METHOD OF MAKING A BUILDING ELEMENT, AN APPARATUS FOR MAKING THE BUILDING ELEMENT, AND A BUILDING ELEMENT MADE BY THE METHOD

• US 20190322003A1
• Filed: 03/25/2019
• Published: 10/24/2019
• Est. Priority Date: 06/04/2013
• Status: Active Application

• Current Assignee: ABEO ApS
• Original Assignee: ABEO ApS
• Inventors: Hertz, Peter, Rasmussen, Morten
• Application Number:
  US16/363,360
• Publication Number:
  US 20190322003A1
• Time in Patent Office: Days
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 1/084 the vibrating moulds or cores being moved horizontally for making strands of moulded articles
• CPC Class Codes: B28B 1/16 for producing layered articles coating B28B11/04
• CPC Class Codes: B28B 19/003 to insulating material
• CPC Class Codes: B28B 23/02 wherein the elements are reinforcing members B28B23/0006 takes precedence
• CPC Class Codes: B28B 7/24 Unitary mould structures with a plurality of moulding spaces , e.g. moulds divided into multiple moulding spaces by integratable partitions, mould part structures providing a number of moulding spaces in mutual co-operation assemblies of individually complete moulds B28B7/26
• CPC Class Codes: E04B 5/04 with beams or slabs of concrete or other stone-like material, e.g. asbestos cement E04B5/08, E04B5/14 take precedence
• CPC Class Codes: E04B 5/38 with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element beams placed against one another and acting as permanent forms E04B5/23
• CPC Class Codes: E04C 2/06 reinforced

Abstract

The invention relates to the manufacture of a reinforced slab-shaped building element (E) having a length (L), a width (W) and a thickness, said slab-shaped building element (E) comprising an upper concrete plate anchored to a lower concrete plate with a top surface and a bottom surface, said upper concrete plate being cast from relatively higher strength concrete laid out upon said top surface, said lower concrete plate being of a less strong concrete, said lower concrete plate including a base contiguous with a plurality of raised portions integral therewith, said raised portions being spaced apart in the direction of said length (L) and said width (W), said plurality of raised portions defining between them a network of recesses, at least some of said recesses including reinforcing bars (R), said raised portions and said recesses together defining said top surface.

Claims

1-8. -8. (canceled)

9. An apparatus for casting a reinforced slab-shaped building element (E) having a length (L), a width (W) and a thickness, said slab-shaped building element (E) comprising an upper concrete plate (20) anchored to a lower concrete plate (10) with a top surface and a bottom surface, said upper concrete plate (20) being cast from relatively higher strength concrete laid out upon said top surface, said lower concrete plate (10) being of a less strong first type concrete, said lower concrete plate (10) including a base (11) contiguous with a plurality of raised portions (14) integral therewith, said raised portions (14) being spaced apart in the direction of said length (L) and said width (W), said plurality of raised portions (14) defining between them a network of recesses (17, 29), at least some of said recesses (17, 29) including reinforcing bars (R), said raised portions (14) and said recesses (17, 29) together defining said top surface, said apparatus including:

a) a first mold (100, 1000) defining a support for said lower plate (10) being cast,

b) at least one second mold (120, 1200) having an internal shape corresponding to a respective one of said raised portions (14),

c) a frame (F) movable along a length of said first mold (1000) and supporting a number of said second molds (120, 1200), said second molds (120, 1200) having an opening at a bottom thereof and being vertically movable in relation to said frame (F),

d) a dosing device (2000, 2000) for administering concrete to said second molds (120, 1200), and

e) vibrating devices (V) for vibrating said second molds.

10. The apparatus of claim 9, including a hopper (H) dispensing said first type concrete into dosing devices (2000) corresponding to a respective second mold (1200), said dosing devices (2000) being movable relative to said second molds (1200) along the length of said first mold (1000).

11. The apparatus of claim 9, including pressure heads (185, 1850) configured to be lowered into said second molds (1200) through an open top thereof, said pressure heads (1850) having a shape corresponding to a top face (15) of said raised portions (14) and configured for compressing concrete in said second molds (1200).

12. The apparatus according to claim 9, further comprising:

a closure being provided to prevent discharge of said first type concrete on said dosing devices (2000) being moved away from said second molds (1200).

13. The apparatus according to claim 9, including tensioning devices arranged at each end of said first mold (1000) for establishing a pre-tension in wires (not shown) extended between said ends.

14. A reinforced slab-shaped building element (E) having a length (L), a width (W) and a thickness, said slab-shaped building element (E) comprising an upper concrete plate (20) anchored to a lower concrete plate (10) with a top surface and a bottom surface, said upper concrete plate (20) being cast from relatively higher strength concrete laid out upon said top surface, said lower concrete plate (10) being of a less strong first type concrete, said lower concrete plate (10) including a base (11) contiguous with a plurality of raised portions (14) integral therewith, said raised portions (14) being spaced apart in the direction of said length (L) and said width (W), said plurality of raised portions (14) defining between them a network of recesses (17, 29), at least some of said recesses (17, 29) including reinforcing bars (R), said raised portions (14) and said recesses (17, 29) together defining said top surface.

15. The building element of claim 14, said lower plate (10) having an open celled porous structure, said top surface providing for said anchoring by a bonding between said relatively higher strength concrete with said open celled porous structure.

16-23. -23. (canceled)

24. An apparatus for casting a reinforced slab-shaped building element (E) having a length (L), a width (W) and a thickness, said slab-shaped building element (E) comprising an upper concrete plate (20) anchored to a lower concrete plate (10) with a top surface and a bottom surface, said upper concrete plate (20) being cast from relatively higher strength concrete laid out upon said top surface, said lower concrete plate (10) being of a less strong first type concrete, said lower concrete plate (10) including a base (11) contiguous with a plurality of raised portions (14) integral therewith, said raised portions (14) being spaced apart in the direction of said length (L) and said width (W), said plurality of raised portions (14) defining between them a network of recesses (17, 29), at least some of said recesses (17, 29) including reinforcing bars (R), said raised portions (14) and said recesses (17, 29) together defining said top surface, said apparatus including

a) a first mold (100, 1000) defining a support for said lower plate (10) being cast,

b) a plurality of said second molds (120, 1200) having an internal shape corresponding to a respective one of said raised portions (14) and having an opening at a bottom thereof, and

c) a dosing device (2000) for administering concrete to said second molds (120, 1200), characterized in

d) a frame (F) movable along said first mold (1000), said frame (F) supporting said plurality of second molds (120, 1200), said second molds (120, 1200) being individually vertically movable in relation to said frame (F), and

e) vibrating devices (V) for vibrating said second molds.

25. The apparatus of claim 24, including a hopper (H) dispensing said first type concrete into dosing devices (2000) corresponding to a respective second mold (1200), said dosing devices (2000) being movable relative to said second molds (1200) along the length of said first mold (1000).

26. The apparatus of claim 24, including pressure heads (185, 1850) configured to be lowered into said second molds (1200) through an open top thereof, said pressure heads (1850) having a shape corresponding to a top face (15) of said raised portions (14).

27. The apparatus according to claim 24, a closure being provided to prevent discharge of said first type concrete on said dosing devices (2000) being moved away from said second molds (1200).

28. The apparatus according to claim 24, including tensioning devices arranged at each end of said first mold (1000) for establishing a pre-tension in wires extended between said ends.