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(11) | EP 2 060 702 B1 |
| (12) | EUROPEAN PATENT SPECIFICATION |
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Mould for casting concrete and method for making same Form zum Gießen von Beton und Herstellungsverfahren dafür Moule pour couler du béton et procédé de réalisation d'un tel moule |
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| Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention). |
Technical Field
[0001] The present disclosure relates to a mould for casting concrete, and to a method for making such a mould.
Background
[0002] In connection with casting of concrete structures, e.g. buildings, bridges, roads etc., there is frequently a need to provide a mould, in which the concrete is poured and allowed to set. After setting, the mould is generally removed. Such moulds are typically made of wood or wood-based materials, such as, plywood or chipboard, or even fibre boards (MDF, HDF etc.).
[0003] In order to reduce costs, it is desirable to reuse the mould material, preferably multiple times. Wood and wood based materials are, however, sensitive to moisture, which limits the number of times wood or wood-based mould materials may be reused. Furthermore, the density of wood and wood-based materials make moulds made of such materials heavy and thus cumbersome to handle.
[0004] EP-0 353 637A1 discloses a sandwich board making use of plastic waste granules in a polyurethane matrix. The board may be used for forming a wall of a concrete shuttering mould.
[0005] Hence, there is a need for an improved or alternative mould, which could eliminate, or at least alleviate, the problems associated with the prior art moulds.
Summary
[0006] It is an object of the present disclosure, to provide a mould for casting concrete, which eliminates or alleviates the problems of prior art moulds.
[0007] The object is wholly or partially achieved by a mould and a method according to the appended independent claims. Embodiments are set forth in the appended dependent claims, and in the following description and drawings.
[0008] According to a first aspect, there is provided a mould for casting concrete, having at least one wall made of a sandwich structure. The mould wall comprises first and second reinforcement fabric layers, which are arranged at respective surface portions of the sandwich structure, a polymer material matrix, in which the first and second reinforcement fabric layers are substantially enclosed, and a foamed core, arranged between the first and second reinforcement fabric layers. The foamed core is formed of the same material and in one piece with the polymer material matrix.
[0009] A mould having such walls may be reused multiple times, as the wall material is substantially insensitive to moisture, and can be made very strong. Still, such a mould is relatively uncomplicated to produce on a large scale, and so a relatively low cost can be achieved.
[0010] The mould walls are thus made from an integrated sandwich board, i.e. a sandwich board, wherein a foaming core material is wetting respective reinforcing webs arranged at the surfaces of the board, since the foam collapses at the surface to form a fiber reinforced skin.
[0011] A spacing web is immersed in the foamed core. This is a simple way of keeping the reinforcement fabric layers at a desirable distance during the production process. The spacing web comprises a sheet of lofty material, having a thickness, which substantially corresponds to a thickness of the foamed core.
[0012] The mould wall may have a thickness of about 8 to about 30 mm. Specific embodiments include 11, 15, 19 and 25 mm wall thicknesses.
[0013] The mould wall may further comprise a facing sheet, which is made from a material other than that of the polymer material matrix.
[0015] The facing sheet may be integrated with the sandwich structure in connection with the forming of the sandwich structure. The facing sheet may e.g. be a thermoplastic material. In particular embodiments, the facing sheet may comprise at least one of thermoplastic olefin, ABS, PMMA and ASA, either as layers or as a co-polymer.
[0016] In the alternative, the facing sheet may be made of a thermosetting polymer. In particular embodiments, the facing sheet may comprise at least one of melamine, urea and phenol or combinations or derivatives thereof.
[0017] The polymer matrix may comprise polyurethane, and/or a polyurethane derivative. Hence, any polymer based on urethane, or polymers having similar properties may be used.
[0018] According to another aspect, there is provided a method for producing a mould wall for a concrete casting mould. The method comprises arranging a first reinforcement fabric in a first wall mould part, arranging a second reinforcement fabric spaced from the first reinforcement fabric, dispensing an expanding polymer matrix forming material into the first wall mould part, providing a second wall mould part, and allowing the polymer matrix forming material to set so as to form a polymer matrix and a foamed core.
[0019] The method further comprises arranging a spacing web on first reinforcement fabric. The spacing web comprises a low density sheet of lofty material, having a thickness, which substantially corresponds to a thickness of the foamed core. The method may further comprise pressing the first and second wall mould parts together.
Brief Description of the Drawings
[0021]
Fig. 1 schematically illustrates a concrete mould.
Fig. 2 schematically illustrates a section of a part of a mould wall.
Description of Embodiments
[0022] Fig. 1 schematically illustrates a mould 1 for casting a concrete structure. Whereas the mould 1 illustrated in Fig. 1 is of a trivial shape, it is recognized that the mould of the present disclosure may have any shape.
[0023] The mould 1 comprises at least one wall 2 having a pair of opposing surfaces 3a, 3b. The mould walls may be attached to each other to form a mould structure using profile sections, which may be integrated into the mould wall elements, or using separate profile sections, to which the mould walls are attached. The mould walls 2 may be planar or curved.
[0024] Fig. 2 schematically illustrates a section of a part of a mould wall 2, intended to illustrate the construction of the mould wall.
[0025] The mould wall 2 comprises a core 3 of a foamed polymer material, such as e.g. polyurethane, polyurethane derivatives or similar materials. At the outermost portions of the mould wall, near its surfaces 3a, 3b, a respective reinforcement fabric layer 4a, 4b; 5a, 5b is provided. The reinforcement fabric layer may be formed by a woven or non-woven material, which may comprise reinforcing fibres of any desired type, such as e.g. glass fibres, carbon fibres, aramid fibres, hemp fibres, etc. In the illustrated embodiment, the reinforcement fabric is a woven fabric, having mutually orthogonal fibres 4a, 5a; 4b, 5b. For example, the material may be made by any combination of weaving, stitching, knitting and/or chopping.
[0026] The mould wall also comprises a low density spacing web 7, which may be in the form of a three dimensional fiber material, typically having low weight/sqm. The spacing web may, but need not, have a reinforcing effect on the mould wall 2.
[0027] At one or both of its surfaces 3a, 3b, a facing sheet 6 may be arranged. The facing sheet may be of any desirable material, and may be used to provide a certain appearance and/or surface structure to a surface 6a of the mould wall 2. For example, the surface structure may provide a surface having improved release properties relative to concrete.
[0028] The mould wall 7 may be produced according to the following. A first reinforcement fabric 4a, 4b is arranged in a first part of a two-part mould. The first part of the two-part mould may be formed as a sheet with edges having a height corresponding to the desired thickness of the mould wall 2 to be produced therein.
[0029] A spacing web 7 may be arranged on top of the first reinforcement fabric 4a, 4b, and a second reinforcement fabric 5a, 5b is arranged on top of the spacing web 7. The spacing web may be formed of glass fibres, carbon fibres, aramid fibres, hemp fibres or any combination thereof.
[0030] A material forming the polymer material matrix and foamed core 3 is then dispensed into the first part of the two-part mould, for example in a fluid or viscous form, possibly as monomer or partially polymerized monomers.
[0031] A second part of the two-part mould is then positioned on top of the first part of the two-part mould, and the material is allowed to set. The second part of the two-part mould may be pressed against the first part of the two-part mould. Energy, in the form of heat and/or pressure, may be added, as desired, to enable or to speed up the setting process.
[0033] If a facing sheet 6 is desirable, it may be provided either at the bottom of the first part of the two-part mould, prior to the insertion of the first reinforcing fabric 4a, 4b, and/or it may be provided at the top of the first part of the two-part mould, subsequent to the insertion of the second reinforcing fabric 5a, 5b. The facing sheet may be reinforced by e.g. glass fibres, carbon fibres, aramid fibres, hemp fibres etc. The facing sheet may be embossed to provide a desired surface structure, or it may be smooth or have specific release properties.
first and second reinforcement fabric layers (4a, 4b; 5a, 5b), which are arranged at respective surface portions (3a, 3b) of the sandwich structure,
a polymer material matrix, in which the first and second reinforcement fabric layers (4a, 4b; 5a, 5b) are substantially enclosed, and
a foamed core (3), arranged between the first and second reinforcement fabric layers (4a, 4b; 5a, 5b), wherein
the foamed core (3) is formed of the same material and in one piece with the polymer material matrix
characterised in that
a spacing web (7) is immersed in the foamed core (3), and in that
the spacing web (7) comprises a sheet of lofty material, having a thickness, which substantially corresponds to a thickness of the foamed core (3).
arranging a first reinforcement fabric (4a, 4b) in a first wall mould part,
arranging a second reinforcement fabric (5a, 5b) spaced from the first reinforcement fabric (4a, 4b),
dispensing an expanding polymer matrix forming material into the first wall mould part,
providing a second wall mould part, and
allowing the polymer matrix forming material to set so as to form a polymer matrix and a foamed core (3)
characterised by
arranging a spacing web (7) on first reinforcement fabric (4a, 4b),
the spacing web comprisingr a sheet of lofty material, having a thickness, which substantially corresponds to a thickness of the foamed core (3).
eine erste und eine zweite Verstärkungsgewebeschicht (4a, 4b; 5a, 5b), die an jeweiligen Oberflächenabschnitten (3a, 3b) des Sandwich-Aufbaus angeordnet sind;
eine Polymermaterialmatrix, in der die erste und die zweite Verstärkungsgewebeschicht (4a, 4b; 5a, 5b) im Wesentlichen eingeschlossen sind; und
einen geschäumten Kern (3), der zwischen der ersten und der zweiten Verstärkungsgewebeschicht (4a, 4b; 5a, 5b) angeordnet ist, wobei
der geschäumte Kern (3) aus dem gleichen Material wie die Polymermaterialmatrix und damit einstückig gebildet ist,
dadurch gekennzeichnet, dass
eine Beabstandungsfaserstoffbahn (7) in dem geschäumten Kern (3) versenkt ist, und dass
die Beabstandungsfaserstoffbahn (7) eine Platte aus einem bauschigen Material mit einer Dicke, die im Wesentlichen einer Dicke des geschäumten Kerns (3) entspricht, umfasst.
Anordnen eines ersten Verstärkungsgewebes (4a, 4b) in einem ersten Wandformteil,
Anordnen eines zweiten Verstärkungsgewebes (5a, 5b) in einer Beabstandung von dem ersten Verstärkungsgewebe (4a, 4b),
Abgeben eines sich ausdehnenden Materials zur Bildung einer Polymermatrix in den ersten Wandformteil,
Bereitstellen eines zweiten Wandformteils, und
Gestatten, dass das Material zur Bildung einer Polymermatrix härtet, um eine Polymermatrix und einen geschäumten Kern (3) zu bilden,
gekennzeichnet durch
Anordnen einer Beabstandungsfaserstoffbahn (7) an dem ersten Verstärkungsgewebe (4a, 4b),
wobei die Beabstandungsfaserstoffbahn eine Platte aus einem bauschigen Material mit einer Dicke, die im Wesentlichen einer Dicke des geschäumten Kerns (3) entspricht, umfasst.
des première et seconde couches de tissu de renfort (4a, 4b ; 5a, 5b), qui sont agencées dans des parties de surface respectives (3a, 3b) de la structure sandwich,
une matrice de matériau polymère, dans laquelle les première et seconde couches de tissu de renfort (4a, 4b ; 5a, 5b) sont sensiblement enfermées, et
une âme mousse (3), agencée entre les premières et seconde couches de tissu de renfort (4a, 4b ; 5a, 5b), dans lequel
l'âme mousse (3) est formée du même matériau et de façon monobloc avec la matrice de matériau polymère,
caractérisé en ce que
un voile d'espacement (7) est immergé dans l'âme mousse (3), et en ce que
le voile d'espacement (7) comprend une feuille à basse densité de matériau résilient, possédant une épaisseur, qui correspond sensiblement à une épaisseur de l'âme mousse (3).
l'agencement d'un premier tissu de renfort (4a, 4b) dans une première partie de paroi de moule,
l'agencement d'un second tissu de renfort (5a, 5b) espacé du premier tissu de renfort (4a, 4b),
la distribution d'un matériau de formation de matrice polymère expansible dans la première partie de paroi de moule,
la fourniture d'une seconde partie de paroi de moule, et
la prise du matériau de formation de matrice polymère afin de former une matrice polymère et une âme mousse (3),
caractérisé par
l'agencement d'un voile d'espacement (7) sur le premier tissu de renfort (4a, 4b), le voile d'espacement comprenant une feuille de matériau résilient, possédant une épaisseur qui correspond sensiblement à une épaisseur de l'âme mousse (3).
REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.
Patent documents cited in the description