EP0749815A1 - Moulded article with inlays and process and apparatus for making it - Google Patents

Abstract

At least the cavities (34) are filled with at least one filling material of different properties or composition. The cavities or projections (35) are formed on one upper side (33) of the basic body (32). A pressure component (26) comprising at least two relatively adjustable pressure bodies (27,28) is moved into the mould (21) filled with under-concrete, thus pre-forming the basic body. After pre-forming the basic body, a second pressure body (28) is moved parallel in relation to the first pressure body and is so adjusted relatively that lower edges (36,37) of both pressure bodies lie in a plane at the height of an upper side (38) of the projections.

Description

The invention relates to a method for producing a molded article according to the preamble of claim 1. Furthermore, the invention relates to a device for producing a molded article according to the preamble of claim 15 and a molded article according to the preamble of claim 17.

Moldings, in particular moldings made of concrete or materials containing concrete, such as paving stones or slabs, and floor coverings or the like composed of moldings are intended to meet not only functional but also aesthetic requirements. In terms of aesthetic requirements, color design effects, in particular color samples, play an important role.

These design effects have hitherto been achieved in floor coverings or the like composed of moldings in that moldings with different surface designs, e.g. Color, alternately or according to a geometric pattern, each molding as such has a uniform surface design. However, this has the disadvantage that different moldings with different surface designs have to be produced and these are then to be laid with great manual effort (in accordance with the predetermined geometric pattern).

Furthermore, in order to achieve, for example, color design effects, it is already known to mix several colors within one molding, so that different colors appear in a cloud-like or marbled manner within a molding. However, this has the disadvantage that the colors run within the molding, that is to say that no geometrically clearly delimited segments within a molding with different color designs or the like can be realized.

Proceeding from this, the present invention is based on the problem of creating a molded article with a geometric surface design, as well as a method and an apparatus for producing such a molded article.

To solve this problem, the method according to the invention has the measures of claim 1. The fact that at least the depressions in the base body are filled with a filling material of a different nature (which also means different colors) and / or composition creates a molding which has geometrically clearly delimited or defined segments of different surface designs.

For the preforming of the base body and thus for the introduction of the depressions and / or projections into the base bodies, a pressure element comprising at least two pressure bodies which are adjustable relative to one another is preferably moved into the mold. This has the advantage that with the aid of the pressure element consisting of two relatively adjustable pressure bodies, any contours of depressions and / or projections can be introduced into the base body in a simple manner, wherein the depressions can be poured out with materials of different colors.

According to an advantageous embodiment of the method according to the invention, a cavity formed during the preforming of the base body is filled with a filler material in such a way that an entire upper side of the base body (ie also the projections) is covered with the filler material. Subsequent removal of the filler material over the entire area into the areas of the projections results in the desired surface pattern of the molding in a simple manner, at the same time creating a flat and possibly polished decorative surface. In this way, moldings can be produced particularly easily.

In a further particularly advantageous embodiment, which may also be an independent invention, of the method according to the invention, the base body is raised, such that the tops of the projections are flush against an upper side of the mold. This makes it easy to produce moldings in which only the depressions are filled with filler material. This has the advantage that post-processing of the moldings to expose the desired surface pattern by grinding or the like is superfluous.

Preference concrete, concrete suspension or resin-bonded concrete is preferably used as the filling material. Alternatively, concrete, mortar, resin-bonded mortar or the like can also be used. It is also conceivable to use mixtures of the aforementioned materials. This has the advantage that different filling materials, in particular types of concrete, can be combined with one another on the top and thus the visible side of the molding. This increases the possibilities for the surface design of a molding.

According to a particularly advantageous development of the method according to the invention, the depressions are filled with a plurality of different filling materials, at least one depression being filled with a filling material of a different color than the other depressions, in that some depressions are filled with a filling material of a different color and / or composition. This has the advantage that moldings with multicolored ornaments can be formed on their top.

The filling materials are preferably fed to the respective depressions through bores arranged in the first pressure body and preferably closable via valves. This allows a dosed and controlled feeding of the filling materials into the depressions of the basic body.

The device according to the invention for the production of moldings, in particular paving stones or slabs, has the features of claim 15. With the help of the pressure element from at least two pressure bodies which are adjustable relative to one another, at least one pressure body having feed means through which the respective filler material can be introduced into the corresponding recess, moldings with geometrically clearly delimited or defined segments of different surface designs can be produced easily.

The molding according to the invention has the features of claim 17. The depressions arranged at least on an upper side of the base body are filled with at least one filling material of a different nature and / or composition.

A molded piece designed in this way has clearly demarcated segments of different surface designs.

Preferred developments of the invention result from the subclaims and the description.

Fig. 1

eine schematisierte Darstellung einer Vorrichtung zur Herstellung von Formlingen in einem Anfangszeitpunkt (Zustand A) eines Verfahrens zur Herstellung von Formlingen,

Fig. 2

die Vorrichtung gemäß Fig. 1 in einem Zustand A folgenden Zeitpunkt (Zustand B),

Fig. 3

die Vorrichtung gemäß Fig. 1 und 2 in einem Zustand B folgenden Zeitpunkt (Zustand C),

Fig. 4

die Vorrichtung gemäß Fig. 1 bis 3 in einem Zustand C folgenden Zeitpunkt (Zustand D),

Fig. 5

die Vorrichtung gemäß Fig. 1 bis 4 in einem Zustand D folgenden Zeitpunkt (Zustand E),

Fig. 6

einen mit Hilfe des Verfahrens gemäß Fig. 1 bis 5 (Zustände A bis E) gebildeten Rohling bei einer Nachbearbeitung,

Fig. 7

einen Formling nach einem ersten Ausführungsbeispiel der Erfindung in Draufsicht,

Fig. 8

einen Querschnitt durch den Formling gemäß Fig. 7 nach dem Schnitt VIII-VIII in der Fig. 7,

Fig. 9

einen Formling nach einem zweiten Ausführungsbeispiel der Erfindung in einer Ansicht analog zu Fig. 7,

Fig. 10

einen Formling nach einem dritten Ausführungsbeispiel der Erfindung in einer Ansicht analog zu Fig. 7 und 9,

Fig. 11

einen Formling nach einem vierten Ausführungsbeispiel der Erfindung in einer Ansicht analog zu Fig. 7, 9 und 10,

Fig. 12

einen Formling nach einem weiteren Ausführungsbeispiel der Erfindung in Draufsicht,

Fig. 13

einen Formling nach einem weiteren Ausführungsbeispiel der Erfindung in Draufsicht,

Fig. 14

einen Formling nach einem weiteren Ausführungsbeispiel der Erfindung in Draufsicht,

Fig. 15

eine schematisierte Darstellung einer Gesamtanlage zur Herstellung von Formlingen,

Fig. 16

eine schematisierte Darstellung einer Vorrichtung zur Herstellung von Formlingen nach einem zweiten Ausführungsbeispiel der Erfindung,

Fig. 17

ein vergrößertes Detail aus der Vorrichtung gemäß Fig. 16,

Fig. 18

eine schematisierte Darstellung einer Vorrichtung zur Herstellung von Formlingen nach einem dritten Ausführungsbeispiel der Erfindung in einem Zustand des Verfahrens mit abgesenktem Formboden und

Fig. 19

ein vergrößertes Detail aus der Vorrichtung gemäß Fig. 18 in einem Zustand des Verfahrens mit nach oben bewegtem Formboden.

Preferred embodiments of the invention are explained in more detail below with reference to the drawing. The drawing shows:

Fig. 1

1 shows a schematic representation of a device for the production of moldings at an initial point in time (state A) of a method for the production of moldings,

Fig. 2

1 in a state A following time (state B),

Fig. 3

1 and 2 in a time B following state (state C),

Fig. 4

1 to 3 in a state C following time (state D),

Fig. 5

1 to 4 in a state D following time (state E),

Fig. 6

a blank formed by means of the method according to FIGS. 1 to 5 (states A to E) during post-processing,

Fig. 7

a molding according to a first embodiment of the invention in plan view,

Fig. 8

7 after the section VIII-VIII in FIG. 7,

Fig. 9

7 shows a molded article according to a second exemplary embodiment of the invention in a view analogous to FIG. 7,

Fig. 10

a molding according to a third embodiment of the invention in a view analogous to FIGS. 7 and 9,

Fig. 11

a molding according to a fourth embodiment of the invention in a view analogous to FIGS. 7, 9 and 10,

Fig. 12

a molding according to a further embodiment of the invention in plan view,

Fig. 13

a molding according to a further embodiment of the invention in plan view,

Fig. 14

a molding according to a further embodiment of the invention in plan view,

Fig. 15

a schematic representation of an overall system for the production of moldings,

Fig. 16

2 shows a schematic representation of a device for producing moldings according to a second exemplary embodiment of the invention,

Fig. 17

16 shows an enlarged detail from the device according to FIG. 16,

Fig. 18

a schematic representation of an apparatus for producing moldings according to a third Embodiment of the invention in a state of the method with lowered mold bottom and

Fig. 19

an enlarged detail from the device according to FIG. 18 in a state of the method with the mold base moved upwards.

The devices shown in the drawing are used to produce moldings, in particular paving stones or slabs made of concrete and / or materials containing concrete, with segments which are geometrically clearly delimited within the molding and have at least two different colors.

A method and a device for producing a plate with a two-colored ornament on a surface of the plate is described with reference to FIGS. 1 to 6:

A mold 21 is positioned on a board 20 serving as a base, side walls 22, 23, 24 of the mold 21 together with the board 20 enclosing a space 25 that is completely open at the top. A pressure element 26 can be moved into and out of the space 25 from the open upper side from at least two pressure bodies 27, 28 which are adjustable relative to one another. The pressure elements 27 and 28 of the pressure element 26 in the exemplary embodiment of FIGS. 1 to 6 consist of a plurality of pressure bars 29 and 30 running parallel to one another. The pressure bars 29 and 30 of a pressure element 27 and 28 are arranged at a distance from one another. A pressure bar 30 of the pressure body 28 protrudes between two pressure bars 29 of the pressure body 27. The pressure bodies 27, 28 of the pressure element 26 are adjustable relative to one another in such a way that the pressure bars 29 of the pressure body 27 can be adjusted in height relative to the pressure bars 30 of the pressure body 28.

In order to produce the plate with two-colored ornaments on its surface, the space 25 shown at the start (state A) according to FIG. 1 and delimited by the mold 21 and the board 20 is completely filled with a material 31, in particular a sub-concrete.

Subsequently, the pressure element 26 with the pressure bodies 27, 28, which are height-adjusted relative to one another, is moved into the mold 21 filled with the material 31, with simultaneous introduction of compression energy into the material 31. Here, a base body 32 is preformed from the material 31 (state B according to FIG. 2). As a result of the pressure bodies 27, 28 or pressure bars 29, 30 of the pressure element 26, which are adjusted in height relative to one another, the base body 32 is preformed in such a way that it has 33 depressions 34 and projections 35 on its upper side. The preforming of the base body 32 is also referred to as pre-compression or intermediate diving.

Subsequent to the preforming of the base body 32, the pressure body 28 of the pressure element 26 is displaced parallel to the pressure body 27 in such a way that undersides 36 and 37 of the pressure beams 29 and 30 of the pressure bodies 27 and 28 of the pressure element 26 in one plane at the level of an upper side 38 of the projections 35 lie (state C according to FIG. 3). The pressure elements 27, 28 or pressure bars 29, 30 of the pressure element 26 are accordingly retracted to one level.

The entire pressure element 26 is then moved out of the mold 21 (state D according to FIG. 4). As a result of the pre-compression of the material 31 or of the base body 32, a cavity 39 is formed in the mold 21, which is then filled with a filler material 40 of a different color and possibly of a different nature and / or composition. In this case, the entire upper side 33 of the base body 32 is covered with the filling material 40. A different colored facing concrete, a different colored concrete suspension or a different colored synthetic resin bonded concrete is used as the filling material 40. In addition to the color, the filler material 40 can have other different properties than the material 31 of the base body 32.

After the depressions 34 have been filled with the filling material 40, the pressure element 26 with the pressure bodies 27, 28 drawn back to one plane is moved in the direction of the mold 21 in order to completely compress the molding to be produced. With simultaneous entry of compression energy, this becomes Material 31 of the base body 32 and the filling material 40 are fully compressed into a blank 41 (state E according to FIG. 5).

After compacting, the blank 41 formed in this way is demolded and reworked. The post-processing of the blank 41 is carried out in particular with the aid of a grinding device 42 which is moved past an upper side 43 of the blank 41 (state F according to FIG. 6). Alternatively, the blank 41 can also be reworked by milling or washing. In any case, so much material is removed from the upper side 43 of the blank 41 during the reworking that the upper sides 38 of the projections 35 of the base body 32 are also exposed. As a result of the postprocessing, the material 31 of the projection 35 and the filler material 40 of the filled-in depressions 34 are alternately visible, a flat surface of the plate being produced at the same time. Subsequently, processing by blasting, sticking or grinding can be carried out.

A plate 44 shown in FIGS. 7 and 8 is also produced with the aid of the production method described with reference to FIGS. 1 to 6. The plate 44 accordingly consists of the base body 32 with the projections 35, the depressions 34 of which are filled with the filling material 40. As a result of the fact that the pressure elements 27, 28 of the pressure element 26 consist of parallel pressure bars 29, 30, a two-colored stripe pattern has arisen on an upper side 45 of the plate 44. Accordingly, the material 31 alternates with the filling material 40 on the upper side 45 of the plate 44 in strips. Here, all design options can be fully used. For example, Material 31 and filler 40 have different colors by coloring the respective materials with pigments. Furthermore, material 31 and filler material 40 can have different aggregate grains, which can be exposed or processed by milling, grinding or blasting and accordingly result in a corresponding surface structure.

It goes without saying that, with the aid of the previously described method or the described device, depending on the configuration of the pressure element 26 or the pressure body 27, 28 can be introduced on the top of a plate or a molding any pattern or ornaments. For example, FIG. 9 shows a plate 46, the top 47 of which has a punctiform ornament. For this purpose, a pressure element has round, namely cylindrical, pressure bodies. 10 and 11 each show a plate 48, 49, the upper sides 50, 51 of which have rectangular ornaments. In the case of the plate 48 according to FIG. 10, the rectangles of the ornament of the upper side 50 run vertically and horizontally, whereas the plate 49 according to FIG. 11 runs diagonally. FIGS. 12, 13 and 14 show further plates 52, 53, 54, the upper sides 55, 56, 57 of which have two-colored or more than two-colored ornaments. It goes without saying that the printing element 26 must be designed accordingly in order to achieve these ornaments. In addition to the examples shown here, any ornaments on the top of a molding are conceivable.

Starting from the above-described method for producing plates or moldings with two-colored ornaments on their upper side, a method for producing plates with multicolored ornaments on their upper side will be described below in conjunction with FIGS. 15 to 17.

A pressure element 58 for preforming or pre-compressing a base body 59 consists of two pressure bodies 60, 61 which are height-adjustable relative to one another. The pressure bodies 60, 61 again consist of pressure bars 62, 63 analogously to FIGS. 1 to 6, but can also be designed in any other way . With regard to the height adjustability and spacing of the pressure bars 62, 63 or pressure bodies 60, 61, the statements made regarding the pressure bars 29, 30 or pressure bodies 27, 28 apply analogously.

The pressure bars 63 of the pressure body 61 are each assigned at least one bore 64, in which supply lines 65 are guided. The bores 64 or feed lines 65 can be closed with the aid of one valve 66 each. Furthermore, the feed lines 65 are preferably designed as flexible hoses and connected to storage containers 67 for filling material. Via filling pumps 68, the filling materials can be removed from the storage containers 67 and can be fed to the feed lines 65.

A molding with multicolored ornaments on its surface is produced as described in more detail: A mold 70 positioned on a board 69 is filled with a sub-concrete provided by a concrete mixer 71. This sub-concrete is fed to the form 70 via a filling car 72. After this form 70 has been filled, the sub-concrete is precompacted to form the base body 59. Here, depressions 73 and projections 74 are introduced into the base body 59. In this regard, the production process works analogously to the process described in detail in connection with FIGS. 1 to 3. Accordingly, the originally height-adjusted pressure bodies 60, 61 of the pressure element 58 are withdrawn in such a way that undersides 75, 76 of the pressure bars 62, 63 lie in a plane with top sides 77 of the projections 74. Subsequently, only the depressions 73 are filled via the supply lines 65 in a controlled manner via the valves 66 with filler material which is removed from the storage containers 67 via the pumps 68. In this case, each feed line 65 can be connected to a separate storage container 67 which contains a concrete suspension of a different color and / or a different composition. However, it is also conceivable that several or all feed lines 65 are connected to a storage container 67. When the depressions 73 are filled, the pressure bars 63 used to form the same are continuously raised, in a manner analogous to the increasing filling of the depressions 73 with filler material.

After filling the depressions 73 with the concrete suspensions, namely when the undersides 75, 76 of all pressure beams 62, 63 lie approximately in one plane (FIG. 3), the valves 66 are closed and the entire pressure element 58 is moved out of the mold 70. There is no need to compact the concrete suspension filled into the depressions 73. This method also eliminates the need to rework the surfaces of the plates, for example by grinding. Preferably, however, the blank is hardened after the concrete suspension has hardened eg milling, blasting or washing out. It is also conceivable to wash out the blank thus formed in the fresh state.

The entire process can of course also be carried out if a conventional facing concrete is used as filler material. It is only necessary to note that the sub-concrete and facing concrete may only be filled in one after the other with intermediate vibrations. This is followed by final compression with the pressure element.

As an alternative to the above-mentioned methods, a method for producing panels with two-colored or multi-colored ornaments is to be described below, in which subsequent processing to expose the ornaments, for example by grinding, can be omitted.

A pressure element 78 for preforming or pre-compressing a base body 79 consists of two pressure bodies 80, 81 which are adjustable in height relative to one another. The pressure bodies 80, 81 have striking plates 82, 83. With regard to the height adjustability and spacing of the striking plates 82, 83 or pressure elements 80, 81, the statements made for the pressure beams 29, 30 or pressure elements 27, 28 apply analogously.

A mold 84 essentially consists of a mold frame 85 and a mold base 86. The mold base 86 can be moved up and down by lifting elements, not shown.

A molding with two-colored ornaments on its surface is produced as described in detail:

The form 84 is filled with a sub-concrete via a filling car, not shown. The sub-concrete is then pre-compacted to form the base body 79 and the profiling with depressions 88 and projections 89 is formed on an upper side 90 of the base body 79. In this regard, the method corresponds to the method described in FIGS. 1 to 3. Thereafter, the lower striking plate 83 becomes the recesses 88 withdrawn in such a way that lower edges 91, 92 of the striking plates 82, 83 lie in one plane. Subsequently, the striking plates 82, 83 are completely raised together (FIG. 18).

Now the mold base 86 is moved upwards by lifting elements, not shown, so that the base body 79 resting on the mold base 86 is flush with the top sides 93 of the projections 89 with an upper side 94 of the mold 84. A filling car 95 then travels over the raised base body 79 in such a way that the filling car 95 lies flush with an underside 96 on the upper sides 93 of the projections 89 (FIG. 19). Only the depressions 88 are now filled with filling material, in particular facing concrete, from the filling car 95. The upper sides 93 of the projections 89 remain largely free of facing concrete, since overfilling of the higher projections 89 is prevented by the flush-fitting filling car 95. Finally, the main compaction of the sub-concrete and the facing concrete is carried out by combined tamping using tampers 97, 98 and vibration to form a blank. After stripping and setting down the blanks, the actual process is finished. Post-processing, for example by grinding or the like, to expose the ornaments is not necessary. However, the surface is preferably reworked by blasting or the like.

The method can of course also be carried out if filler materials of different colors and / or compositions are used. The principle corresponds to the method described in FIGS. 15 to 17.

The method described in FIGS. 18 and 19 is preferably carried out on a ramming press with a clocked rotary table. The different work steps are carried out in a circular system at different stations on the turntable. However, it is also conceivable to use the method on a board machine.

Claims (18)

Process for the production of moldings, in particular paving stones or slabs, characterized in that in a mold (21, 70, 84) a base body (32, 59, 79), preferably made of concrete, is preformed in such a way that it has depressions (34 , 73, 88) and / or projections (35, 74, 89), and that at least the depressions (34, 73, 88) are then filled with at least one filling material of a different nature and / or composition. A method according to claim 1, characterized in that the depressions (34, 73, 88) and / or projections (35, 74, 89) on an upper side (33, 90) of the base body (32, 59, 79) are introduced into the same . Method according to claim 1, characterized in that a pressure element (26, 58, 78) made of at least two relatively adjustable pressure elements (27, 28; 60, 61; 80, 81) into the form (21, 70, preferably filled with 84) is moved in and the base body (32, 59, 79) is preformed. Method according to one or more of claims 1 to 3, characterized in that after the preforming of the base body (32, 59, 79), a second pressure body (28, 61, 81) displaced parallel to a first pressure body (27, 60, 80) of the pressure element (26, 58, 78) is relatively adjusted such that lower edges (36, 37; 75, 76; 91, 92) of both pressure elements (27, 28; 60, 61, 80, 81) in one plane at the level of one Top (38, 77, 93) of the projections (35, 74, 89) are. Method according to one of the preceding claims, characterized in that a cavity (39) formed in the mold (21) during the preforming of the base body (32) is filled with a filling material (40) in such a way that an entire top side (33) of the base body ( 32) is covered with the filling material (40). Method according to one of the preceding claims, characterized in that the filling material used is different colored concrete, mortar, facing concrete, resin-bound mortar, concrete suspension and / or resin-bound concrete. Method according to one of the preceding claims, characterized in that the pressure element (26) for final compression of a blank (41) is moved into the mold (21), the undersides (36, 37) of the pressure body (27, 28) in one plane lie. Method according to one of the preceding claims, characterized in that the blank (41) is reworked, in particular by milling, grinding and / or washing, in such a way that upper sides (38) of the projections (35) of the base body (32) are exposed. Method in particular according to one of claims 1 to 4, characterized in that the base body (79) is raised before the filling material is filled in, in particular a mold base (86) of the shape (84) is raised, on which the base body (79) rests, such that the upper sides (93) of the projections (89) are flush with an upper side (94) of the mold (84). Method in particular according to claim 8 or 9, characterized in that a filling carriage (95) is moved over the base body (79), a lower edge (96) of the filling carriage (95) being flush with the upper sides (93) of the projections (89) , so that only the depressions (88) are filled with at least one filling material, in particular concrete suspension, and the upper sides (93) of the projections (89) are free of filling material. Method according to one of the preceding claims, characterized in that a completely compacted blank is reworked by blasting or the like. Method according to one or more of claims 1 to 4, characterized in that the depressions (73) are filled with several different filling materials, in particular concrete suspensions, in such a way that at least one depression (73) has a differently colored filling material than other depressions (73), each recess (73) being filled with only one filler. Method according to claim 12, characterized in that the filling materials, in particular concrete suspensions, pass through the respective depressions (73) in the first pressure body (63). arranged bores (64), preferably closable via valves (66), are supplied. A method according to claim 12 or 13, characterized in that a blank is reworked by washing, milling, blasting or the like. Device for the production of moldings, in particular for carrying out the method according to one of the preceding claims, characterized by a pressure element (58) composed of at least two pressure bodies (60, 61) which can be adjusted relative to one another, at least one feed means for filling material being assigned to at least one pressure body (61) is. Apparatus according to claim 15, characterized in that the pressure bodies (60, 61) are height-adjustable relative to one another. Shaped piece, in particular paving stone or slab made of concrete or material containing concrete, characterized by a base body (32, 59, 79) which has recesses (34, 73, 88) and / or projections (35, 74, 89) on at least one side, wherein the depressions (34, 73, 88) are filled with at least one filling material of a different nature and / or composition. Shaped article according to claim 17, characterized in that the upper sides (38, 77, 93) of the projections (35, 74, 89) and the filling material lie in one plane, and in particular the base body (32, 59, 79) and the or each Filling material are of a different color.

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