|
(11) | EP 0 049 692 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||||||
| (54) | Process for producing double slabs, and a device suitable for realizing said process |
| (57) The invention concerns a process to produce and obtain double slabs, and also a device
to obtain double slabs, whereby the double slabs are advantageously suitable for building
use and consist of at least two substantially plane-parallel layers of cemented conglomerate
in which electrically welded wire mesh elements are embedded, and whereby said layers
are separated from each other by trellis elements (26) which are advantageously flat
trellises, said device being suitable to carry out the process of the preceding claim
and comprising in mutual cooperation and coordination:
- table means (14) to form the first slab (30), equipped with vibrating means (15), - mould means (20) with combs and with means (1125-129) to retain conglomerate and with at least one end bar (18) for positioning and handling purposes having means (34) for its detachment, - supporting surface means (33) with positioning means (19) and adjustable means (32), whereby said supporting means (33) are independent and able to uphold means with combs (20), and whereby there are vibrating means (15), - withdrawal table means (12) with substantially horizontal withdrawal means (13) together with means (112-37-137) to sustain and possibly to guide said mould means with combs (20). |
[0001] This invention concerns a process to obtain double slabs and therefore also concerns a device suitable for realizing said process.
[0002] To be more exact, this invention concerns a process . suitable for obtaining double slabs by making use advantageously of flat trellises able to support and position . reciprocally and temporarily the electrically welded wire . mesh which is thereafter contained and embedded in the castings which constitute the two plane-parallel slabs forming the double slab.
Double slabs are known which are typically composed of an element with a continuous or semi-continuous surface cooperating with another substantially similar element, both . elements consisting advantageously of cemented conglomerate, whereby metallic elements having stiffening and distancing characteristics are interposed between the two slabs.
[0003] Double slabs are also known in which insulating and/. or sound-proofing elements are made to cooperate.
[0004] Our invention concerns a new process to obtain said double slabs and also concerns a new device suitable for realizing said process.
[0005] In the known art there is, for instance, patent applie- ation IT I974IA/77 in the name of Sartorio, wherein the structure and the processes for making and applying a building element are described.
[0006] Said building elements are made with automatic equip-. ment working with a continuous cycle. Said automatic equipment comprises a movable working surface consisting of an endless mat of plastic material moved by suitable rollers.
[0007] Parallel rings of a suitable section are also envisa-- ged as delimiting the side zones of formation of said building element.
[0008] This device involves many drawbacks in that its continuous movement makes it impossible to vary, as wished, the structure of the panels thus made, and moreover it is not suited to the diverse operations which have to be carried out to make said building element.
[0009] Furthermore, if working is carried out with a discontinuous cycle, a plurality of interferences begins to take place among the various operations or functions performed on the same working surface.
[0010] Moreover, the patent does not say how the working surface is limited in its lengthwise direction, nor does it indicate any other functional elements required.
[0011] Patent application IT 23223A/77, also in the name of Sartorio, describes some presumed improvements to the preceding patent. This patent application shows in a fanciful- way a new method to obtain double slabs; this method envisages the descent from above of both the wire mesh and the distancing and separating elements into a mass of cemented conglomerate that is still not solidified.
[0012] Besides being substantially fanciful, as we said, this device too requires a very liquefied concrete mass with very long drying and hardening times and involves many drawbacks and shortcomings which make it substantially impossible to apply.
[0013] There is also patent application IT 25325A/77, again in the name of Sartorio, wherein a system is substantially. visualised for a bond between neighbouring panels with a double slab; a special panel is also envisaged which repeats substantially an old patent of Sartorio, namely IT 713072.
[0014] Moreover, a further patent in the name of Sartorio has been set forth wherein the realization of double slabs is envisaged by means of a system of crosswise supports cooperating with sound-proofing elements.
[0015] This process is described in IT 27620A/78 and can also be deemed to be essentially fanciful in that the elements cooperating with the distancing trellises comprise special conformations which cannot be readily handled on a building site.
[0016] In any event this patent foresees rather imaginary and unreal solutions in view of normal working methods.
[0017] An application also exists in the name of Impianti In- dustriali, which was submitted under No. 83345A/78 and deals . with a system for realizing double slabs by withdrawal from . above of the mould forming the empty spaces.
[0018] This patent deals with a particularly advantageous device which, however, has inborn limitations because of the height of the shed which it assumes to be available.
[0019] Our present invention aims at the realization of two- . slab panels with a device which is in itself simple and by the employment of a process which can also be applied to . the normal existing tables for making slabs.
[0020] This invention, therefore, enables double slabs to be- made even in cooperation with and on tables already suitable for producing single slabs.
[0021] According to the invention arrangements are made to lay on a suitable table an electrically welded wire mesh and advantageously to apply the flat trellises, after which it is arranged to pour the concrete mass and create a homogeneous with vibrations, this phase being substantially the same as that normally employed for flat slabs.
[0022] On this layer a mould with combs is applied, of which the upper surface forms the lower inner surface of the upper slab constituting the double slab, whereby the mould is suitable for not interfering lengthwise with the intermediate trellises.
[0023] The upper surface of the mould with combs is positioned with suitable distancing shims, which thereby regulate the thickness of the double slab; said distancing shims cooperate with appropriate supports not connected to the vibrating surface on which the first slab has been predisposed and obtained.
[0024] On the mould with combs an intermediate layer of insulating and/or sound-proofing material can be spread out or . deposited.
[0025] This intermediate layer can consist of a plurality of elements made of sound-proofing and/or insulating material, on which an electrically welded wire mesh is advantageously laid and anchored to the flat vertical protruding elements.
[0026] When the electrically welded wire mesh has been predisposed, arrangements are made to cast the concrete and vibrate the upper slab; the vibration takes place independently of that of the lower slab since the mould with combs receives its vibration either from independent supports or. direct and discharges said vibration onto independent supports.
[0027] When vibration has taken place or earlier, the surface of the upper slab is finished with a levelling board, which may perhaps vibrate, the purpose being to obtain diverse finishes for the usage phase of the slab.
[0028] Next, steps are taken to anchor the mould with combs to a crane and to hoist it in a substantially horizontal position, thereby also lifting the double slab in which the mould with combs is lodged.
[0029] The double slab, with the mould with combs lodged inside it, is rested on an appropriate table. During this phase the mould with combs detaches itself independently, owing to the force of its own weight, from the upper slab and rests on the lower slab, thus being ready to be withdrawn.
[0030] When one end of the mould with combs has been removed, it is possible to apply to the other end a suitable towing means, which may be a winch.
[0031] By means of this towing means steps are then taken to withdraw the mould with combs from the double slab on a substantially horizontal surface.
[0032] According to the invention the weight of the mould during withdrawal is advantageously borne not by the slab . but on appropriate rollers positioned on the table itself . and on a possible plurality of bearings solidly fixed to the mould with combs and running on appropriate guides.
[0033] The double slab thus formed can be left on the with- . drawal table for final hardening or can be rested on suit-. . able surfaces; the double slab is normally transported with . a bridge crane or lift truck.
[0034] According to a variant of the invention the mould with . combs is suitable for the circulation of a hot substance able to speed up the drying and hardening process.
[0035] . According to another variant said hot substance will advantageously be hot air and/or steam and perhaps will be allowed to flow between the mould and the double slab so as to improve the drying and hardening action.
[0036] The device suitable for carrying out this process, . therefore, is envisaged as having a moulding surface with vibration means, whereby said surface and said means can be the same as those required now to make a single slab.
[0037] The use of a lifting means and of auxiliary means to position the mould with combs is also envisaged. Independ-- ent supporting and/or vibrating means cooperating with the- mould with combs are also envisaged.
[0038] According to a variant said mould means are suitable for the circulation and distribution of hot substances and- advantageously of steam.
[0039] In cooperation with the forming table a withdrawal table is envisaged as having substantially horizontal towing - means, the mould means being advantageously guided and supported thereon.
[0040] The invention is therefore embodied in a process for . manufacturing and obtaining double slabs, whereby the double slabs are advantageously suitable for building purposes and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are embedded; said plane-parallel layers are kept apart from each other by trellis elements- advantageously consisting of a flat trellis; said process is characterized by the fact that an electrically welded wire mesh cooperating with advantageously flat trellises is put in a known manner on a forming surface; thereafter conglomerate is cast in a known manner and is vibrated, and then, after suitable distancing means have been regulated, a mould with combs is predisposed, on which a layer of in- . sulating and/or sound-proofing material is perhaps laid and on which is placed an electrically welded wire mesh anchored to the protruding trellises; next, a mass of cemented conglomerate is cast and vibrated independently; the whole is then lifted and moved onto a substantially horizontal. with- drawal surface, where the mould with combs is withdrawn axially.
[0041] Furthermore, the invention is embodied in a device to obtain double slabs, whereby the slabs are advantageously suitable for building purposes and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are embedded, and whereby said plane-parallel layers are kept apart from each other by trellis elements advantageously consisting of a flat trellis, said device being characterized by comprising in mutual cooperation and coordination:
- vibrating surface means to form the first slab,
- mould means with combs having circumferential means to retain the conglomerate, and at least one removable end for positioning and handling purposes,
- independent adjustable means to support the mould means with combs, there also being vibrating means,
- substantially horizontal surface means with means to sustain and possibly to guide the mould means with combs,
- and means to withdraw the mould means with combs.
[0042] With the help of the attached tables, which have been . given as an illustrative but not restrictive example, let us now look at a preferential solution of the invention.
[0043] The tables are as follows:
. Fig. I shows from above a plant with two forming tables and two withdrawal tables;
Fig. 2 gives a side view of the plant of Fig. I;
Fig. 3 gives a three-dimensional view of the forming table with the mould with combs in the process of . being positioned;
Fig. 4 shows the plant with the mould with combs in position and the electrically welded wire mesh fitted;
Fig. 5 shows the plant of Fig. 4 with the second slab being cast;
Fig. 6 shows a successive phase of levelling and vibrating the second layer;
Fig. 7 shows the mould/double slab assembly being removed with a winch;
Fig. 8 shows a double slab positioned on the supporting table, while the mould with combs is already connected to the winch and has been partially withdrawn;
Fig. 9 shows the mould with combs fully withdrawn from the double slab;
Fig. 10 gives. an example of the combs of the mould means.
[0044] With reference to the figures, we have as follows: according to the example shown in the figures the forming table 14 is supported by one or more beams 16 resting on independent legs 117, which in this instance are anchored to the floor. The forming table 14 has in a position beneath itself some vibrators 15 which cooperate with the table 14 itself.
[0045] On its upper side the forming table 14 has the ability to anchor some suitable movable and shaped side boards 29, which can be fixed with locking pins 28 or other means.
[0046] These movable side boards 29 serve to conform the edge of the lower slab 30 and at the same time to contain the cast concrete.
[0047] In cooperation with the forming table 14 and at the sides thereof there are supports 33 which are independent of the forming table 14 and which cooperate with the legs 17 and have vibrating elements 115. The independent sup - ports with bearing surface 33 comprise an alignment pin 19 and possible variable shims 32 for the vertical positioning of the mould with combs 20. Instead of the variable shims . 32 other means to adjust height could be employed.
[0048] A vibrator 15 which is suitable for transmitting the . vibration desired to the mould means with combs 20 and only to said mould means 20 cooperates with the supporting surface 33.
[0049] Between the supporting surface 33 and the legs 17 vibration-damping means 31 may be envisaged which do not let- the vibrations of the vibrator 15 pass on.
[0050] The forming of the double slab takes place substantially as follows: the forming table 14 is made ready beforehand, and on it the movable side boards 29 are positioned and secured with suitable means 28 so as to limit circumferentially in a desired manner the slab to be obtained.
[0051] Within the perimeter formed by these side boards 29 is laid an electrically welded wire mesh, to which are anchored, in our example, by means of the hooks 27 some trellises 26. for connecting and distancing purposes.
[0052] Said trellises 26 are advantageously flat and are characterized by suitable hooks 27 which enable a trellis to be anchored to the electrically welded wire mesh by a simple . . sideways displacement of the trellis 26 in respect of the wire mesh.
[0053] Other trellises 26, however, can be employed which are . substantially suitable for use but have no hooks 27.
[0054] . Within the perimeter formed by the movable side boards 29 the conglomerate, which may be a cemented conglomerate, . is then poured until the thickness desired for the lower . slab 30 has been reached. Next, the whole is vibrated with . the vibrators 15 cooperating with the forming table 14.
[0055] . When the first layer or first slab 30 has been obtained, steps are taken to position the mould means with combs 20 by making use of a crane 24 with slings 23 cooperating with appropriate hook holes 22 in the frontal connection . bars 18.
[0056] The frontal bars 18 position between themselves the . combs 120 of the mould means 20 and are anchored to the mould by connecting pins 34 able to be inserted wherever needed.
[0057] The frontal bars 18 comprise at their ends at 21 some appropriate holes able to cooperate with the positioning means or pins 19 present on the supporting surface 33.
[0058] Thus, the mould with combs rests on separate and auxiliary structures 17-33 which do not cooperate directly with the forming table 14.
[0059] This makes it possible to use already existing forming tables 14 too and merely to add legs 17 and supporting surfaces 33 like those shown.
[0060] The frontal bars 18 include at their end some guide bearing means 118 which are suitable, during the withdrawal phase, for cooperating with the lateral guide 137 of the withdrawal group 13.
[0062] The combs 120 and frontal bars 18 are fixed to each other, for instance, with pins 34, so that by removing the pins 34 it is possible to remove the frontal bars 18.
[0063] Arrangements are then made to position the mould means 20 in such a way that the combs 120 are disposed alongside the trellises 26 and lengthwise thereto so that the corresponding spaces 25 cooperate with the trellises 26 themselves.
[0064] The spaces 25 are closed upwardly advantageously by .elastic means 125 which prevent the conglomerate from passing through and enable a moulding surface 114 to be obtained.
[0066] When positioning the frontal bars 18, care should be taken to ensure that the holes 21 in said frontal bars 18 coincide with the positioning means or pins I9 so as to permit both a suitable anchorage and a coordinated seat on the surface 33.
[0068] To regulate the interspace which has to be kept between the upper and lower layers, steps are taken to predispose shims 32 of various sizes until the required height is reached.
[0070] A layer of insulating and/or sound-proofing material is placed on the mould means 20 on the new forming surface II9, or nothing is placed thereon, depending on the specific requirements.
[0071] Electrical and/or hydraulic circuits can also be predisposed together with possible junction boxes or sockets, thus enabling the various electrical, hydraulic and intercom circuits, etc. to be obtained or making it possible to obtain spaces which are equipped or can be equipped, such as windows or doors and the like while the double slab is being made.
[0072] The electrically welded wire mesh 42 is put on the mould with combs 20 and possibly on the possible layer of insulating material when so predisposed, and is anchored to the trellises 26.
[0073] . When the electrically welded wire mesh has been anchored to the trellises 26, the plant is ready to make the second slab 43.
[0074] . As said earlier, the trellises 26 are made to pass . through the mould means 20 by making use of lengthwise slits 25, which are closed lengthwise 25 to the passage of con -. crete material by means 125 made of an elastic material.
[0075] - Around the mould means 20 and on its upper side, suit-. able movable side boards 129 are provided and fixed to the. mould means itself 20 and to the bars 18 and serve to limit and delimit the second slab 43.
[0076] When the upper surface II4 too has been made ready, steps are taken to pour and level the conglomerate, as shown in Figs. 4, 5 and 6 as an example.
[0077] Levelling can be done with a levelling board 41, which may be motorized or not and which can cooperate with vibrator means 215.
[0078] As soon as the upper surface has been levelled and the product has been hardened enough, arrangements are made to lift with the crane 24 the whole assembly consisting of the double slab 30-43 and the mould means with combs 20, as shown in Fig. 7 as an example.
[0079] The mould means 20 can be provided with suitable ducts through which steam or hot air or another heating means can pass so as to dry and normalise the double slabs more quickly.
[0080] According to a variant the combs 120 include a plurality of holes 220 which permit the the coordinated outgoing - of steam and/or hot air which comes into contact with the - conglomerate and speeds up drying. Said holes 220 can be of any desired type and shape and can be located anywhere.
[0081] The double slab 30-43 and mould means 20 are lifted together and the whole is rested on the withdrawal table 12, care being taken that the rear end bar 18 cooperating with- the rear end of the mould means 20 cooperates advantageously with the pins 119 on the withdrawal table 12.
[0082] When the double slab 30-43 and the mould means 20 are. rested on the withdrawal table I2, the mould means 20 de- - taches itself from the upper slab 43 owing to the. action of its own weight and rests on the lower slab 30, thus freeing itself.
[0083] On the withdrawal table 12 the double slab can be rested advantageously on the supports 112 covered with wood or with an elastic material.
[0084] Next, the end bar 18 present at the front of the mould means 20 is anchored to the winch means 35 with a carriage or carriages with a towing wire 36.
[0085] The rear end bar 18 cooperating with the pins 119 is then detached by removing the connections consisting of the connection pins 34, if existent; the mould means 20 is thus left with only the front end bar 18.
[0086] By using the winch 35, the mould means 20 is caused to leave by being pulled out from the double slab and is advantageously made to slide on the supporting rollers 37 so that said mould means 20 does not press on the lower slab 30 and thereby create stresses or breakage.
[0087] To reduce the pressure still further, the bar 18 comprises bearing means 118 that slide on the lateral guides 137 and are sustained thereby.
[0088] When the whole mould means 20 has been withdrawn, the slab is available for transfer to any desired place.
[0089] Ledge means 234 can be emvisaged which are able to permit the mould means to continue to be supported both by the bearing means 118 (at its front) and by the roller or rollers 37 (at its rear).
[0090] As soon as it has been withdrawn, the mould means 20 is cleaned and re-assembled, and the end bar I8 which was . temporarily detached is mounted again thereon; the mould . means 20 is used again for the next cycle of moulding double . slabs, said cycle beginning with the time of use of the mould means 20 itself.
[0091] In fact, the forming table 14 has been cleaned in the meanwhile, the electrically welded wire mesh has been predisposed, the trellises 26 have been predisposed, the first casting of conglomerate has been carried out and vibrating has been done.
[0092] This makes available the instalment of the mould means 20 which has been withdrawn just now from the double slab 30-43.
[0093] A plant II according to the invention can include one-or more forming tables 14, perhaps aligned, and one or more withdrawal tables 12-13 with one or more winch means 35, depending on the production rate.
[0094] We have described here a preferential solution of the invention, but variants are possible. Thus the proportions; times, sizes and lay-outs can be varied; it is possible to conform the mould means 20 in any desired way; the invention can be combined with forming tables 14 already existing, etc. These and other variants are all possible for a technician in this field.
I. Process to produce and obtain double slabs, whereby the slabs are advantageously
suitable for building uses and consist of two substantially plane-parallel layers
of cemented conglomerate in which electrically welded wire mesh elements are embedded,
and whereby said parallel surfaces are separated from each other by trellis elements
which are advantageously flat trellises, said process being characterized by the fact
that on one forming surface (14) is placed in a known manner an electrically welded
wire mesh (42) cooperating with trellises (26) which are advantageously flat, and
that a casting of conglomerate is then carried out in a known manner and is next vibrated
to obtain the first surface (30), and that, after regulation with suitable distancing
means (32), a mould means with combs (20) is predisposed on which a layer of insulating
and/or sound-profing material is possibly laid and over which an electrically welded
wire mesh (42) is placed and anchored to said protruding trellises (26), and that
a mass of cemented conglomerate is then poured which is vibrated independently, the
second surface (43) being thus obtained, whereby the whole (23-24) is then lifted
and moved onto a substantially horizontal withdrawal surface (12), where said mould
means with combs (20) is withdrawn axially (35-37).
2. Device to obtain double slabs, whereby the double slabs are advantageously suitable
for building uses and consist of at least two substantially plane-parallel layers
of cemented conglomerate in which electrically welded wire mesh elements are embedded,
and whereby said parallel surfaces are separated from each other by trellis elements
(26) · which are advantageously flat trellises and the device is · suitable for embodying
the process of the Claim hereinbefore, said device being characterized by comprising
in mutual cooperation and coordination:
- table means (14) to form the first slab (30), equipped with vibrating means (I5),
- mould means with combs (20) together with means to retain the conglomerate (125-129) with at least one end bar (I8) to obtain positioning and handling,
- supporting surface means (33) with positioning means (19) and adjustable means (32), said supporting means (33) being independent and able to sustain mould means with combs (20), there being vibrating means (I5),
- withdrawal table means (12) with substantially horizontal withdrawal means (13) together with means (112-37-137) to support and possibly to guide the mould means with combs' (20).
3. Device to obtain double slabs, as in Claim 2, characterized by the fact that the
supporting means (33) bear positioning means (19) and means to regulate thickness
(32) and are upheld by independent legs (17), whereby there are advantageously vibration-damping
means (31) and whereby vibrator means (15) are present.
4. Device to obtain double slabs, as in Claims 2 and 3, characterized by the fact
that the mould means (20) comprises a plurality of interspaced (25) combs (120), whereby
said plurality of combs (120) is positioned by end bar means (I8) and at least one
of said end bar means is removable, and whereby said spaces (25) between said combs
(120) include elastic means (125) to retain conglomerate at least at their upper side.
5. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims
thereafter, characterized by the fact that the end bar means (I8) include holes (21)
to cooperate with positioning means (19) and bearing means (II8) to cooperate with
guide means (137), whereby there are advantageously means to anchor side boards (129)
and hook means (22).
6. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims
thereafter, characterized by the fact that the combs (120) include means to receive
and- convey hot substances (air and/or steam), whereby distri - · bution means (220)
are advantageously present.
7. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims
thereafter, characterized by the fact the the withdrawal table means (12) with withdrawal
means comprise a supporting surface (12) for the double- slab (30-43)/mould means
(20) assemblage and, at their front, towing means (35-36) and guiding (137) and supporting
(37) means and possibly a stop (234).
8. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims
thereafter, characterized by the fact that the supporting surface means (12) has supporting
surfaces (112) covered with soft materials (wood, rubber, etc.).
9. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims
thereafter, characterized by the fact that the towing means (35-36) consist of winch
· means (35) cooperating with a cable (36) anchored to the end bar (18) solidly fixed
to the plurality of combs (I20).
· 10. Process to produce and obtain double slabs advantag- · eously suitable for building
uses, and device to realize said process, as described and shown and for the purposes
· allowed.