EP1989029B1 - Method and apparatus for producing moulded bricks with fibres - Google Patents

Abstract

The present invention relates to a method and device for producing moulded bricks made of hydraulically binding materials and with fibres, mats, bonded fabrics and wovens embedded therein, a formwork (1) composed of a frame (2) and a vertically movable base (3) being used. According to the invention, the base (3) is first adjusted to a height s below the top edge of the formwork, said height corresponding to the height of a layer of hydraulically binding material (5) and fibres, mats, bonded fabrics and wovens (6). The formwork (1) is then filled up to its upper edge with hydraulically binding material (5) by means of a mortar carriage (4). The fibres, mats, bonded fabrics and wovens are inserted into the fresh hydraulically binding material (5) in the desired orientation and the base (3) of the formwork (1) is subsequently lowered by a value corresponding to the height s. These steps are repeated until the desired height of the moulded brick is reached or until the base (3) of the formwork (1) may not be lowered further.

Description

The present invention relates to the production of molded blocks from a hydraulically setting mass, in which fibers, in particular optical fibers are embedded, as well as a device suitable for this purpose

Molded blocks of hydraulically setting compounds with integrated fibers have long been known. Hydraulically setting compounds, hereinafter also referred to as matrix, are to be understood as meaning concrete, fine concrete, mortar, gypsum and similar materials, which as a rule contain a hydraulic binder, aggregates, admixtures, additives and water. In the context of the invention is spoken of stones, including in addition to the classic stones with square or rectangular base and those with triangular, trapezoidal or diamond-shaped base and all imaginable round shapes, such as circle, ellipse, etc., be included.

The progressive development of optical fibers continues to lower their costs. In addition, the demand for exclusive design effects is increasing. Under these boundary conditions were in DE 93 10 500 U and WO 03/097954 Molded blocks of hydraulically setting or cast masses proposed in which optical fibers are embedded so that brings light through the stones.

This in WO 03/097954 However claimed manufacturing process is complicated and unsuitable for large-scale production. It is difficult to achieve a constant matrix addition and distribution in the formwork. The maintenance of constant layer thicknesses in the individual matrix or fiber layers is problematic. The DE 93 10 500 U is silent on the question of production.

JP-A-61291105 discloses a method of making mold stones from hydraulically setting masses and embedded fibers, mats, mats or fabrics

DE-A1-3807973 discloses an apparatus according to the preamble of claim 9.

The object of the present invention was therefore to find a method by which fibers with a defined orientation can be introduced into shaped blocks, in particular of concrete.

This object is achieved by a method and an apparatus for producing shaped bricks from hydraulically setting compounds (matrix) and fibers embedded therein according to claims 1 and 9.

From the shaped block thus produced, smaller stones can also be obtained by means of separation transversely and / or longitudinally to the fiber direction.

The hydraulic binder for the matrix is above all cement. Examples of suitable cements include Portland cement, Portland metallurgical cement, Portland fly ash cement, Portland limestone cement, Portland composite cement and blast furnace cement. Particularly preferred are Portland cement and Portland cottage cement.

The matrix may contain natural and / or artificial aggregates, additives and / or additives in a manner known per se.

Additives are, for example, natural and artificial pozzolans, color pigments, plastic dispersions, minerals, etc. Typical amounts are, for example, 3 to 8% by weight for color pigments and up to 30% by weight for fly ash, minerals etc.

Additives are-e.g. Air entraining agents, plasticizers, flow agents, accelerators, retarders, etc. If present, amounts of up to 5% by weight, in individual cases of up to 10% by weight, are used.

As an aggregate sand, gravel or grit can be used in principle. In order to achieve a uniform and dense distribution of the light-conducting fibers, sand mixtures having a maximum particle size of about 2 mm have proved successful. The mass ratio of cement to sand is usually between 1: 1 and 1: 3.

The fibers are, in particular, optical fibers, so that the molded blocks produced according to the invention are translucent in the direction of the incorporated fibers. However, the method and the device are also best suited for embedding other fibers, in particular where it depends on a specifically adjustable arrangement and orientation of the fibers within the molded block.

Accordingly come as fibers into consideration textile glass fibers, plastic fibers, carbon fibers, natural fibers, etc. Instead of individual fibers and mats, scrims, rovings or particularly preferred tissue can be incorporated, hereinafter referred to as tissue.

It is understood that fibers and hydraulically setting mass must be compatible with each other, as is the case for example in the known optical fibers of silicate glass and cement.

Furthermore, the proportion of fibers in the matrix is adjusted so that the required strength and resilience of the molded block is guaranteed. In the case of optical fibers, for example, proportions of 2 to 10 vol.%, preferably 5 to 8 vol .-%, with which a satisfactory light transmission is achieved.

The formwork is preferably to be adapted in width, length and depth to the desired dimensions of the molded blocks. For example, dimensions of 50 cm x 200 cm are suitable. The depth which determines the maximum height of the block may e.g. 50 cm. In the method and apparatus of the invention, it is advantageous that the height can be varied freely within the minimum height and depth of the formwork determined by the height of a layer of hydraulic mass and fibers.

The formwork should be made of a material or be provided at least in the interior with a material of which the matrix dissolves sufficiently to ensure a damage-free demoulding. Accordingly, the formwork materials used in the precast concrete area are suitable. The use of release agents, as they are also known from the manufacture of finished parts, is possible.

The adjustment of the soil can be done in a conventional manner via a spindle drive, a hydraulic system or the like. It is for demolding and possibly necessary cleaning advantageous if the side walls of the formwork are hinged.

For introducing the matrix is preferably a device, as it is already known as a mortar carriage. Mortar sleds are used in the laying of large-sized bricks (bricks, aerated concrete, sand-lime bricks) using a thin-bed process (thin mortar layer with a thickness of approx. 5 mm). Here, the masonry mortar is applied to the top of each stone layer using a mortar carriage. The mortar sled is a rectangular metal box that is open at the top and bottom and its width with the stone width used matches. From above it is filled with mortar and then pulled over the top of a stone layer in the wall longitudinal direction. A thin layer of mortar is applied to the upper side of the stone via the open underside of the box and a defined gap.

Alternatively, the matrix can also be applied by means of a spraying device.

In a particularly preferred embodiment, the fibers or fabrics are held on one or more roll (s) and deposited from there on the mass and cut to length according to the required length. The fibers are stretched and fixed over the mold length with a clamping device, which advantageously avoids shifting the fibers within the mass. This determines the fibers or fabrics on both sides of the formwork.

Alternatively, finely cut fibers can also be inserted into the formwork, especially when the fibers are stiff.

The incorporation of the fibers or fabrics and, if necessary, a simultaneous venting of the mass is expediently carried out by surface or external vibrators. A smoothing device with integrated vibration device is also useful.

In a preferred embodiment, the mortar carriage or the spraying device can be guided over the formwork and / or the formwork is moved under the mortar carriage or the spraying device. With a movement of formwork and mortar carriage or spraying device can be realized particularly high production speeds.

In a particularly preferred embodiment, the fibers or the fabric are introduced through the mortar carriage and so introduced together with the hydraulically setting compound in the formwork. In this case, a bleeding of the mass is expediently carried out by an internal or external vibrator on the mortar carriage.

With the method and apparatus according to the invention, it is also possible to produce patterns in the shaped brick. For this purpose, the fibers can be completely or partially omitted in one or more layers.

The invention will be explained in more detail with reference to the accompanying figures, but without being limited to the described embodiments. Unless otherwise indicated, all% data are by weight.

Figur 1:

Schema einer Vorrichtung

Figur 2:

Schema einer Schalung zu Produktionsbeginn

Figur 3:

Schema einer alternativen Vorrichtung

Figur 4:

Varianten für den Verfahrensablauf

Figur 5 a-f:

Schema einer erfindungsgemäßen Vorrichtung mit Klemmvorrichtung zur Fixierung der Fasern bzw. Gewebe in verschiedenen Stadien des Verfahrens

Show it:

FIG. 1:

Scheme of a device

FIG. 2:

Scheme of a formwork at the beginning of production

FIG. 3:

Scheme of an alternative device

FIG. 4:

Variants for the procedure

Figure 5 af:

Scheme of a device according to the invention with clamping device for fixing the fibers or tissues in various stages of the process

In FIG. 1 a device is shown schematically. It includes the formwork 1 from frame 2 and vertically movable bottom 3. Furthermore, a mortar carriage 4 is provided, which fills the hydraulically setting compound 5 in a controllable amount in the formwork 1. The fibers 6 are unrolled from a roll 7. Not shown are the drive of the bottom 3, the devices for cutting the fibers 6 and the smoothing device for incorporating the fibers.

The bottom 3 of the formwork 1 is located at the beginning of production with a defined height difference s below the formwork upper edge. This height difference s corresponds to the height of a layer of hydraulically setting compound 5 and fibers 6. The mortar carriage 4 travels along the formwork 1 along its upper edge and thereby fills a precisely adjustable amount of matrix 5. Subsequently, the fibers 6 required for a layer, either as Einzetfasern or as a fabric, placed on the fresh surface of the matrix 5; installed with the smoothing device and cut to length.

For the next step, the bottom 3 of the formwork 1 is lowered by the height s of a layer of matrix 5 and fibers 6 and the filling process is repeated in the same way. During the filling process, the formwork 1 for venting the matrix 5 can be vibrated from the outside or there is a compression by means of the smoothing device.

In FIG. 2 a formwork 1 of a device is shown, wherein the bottom 3 is in the uppermost position, which is set at the beginning of production.

The FIG. 3 shows a variant of the device, like parts are designated by like reference numerals. Here, the fibers 6 are unrolled from the roll 7 and incorporated in the mortar carriage 4 in the matrix 5. The filling of matrix 5 and fibers 6 takes place at the same time. Preferably, in this embodiment, the mortar carriage 4 is provided with an internal or external vibrator for venting the matrix 5, a smoothing device is thereby unnecessary but can also be integrated on the mortar carriage.

In FIG. 4 three variants of the device are shown. In the first variant, shown in FIG. 4a , the mortar sledge 4 is movable and moves over the Formwork 1 away to fill the mass 5. In the second variant, shown in FIG. 4b , the mortar carriage 4 is arranged stationary and the formwork 1 is movable, so that for filling the mass 5, the formwork 1 is guided under the mortar slide 4 along. In the third variant, shown in Figure 4c Both mortar slide 4 and formwork 1 are movable and are moved to fill the mass 5 and, if necessary. Also the fibers 6 against each other. This allows an increase in production speed.

In FIG. 5 af the process flow and schematically a corresponding device is shown, wherein a clamping device fixes the fibers or tissue during smoothing and cutting to length. The procedure and basic structure corresponds to that of FIG. 1 , After the layer of the light-conducting glass fibers 6 (single fiber strands or fabric) has been placed on the fresh matrix layer 5, the glass layer 6 is fixed immediately outside the formwork 1 on one side with a clamping device 8 (see FIG. FIG. 5a ). Then, as in FIG. 5b shown, pressed with a pressure roller 10, the glass layer 6 on the surface of the matrix 5. In FIG. 5c , It can be seen how then the other side of the glass layer 6 is fixed with a clamping device 9. The clamping device 8, 9 can be positioned so that a certain amount of tension is exerted on the glass layer 6. Then there is a smoothing and compacting process with a screed plate 11, the in FIG. 5d is shown. Analogous to the procedure in a road paver, an additional compaction energy can be applied via the screed plate 11 by means of vibrator / vibrator 12.

Subsequently, as in FIG. 5e represented, the glass layer 6 between the clamping device 8 and 9 severed by a suitable sawing device 13. The clamping devices 8, 9 prevent a shifting of the fiber layer 6 in the fresh matrix 5 both during smoothing and compacting as well as during the severing of the fibers 6.

After severing the clamping device 8, 9 is released, the bottom 3 of the formwork 1 is lowered and filled again matrix 5. Then the process repeats, s. FIG. 5f ,

The invention has been explained using the example of a rectangular stone, by appropriate selection of the formwork can be analog other forms with triangular, trapezoidal, polygonal, round or curved bases obtained. The walls can be designed vertically or inclined to the base. Moreover, it is possible by mechanical post-processing, e.g. Saws to adapt the outer contour even more specifically to desired shapes.

Although the method is particularly useful in translucent bricks, there is also a beneficial application for other fibers where exact alignment is desirable.

LIST OF REFERENCE NUMBERS

1

formwork

2

frame

3

ground

4

mortar carriage

5

hydraulically setting mass / matrix

6

Fibers / tissue

7

Role (storage of fibers / tissue)

8th

clamping device

9

clamping device

10

pressure roller

11

smoothing plate

12

RüttlerVibrator

13

sawing

Claims (16)

1. Process for the production of molded blocks from hydraulically setting compounds with fibers, mats, bonded fabrics or woven fibers embedded therein, characterized in that a formwork (1) made up of a frame (5) and a vertically movable base (3) is used, wherein

   a) the base (3) is set to a height s below the upper edge of the formwork that corresponds to the height of one layer of hydraulically setting compound (5) and fibers (6)

   b) the formwork (1) is filled up to the upper edge with hydraulically setting compound (5) by means of a mortar carriage or a spraying device (4)

   c) fibers, mats, bonded fabrics or woven fabrics (6) are placed into the fresh hydraulically setting compound (5) in the desired orientation, stretched over the upper edge of the formwork by a clamping device (8, 9) and fixed and are then cut to length

   d) the base (3) of the formwork (1) is lowered by a height s, which corresponds to the height of one layer of hydraulically setting compound (5) and fibers (6), and

   steps b) d) are repeated until the desired height of the molded block is reached and/or the base (3) of the formwork (1) cannot be lowered any further.
2. Process as claimed in claim 1, characterized in that the hydraulically setting compound (5) is a cement, to which aggregates, additives and or admixtures are possibly added.
3. Process as claimed in claim 2, characterized in that the hydraulically setting compound (5) is a Portland cement, Portland slag cement, Portland fly-ash cement, Portland limestone cement, Portland composite cement, blastfurnace cement or a mixture thereof and contains an aggregate, preferably sand.
4. Process as claimed in one of claims 1 to 3, characterized in that the fibers, mats, bonded fabrics or woven fabrics (6) are optical fibers, mats, bonded fabrics or woven fabrics.
5. Process as claimed in one of claims 1 to 4, characterized in that the fibers, mats, bonded fabrics or woven fabrics (6) are unrolled from a roller (7) and placed onto the hydraulically setting compound (5).
6. Process as claimed in one of claims 1 to 5, characterized in that, after being placed in, the fibers (6) are incorporated in the hydraulically setting compound (5) by a smoothing device.
7. Process as claimed in one of claims 1 to 5, characterized in that, instead of steps b) and c), the fibers (6) are introduced into the hydraulically setting compound (5) in the mortar carriage (5) and the fibers (6) are filled together with the hydraulically setting compound (5) into the formwork up to the upper edge.
8. Process as claimed in claim 7, characterized in that the hydraulically setting compound (5) is deaerated in the mortar carriage by an internal or external vibrator.
9. A device for the production of molded blocks from hydraulically setting compounds with fibers, mats, bonded fabrics or woven fabrics embedded therein, wherein it comprises a formwork (1) made up of a frame (2) and a vertically movable base (3) as well as a mortar carriage or a spraying device (4) characterized in that a clamping device (8, 9) is provided for fixing the fibers, mats, bonded fabrics or woven fabrics (6).
10. Device as claimed in claim 9, characterized in that it comprises a smoothing device (12) for incorporating the fibers, mats, bonded fabrics or woven fabrics (6) in the hydraulically setting compound (5).
11. The device as claimed in claim 9 or 10, characterized in that an internal or external vibrator is provided on the formwork (1) and/or the mortar carriage (4) for deaerating the hydraulically setting compound (5).
12. The device as claimed in one of claims 9 to 11, characterized in that the mortar carriage or the spraying device (4) can be moved over the formwork (1)
13. The device as claimed in one of claims 9 to 11, characterized in that the formwork (1) can be moved under the mortar carriage or the spraying device (4).
14. The device as claimed in one of claims 9 to 11, characterized in that the mortar carriage or the spraying device (4) and the formwork (1) can be moved with respect to one another.
15. The device as claimed in one of claims 9 to 14, characterized in that the base (3) of the formwork (1) is adjustable by means of a spindle drive and/or a hydraulic mechanism.
16. The device as claimed in one of claims 9 to 15, characterized in that the frame (2) of the formwork (1) can be folded up.

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