• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A moulding system (2) for moulding a plurality planar mineral-based foam material building elements (4), said moulding system comprises a mould enclosure arrangement (6), and a predetermined number of planar separating elements (8) detachably arranged above each other in said mould enclosure arrangement (6) in an essentially horizontal orientation and forming a pile of separating elements (8). The separating elements are arranged essentially parallel to each other and are arranged at a distance from each other such that a space (10) is obtained between two neighbouring separating elements. The spaces are to be filled up with foam material fluid (12) to form the planar foam material building elements (4), wherein the moulding system is provided with one or many openings (14) to ensure that foam material fluid will reach all building element spaces within the mould enclosure arrangement (6).(Figure 1)
    公开号:SE1551266A1
    申请号:SE1551266
    申请日:2015-10-02
    公开日:2017-04-03
    发明作者:Persson Johan
    申请人:Concentus Properties Ab；
    IPC主号:
    专利说明:

    A moulding system Technical fieldThe present disclosure relates to a moulding system for moulding a plurality of planarfoam material building elements, and in particular for moulding building elements made from low density foam concrete or foam cement.
    Background In the building industry various materials are tested in order to achieve lightweight andenvironmentally friendly building elements. Materials of particular interest are mineral-based foam materials, e. g. foam cement or foam plaster or foam bumt lime.
    Foam concrete (FC), also known as foamed concrete, is a cellular lightweight concrete orreduced density concrete, that is a slurry that is created by injecting mortar or cement pastewith a synthetic aerated foam. In common with most modem implementations ofautoclaved aerated concrete, foam concrete likewise contains almost no coarse aggregate,so the term concrete is somewhat erroneous, though both are in the cementitiouscomposites family. Foamed concrete differs from autoclaved aerated concrete primarily bytheir specific mode of manufacture, as the latter generates its foaming agent/syntheticaerating gas, for foam bubble formation, by employing an in-situ chemical reactionbetween aluminum powder and lime/calcium hydroxide to generate hydrogen gas. Withthis latter reaction also making it a calcium aluminate cement. While foamed concrete might contain a negligible amount of aluminates, depending on the ores it is made from.
    Foamed concrete typically consists of a slurry of cement and fly ash or sand and water.This slurry is fiarther mixed with a synthetic aerated foam in a concrete mixing plant. Thefoam is created using a foaming agent, mixed with water and air from a generator. Thefoaming agent used must be able to produce air bubbles with a high level of stability,resistant to the physical and chemical processes of mixing, placing and hardening.Foamed concrete mixture may be poured or pumped into moulds, or directly intostructural elements. The foam enables the slurry to flow freely due to the thixotropicbehavior of the foam bubbles, allowing it to be easily poured into the chosen form or mould. After six to eight hours, depending on ambient temperature and humidity, the 2 mixture may be removed from the moulds and cut into different sizes before being stackedfor curing.
    Foam concrete is produced in a variety of densities from 200 kg/m3 to 1,600 kg/m3depending on the application.
    Thus, a building element made from foam concrete is lightweight and has moistureprotection, fire protection, sound insulation, and good heat insulation; therefore, it hasbeen successfully applied in oil-well cementing projects, used as a backfill material inexcavation projects, and used for sound and heat insulation in building panels, fire-protection wall, energy-absorbing pads in roads, road subbase, structural fill, foundations, and geotechnical and mine fill applications.
    Foam concrete having a density of less than 300 kg/m3 is sometimes denoted as ultralight foam concrete.
    There are continuous ongoing experimentation to achieve more and more ultralight (<3 00 kg/m3) FC, to be used e. g. for therrnal insulation material for building extemalwalls, backfill material for heat preservation pipes, foundation for the highway roads, andso on. In these applications, the compressive strength demand is not very high; usually0.3~0.5 MPa will be enough.
    An important aspect of these materials is that they relate to a new energy-conservation andenvironmental-protection building material, and is particularly suitable for the therrnal insulation engineering of building extemal walls.
    One difficulty with mineral-based foam materials is that foam on a lower level willdisappears when cast is too high because too much pressure is loaded and the foam has aweak bearing ability; therefore causes collapse, or a density difference, such that there willbe a higher density in a lower level. This technical problem has caused foamed materialcasting height remains at 10-20cm, and no one has reached 60 cm.
    Traditional moulding techniques where vertical moulds are filled with material, e.g.concrete, are not applicable when moulding foam material as the filled up material will self-collapse. This may happen when the height is above 30 cm. 3 Instead the mould of each building element must have a horizontal orientation during themoulding procedure. However, this Will result in a moulding procedure that requires large areas, long time for preparing the moulds and also a long time for f1lling up the moulds.
    The object of the present invention is to achieve a moulding system for moulding aplurality of planar mineral-based foam material building elements that have an essentiallyeven density. A further object is to achieve a moulding system that requires little spaceand that is less labour-intensive. In addition the system should be easy to transport and toinstall at a remote location. Furthermore, the moulding system should be ready to start the moulding process Within a short period of time after installation.
    SummaThe above-mentioned objects are achieved, or at least mitigated, by the present invention according to the independent claim.
    Preferred embodiments are set forth in the dependent claims.
    According to an aspect the invention relates to a moulding system for moulding a pluralityplanar mineral-based foam material building elements, the moulding system comprises amould enclosure arrangement and a predeterrnined number of planar separating elementsdetachably arranged above each other in the mould enclosure arrangement in anessentially horizontal orientation and forrning a pile of separating elements. The separatingelements are arranged essentially parallel to each other and are arranged at a distance fromeach other such that a space is obtained between two neighbouring separating elements.The spaces are to be filled up With foam material fluid to form the planar foam materialbuilding elements, Wherein the moulding system is provided With one or many openings toensure that foam material fluid Will reach all building element spaces Within the mould enclo sure arrangement.
    One object of the separating elements is to separate the building elements from each otherduring the moulding procedure such that a plurality of planar building elements may be moulded at the same time. Furthermore, the planar building elements have a maximal thickness of 30 cm and are moulded in an essentially horizontal orientation which is important in order to achieve an essentially even density throughout the building element.
    The building elements may e.g. be used for building many small houses at a very short period of times, e. g. at refugee camps, houses for students.
    One preferred shape of the enclosure arrangement is a rectangular cuboid, e. g. a standardized shipping container.
    The mineral-based foam material is e. g. foam cement, foam concrete, foam plaster or foam bumt lime.
    Brief description of the drawings Figure l is a schematic perspective view illustrating the moulding system according to thepresent invention.
    Figure 2 is a schematic perspective view illustrating the moulding system according to oneembodiment of the present invention.
    Figure 3 is a schematic top view of a separating element and the enclo sure arrangementaccording to one embodiment of the present invention.
    Figure 4 is a schematic top view of a separating element and the enclo sure arrangementaccording to another embodiment of the present invention.
    Figure 5 is a schematic side view illustrating one embodiment of the moulding system according to the present invention.
    Detailed description The moulding system will now be described in detail with references to the appendedfigures. Throughout the figures the same or similar items will have the same referencesigns.
    Herein, by the expression foam material it is meant any mineral-based foam material, e.g.foam cement, foam concrete, foam plaster, foam bumt lime, or any material having similar characteristics. 5 The terrn foam material should herein advantageously be interpreted as a low density foammaterial, preferably having a density below 400 kg/m3.
    Thus, with reference to the schematic illustration in figure l a moulding system 2 formoulding a plurality planar mineral-based foam material building elements 4 is shown.The moulding system comprises a mould enclo sure arrangement 6 that preferably has theshape of a rectangular cuboid. In one advantageous embodiment the mould enclosurearrangement is a standardized shipping container.
    An interrnodal container is a large standardized shipping container, designed and built forinterrnodal freight transport, meaning that these containers can be used across differentmodes of transport - from ship to rail to truck - without unloading and reloading theircargo. Interrnodal containers are primarily used to store and transport materials andproducts eff1ciently and securely in the global containerized interrnodal freight transportsystem, but smaller numbers are in regional use as well. Interrnodal containers exist inmany types and a number of standardized sizes, but ninety percent of the global containerfleet are so-called "dry freight" or "general purpose" containers, durable closed steelboxes, mostly of either twenty or forty foot (6 or l2m) standard length. The commonheights are 8 feet 6 inches (2.6 m) and 9 feet 6 inches (2.9 m) -the latter are known asHigh Cube or Hi-Cube containers.
    By using a standardized container the moulding system may be easily transported toremote locations; e.g. one container may be applied for the moulding procedure andanother for transporting necessary equipment and supply to produce the foam materialfluid. Thus, the mould enclosure arrangement comprises an essentially horizontallyoriented bottom wall and essentially Vertically oriented side walls attached to the bottomwall.
    With continued reference to figure 1, the moulding system 2 comprises a predeterrninednumber of planar separating elements 8 detachably arranged above each other in themould enclosure arrangement 6 in an essentially horizontal orientation and forrning a pileof separating elements 8. The separating elements are arranged essentially parallel to eachother and are arranged at a distance from each other such that a space l0 is obtained between two neighbouring separating elements. 6 The spaces 10 are to be filled up with mineral-based foam material fluid 12 to form theplanar foam material building elements 4.
    Preferably, the distance between neighbouring separating elements is less than 30 cm, andapproximately in the range of 15-25 cm depending on the intended use of the buildingelements.
    One important advantage of the presently disclosed moulding system is to be able tomould a plurality of building elements in each moulding procedure. The predeterrninednumber of planar separating elements is at least five, but preferably in the range of 10-30 depending e.g. of the thickness of each of the building elements.
    The distances between separating elements within one enclosure arrangement are norrnallyequal, but different distances, resulting in different thicknesses of the building elements, are also possible.
    To ascertain that the foam material fluid will reach all building element spaces within themould enclosure arrangement 6, the moulding system is provided with one or manyopenings 14.
    In one embodiment these openings 14 are provided between edges of each of theseparating elements and side walls of the mould enclosure arrangement.
    In another embodiment the openings 14 are through-going openings in each of the separating elements.
    During the moulding procedure foam material fluid is pumped into the enclosurearrangement. To ascertain that the fluid remain in the enclosure arrangement it ispreferably provided with sealing members such that the enclosure arrangement provides for a fluid proof enclosure for foam material fluid.
    The side walls of the enclo sure arrangement are preferably covered with a flexible andelastic damping material having a low-frictional surface facing the inner of the enclosurearrangement. The surface is made e. g. from a rubber material, or a silicone material. The flexible material will prevent or minimize leakage between the building elements.
    The system further comprises a foam material fluid feeding member 16 configured tosupply foam material fluid 12 to the enclosure arrangement 6. When foam material fluid issubj ected to pressure some of the air bubbles Within the fluid may collapse resulting inthat additional foam material fluid must be supplied to fill up the enclosure arrangement.Therefore, the feeding member is configured to ensure that foam material fluid is suppliedto the enclosure arrangement until the foam material no longer is compressed, i.e. Whenthe foam material starts to set and cure.
    In one embodiment, illustrated in figure 2, the feeding member 16 comprises a feedingcontainer 18 to be arranged close to the enclosure arrangement, Wherein the feedingcontainer provides supply of material fluid 12 until the foam material no longer is compressed.
    When foam material fluid is pumped into the enclo sure arrangement it is important toassure that all spaces Within the arrangement are filled up With the fluid and that air isallowed to escape from the enclosure arrangement, e.g. through the same passagewaysWhere the foam material fluid is inj ected/poured into the enclo sure arrangement. Withreferences to figure 5, the moulding system therefore comprises a tilting arrangement 20,Which is arranged in relation to the mould enclosure arrangement and structured to applyforces to the mould enclo sure arrangement such that the arrangement is tilted apredeterrnined angle, e. g. in the range of 5-15 degrees, to ensure that all spaces of thearrangement are filled up With foam material.
    To further improve filling of the enclo sure arrangement the tilting arrangement may beconfigured to apply forces to the mould enclo sure such that it is moved according to a moulding tilt procedure, e. g. slowly lifted and loWered 5-10 times during some hours.
    In one embodiment the planar separating elements are rigid and having a geometricalshape, e. g. rectangular, that correspond to and being slightly smaller than the geometricalcross-section in a horizontal plane of the enclosure arrangement. The supporting elementmay have a planar sheet-like shape made from a material having shape integrity enough tohold up the Weight of building elements Without losing its shape.
    The separating elements may be attached to the inner Walls of the enclo sure arrangement by suitable attachment members, e.g. bars, hooks, supporting shelves, etc. such that the 8 distance between each separating element is obtained. As an alternative supportingdistance elements may be provided between the separating elements assuring that thedistance is obtained.
    In one further embodiment each separating element comprises tWo planar sheet-likeboards having essentially a similar geometrical shape and being conf1gured to bedetachably attached to each other during the moulding procedure. The side of the boardarranged to face and being attached to the other board in one separating element isprovided With a surface layer being structured to the future use of the foam materialbuilding element. The surface layer may e.g. be painted or provided With Wallpaper if to be used as an inner Wall in a building.
    When the foam material fluid has set, norrnally Within 24 hours, the stack of buildingelements is taken out from the enclosure arrangement, preferably by removing or openingone of the side Walls. The building elements are separated from each other and stored therequired time for the foam material to be completely cured and hardened. Thereafter the building elements may be assembled e. g. to a building.
    The present invention is not limited to the above-described preferred embodiments.Various altematives, modifications and equivalents may be used. Therefore, the aboveembodiments should not be taken as limiting the scope of the invention, Which is defined by the appending claims.
    权利要求:
    Claims (14)
    [1] 1. A moulding system (2) for moulding a plurality planar mineral-based foammaterial building elements (4), said moulding system comprises a mould enclosurearrangement (6), c h a r a c t e r i z e d i n that the moulding systern (2) comprises a predeterrnined number of planar separating elements (8) detachably arranged above eachother in said mould enclo sure arrangement (6) in an essentially horizontal orientation andforming a pile of separating elements (8), wherein said separating elements are arrangedessentially parallel to each other and are arranged at a distance from each other such that aspace (10) is obtained between two neighbouring separating elements, and that said spacesare to be filled up with mineral-based foam material fluid (12) to form said planar foammaterial building elements (4), wherein said moulding system is provided with one ormany openings (14) to ensure that foam material fluid will reach all building element spaces within said mould enclosure arrangement (6).
    [2] 2. The moulding system according to claim 1, wherein said enclosurearrangement is provided with sealing members such that said enclosure arrangement provides for a fluid proof enclo sure for foam material fluid.
    [3] 3. The moulding system according to claim 1 or 2, wherein said distance between neighbouring separating elements is less than 30 cm.
    [4] 4. The moulding system according to any preceding claim, wherein said predeterrnined number of planar separating elements is at least five.
    [5] 5. The moulding system according to any preceding claim, wherein saidopenings (14) are provided between edges of the separating elements and side walls of the mould enclosure arrangement.
    [6] 6. The moulding system according to any of claims 1-4, wherein said openings are through-going openings in said separating elements.
    [7] 7. The moulding system according to any of claims 1-6, wherein the system comprises a foam material fluid feeding member (16) configured to supply foam materialfluid to the enclosure arrangement, Wherein the feeding member is configured to ensurethat foam material fluid is supplied to the enclosure arrangement until the foam material no longer is compressed.
    [8] 8. The moulding system according to claim 7, Wherein the feeding membercomprises a feeding container (18) to be arranged close to said enclosure arrangement,Wherein the feeding container provides supply of material fluid until the foam material no longer is compressed.
    [9] 9. The moulding system according to any of claims 1-8, Wherein said systemcomprises a tilting arrangement (20), Which is arranged in relation to said mould enclosurearrangement and structured to apply forces to said mould enclosure arrangement such thatthe arrangement is tilted a predeterrnined angle, to ensure that all spaces of the arrangement are filled up With foam material.
    [10] 10. The moulding system according to any of claims 1-9, Wherein said mouldenclo sure arrangement has the shape of a rectangular cuboid that comprises an essentiallyvertically oriented bottom Wall and essentially vertically oriented side Walls attached to said bottom Wall.
    [11] 11. The moulding system according to any of claims 10, Wherein at least a partof said side Walls are covered With an elastic material having a loW-frictional surface facing the inner of the enclo sure arrangement.
    [12] 12. The moulding system according to any of claims 1-11, Wherein said planar separating elements are rigid.
    [13] 13. The moulding system according to any of claims 1-12, Wherein eachseparating element comprises tWo planar sheet-like boards having an essentially similargeometrical shape and being configured to be detachably attached to each other during the moulding procedure, Wherein the side of the board arranged to face and being attached to ll the other board is provided With a surface layer being structured to the use of the foam material building element.
    [14] 14. l4. The moulding system according to any of claims l-l0, Wherein said mineral- based foam material is foam cement or foam concrete.
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    同族专利:
    公开号 | 公开日
    SE540101C2|2018-03-27|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    SE1551266A|SE540101C2|2015-10-02|2015-10-02|A molding system|SE1551266A| SE540101C2|2015-10-02|2015-10-02|A molding system|
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