellt wird.Thirdly, slab-shaped shaped stones are also produced in an inorganic bond. For example, so-called "washed concrete slabs" are known. However, these known shaped stones are raw in appearance and comparatively sensitive to breakage, in particular due to air pores. Therefore, such slabs have so far almost exclusively been shown to be suitable as “walkway slabs,” wherever a comparatively low demand is made on aesthetic demands.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, einen plattenförmigen Formstein, der preiswert, feuerfest und UV-beständig sowie ästhetisch hochwertig ist, und ein Verfahren zu seiner Herstellung zu schaffen.The present invention has for its object to provide a plate-shaped molded block which is inexpensive, fire-resistant and UV-resistant and aesthetically high quality, and a method for its production.
Dieser Aufgabe wird erfindungsgemäß von einem Verfahren mit den Merkmalen des Anspruchs 1 und einem Formstein mit den Merkmalen des Anspruchs 11 gelöst. Bevorzugte Ausgestaltungen der Erfindung sind in den Unteransprüchen angegeben.According to the invention, this object is achieved by a method having the features of claim 1 and a molded block having the features of claim 11. Preferred embodiments of the invention are specified in the subclaims.
Erfindungsgemäß wird ein plattenförmiger Formstein dadurch hergestellt, eine Mischung mindestens aus Zement, Mineralien und Wasser selbstverdichtend in eineAccording to the invention, a plate-shaped shaped block is produced by self-compacting a mixture of at least cement, minerals and water into one
Form zu gießen und, vorzugsweise ausschließlich, anorganisch gebunden hart werden zu lassen. Die Mischung ist dabei so dünnflüssig, daß sie in der Form ohne zusätzlichen Druck verfließen und sich selbst verdichten kann. Dennoch in der gegossenen Mischung enthaltene Gasblasen werden aus der vergossenen Flüssigkeit durch Rütteln der Form, durch Unterdruck, mit dem die Form beaufschlagt wird, und/oder durch das Durchdringen der vergossenen Flüssigkeit mit den Stacheln einer Stachelwalze entfernt. Das Entgasen kann durch ein Entgasungsmittel als zusätzlichem Bestandteil der Mischung unterstützt werden.Pour form and, preferably exclusively, become inorganic bound hard allow. The mixture is so thin that it can flow in the mold without additional pressure and compress itself. However, gas bubbles contained in the poured mixture are removed from the poured liquid by shaking the mold, by negative pressure with which the mold is applied and / or by penetrating the poured liquid with the spikes of a spiked roller. The degassing can be supported by a degassing agent as an additional component of the mixture.
Besonders bevorzugt ist die Form in Gestalt eines flachen Behälters mit einem ebenen Boden. Er hat dann Ränder entsprechend der Außenkontur des hergestellten plattenförmigen Formsteins. Zum Beispiel ist er rechteckig und zum Beispiel aus einem Leichtmetallrahmen mit einem beschichteten Leichtmetallrahmen und einem Schalungsbrett als Boden hergestellt. In die nach oben offene Form hinein wird dann die flüssige Mischung gegossen, was von einem zusätzlichen Verflüssigungsmittel als Bestandteil der Mischung begünstigt werden kann.The shape in the form of a flat container with a flat bottom is particularly preferred. It then has edges corresponding to the outer contour of the plate-shaped shaped block produced. For example, it is rectangular and, for example, made of a light metal frame with a coated light metal frame and a formwork board as the floor. The liquid mixture is then poured into the mold which is open at the top, which can be favored by an additional liquefier as a component of the mixture.
Die Füllhöhe der Form beträgt vorzugsweise weniger als 40 mm oder sogar weniger als 20 mm, so daß besonders dünnwandige Platten entstehen. Diese sind aufgrund der Herstellung aus der flüssigen Mischung wegen eines geringen Porenanteils dennoch bruchfest. Das erfindungsgemäße Verfahren gestattet eine Herstellung von Platten mit einer Kantenlänge von größer als 1 m x 1 m, sogar größer als 1 ,4 m x 2,8 m bei einer Wandstärke von bis zu ungefähr nur 12 mm. Der geringe Porenanteil erlaubt dabei, daß ein Schleifen und/oder Polieren der Plattenoberfläche zu einem sehr hochwertigen Erscheinungsbild des plattenförmigen Kunststeins führt. So lassen sich von Natursteinen kaum zu unterscheidende Platten in einer Größe herstellen, in welcher Natursteine kaum zur Verfügung stehen. Dies ist insbesondere zur Verwendung in der Architektur als Fassadenmaterial vorteilhaft.The filling height of the mold is preferably less than 40 mm or even less than 20 mm, so that particularly thin-walled plates are produced. Due to the fact that they are made from the liquid mixture, they are non-breakable due to the low proportion of pores. The method according to the invention permits the production of panels with an edge length of greater than 1 m × 1 m, even greater than 1.4 m × 2.8 m, with a wall thickness of up to approximately only 12 mm. The low proportion of pores allows grinding and / or polishing of the plate surface to result in a very high-quality appearance of the plate-shaped artificial stone. This means that slabs that are hard to distinguish from natural stones can be produced in a size in which natural stones are hardly available. This is particularly advantageous for use in architecture as a facade material.
Auch zum Erzeugen unterschiedlicher Erscheinungsbilder der Plattenoberfläche können der flüssigen Gußmischung unterschiedliche Zuschläge und/oder Zusätze beigefügt sein: Besonders bevorzugt sind Sand und/oder Splitt mit mehr als 90 % Quarzanteil - vorzugsweise mit einer Korngröße über 0,3mm. Auch Quarzit, Granit, Basalt und/oder andere Natursteine und/oder Glas und/oder Metall wie zum Beispiel Aluminium, Kupfer und/oder (Edel-)Stahl zum Beispiel als Korn und/oder Splitter können Zusätze sein. Insbesondere bei polierter Oberfläche des erfindungsgemäßen Formsteins entsteht ein von diesen Materialien und ihren Formen geprägtes Bild. Die flüssige Mischung kann auch Farbpigmente aufweisen, so daß der Formstein vollständig durchgefärbt ist. Insbesondere bei der Verwendung von Weiß-Zement ergibt sich vorteilhaft schon bei geringer Menge von Pigmenten eine starke Leuchtkraft und Farbwirkung.Different additives and / or additives can also be added to the liquid casting mixture in order to produce different appearances of the plate surface: sand and / or grit with more than 90% quartz content are preferred - preferably with a grain size of more than 0.3 mm. Quartzite, granite, basalt and / or other natural stones and / or glass and / or metal such as, for example, aluminum, copper and / or (stainless steel), for example as grain and / or chips, can also be additives. In particular with a polished surface of the shaped stone according to the invention, an image is formed which is shaped by these materials and their shapes. The liquid mixture can also have color pigments, so that the molded block is completely colored. Particularly when using white cement, a strong luminosity and color effect is advantageously obtained even with a small amount of pigments.
Ein weiterer Vorteil der erfindungsgemäß hergestellten Formsteine besteht darin, Fugen zwischen den Formsteinen auf der Baustelle mit derselben flüssigen Mischung auszufüllen. Nach geeigneter Oberflächenbehandlung der Fuge kann sich diese dann dem Erscheinungsbild der verfugten Formsteine anpassen. Zum Beispiel bei der Verwendung erfindungsgemäßer Formsteine als Küchenarbeitsplatte lassen sich L- förmig über Eck verlegte Formsteine zu einer fugenlosen Arbeitsplatte mit durchgehend polierter Oberfläche verbinden, indem zum Beispiel auf Gehrung zu einander passend geschnittene Formsteine eben L-förmig aneinander gesetzt werden, die Gehrungsfuge mit flüssiger Mischung ausgefüllt und nach dem Hartwerden ebenso wie die Oberfläche der Formsteine poliert wird.Another advantage of the shaped blocks produced according to the invention is to fill joints between the shaped blocks on site with the same liquid mixture. After a suitable surface treatment of the joint, it can then adapt to the appearance of the grouted molded blocks. For example, when using shaped stones according to the invention as kitchen worktops, L-shaped shaped stones laid in a corner can be connected to form a seamless worktop with a continuously polished surface, for example by mitred shaped stones that are cut to fit each other and placed in an L-shaped manner, the miter joint with liquid The mixture is filled in and polished after hardening, just like the surface of the molded stones.
Um die erfindungsgemäßen Vorteile zu erreichen, ist es besonders bevorzugt, daß der Zementanteil der Mischung von Hochleistungsmörtel mit Portlandzement und Feinstbindemittel gebildet wird. Dieser kann eine Korngröße kleiner als 0,5 mm und/oder einen Wasser-/Zementwert kleiner als 0,35 aufweisen.In order to achieve the advantages according to the invention, it is particularly preferred that the cement portion of the mixture of high-performance mortar with Portland cement and fine binder is formed. This can have a grain size smaller than 0.5 mm and / or a water / cement value smaller than 0.35.
So lassen sich erfindungsgemäß Formsteine herstellen, deren Gasporen Durchmesser kleiner als 1 mm oder sogar kleiner als 0,1 mm ist. Der Gasporen-Volumenanteil kann kleiner sein als 0,1 % oder sogar kleiner als 0,01 %.According to the invention, shaped stones can be produced whose gas pores have a diameter of less than 1 mm or even less than 0.1 mm. The gas pore volume fraction can be less than 0.1% or even less than 0.01%.
Ein Ausführungsbeispiel eines erfindungsgemäßen plattenförmigen Formsteins und ein Verfahren zu seiner Herstellung wird im Folgenden mit Bezug auf die beigefügten Zeichnungen beschrieben.An embodiment of a plate-shaped shaped block according to the invention and a method for its production is described below with reference to the accompanying drawings.
Figuren 1 bis 8 zeigen schematische Schnittansichten der Schritte eines Ausführungsbeispiels des erfindungsgemäßen Herstellungsverfahrens eines plattenförmigen Formsteins.Figures 1 to 8 show schematic sectional views of the steps of an embodiment of the manufacturing method of a plate-shaped shaped block according to the invention.
Figur 1 zeigt eine flüssige Mischung 2 aus Zement, Mineralien und Wasser, die allein aufgrund ihres Eigengewichtes aus einem Trichter 4 fällt und durch Öffnen eines Schiebers 6 in eine Form 8 gegossen wird. Die Form 8 ist ein flacher Behälter mit einem ebenen Boden 10 und einer rahmenförmigen Randkontur 12, die in der Draufsicht (nicht dargestellt) rechteckig ist. Der Boden 10 ist aus einem Schalungsbrett - einem Brett aus Holzwerkstoff, das zur leichteren Entformung beschichtet ist - hergestellt, und der Rahmen 12 aus innenseitig zur leichteren Entformung mit Teflon beschichtetem Aluminiumblech ist oberseitig auf das Schalungsbrett 10 geschraubt. Der Rahmen 12 verjüngt sich zum besseren Entformen der gemäß Figur 4 später ausgehärteten Platte 14 in Richtung des Bodens 10.Figure 1 shows a liquid mixture 2 of cement, minerals and water, which falls from a funnel 4 solely by its own weight and by opening one Slider 6 is poured into a mold 8. The shape 8 is a flat container with a flat bottom 10 and a frame-shaped edge contour 12 which is rectangular in plan view (not shown). The floor 10 is made of a formwork board - a board made of wood-based material, which is coated for easier demolding - and the frame 12 made of aluminum sheet coated with Teflon on the inside for easier demolding is screwed onto the top of the formwork board 10. The frame 12 tapers in the direction of the base 10 for better demolding of the plate 14 which later hardened according to FIG. 4.
Die Mischung 2 fließt selbstverdichtend in die Form 8 und verteilt sich dort gleichmäßig. Zur schnelleren Befüllung insbesondere zur Herstellung besonders großflächiger Platten-Formsteine kann der Trichter 4 in einer horizontalen Ebene parallel über dem Boden 10 der Form 8 verfahren werden. In einer nicht dargestellten alternativen Ausführungsform gibt es anstelle des Trichters 4 ein großvolumiges Silo, das mit der Mischung 2 gefüllt ist und aus dem unterseitig ein schlauchförmiger Stutzen herausführt. Der Schlauchstutzen läßt sich dann vorteilhaft in der waagerechten Ebene parallel über dem Boden 10 der Form 8 zum Gießen der Mischung 2 in die Form 8 verfahren.Mixture 2 flows self-compacting into mold 8 and is distributed evenly there. For faster filling, in particular for the production of particularly large shaped slabs, the funnel 4 can be moved in a horizontal plane parallel to the bottom 10 of the mold 8. In an alternative embodiment (not shown), instead of the hopper 4, there is a large-volume silo which is filled with the mixture 2 and from which a tubular connecting piece leads out on the underside. The hose connector can then advantageously be moved in the horizontal plane parallel above the bottom 10 of the mold 8 for pouring the mixture 2 into the mold 8.
In den Figuren 1 bis 8 sind die Kantenlängen des dargestellten Querschnitts des Platten-Formsteins nicht proportional dargestellt. Erfindungsgemäß bevorzugt ist nämlich ein extremeres Verhältnis zwischen der Füllhöhe der Form 8 - also der Dicke der Platte (vorzugsweise kleiner als dargestellt) - und dem Kantenmaß der Platte (vorzugsweise größer als dargestellt). Besonders bevorzugt ist ein Kantenmaß von ungefähr 1 ,9 m x 3,8 m bei einer Füllhöhe zwischen 12 mm und 40 mm in dem Schritt gemäß Figur 1.In Figures 1 to 8, the edge lengths of the cross section of the shaped slab shown are not shown proportionally. According to the invention, an extreme relationship between the filling height of the mold 8 - that is to say the thickness of the plate (preferably smaller than shown) - and the edge dimension of the plate (preferably larger than shown) is preferred. An edge dimension of approximately 1.9 m × 3.8 m with a filling height between 12 mm and 40 mm in the step according to FIG. 1 is particularly preferred.
Gemäß Figur 2a wird das in Figur 1 beim Gießen mit der Mischung 2 in die Form 8 gelangte Gas, das sich wegen der flüssigen Konsistenz der Mischung 2 in nur sehr kleinen Blasen 16 in der noch flüssigen Mischung 2 befindet, durch Unterdruck in einer Umhausung 18 an die freie Oberfläche der Mischung 2 in der Form 8 transportiert. Diese Entgasung wird zusätzlich durch Rütteln des Tisches 20, auf dem die Form 8 gelagert ist, unterstützt. Alternativ oder ergänzend kann gemäß Figur 2b mit einer Stachelwalze 22 durch die flüssige Mischung 2 in der Form 8 gefahren werden, was ein besonders einfaches Verfahren zum Unterstützen der Entgasung darstellt. lm Schritt gemäß Figur 3 wird die freie Oberseite der Form 8 abgedeckt, um zu rasche Austrockung und/oder frühzeitige Erhärtung an der freien Oberseite des Rohlings 14 zu verhindern. Vor dem Abdecken kann noch eine zweite Mischung (nicht dargestellt) zu der ersten Mischung in die Form gegossen werden, und zwar mit einer anderen Färbung und, um zu steuern, wie stark die zwei Mischungen ineinander verfließen, nach einem gewissen Abbinden der ersten Mischung und/oder mit einer organischen Bindekomponente der zweiten Mischung. Durch Gießen in bestimmter Spur und Menge lassen sich auf diese Weise Schlieren, Marmorierungen, Muster, Schriften und dergleichen herstellen. Die Oberfläche der in die Form gegossenen Masse kann auch in direktem Kontakt mit einer strukturierten Abdeckung abgedeckt werden, so daß sich die Struktur zum Beispiel in Gestalt einer gehauenen Gesteinsoberfläche auf den später hart gewordenen Formsein abbildet. In diesem Fall wird die so abgedeckte Oberfläche nicht gemäß Figur 6 und/oder 8 weiter abtragend bearbeitet.According to FIG. 2a, the gas that came into the mold 8 in FIG. 1 when pouring with the mixture 2, which because of the liquid consistency of the mixture 2 is only in very small bubbles 16 in the still liquid mixture 2, is under pressure in a housing 18 transported to the free surface of the mixture 2 in the mold 8. This degassing is additionally supported by shaking the table 20 on which the mold 8 is supported. Alternatively or additionally, a spike roller 22 can be used to drive through the liquid mixture 2 in the mold 8 according to FIG. 2b, which is a particularly simple method for supporting the degassing. In the step according to FIG. 3, the free upper side of the mold 8 is covered in order to prevent rapid drying and / or premature hardening on the free upper side of the blank 14. Before covering, a second mixture (not shown) can be poured into the mold to the first mixture, with a different color and to control how much the two mixtures flow into one another after the first mixture and has set / or with an organic binding component of the second mixture. By casting in a specific trace and quantity, streaks, marbling, patterns, writings and the like can be produced in this way. The surface of the mass poured into the mold can also be covered in direct contact with a structured cover, so that the structure, for example in the form of a hewn stone surface, is reproduced on the later hardened form. In this case, the surface covered in this way is not machined further in accordance with FIGS. 6 and / or 8.
In Figur 4 ist die in der Form 8 ausgehärtete Platte 14 erkennbar. Während der Aushärtung hat sich unter der freien oberen Oberfläche eine Schicht 24 mit übermäßiger Konzentration von Bindemittel gebildet sowie als Grenzschicht zum Boden 10 der Form 8 eine Schicht 26, deren Konsistenz zum Beispiel von auf die Formoberfläche aufgebrachtem Trennmittel beeinflußt ist. Selbige Schichtkonsistenz 26 findet sich auch im Randbereich zum Rahmen 12 der Form 8.The plate 14 hardened in the mold 8 can be seen in FIG. During the hardening, a layer 24 with excessive concentration of binder has formed under the free upper surface and, as a boundary layer with the bottom 10 of the mold 8, a layer 26, the consistency of which is influenced, for example, by release agent applied to the mold surface. The same layer consistency 26 is also found in the edge area of the frame 12 of the shape 8.
Figur 5 zeigt den aus der Form 8 ausgeformten Rohling 14 des Platten-Formsteins. Er wurde nach dem Aushärten gemäß Figur 4 zum Beispiel mittels Unterdrucksaugern (nicht dargestellt), die die Oberseite des Rohlings 14 ergriffen, aus der Form 8 gehoben.FIG. 5 shows the blank 14 of the slab molded from the shape 8. After the hardening according to FIG. 4, it was lifted out of the mold 8, for example by means of vacuum suction devices (not shown) which gripped the top side of the blank 14.
Zur Beseitigung der minderwertigen Schichten 24, 26 gemäß Figur 4 wird gemäß Figur 6 nun durch Schleifen, Fräsen und/oder Sägen mittels geeigneter Werkzeuge 28 die jeweilige Schicht 24, 26 abgetragen. Auch die mit dem Rahmen 12 der Form 8 in Berührung gestandenen Ränder des Rohlings 14 werden anschließend mittels geeigneter Werkzeuge besäumt (nicht dargestellt).To remove the inferior layers 24, 26 according to FIG. 4, the respective layers 24, 26 are removed by grinding, milling and / or sawing using suitable tools 28 according to FIG. The edges of the blank 14 that have been in contact with the frame 12 of the mold 8 are then trimmed using suitable tools (not shown).
Gemäß Figur 7 wird nun der Formstein 14 weiter härten gelassen, was in klimatisierter Atmosphäre durchgeführt werden kann. Gemäß Figur 8 wird abschließend mindestens die als sichtbare Oberseite vorgesehene Oberfläche des Formsteins 14 vorzugsweise mit Körnung 800 mittels geeigneter Werkzeuge 30 poliert. Die Platte der genannten Kantenmaße kann nun eine Dicke von nur 10mm aufweisen. According to FIG. 7, the molded block 14 is now allowed to harden further, which can be carried out in an air-conditioned atmosphere. According to FIG. 8, at least the surface of the shaped stone 14, which is provided as the visible upper side, is preferably polished with grit 800 using suitable tools 30. The plate of the mentioned edge dimensions can now have a thickness of only 10 mm.

Claims

Ansprüche Expectations
1. Verfahren zum Herstellen von plattenförmigen Formsteinen mit den Schritten, eine flüssige Mischung mindestens aus Zement, Mineralien und Wasser selbstverdichtend in eine Form zu gießen und anorganisch gebunden hart werden zu lassen.1. A process for the production of plate-shaped shaped stones, comprising the steps of pouring a liquid mixture of at least cement, minerals and water into a mold in a self-compacting manner and allowing it to become inorganically bound.
2. Verfahren nach Anspruch 1 , mit dem zusätzlichen Schritt, die gegossene Mischung in der Form zu entgasen.2. The method of claim 1, with the additional step of degassing the cast mixture in the mold.
3. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Entgasen mittels Unterdruck, Rütteln und/oder Stachelwalze durchgeführt wird.3. The method according to any one of the preceding claims, characterized in that the degassing is carried out by means of vacuum, shaking and / or spiked roller.
4. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Form rechteckig ist mit einer Kantenlänge größer als 1m mal 1 m, insbesondere größer als 1 ,4m mal 2,8m.4. The method according to any one of the preceding claims, characterized in that the shape is rectangular with an edge length greater than 1m by 1m, in particular greater than 1.4m by 2.8m.
5. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Fläche der Form größer ist als 1 m2, insbesondere größer ist als 2m2.5. The method according to any one of the preceding claims, characterized in that the area of the mold is larger than 1 m 2 , in particular is larger than 2 m 2 .
6. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Höhe der Mischung in der Form kleiner ist als 40mm, insbesondere kleiner ist als 20mm.6. The method according to any one of the preceding claims, characterized in that the height of the mixture in the mold is less than 40mm, in particular is less than 20mm.
7. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass der Zement-Anteil der Mischung von Hochleistungsmörtel mit Portlandzement und Feinstbindemittel mit einer Korngröße kleiner als 0,5mm und/oder einem w/z-Wert kleiner als 0,35 gebildet wird.7. The method according to any one of the preceding claims, characterized in that the cement portion of the mixture of high-performance mortar with Portland cement and fine binder is formed with a grain size less than 0.5mm and / or a w / z value less than 0.35.
8. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Mineralien Quarzit, Granit, Basalt, Glas und/oder Metall als Körner und/oder Splitter und/oder Sand und/oder Splitt mit mehr als 90% Quarz aufweisen.8. The method according to any one of the preceding claims, characterized in that the minerals quartzite, granite, basalt, glass and / or metal as grains and / or chips and / or sand and / or chips with more than 90% quartz.
9. Verfahren nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Mischung zusätzlich Verflüssigungsmittel und/oder Entgasungsmittel und/oder Farbpigmente aufweist.9. The method according to any one of the preceding claims, characterized in that the mixture additionally comprises liquefying agents and / or degassing agents and / or color pigments.
10. Verfahren nach einem der vorhergehenden Ansprüche mit dem zusätzlichen Schritt, den hart gewordenen Formstein zu polieren.10. The method according to any one of the preceding claims with the additional step of polishing the hardened stone.
H .PIattenförmig, gegossener Formstein, dadurch gekennzeichnet, dass er mindestens aus Zement, Mineralien und Wasser gegossen anorganisch gebunden ist.H .PI plate-shaped, molded stone, characterized in that it is inorganic bound at least when poured from cement, minerals and water.
12. Formstein nach Anspruch 11 , gekennzeichnet durch Gasporendurchmesser kleiner als 1mm, insbesondere kleiner als 0,1mm.12. Shaped stone according to claim 11, characterized by gas pore diameter less than 1mm, in particular less than 0.1mm.
13. Formstein nach einem der Ansprüche 11 oder 12, gekennzeichnet durch einen Gasporen-Volumenanteil kleiner als 0,1%, insbesondere kleiner als 0,01%.13. Shaped stone according to one of claims 11 or 12, characterized by a gas pore volume fraction less than 0.1%, in particular less than 0.01%.
14. Formstein nach einem der Ansprüche 11 bis 13, gekennzeichnet durch eine rechteckige Außenkontur mit einer Kantenlänge größer als 1m mal 1m, insbesondere größer als 1 ,4m mal 2,8m. 14. Shaped stone according to one of claims 11 to 13, characterized by a rectangular outer contour with an edge length greater than 1m by 1m, in particular greater than 1.4m by 2.8m.
15. Formstein nach einem der Ansprüche 11 bis 14, gekennzeichnet durch eine Fläche größer als 1m2, insbesondere größer als 2m2.15. Molded stone according to one of claims 11 to 14, characterized by an area larger than 1 m 2 , in particular larger than 2 m 2 .
16. Formstein nach einem der Ansprüche 11 bis 15, gekennzeichnet durch eine Dicke kleiner als 40mm, insbesondere kleiner als 20mm.16. Shaped stone according to one of claims 11 to 15, characterized by a thickness less than 40mm, in particular less than 20mm.
17. Formstein nach einem der Ansprüche 11 bis 16, gekennzeichnet durch eine polierte Oberfläche.17. Shaped stone according to one of claims 11 to 16, characterized by a polished surface.
18. Formstein nach einem der Ansprüche 11 bis 17, dadurch gekennzeichnet, dass der Zement-Anteil von Hochleistungsmörtel mit Portlandzement und Feinstbindemittel mit einer Korngröße kleiner als 0,5mm und/oder einem w/z- Wert kleiner als 0,35 gebildet ist.18. Stone according to one of claims 11 to 17, characterized in that the cement portion of high-performance mortar with Portland cement and fine binder is formed with a grain size less than 0.5mm and / or a w / z value less than 0.35.
19. Formstein nach einem der Ansprüche 11 bis 18, dadurch gekennzeichnet, dass die Mineralien Quarzit, Granit, Basalt, Glas und/oder Metall als Körner und/oder Splitter und/oder Sand und/oder Splitt mit mehr als 90% Quarz aufweisen.19. Shaped stone according to one of claims 11 to 18, characterized in that the minerals have quartzite, granite, basalt, glass and / or metal as grains and / or chips and / or sand and / or grit with more than 90% quartz.
20. Formstein nach einem der Ansprüche 11 bis 19, dadurch gekennzeichnet, dass er mit Farbpigmenten durchgefärbt ist. 20. Shaped stone according to one of claims 11 to 19, characterized in that it is colored through with colored pigments.
PCT/DE2003/001300 2002-05-06 2003-04-17 Plate-shaped molded block and method for the production thereof WO2003092974A1 (en)

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Publication number Priority date Publication date Assignee Title
WO2006056148A1 (en) * 2004-11-29 2006-06-01 Rode Betontechnologie Method and device for efficiently producing smooth-surface profiled concrete blocks without mechanical compacting
WO2007009408A1 (en) * 2005-07-16 2007-01-25 Rode Betontechnologie Gmbh Mixture for producing self-compacting concrete

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