WO2009039817A2

WO2009039817A2 - Mold for producing molded bricks and device for producing molded bricks

Info

Publication number: WO2009039817A2
Application number: PCT/DE2008/001471
Authority: WO
Inventors: Martin Maeser
Original assignee: Via Domo Gmbh
Priority date: 2007-09-24
Filing date: 2008-09-05
Publication date: 2009-04-02
Also published as: WO2009039817A3; DE102008024618A1

Abstract

The invention relates to a mold (1) and to a device for producing molded bricks using a mold (1). For this purpose, the mold (1) is configured in one piece and is elastically deformable.

Description

"Mold for the production of shaped bricks and device for the production of shaped bricks"

The invention relates to a mold for the production of molded bricks according to the preamble of claim 1 and to an apparatus for the production of bricks according to the preamble of claim 12.

From GB 1 469 290 a one-piece mold for the production of molded bricks is known, which has recesses separated by walls and is flexible. The stones are released by bending the mold out of the recesses. Such a form is due to the complex and irreproducible Entschalungsvorgangs suitable only for the production of small batches.

The invention has for its object to develop a mold for the production of molded bricks, which is inexpensive to produce and in particular the delimbing of molded bricks, which are produced in the so-called wetcasting process easier.

This object is based on the features of the preamble of claim 1 or _. , of the preamble of claim 12 by the characterizing features of claim 1 and claim 12, respectively. In the dependent claims advantageous and expedient developments are given.

In the mold according to the invention for the production of molded blocks, in particular concrete with at least two Mold cavities are adjacent mold cavities separated by double-walled nest walls, wherein the double-walled nest walls consist of a first, a mold cavity associated wall and the second mold cavity associated second wall, the double-walled nest walls are connected by spacers and wherein the nest walls, nest floors and the spacer webs are formed in one piece of an elastic material, wherein a stiffness of the nest walls of a mold cavity by selecting suitable Nestwandparameter particular composition of the material and / or thickness of the material and / or structure of the material of the nest wall is predetermined so that the nest walls by the fresh concrete form out of the mold cavity on the nest walls acting hydrostatic pressure at most a slight bulge, the weak bulge is within a tolerance range for the dimensions of the hardened molded block and that by a to the decision alen the hardened stones perpendicular to the respective nest floor acting pressure force a strong bulge of the nest walls can be generated, the bulge lies in the elastic region of the nest walls and with the nest walls peel off in this change in shape of the respective hardened stone shape. With such a shape executed, it is possible to carry out the descaling process specifically and safely, wherein the delamination process can be initiated by a detachment of the mold walls delimiting the shaped block of the molded block. The core of the invention is a shape that is elastically deformable so that the mold walls with targeted force on the mold bottom of the mold in the direction of their normal from side walls of the molded block. This new way to release the stone from its mold cavity is It is possible to dispense with the use of formwork oil, which is used in conventional stone molds to prevent adhesion of the molded block to the mold as far as possible. Dispensing with the use of formwork oil protects the environment, saves costs and increases the quality of the molded blocks, since stains on the stone surface caused by the formwork oil are reliably avoided. Furthermore, the demoulding process with such a shape is repeatable without deviations and thus allows industrial production of molded bricks.

The invention provides to form the mold cavity higher than the molded block to be produced therein. As a result, there is a free space in the mold cavity after turning the mold under the molded block, which after the release of the molded block allows the molded block to slide down on the walls of the mold cavity without the mold having to be lifted. Thus, the entire dissolving process, in which the stones from the walls of the mold cavity and the nest bottom of the mold cavity dissolve occur on the production board lying form.

The device according to the invention for the production of molded bricks with an elastic mold, in particular in a wet-casting process, in which flowable molding material is filled into molds, the molding compound hardens to form bricks in the molds, the molds turned by 180 ° and the mold stones are subsequently de-energized , It provides the device of an elastic mold, a pressure medium and a production board, wherein the turned mold on a mold bottom with elastic deformation of walls of a mold cavity of the mold on the production board depressible. With such a shape can be produced on an industrial scale, because the Entschalungsvorgang is simple and reproducible and not manually or by undefined measures.

In multiple molds, that is, molds having at least two mold cavities, the vertical mold walls of adjacent nests are separated from each other. This allows a special elasto-mechanical behavior of the mold cavity, because the vertical mold walls can move or deform substantially horizontally or laterally in the x-direction, and because the horizontal mold wall forming a mold bottom or nest floor is substantially upwards and downwards or downwards can move vertically in the z direction. Due to this semi-elastic construction of each mold cavity, the mold removal behavior is favored on the one hand and on the other hand guarantees the necessary dimensional accuracy for the cast stone. In the manufacturing process, the mold is on a production board. The individual mold chambers of the mold are filled with concrete, for example. After curing of the concrete, the stones are de-energized. The Entschalungsrichtung is after turning the mold parallel to the vertical mold walls through the mold opening therethrough. Stones that are cast in mold chambers stick together after curing of the concrete with the mold wall. To reduce this, for example, scarf oil is used. Adhesive bonds have very high strengths under shear stress. Under tensile load, a bond can withstand only low forces. If the molding chamber were very inelastic and would not deform, immense forces would have to be applied to decoating the product to break the shear forces of the bond to the vertical sidewalls. Therefore, it is advantageous to ensure during the demoulding that the vertical side walls of the mold in the normal direction to the stone surface of this solve, because then under tensile stress, the adhesive bond is cracked on the side walls. For demoulding, a pressure is exerted on the mold bottom or nest base with the production board lying on top of the mold after turning over the mold, which presses for buckling or bulging out of the mold Form walls leads. The bond between the vertical flanks of stone and form is broken by a tensile stress when deforming the mold walls. Due to the underfilling of the mold, in which the mold cavity was not poured to full height with concrete, formed when buckling or bulging of the mold walls between the stone and mold cavity a gap through which air penetrates between the stone and the dissolving wall. The stones are released from the mold and fall down through. More precisely, the de-scaling process or the detachment of the mold from the molded bricks can be controlled if, in particular, punctiform pressure is applied to the mold bottom instead of a surface-acting pressure. This results in that the mold bottom is also deformed and thus the bonding of an end face of the stone with the nest floor is opened under train. The lower the resistance moment of the side walls is chosen against bending, the easier the descaling process will proceed. The bending strength of the side walls is determined in particular by the parameters E modulus of the molding material used and / or wall thickness of the mold walls and / or ribbing on the mold walls. When designing the mold, the hydrostatic pressure of the filled liquid concrete must be taken into account, which can lead to a bulging of the vertical side walls in the mold cavity. Therefore, the moment of resistance at the form walls should be chosen so that the bulge is in the tolerated range of the stone tolerance. For molds made with models such as casting resin or injection molding, or vacuum thermoforming, there is also the possibility of providing a negative dent on the model. In particular, the invention provides that the walls of the unfilled mold are curved in the direction of the mold cavity in order to counteract a hydrostatic pressure of a filling compound. For the invention, it is essential that as many as possible and as large as possible mold surface in the normal direction of the stone surface to solve. The Bondings are solved so easily and efficiently. Therefore, you can work without formwork oil in these forms.

Further details of the invention are described in the drawing with reference to schematically illustrated embodiments.

Hereby shows:

Figure 1 is a perspective view of a mold, wherein the mold is shown broken at a corner;

FIG. 2 is a detailed view of the mold shown in FIG. 1 in the area of the broken mold cavities;

Figure 3 is a schematic sectional view of a running according to Figures 1 and 2 form rests on a production board and the nests are already filled with concrete;

Figure 4 is a detail view of Figure 3, wherein the concrete is already hardened;

Figure 5 is a detail view corresponding to Figure 4, wherein the mold is already turned with the solidified therein stone and already rests on a bottom of the mold a pressure plate.

FIG. 6: a snapshot during the

Entschalungsvorgangs, wherein the turned form is just loaded or deformed maximum with the pressure plate;

FIG. 7 is a detail view of FIG. 6; FIG. 8 shows the shape still stressed by the pressure plate, wherein the conglomerates are already detached from the nest walls and the nest bottoms;

Figure 9: the lifting of the mold and the pressure plate of the dissolved from the mold cavities formstones;

FIG. 10 is a schematic representation of an alternative approach to demoulding;

FIG. 11 shows a schematic illustration of a further alternative procedure for demoulding;

FIG. 12: a perspective view of a mold with

Stiffening ribs, wherein the shape is shown broken at a corner;

FIG. 13 is a detailed view of the mold shown in FIG. 12 in the area of the broken mold nests;

Figure 14 is a perspective view of an underside of the mold shown in Figure 12 with the mold nests closed to the bottom by their nesting bottoms;

Figures 15-17: show a variant of the embodiment shown in Figures 12 to 14 and

Figure 18, 19: two schematic representations of a device according to the invention.

FIG. 1 shows a form 1 in a perspective view, wherein the mold 1 is shown broken at a corner E. The mold 1 is formed in one piece and consists of an elastically deformable material M. FIG. 2 shows a detail view of the in FIG 1 in the region of the corner E. In the detailed view, three mold cavities FN or 3, 4, 5 can be seen in the intersection region. The mold cavities FN are separated from each other by double-walled nest walls NW. The nest walls NW each consist of two thin walls W eg 3d, 4b and 4c, 5a adjacent mold cavities FN and 3, 4 and 4, 5. The thin walls W are connected by spacers DS. The individual walls W of the individual mold cavities FN are connected to a bottom FU of the mold 1 in each case by nesting floors NB. An upper surface FO of the mold 1 is defined by the spacer webs DS. Notches 7 are formed in the walls W of the individual mold cavities FN. Thus, the mold 1 is suitable for the production of molded blocks with spacer webs. The spacer webs DS have a thickness d-DS, the walls W a thickness dW and the nest bases NB a thickness d-NB. According to a preferred embodiment for the mold 1, d-DS = dW = d-NB, the thicknesses being in a range from 1 mm to 4 mm and in particular 2 mm, provided that the spacer webs or walls or nest bottoms have no stiffening structures. A distance between adjacent walls d-WW is particularly dimensioned so that both walls can be bulged without obstructing the other wall.

FIG. 3 shows, in a schematic sectional view, a mold 1 designed in the manner of the mold shown in FIGS. 1 and 2. This mold 1 lies with its underside FU on a production board 8 and their mold cavities FN are already filled with fresh, liquid concrete BF. The mold cavities FN have a height H, wherein the fresh concrete BF fills the mold cavities FN only up to a height h, which is less than the height H of the mold cavities FN. According to the invention, it is provided in particular that the filling level h is about 70% to 90% of the height H of the mold cavity FN and in particular is about 80% of the height H of the mold cavity FN. This leaves in the mold cavity FN a free space 9, which in the middle mold cavity FN by a Hatching is indicated. Due to a hydrostatic pressure p, with which the fresh concrete BF acts on the thin, elastic walls W of the mold cavity FN, a weak bulge Bl adjoins it, which in FIG. 3 is an example on the left wall W of the left mold cavity FN and exaggerated. The shape 1 is constructed by the choice of material and / or material thickness and / or structure such that a maximum bulge the individual wall W is consumed by a maximum permissible for this wall W tolerance. This deviation in the x 'direction is, for example, at bl = 0.4 mm.

FIG. 4 shows the left mold cavity FN of FIG. 3 in a detailed view, wherein the fresh concrete has already solidified into a hardened concrete BE and forms a shaped brick 2. Upon hardening, the resulting shaped brick 2 increasingly adheres to the thin walls W of the mold 1 and to the nest floor NB of the mold 1. As a result of these two-dimensional adhesion or bonding 10, the shaped brick 2 is held in its mold cavity FN, the adhesion or bonding 10 between side surfaces 11, 12 and a bottom surface 13 of the molded brick 2 and the mold cavity FN being so strong that the shaped brick 2 also is held in the mold when it is turned to demoulding such that the mold 1 rests with its top side FO on a further production board 14, as shown in Figure 5. The first production board 8 now serves as a pressure plate 15, which, however, does not significantly burden the mold 1. The free space 9 described above now lies between the second production board 14 and the molded block 2 adhering in the mold 1.

FIG. 6 shows a snapshot during the process of defined deletion of the molded block 2 from the mold 1. For this purpose, with the pressure plate 15, a compressive force D is exerted in an arrow direction z downwards in the direction of the second production board 14, which results in an elastic Deformation in particular of the individual walls W of the double-walled nest walls NW leads. In this case, the adjacent walls W, which respectively form the double-walled nest wall NW, approach one another and form bulges B2. Thus, the walls W are forced in directions x, x 'so each perpendicular to the side surfaces 11, 12 stand out from the shaped block 2. With such a movement of the walls W, the adhesions or adhesions 10 of the walls W on the molded block 2 can be released comparatively easily. As shown in FIG. 7, which shows an enlarged section of FIG. 6, the release is assisted, in particular, by the fact that air can flow in between the wall W of the cavity FN and the shaped brick 2 from the free space 9 below the shaped brick 2. After detachment of the walls W of the mold cavity FN of the molded block 2 this adheres only to the nest bottom NB of the mold cavity FN. Since the molded block 2 is held only after the detachment of the walls W by the bond 10 with the nest bottom NB and this constantly charged with its acting in the direction of arrow z weight force, the bond 10 guasi dissolves by itself and the shaped block 2 falls through the Free space 9 on the production document 14. This situation is shown in FIG. The elastic deformation of the mold 1 by the pressure plate 15 is maintained until all blocks 2 have detached from the nest floors NB. This release is inventively supported in particular by slight vibrations of the production pad 14 and / or the pressure plate 15.

Finally, FIG. 9 shows how the pressure plate 15 together with the mold 1 is lifted off the molded bricks 2 released from the mold cavities FN and lying on the production base 14. In this illustration, it can be seen that the mold 1 has completely deformed back from its elastic deformation (cf. FIGS. 6 to 8). FIG. 10 schematically shows an alternative procedure for demoulding. In contrast to the procedure illustrated in FIGS. 3 to 9, the mold bottom side of the mold used for demoulding is not acted upon here, but the mold 1 turned to demoulding is deformed by pins 17 on its mold bottom side FU in the area of the nest floors NB. which act in particular centrally on the nest bases NB and in this case also assist the detachment of the bottom surface 13 of the molded block 2 from the nest base NB, by pressing the shaped brick 2 except for the production base 14.

FIG. 11 schematically shows another alternative approach to demoulding. FIG. 11 shows a plan view of a lower mold surface FU of a mold 1. Dotted lines indicate walls W which merge at the peripheral edge K into the nest floors NB and form FN with these mold cavities. For de-molding, the mold 1 is loaded by stamps, not shown, which are fastened to a printing plate, for example, in hatched areas of pressure 18 (shown by way of example on one of the mold cavities). The pressure areas 18 are in the region of the peripheral edges 19. In particular, it is provided that the edges 19 only in central areas 20 to load and thus the pressure area 18 does not extend to corner regions 21. As a result, a strong deformation of the corner regions 21 is avoided.

In the figure 12 is a perspective view of a mold 1 with stiffening ribs VR, wherein the mold is shown broken at a corner E. As in the case of the mold 1 shown in FIGS. 1 and 2, adjacent mold cavities FN or 3 to 6 are separated from one another by double-walled nest walls NW. FIG. 13 shows a detailed view of the shape shown in FIG. 12 in the region of the corner E. In the detail view, the three mold cavities FN or 3, 4, 5 can be seen in the section area. The mold cavities FN are separated from each other by double-walled nest walls NW. The nest walls NW each consist of two thin walls W, for example 3d, 5b and 3a, 4c of adjacent mold cavities FN and 3, 5 and 3, 4. The thin walls W are connected by spacer webs DS. The individual walls W of the individual mold cavities FN are connected to a bottom FU of the mold 1 in each case by nesting floors NB. An upper surface FO of the mold 1 is defined by the spacer webs DS. Notches 7 are formed in the walls W of the individual mold cavities FN. Thus, the mold 1 is suitable for the production of molded blocks with spacer webs. In the nest walls NW or between the thin elastic walls W are stiffening ribs VR are arranged, which together form a rib grid RG, in which intersect the stiffening ribs VR as upstanding strips ST. The rib grid RG is integrally formed on the spacer webs DS and thus reinforces the shape 1. A mold removal of the mold 1 shown in Figures 12 and 13, for example, takes place analogously to the illustrations in Figures 10 and 11. Here, it is avoided pressure on the stiffening ribs Exercise VR. The stiffening ribs VR have a thickness d-VR, which is in particular at least twice as large as a thickness dW of the walls W.

FIG. 14 shows a perspective view of an underside FU of the mold 1 shown in FIG. 12, wherein the individual mold cavities FN are closed to the underside FU by their nest floors NB.

In the figures 15 to 17 a mold 1 is shown in a schematic sectional view. In contrast to the form shown in FIGS. 12 to 14, the mold 1 has a ribbed grating RG which is set back in relation to a mold bottom side FU is. This makes it possible to use a flat production board 8 as a pressure plate 15 (see FIG. 16) and in the mold 1 turned off for demoulding the mold bottom side FU in a direction z to depress a distance a against another production board 14, without loading the ribbed grid RG or deform. In the figure 17, the mold 1 is shown at niedergefahrener pressure plate 15. The distance between the pressure plate 15 and the production board 14 has decreased from Al to A2 by a. Stiffening ribs VR of the rib grid RG remain in their position without deformation and walls W of the mold 1 bulge due to the pressure load from mold cavities FN out in the direction of the stiffening ribs VR of the rib grid RG and are thereby elastically deformed. In a relief of the mold 1, the undeformed state shown in Figure 16 again sets in, in which the stiffening ribs VR and the walls W are parallel to each other. Figures 16 and 17 show two views of a device V according to the invention, which is composed of the mold 1, the pressure plate 15 and the production board 14.

A further device V according to the invention is schematically illustrated in FIGS. 18 and 19 on the basis of FIGS. 16 and 17. The device V comprises a mold 1, a pressure medium DM and a production board 14. The mold 1 has mold cavities FN which are separated from each other by double-walled nest walls NW each comprising two walls W connected by a spacer web DS. On a lower mold surface FU, the mold 1, which is already shown in a turned position in FIG. 18, has a structure Sl, which is formed by ribs R, which are arranged on the mold bottom side FU surrounding nesting bottoms NB of the mold cavities FN. By way of example, an already hardened shaped brick 2 is shown in the right mold cavity FN. The pressure medium DM is designed as a pressure plate 15, which on a pressure side B has a structure S2 through Pins 17 are formed, which are aligned centrally on the nest bases NB of the mold cavities FN. By depressing the pressure medium DM onto the underside FU of the mold 1 lying on the production board 8 (see FIG. 17), in particular the walls W and the nest floors NB of the mold cavities FN of the mold 1 are elastically deformed and thereby the molded bricks 2 attached to the mold 1 solved. Here, the structure Sl of the mold 1 in particular leads to a deformation of the walls W and the structure S2 of the pressure medium DM leads in particular to a deformation of the nest floors NB.

The invention is not limited to illustrated or described embodiments. Rather, it includes developments of the invention within the scope of the patent claims.

LIST OF REFERENCE NUMBERS

1 form

2 shaped stone

3 - 6 mold cavity

7 notch

8 production board

9 free space

10 adhesions or adhesions

11, 12 side surface of 2

13 floor area of 2

14 more production board

15 printing plate

16

17 pen

18 pressure range

19 edges

20 middle areas

21 corner areas

Al distance between 15 and 14

A2 distance between 15 and 14 a distance

B print side of DM

BF fresh concrete

Bl weak bulge bl measure for Bl

D pressure force

DG distance grid

DM pressure medium

DS Spacer bar d-DS Bar thickness of DS d-NB Bar thickness of NB dW Bar thickness of W d-WW Distance between adjacent walls W d-VR Average Bar Thickness of VR E corner of 1

EKl first elastic component

EK2 second, less elastic component

FN mold nest

FO top of the mold 1

FU base of the mold 1

H height of FN h height h of 2

M elastic material

NB nest floor

NW double walled walls of hydrostatic pressure by BF

R rib at 1

RG rib grid RG

ST stripes

• STG flat lying footbridges

51 Structure of 1

52 Structure of DM V device

VR stiffening ribs VR

W wall x, x 'directions

ZKK two-component plastic z Arrow direction

Claims

Claims :

1. mold (1) for the production of molded blocks (2) in particular of concrete (BF), wherein the mold (1) at least two mold cavities (FN; 3-6), characterized in that adjacent mold cavities (FN; 3, 4; 3, 5, 3, 6) are separated from each other by double-walled nest walls (NW), wherein the double-walled nest walls (NW) consist of a first wall associated with a mold cavity (FN; 3)

(W; 3a, 3b, 3d) and a second mold cavity (FN;

4; 5; 6) associated second wall (W; 4c; 5b), wherein the double-walled walls (NW) by means of

Distance webs (DS) are connected and whereby the nest walls (NW), nest soils (NB) and the

Spacer webs (DS) in one piece from an elastic

Material (M) are formed, wherein a stiffness of the nest walls (NW) of a

Formnests (3) by selection of suitable nest wall parameters such as in particular composition of the material (M) and / or thickness (dW, d-DS, d-NB) of the material (M) and / or structure of the material (M) of the nest wall (NW) is predetermined such that the nest walls (NW) by the fresh concrete from the mold cavity (FN; 3, 4, 3, 5, 3, 6) out on the nest walls (NW) acting hydrostatic pressure

(p) at best develop a weak bulge (Bl), ^■ wherein the weak bulge (BL) within a tolerance range of the dimensions of the cured molded block (2) and that by the stripping of the cured molded bricks (2) perpendicular to the respective nest bottom (NB) acting pressure force (D) a strong bulge ( B2) of the nest walls (NW) can be generated,

^■ where the strong bulge (B2) lies in the elastic region of the nest walls (NW) and

■ whereby the nest walls (NW) detach from the respective hardened shaped block (2) during this change in shape.

2. Mold according to claim 1, characterized in that the mold cavity (FN) has a height (H) which is higher than a height (h) of a mold cavity (FN) producible molded block (2).

3. Form according to one of the preceding claims, characterized in that between the double-walled nest walls (NW) stiffening ribs (VR) are arranged.

4. mold according to claim 3, characterized in that the stiffening ribs (VR) without contact to the nest walls (NW) extend.

5. Form according to one of the preceding claims 3 to 4, characterized in that the stiffening ribs (VR) are integrally formed from an elastic material (M).

6. Form according to one of the preceding claims 3 to 5, characterized in that the stiffening ribs (VR) with each other form a rib grid (RG), in which intersect the stiffening ribs (VR) as upstanding strip (ST).

7. Mold according to one of the preceding claims, characterized in that the spacer webs (DS) together form a spacer grid (DG), in which the spacer webs (DS) intersect as lying flat webs (STG).

8. Mold according to one of the preceding claims 3 to 7, characterized in that the stiffening ribs (VR) are each connected exclusively by means of the spacer webs (DS).

9. Mold according to one of the preceding claims, characterized in that the mold (1) made of a two-component plastic (ZKK) with a first elastic component (EKL) and a second compared to the first component (EKL) less elastic component (EK2) can be produced, wherein the nest walls (NW), the nest bases (NB) and the spacer webs (DS) of the first elastic component (EKL) can be produced and wherein the stiffening ribs (VK) from the second less elastic component (EK2) can be produced.

10. Form according to one of the preceding claims, characterized in that an average web thickness (d-VR) of the stiffening ribs (VR) is at least twice as large as an average web thickness (d-DS, dW, d-NB) of the spacer webs (DS ) or nest walls (NW) or nest floors (NB).

11. Mold according to one of the preceding claims, characterized in that as the elastic material (M) polyamide is usable.

12. Device (V) for the production of molded bricks with an elastic mold (1) in particular in a wet-casting process, characterized in that the device (V) the elastic mold (1), a pressure means (15) and a production board (8), wherein the mold (1) on a mold bottom (FU) with elastic deformation of walls (W) of a ^{^} Formnests (FN) of the mold (1) on the production board (8) is depressible.

13. The device according to claim 12, characterized in that the mold (1) has at least two mold cavities (FN) and that nest walls (NW) between adjacent mold cavities

(FN) are each formed by two spaced apart walls (W).

14. The apparatus of claim 12 or 13, characterized in that the lower mold side (FU) of the mold (1) and / or one of the mold bottom side (FU) of the mold (1) facing the pressure side (B) of the pressure means (15) has a structure ( Sl, S2) by means of which the mold (1) can be deformed with priority in at least one area.

15. Device according to claim 12 or 13 or 14, characterized in that each mold cavity (FN) has a height (H) which is greater than a height (h) of a mold cavity (FN) producible molded block (2).