A casting mold system, a casting mold and a method for manufacturing an element

Abstract

 A casting mould system comprising at least one plate (1, 1') that is made of heat insulating material, on the surface of which grooves (6, 6') are in the longitudinal and/or lateral direction of the plate, and side mould pieces (2, 2', 2"), which pieces are at at least one of their edges formed compatible with the grooves (6, 6') arranged on the surface of the plate (1,1'). Elements comprising a cast layer and a heat insulating layer in connection with it can be manufactured with the casting mould system.

Description

Field of the invention

[0001] The invention relates to a casting mould system according to the preamble of the appended independent claim. The invention also relates to a casting mould for manufacturing an element, which has been manufactured using a casting mould system according to the invention as well as a method for manufacturing an element using the casting mould system and a wall element.

Background of the invention

[0002] Various elements used in construction are usually cast and manufactured at the factory, from which they are transported to the construction site. Especially wall elements of buildings are large in size and their transport from one location to another is challenging.

Object and description of the invention

[0003] An object of the present invention is to provide a casting mould system that enables an easy, fast and flexible realisation of a casting mould, whereby the elements can for example be cast at the construction site.

[0004] Especially it is an object of the invention to provide a casting mould system that enables a casting of wall elements as casting on flat, in such a manner that the heat insulating layer is at the same time made part of the element.

[0005] To attain this purpose, the casting mould system, casting mould, method for manufacturing an element and wall element according to the invention is primarily characterised in what is presented in the characterising parts of the appended independent claims.

[0006] The other, dependent claims present some preferred embodiments of the invention.

[0007] A typical casting mould system according to the invention comprises

• at least one plate that is made of extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PIR/PUR), and which comprises a first planar surface and a second planar surface, of which planar surfaces at least one comprises grooves arranged on the surface of the plate in the longitudinal and/or lateral direction of the plate, and
• side mould pieces, which are made of extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PIR/PUR), and which pieces are at at least one of their edges formed compatible with the grooves.

[0008] A typical casting mould for the manufacturing of an element is manufactured using a casting mould system according to the invention, in such a manner that the bottom of the casting mould is formed of one or more plates of the casting mould system and the vertical walls of the casting mould are formed of the side mould pieces of the casting mould system.

[0009] In a typical method according to the invention for manufacturing an element as casting on flat, which element comprises a cast layer and a heat insulating layer in connection with it,

• a casting mould is manufactured using a casting mould system according to the invention, in such a manner that the bottom of the casting mould is formed of one or more plates of the casting mould system and the vertical walls of the casting mould are formed of the side mould pieces of the casting mould system by arranging side mould pieces to the grooves on the plate or plates,
• iron reinforcement is arranged in the mould, and
• the casting compound is arranged in the mould.

[0010] A typical wall element according to the invention comprises a cast layer and a heat insulating layer in connection with it, which element is manufactured as casting on flat according to a method that uses a casting mould system according to the invention. The casting mould system according to the invention enables the manufacturing of the elements in such a manner that the heat insulating layer functioning as the bottom plate of the casting mould is made part of the cast element.

[0011] The casting mould system according to the invention enables the easy and fast manufacturing of a casting mould required for casting elements comprising a cast layer and a heat insulating layer in connection with it, as a result of plates and side mould pieces compatible with each other, since the side mould pieces of the casting mould systems can be fixed to the grooves of the plates forming the bottom of the casting mould, without a separate fixing. The casting mould system according to the invention also enables easy modifiability of the casting moulds, since the plates of the casting mould system comprise typically grooves on the whole area of the plate and since the casting mould can be rapidly assembles from pieces that are compatible with each other.

[0012] The casting mould system according to the invention comprises a plate or plates that form the bottom (bottom plate) of the casting mould, and side mould pieces that are arranged into the grooves on the surface of the bottom plate, forming the vertical walls of the casting mould. In a finished casting mould, the side mould pieces are typically essentially perpendicular to the bottom plate of the casting mould. The side mould pieces are arranged tightly one against the other, whereby uniform casting mould walls can be formed. The side mould pieces do not need to be separate fixed to the bottom plate, but they can be attached to the grooves in a sufficiently strong manner and thereby they are also easily detachable after the casting step.

[0013] The plate/plates forming the bottom plate of the casting mould according to the invention also form, at the same time, the heat insulating layer of the finished element, which layer is in connection with the cast layer.

[0014] The plate or plates of the casting mould system according to the invention can be manufactured from any heat insulating material suitable for the use, which material's heat conductivity (lambda 10-value) is less than 0.1 W/(m K) The side mould pieces of the casting mould system can be manufactured in any suitable material for this use. In one embodiment of the invention, the plate/plates and side mould pieces of the casting mould system have been manufactured of cellular plastic such as extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PIR/PUR). Typically the plate/plates and the side mould pieces are manufactured from a same material. In one preferred embodiment of the invention, the plate or plates and the side mould pieces are manufactured from extruded polystyrene. The plates manufactured from a heat insulating material used in the casting mould system can also be coated, whereby the core layer of the plate is made from any of the afore-mentioned heat insulating material.

[0015] The thickness of the plates used in a casting mould system according to the invention is typically 50-600 mm, more typically 80-500 mm and most typically 100-400 mm.

[0016] The casting mould system according to the invention does not place any limitations as to the shape or size of the plates used. The plates of the casting mould system according to the invention usually have a rectangular shape, which comprises a first planar surface and a second planar surface, and a first and second parallel long side edge and parallel first and second short side edges, which are perpendicular to the long side edges, delimiting the surfaces. The length of the long side edge of the wall plate is typically 600 to 6000 mm, more typically 1200 to 4000 mm, even more typically 1200 to 3000 mm. The length of the short side edge of the wall plate is typically 300 to 1500 mm, more typically 500 to 1300 mm, even more typically 600 to 1200 mm. The long side edges of the plate define the longitudinal direction of the plate and the short side edges of the plate define the lateral direction of the plate.

[0017] At least one of the planar surfaces of the plate comprises grooves in at least the longitudinal and/or lateral direction of the plate, on the area of the whole planar surface of the plate. In a preferred embodiment, several grooves are on both the lateral and the longitudinal direction on the area of the whole planar surface of the plate. The distance between the grooves (measured from the middle to the middle) may vary, typically the distance between the grooves is about 80-150 mm, most typically about 100 mm. The distance between the grooves may also be different in the lateral direction and the longitudinal direction of the plate. Also the width of the grooves may vary, depending on the thickness of the side mould pieces used, typically the width of the grooves is about 20-50 mm. In one preferred embodiment of the invention, the width of the grooves arranged on the surface of the plate is about 25 mm. The depth of the grooves may also vary, typically the depth is about 10-25 mm, which enables the arranging into place of the side mould pieces. At least one edge of the side mould pieces that are part of the system is formed such that the side mould pieces are tightly arrangeable into the grooves of the plates.

[0018] The grooves on the plates of the casting mould system according to the invention enable the easy modifiability of the casting mould. For example, if the distance between the grooves is 100 mm (measured from the middle to the middle), the width of the groove is 25 mm and the thickness of the side mould pieces is 50 mm, then the side mould pieces may be arranged on the bottom plate at a minimum of 25 mm spacing, at any position on the plate. The grooves on the surface of the bottom plate both in the lateral and the longitudinal direction enable the positioning of the side mould pieces vertical against each other. The grooving of the plates enables for example in a casting mould for a wall element the free positioning of openings for windows and doors and thereby different elements can be easily manufactured by the casting mould system.

[0019] The side mould pieces belonging to the casting mould system according to the invention are typically manufactured in such a manner that one larger plate comprises several side mould pieces. The side mould pieces are readily formed on an entire plate in such a manner that they can be detached from each other by bending. Thus the side mould pieces are easy to manufacture and to transport as one larger plate.

[0020] The length of the side mould pieces is typically 600 to 6000 mm, more typically 1200 to 4000 mm, even more typically 1200 to 3000 mm. The height of the side mould pieces can vary, typically 50-200 mm and most typically 100-150 mm. The thickness of the side mould pieces is typically 40-100 mm, most typically 50 mm.

[0021] The cross-section of the side mould pieces may vary and can be freely chosen depending on the requirements set by the element to be manufactured. Typically the cross-section of the side mould piece is a rectangle, of which one side edge a tongue (male tongue and groove) has been formed, which tongue is arrangeable into the groove on the plate. The width of this tongue is compatible in size with the grooves arranged on the plates. The other edge of the side mould pieces, which does not comprise a tongue, i.e. a tongue and groove, enabling the fixing to a plate, can be freely formed depending on the application. A casting mould system according to the invention may comprise several different and differently shape side mould pieces, which are at one of their edges arrangeable into the grooves in the plate.

[0022] In one embodiment of the invention, the casting mould system comprises two or more plates, which edges of the plates to be arranged one against the other are formed compatible with each other. The plates are arranged tightly one against the other, forming a uniform bottom plate of the casting mould. Typically tongues and grooves are formed on the edges of the plates, enabling tight fixing of the plates to each other via the tongue and groove joint. Preferably the side edges of the plates that are arrangeable one against the other are half-grooved, that is, the side edge of the wall plate comprises a step-wise form, in which a tongue (male tongue) is formed on one side of the side edge and a groove (female groove) is formed on the other side of the edge, into which groove the tongue (male tongue) of the plate next to it is positioned, to form a tight joint. Also other types of tongue and groove joints can be used to fix the plates to each other. A casting mould system according to the invention is thus adapted for manufacturing any size of casting mould by using standard sized plates.

[0023] In a method according to the invention for manufacturing an element the plate or plates forming the bottom plate is/are positioned on an even support. If several plates are needed to form a bottom plate of required size, they are arranged tightly one against the other via for example a tongue and groove joint or via another similar form. Alternatively, the plates can be fixed to each other by gluing. Thereafter the side mould pieces are arranged to the grooves of the bottom plate to desired locations, depending on the element to be cast. The side mould pieces are shortened or extended by gluing according to the need, so that uniform casting mould walls can be formed. At the corners of the walls, the side mould pieces are positioned tightly against one another at right angles. In the case of a wall element to be cast, also the required openings for windows and doors are formed into the casting mould by the side mould pieces. The side mould pieces do not need to be fixed to the bottom plate but instead they are attached in place in a sufficiently tight manner with the grooves in the plates, which grooves are compatible with the side mould pieces. If necessary, the side mould pieces can be fixed to the bottom plates by gluing or mechanically.

[0024] Once the casting mould is finished with the bottom plate and the side mould pieces, the casting mould is ready for iron reinforcement. The iron reinforcement may be done using regular products used in iron reinforcement.

[0025] When the casting mould has be reinforced, the mould can be filled with casting compound. The side mould pieces of the casting mould are usually dismounted, when the casting compound has reached a sufficient strength. In some cases, the side mould pieces can however be left in place as part of the cast element. The bottom plate of the casting mould remains a part of the cast element.

[0026] A casting mould system according to the invention is suitable for use in the manufacturing of all types of elements, which elements comprise a heat insulating layer and a cast layer in connection with it. The casting mould system according to the invention is especially used for manufacturing wall elements. The casting mould system according to the invention enables an easy manufacturing of casting mould and thus the elements can be for example cast only at the construction site, whereby the elements do not need to be separately transported to the construction site.

Short description of the drawings

[0027] In the following, the invention will be described in more detail with reference to the appended drawings, in which

Figure 1

shows the structure of a bottom plate used in a casting mould system according to the invention,

Figure 2

shows the plate of Figure 1 seen from the side,

Figure 3

shows the side mould pieces used in a casting mould system according to the invention as a plate, from which the side mould pieces are detachable,

Figure 4

shows the side mould pieces seen from the side,

Figure 5

shows some other side mould pieces, and

Figure 6

shows a casting mould that is manufactured using a casting mould system according to the invention, seen from the side.

Detailed description of the invention

[0028] Figure 1 illustrates a plate 1 according to a casting mould system according to the invention, which plate comprises a first planar surface 4 and a second planar surface 5, of which planar surfaces at least one comprises grooves (6, 6') arranged on the surface of the plate in the longitudinal and lateral direction of the plate. Figure 2 shows the cross-section of the plate 1.

[0029] Figure 3 illustrates some the side mould pieces 2, 2' used in a casting mould system according to the invention as a plate, from which the side mould pieces 2, 2' are detachable by folding. In Figure 4, single side mould pieces 2, 2' are shown as their cross-section. On at least one edge of the side mould pieces 2, 2', in the longitudinal direction of the side mould piece, a tongue (tongue and groove) has been formed, which tongue is arrangeable into the grooves 6, 6' on the surface of the plate 1. In Figure 5, some alternative side mould pieces 2" are shown, the cross-sections shown in the Figure are examples of some possible cross-sections.

[0030] Figure 6 shows, in an exemplary manner, a casting mould that has been manufactured using a casting mould system according to the invention. The casting mould comprises a bottom plate that is formed of plates 1, 1' fixed to each other, and side mould pieces 2, 2', 2" that are arranged into the grooves 6, 6' on the plates 1, 1'. The side mould pieces form the walls of the casting mould, essentially perpendicular to the bottom plate.

[0031] The invention is not intended to be limited to the above-presented exemplary embodiments, but the intention is to apply the invention widely within the inventive idea defined by the claims defined below.

Claims

1. A casting mould system, characterized in that the system comprises

- at least one plate (1, 1') that is made of extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PIR/PUR), and which comprises a first planar surface (4) and a second planar surface (5), of which planar surfaces at least one comprises grooves (6, 6') arranged on the surface of the plate in the longitudinal and/or lateral direction of the plate, and

- side mould pieces (2, 2', 2"), which are made of extruded polystyrene (XPS), expanded polystyrene (EPS) or polyurethane (PIR/PUR), and which pieces are at at least one of their edges formed compatible with the grooves (6, 6').

2. A casting mould system according to claim 1, characterised in that the plate (1, 1') comprises grooves (6, 6') on the whole planar surface of the plate in the longitudinal and/or lateral direction of the plate.

3. A casting mould system according to claim 1 or 2, characterised in that width of the grooves (6, 6') arranged on the surface of the plate (1, 1') is about 20-50 mm.

4. A casting mould system according to any of the preceding claims, characterised in that the distance between the grooves (6, 6') is about 80-150 mm.

5. A casting mould system according to any of the preceding claims, characterised in that the system comprises two or more plates (1, 1'), which side edges of the plates to be arranged one against the other are formed compatible with each other.

6. A casting mould system according to any of the preceding claims, characterised in that the height of the side mould pieces (2, 2', 2") is about 100-150 mm.

7. A casting mould for manufacturing an element, characterised in that the casting mould is manufactured using a casting mould system according to any of the claims 1-6, in such a manner that the bottom of the casting mould is formed of one or more plates (1, 1') of the casting mould system and the vertical walls of the casting mould are formed of the side mould pieces (2, 2', 2") of the casting mould system.

8. A method for manufacturing an element as casting on flat, which element comprises a cast layer and a heat insulating layer in connection with it, characterised in that in the method

- a casting mould is manufactured using a casting mould system according to any of the claims 1-6, in such a manner that the bottom of the casting mould is formed of one or more plates (1, 1') of the casting mould system and the vertical walls of the casting mould are formed of the side mould pieces (2, 2', 2") of the casting mould system by arranging side mould pieces to the grooves (6, 6') on the plate or plates (1, 1'),

- iron reinforcement is arranged in the mould, and

- the casting compound is arranged in the mould.

9. A method according to claim 8, characterised in that the side mould pieces of the casting mould are dismounted when the casting compound has reached a sufficient strength.

10. A method according to claim 8 or 9, characterised in that the element is a wall element.

11. A wall element comprising a cast layer and a heat insulating layer in connection with it, characterised in that the wall element is manufactured according to a method according to any of the claims 8-10.

Drawing