Mold, production method and product for integrally forming thin-walled concrete bathroom structure

Abstract

The present invention discloses a mold, production method, and product for integrally forming a thin-walled concrete bathroom structure, which relates to the field of construction. The mold includes an outer mold and an inner mold, wherein the outer mold is mounted on a cross-shaped sliding bracket; the outer mold includes an outer bottom mold, an outer vertical mold, and an outer special mold; a doorway mold is mounted on the inner mold; a positioning reinforcement steel beam is mounted on the top of the outer mold and the inner mold; an adjustable support member is mounted inside the inner mold; the inner mold includes an inner bottom mold and an inner vertical mold, wherein the inner bottom mold includes an inner bottom middle plate and a plurality of inner bottom side plates mounted on the outer circumference of the inner bottom middle plate; a cavity mold is mounted on the inner vertical mold; a bottom grouting port is provided on the inner bottom middle plate; and the method includes foundation preparation, mold assembly, casting and molding, and mold removal. The mold can integrally cast a thin-walled concrete bathroom structure, is simple and convenient to operate, has size adjustment capability, good versatility, and has strong casting uniformity, saving assembly costs.

Description

Technical Field

[0001] The present invention relates to the field of building technology, and in particular to a mold for integrally forming a thin-walled concrete toilet structure, a production method and a product. Background Art

[0002] The common method of forming thin-walled concrete bathroom structures is to use flat molds to produce wall panels and chassis, which are connected using mortise and tenon joints. The flat mold production process first produces the wall panels and chassis components, and then assembles the wall panels and chassis structures. Since the wall panels and chassis components are produced separately, the complexity of the mold for a single component is relatively low. The molds for the chassis and wall panels are composed of core molds and side molds. For example, the invention patent disclosed in the application publication number CN118498525A discloses an assembled integral bathroom structure, which includes a chassis and assembled wall panels connected to the chassis. The chassis is an internal hollow square shell composed of enclosing panels, wherein a side drainage pipe is provided on one of the enclosing panels, and a floor drain connected to the side drainage pipe is provided near the side drainage, and the bottom surface of the chassis is inclined toward the floor drain through a linear slope. The side drainage pipe is connected to the main vertical pipe through a U-shaped return pipe, and the toilet and washing machine both use a wall drainage mode. The pipes of the toilet and washing machine are also connected to the main vertical pipe. The side drainage pipe is installed on the enclosing panel and is connected to the main vertical pipe using the side drainage method. The connection with the main vertical pipe is more convenient, which has the effect of optimizing the drainage performance of the assembled integral bathroom. However, the flat mold process needs to consider the assembly of the chassis and wall panel components. When designing the mold, the accuracy of the numerous assembly nodes between the wall panels and the wall panels, and between the wall panels and the chassis parts needs to be considered to avoid conflicts between the wall panels and the chassis during assembly. Therefore, although the structure of a single mold is simple, for the entire bathroom structure, there are too many nodes that need to be controlled, which can easily cause assembly failure or node damage, resulting in high component processing costs. At the same time, the gaps between the chassis and the wall panels, and between the wall panels and the wall panels need to be injected with structural glue, and the cost of glue injection is high. For a single bathroom, 1 chassis mold and 4 wall panel molds are required, and the mold occupies a large area. In response to the above pain points, it is urgent to develop a new vertical mold production process to eliminate the glue injection process in the assembly gaps between the wall panels and the wall panels, and between the wall panels and the chassis, and to improve the overall prefabrication rate of thin-walled concrete bathroom structures. Summary of the Invention

[0003] The purpose of the present invention is to provide a mold, production method and product for integrally forming a thin-walled concrete bathroom structure. The mold can integrally cast the thin-walled concrete bathroom structure, is simple and convenient to operate, has size adjustment capability, good versatility, and strong casting uniformity, saving assembly costs.

[0004] To achieve the above object, the present invention adopts the following technical solutions:

[0005] A mold for integrally forming a thin-walled concrete toilet structure, comprising an outer mold and an inner mold arranged inside the outer mold, a casting cavity with a top opening formed between the outer mold and the inner mold, the outer mold being mounted on a cross-shaped sliding bracket; the outer mold comprising an outer bottom template, three outer vertical templates sequentially arranged vertically on the outside of the outer bottom template, and an outer special template, the outer bottom template being fixedly mounted on the cross-shaped sliding bracket; door openings corresponding to the positions of the outer special template and the inner mold are provided, a doorway template is detachably mounted at the door opening, and the inner cavity of the inner mold can be entered through the door opening; The top of the mold and the inner mold are detachably installed to position and reinforce the steel beam; a plurality of adjustable supports are installed inside the inner mold; the inner mold includes an inner bottom mold and four inner vertical molds fixedly installed on the top of the inner bottom mold, and the inner bottom mold includes an inner bottom middle plate and a plurality of inner bottom side plates installed on the outer circumference of the inner bottom middle plate; a plurality of cavity molds are installed on the inner vertical mold, and the gap between two adjacent cavity molds forms a reinforcing rib; a bottom grouting port is provided on the inner bottom middle plate, and an observation port is provided on the outer vertical mold; a thin-walled concrete bathroom structure is formed by grouting from bottom to top through the bottom grouting port.

[0006] Preferably, a slide groove is provided on the cross-shaped sliding bracket; a reinforcement bracket is fixedly installed on the outer side of the outer vertical formwork and the outer special formwork, a pulley is installed at the bottom of the reinforcement bracket, and the pulley is slidably installed in the slide groove.

[0007] Preferably, the length of the outer dedicated template is the same as the length of the corresponding side of the outer bottom template; the length of the outer vertical template is greater than the length of the corresponding side of the outer bottom template.

[0008] Preferably, the doorway template includes door corner templates arranged at the four corners of the rectangle and a vertical connecting template or a horizontal connecting template fixedly installed between two adjacent door corner templates; wedge-shaped connecting parts are provided at the ends of the vertical connecting template and the horizontal connecting template, and a connecting plate is provided at the end of the door corner template, and the connecting plate is detachably connected to the corresponding wedge-shaped connecting part.

[0009] Preferably, the positioning and reinforcement steel beams include two first steel beams arranged in parallel and spaced apart and two second steel beams arranged perpendicular to the first steel beams. Connectors are fixedly installed at the bottom of both ends of the first steel beams and the second steel beams, and the connectors are connected to the top of the outer mold and the inner mold.

[0010] Preferably, the adjustable support member includes a threaded sleeve, two adjusting screws installed at both ends of the threaded sleeve through threads, and a support seat installed at the ends of the adjusting screws, and the support seat is fixedly installed inside the inner mold; the threads at both ends of the threaded sleeve have opposite rotation directions.

[0011] Preferably, the inner vertical template includes inner corner templates arranged at the four corners of the rectangle and an inner connecting template fixedly installed between two adjacent inner corner templates, and a connecting inclined plate is provided at the position where the inner connecting template and the inner corner template are connected.

[0012] Preferably, a nylon block is installed on the outer side of the inner bottom side plate, and the width of the nylon block is smaller than the thickness of the inner bottom template; six inner bottom side plates are provided, and two adjacent inner bottom side plates are connected by an inner bottom inclined plate.

[0013] Preferably, an operating platform is provided on the outside of the outer mold, and a staircase is provided on one side of the operating platform.

[0014] A method for producing a mold for integrally forming a thin-walled concrete bathroom structure, comprising the following steps:

[0015] Step 1: Prepare the foundation. Level the ground in the mold installation area. Ensure the surface flatness deviation is no more than 1mm. Then, hoist the cross-shaped sliding bracket onto the installation area and secure it with expansion bolts.

[0016] Step 2: Assemble the mold. Fix the outer bottom template at the top center of the cross-shaped sliding bracket; assemble the inner mold simultaneously, fix the four inner vertical templates on the top of the inner bottom template, install the positioning reinforcement steel beam on the top of the inner vertical template, and then install the adjustable support in the inner cavity of the inner mold to provide internal support for the inner mold; install nylon blocks on the outer bottom of the inner mold; install the door template and multiple cavity molds on the outer side of the inner mold. After the installation is completed, use the lifting equipment to lift the inner mold as a whole to the top of the outer bottom template through the positioning reinforcement steel beam; slide the outer vertical template and the outer special template on the cross-shaped sliding bracket, slide the outer vertical template and the outer special template to the edge of the outer bottom template and fix them to complete the installation of the outer mold; then fix the positioning reinforcement steel beam to the top of the outer mold;

[0017] Step 3: Casting and forming. Grouting is performed in the casting cavity through the bottom grouting port. During the grouting, the grouting condition is observed through the wall panel observation port and the top opening. After the grouting is completed, a thin-walled concrete bathroom structure is formed.

[0018] Step 4: Mould removal. After the thin-walled concrete bathroom structure reaches the designed strength, the mould is removed. First, remove the top connection bolts between the positioning reinforcement steel beam and the outer mould, and remove the adjustable support. Then, remove the inner mould, outer mould and door mould at the same time, and then slide the outer vertical mould and the outer special mould outward. Remove the inner bottom mould and cavity mould, and transport the thin-walled concrete bathroom structure to the designated location. Clean and maintain the removed mould.

[0019] A product formed by a production method is a thin-walled concrete bathroom structure, which includes a chassis, four wall panels integrally arranged on the upper circumference of the chassis, vertical ribs integrally arranged on the wall panels, transverse ribs integrally arranged on the wall panels, a drainage ditch arranged on the chassis, a water outlet arranged in the drainage ditch, and a chassis return platform arranged on the chassis, one end of the water outlet passing through the wall panel to communicate with the outside.

[0020] In this invention, the outer mold side is assembled from three outer vertical templates and one outer dedicated template. The three outer vertical templates are large enough to accommodate mold assembly for bathrooms of varying sizes. When the size changes, only the outer dedicated template and outer bottom template need to be replaced, while the three outer vertical templates only need to be adjusted in position, reducing production costs and providing strong versatility. The outer vertical template and the outer dedicated template are slidably mounted on a cross-shaped sliding bracket, facilitating mold removal and closing operations.

[0021] The outer formwork is constructed of four integral pieces, with the primary load-bearing panels of the exterior vertical formwork constructed of steel plates. The back is constructed of a lattice structure formed by several vertical and horizontal steel plates and strong ribs. Once the exterior vertical formwork opposite the dedicated exterior formwork is removed, it can be completely dismantled to allow the finished product to be horizontally lifted from that side after demolding. This significantly reduces the need to vertically lift the finished product above the mold and then hoist it horizontally, which requires significant crane height.

[0022] The inner bottom formwork is composed of an inner bottom middle plate and multiple inner bottom side plates installed on the outer circumference of the inner bottom middle plate, which minimizes the impact of cracking on the thin-walled concrete bathroom chassis during demoulding. The two adjacent inner bottom side plates are connected by an inner bottom inclined plate, which not only ensures structural strength but also reduces disturbance to the thin-walled concrete bathroom chassis during demolition.

[0023] The door template can be cast in one piece to form the bathroom door opening, avoiding the need for subsequent cutting of the door opening. The cavity mold can form horizontal and vertical ribs in one piece to increase structural strength. The nylon blocks can be removed later to form drainage ditches and a return platform on the chassis, avoiding subsequent secondary construction. The door template is open, which makes it easy for operators to enter the inner cavity of the inner mold from the outside to work, and also makes it easy for operators to enter and exit to observe the grouting situation. The door template is composed of four door corner molds and a vertical connecting template or a horizontal connecting template fixedly installed between two adjacent door corner molds. It is easy to disassemble and assemble, and easy to adjust the size.

[0024] The bottom grouting port is located on the inner bottom mid-plate, and grouting is performed from bottom to top, avoiding the problems of incomplete gas removal and uneven pouring caused by traditional top-down grouting, ensuring uniform pouring of the entire structure. During grouting, the grouting conditions can be observed from different sides through the observation port, allowing construction personnel to have a more comprehensive understanding of the pouring situation.

[0025] The positioning reinforcement steel beams not only enhance the overall structural strength of the inner and outer molds after installation, but also restrict and fix the relative position of the inner and outer molds, ensuring the consistency of the thickness of each side wall. They also facilitate the overall lifting of the inner mold, making one device multi-purpose. The adjustable support members can support the inner mold at different vertical positions to prevent mold expansion.

[0026] The three-sided operating platform can facilitate the operator's grouting operations and mold assembly and disassembly operations, and also make it easy for the operator to observe the grouting situation from the top.

[0027] This method can form a thin-walled concrete toilet structure with reinforcing ribs in one piece, eliminating the assembly process between the chassis and the wall panels, saving the cost of gluing the assembly nodes, greatly reducing the number of nodes that need to be controlled, and the wall panel thickness can be reduced to 1 cm, reducing the use of concrete materials, reducing the overall weight, and avoiding the high cost and large production area disadvantages of concrete toilets produced by mortise and tenon assembly. The use of one-piece casting solves the problem of high concrete strength requirements for the chassis and wall panel structures in the tensile and shear weak areas of the connection nodes of the mortise and tenon connection structure. At the same time, the strength of the thin-walled concrete toilet structure can be appropriately reduced. The civilized construction of the production plant will be greatly improved, and it is more suitable for the advantages of large-scale production on the assembly line. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 It is a schematic top view of the overall structure of the present invention;

[0030] Figure 3 This is a top view of the present invention without the operating platform installed;

[0031] Figure 4 This is a schematic diagram of the external vertical template structure of the present invention;

[0032] Figure 5 This is a partial structural diagram of the cross-shaped sliding bracket of the present invention in an installed state;

[0033] Figure 6 This is a schematic diagram of the positioning and reinforcement steel beam structure of the present invention;

[0034] Figure 7 Schematic diagram of the inner mold structure of the present invention;

[0035] Figure 8 AA cross-sectional schematic diagram of the present invention;

[0036] Figure 9 This is a schematic diagram of the door template structure of the present invention;

[0037] Figure 10 This is a schematic diagram of the vertical template structure in the present invention;

[0038] Figure 11 This is a schematic diagram of the inner bottom template structure of the present invention;

[0039] Figure 12 BB is a cross-sectional schematic diagram of the present invention;

[0040] Figure 13 Schematic top view of the inner bottom template structure of the present invention;

[0041] Figure 14 This is a bottom view schematic diagram of the inner bottom template structure of the present invention;

[0042] Figure 15 This is a schematic diagram of the structure of the adjustable support member of the present invention;

[0043] Figure 16 This is a schematic diagram of the outer bottom template structure of the present invention;

[0044] Figure 17 It is a front view schematic diagram of the overall structure of the present invention;

[0045] Figure 18 This is a schematic diagram of the connection node between the outer vertical formwork and the outer bottom formwork of the present invention;

[0046] Figure 19 This is a schematic diagram of the connection node of two adjacent outer vertical templates of the present invention;

[0047] Figure 20 This is a schematic diagram of the thin-walled concrete bathroom structure formed by pouring the present invention;

[0048] Figure 21 This is a cross-sectional schematic diagram of the thin-walled concrete toilet structure of the present invention in an installed state;

[0049] Figure 22 This is a schematic diagram of the mold assembly process of the present invention;

[0050] Figure 23 This is a schematic diagram of the mold removal process of the present invention;

[0051] Figure 24 This is an enlarged schematic diagram of a partial cross-section of the pouring state of the reserved hole for electromechanical pipelines of the present invention;

[0052] Figure: 1. External formwork; 2. Internal formwork; 3. Cross-shaped sliding bracket; 4. Doorway formwork; 5. Positioning and reinforcement steel beam; 6. Adjustable support; 7. Cavity mold; 8. Bottom grouting port; 9. Observation port; 10. External bottom formwork; 11. External vertical formwork; 12. External special formwork; 13. Operating platform; 14. Stairs; 15. Nylon block; 16. Thin-walled concrete bathroom structure; 20. Internal bottom formwork; 21. Internal vertical formwork; 30. Slide; 31. Reinforcement bracket; 32. Pulley; 40. Door corner formwork; 41. Vertical connection formwork Plate; 42. Horizontal connecting formwork; 43. Wedge-shaped connecting part; 44. Connecting plate; 50. First steel beam; 51. Second steel beam; 52. Connecting piece; 60. Threaded sleeve; 61. Adjusting screw; 62. Support seat; 160. Wall panel; 161. Vertical rib; 162. Chassis; 163. Horizontal rib; 164. Drainage ditch; 165. Water outlet; 166. Chassis upper return platform; 167. Nylon rod; 200. Inner bottom middle plate; 201. Inner bottom side plate; 210. Inner angle mold; 211. Inner connecting formwork; 212. Connecting inclined plate. DETAILED DESCRIPTION

[0053] The present invention will be further described below with reference to the accompanying drawings:

[0054] like Figures 1 to 19 The mold shown is for integrally forming a thin-walled concrete bathroom structure and includes an outer mold 1. The outer mold 1 comprises an outer bottom mold 10, three outer vertical molds 11 arranged vertically on the outside of the outer bottom mold 10, and an outer dedicated mold 12. The length of the outer dedicated mold 12 is the same as the length of the corresponding side of the outer bottom mold 10; the length of the outer vertical mold 11 is greater than the length of the corresponding side of the outer bottom mold 10. When the size of the outer mold 1 needs to be adjusted, only the outer bottom mold 10 and the outer dedicated mold 12 of the corresponding size need to be replaced. The three outer vertical molds 11 are universal. Sealing members are provided at the connection locations between the outer bottom mold 10, the outer dedicated mold 12, and the outer vertical mold 11 to seal the connection.

[0055] Specifically, the outer vertical formwork 11 is composed of a steel plate and stiffening ribs fixedly installed on the back of the steel plate in the vertical and horizontal directions. Bolt holes adjacent to the outer bottom formwork 10 are provided at the bottom of the steel plate, and multiple bolt holes are also provided on the stiffening ribs arranged circumferentially of the steel plate. Multiple triangular stiffening ribs are fixedly arranged between the top stiffening rib and the steel plate, and a lifting lug is fixedly installed above the top stiffening rib.

[0056] The outer bottom formwork 10 is composed of a steel plate and a channel steel or I-beam fixedly installed on the back of the steel plate. A connecting plate is fixedly arranged circumferentially at the bottom of the steel plate, and bolt holes are set on the connecting plate, which is adjacent to the outer vertical formwork 11 through high-strength bolts.

[0057] The outer special formwork 12 is composed of a steel plate and stiffening ribs fixedly installed on the back of the steel plate in the vertical and horizontal directions. Bolt holes adjacent to the outer bottom formwork 10 are provided at the bottom of the steel plate, and multiple bolt holes are also provided on the stiffening ribs arranged circumferentially of the steel plate. Multiple triangular stiffening ribs are fixed between the top stiffening rib and the steel plate, and a lifting lug is fixedly installed above the top stiffening rib.

[0058] The outer mold 1 is installed on the cross-shaped sliding bracket 3. Specifically, the outer bottom template 10 is fixedly installed on the cross-shaped sliding bracket 3 by welding. A plurality of slide grooves 30 are provided on the cross-shaped sliding bracket 3. A reinforcement bracket 31 is fixedly installed on the outer side of the outer vertical template 11 and the outer special template 12. A pulley 32 is installed at the bottom of the reinforcement bracket 31, and the pulley 32 is slidably installed in the slide groove 30. A group of pulleys 32 are respectively installed on both sides of the reinforcement bracket 31, so that the outer vertical template 11 or the outer special template 12 can slide stably. The cross-shaped sliding bracket 3 includes a steel frame arranged in a cross shape, a reinforced scissors support frame fixedly set on the steel frame, and a plurality of embedded plates set on the steel frame. The cross-shaped sliding bracket 3 is fixedly installed by the embedded plate.

[0059] An operating platform 13 is provided on the outside of the outer mold 1 by fasteners or welding. Specifically, an operating platform 13 is provided on each outer vertical template 11. A staircase 14 is provided on one side of the operating platform 13 opposite the outer special template 12. The user can climb up to the operating platform 13 via the staircase 14 to perform operations.

[0060] An inner mold 2 is installed inside the outer mold 1, and a casting cavity with a top opening is formed between the outer mold 1 and the inner mold 2. Concrete is poured into the casting cavity to form a wall concrete bathroom structure. Figure 2 As shown, the shaded area between the outer mold 1 and the inner mold 2 is the forming range of the thin-walled concrete bathroom structure. Figure 3 In the figure, the direction of the arrow is the direction of the finished thin-walled concrete bathroom structure being demoulded.

[0061] The inner formwork 2 includes an inner bottom formwork 20 and four inner vertical formworks 21 fixedly installed on the top of the inner bottom formwork 20 by high-strength bolts. Sealing members are provided at the connection between the inner bottom formwork 20 and the inner vertical formworks 21 and at the connection between two adjacent inner vertical formworks 21 to seal the connection. The inner bottom formwork 20 includes an inner bottom middle plate 200 and a plurality of inner bottom side plates 201 fixedly installed on the outer circumference of the inner bottom middle plate 200. Specifically, six inner bottom side plates 200 are provided, and two adjacent inner bottom side plates 200 are connected by an inner bottom inclined plate. This increases the area of ​​the connection surface and can also reduce the disturbance to the thin-walled concrete bathroom chassis during demolition, and reduce the impact of cracking on the thin-walled concrete bathroom chassis during the demoulding process.

[0062] The inner vertical formwork 21 includes inner corner forms 210 provided at the four corners of the rectangle and an inner connecting formwork 211 fixedly installed between two adjacent inner corner forms 210. A connecting inclined plate 212 is provided at the portion where the inner connecting formwork 211 and the inner corner formwork 210 are connected. Since the wall panels of thin-walled bathrooms are relatively thin, the use of the connecting inclined plate 212 can reduce the impact of cracking on the thin-walled concrete bathroom wall panels during the demolding process. The friction stress of demolding when using the connecting inclined plate 212 is much lower than the friction stress of using a straight plate connection. When demolding, the inner connecting formwork 211 is removed first, followed by the inner corner formwork 210. By demolding in this order, the connecting friction stress of the two adjacent inner vertical formworks 21 will minimize the disturbance effect on the thin-walled wall panels.

[0063] Nylon blocks 15 are installed on the outside of the inner bottom side plate 201. The width of the nylon blocks 15 is smaller than the thickness of the inner bottom template 20. After the nylon blocks 15 are removed, drainage ditches or decorative surface installation platforms can be formed to avoid subsequent secondary construction.

[0064] Multiple cavity molds 7 are mounted on the inner vertical formwork 21. The gaps between adjacent cavity molds form horizontal and vertical ribs, which increase the structural strength of the wall panel. Space for internal piping is reserved within the cavities formed by the cavity molds 7. The cavity molds 7 are made of a thin plastic shell and are bolted to the inner vertical formwork 21 for easy removal.

[0065] Door openings corresponding to the positions are provided on the outer special template 12 and the inner template 2. The doorway template 4 can be detachably installed at the doorway by bolts. The doorway template 4 has a hollow open structure. The inner cavity of the inner mold 2 can be entered through the doorway and the doorway template 4, which is convenient for operators to enter the inner cavity of the inner mold 2 from the outside to operate. The fixedly installed doorway template 4 can form a bathroom doorway in one piece, avoiding subsequent doorway cutting operations.

[0066] The doorway formwork 4 comprises door corner forms 40 arranged at the four corners of the rectangle, and vertical connecting forms 41 or horizontal connecting forms 42 fixedly mounted between adjacent door corner forms 40. Wedge-shaped connecting portions 43 are provided at the ends of each of the vertical connecting forms 41 and 42, and connecting plates 44 are provided at the ends of the door corner forms 40. These connecting plates 44 are detachably connected to the corresponding wedge-shaped connecting portions 43 via bolts, facilitating assembly and disassembly. The door corner forms 40 are connected to the vertical connecting forms 41 or 42 at an angle to prevent disturbance of the siding during demolding, reducing the risk of damage.

[0067] A bottom grouting port 8 is provided on the inner bottom middle plate 200, and an observation port 9 is provided on the outer vertical formwork 11. Grouting equipment is used to inject grout from bottom to top through the bottom grouting port 8 to form the thin-walled concrete bathroom structure. This bottom-up grouting method avoids the problems of incomplete gas removal and uneven pouring caused by traditional top-down grouting, ensuring uniform pouring of the entire structure. During grouting, the observation port 9 allows the grouting conditions to be observed from different sides, allowing construction personnel to have a more comprehensive understanding of the pouring process.

[0068] Removably mounted on the tops of the outer and inner molds 1 and 2 are positioning and reinforcement steel beams 5, which are bolted. These beams 5 comprise two first beams 50 spaced parallel to each other and two second beams 51 perpendicular to the first beams 50. Connectors 52 are fixedly mounted at the bottoms of both ends of the first and second beams 50, 51. These connectors 52 are bolted to the tops of the outer and inner molds 1 and 2. These positioning and reinforcement steel beams 5 not only strengthen the overall structural strength of the installed inner and outer molds 2 and 1, but also restrict and fix the relative position between the two, ensuring the consistency of thickness of the four wall panels. Furthermore, they facilitate the overall hoisting of the inner mold 2.

[0069] A plurality of adjustable support members 6 are installed inside the inner mold 2, and the inner mold 2 is supported at different vertical positions by the adjustable support members 6 to prevent the mold from expanding. The adjustable support member 6 includes a threaded sleeve 60, two adjusting screws 61 installed at both ends of the threaded sleeve 60 by threads, and a support seat 62 installed at the end of the adjusting screw 61. The support seat 62 is fixed to the inside of the inner mold 2 by bolts or welding, and the threads at both ends of the threaded sleeve 60 have opposite rotation directions. When adjusting, the threaded sleeve 60 is rotated so that the two adjusting screws 61 extend or retract synchronously. A nut is installed on the adjusting screw 61. After the threaded sleeve 60 is adjusted to achieve the reinforcement operation, the threaded sleeve 60 and the adjusting screw 61 are fixed by the nut to ensure the stability of the support reinforcement.

[0070] like Figures 1 to 23 The method for producing a mold for integrally forming a thin-walled concrete bathroom structure shown in the figure comprises the following steps:

[0071] Step 1: Foundation preparation: Level the ground in the installation area where the mold is located. After leveling, the surface flatness deviation should not exceed 1mm. Then, hoist the cross-shaped sliding bracket 3 on the installation area and fix it with expansion bolts.

[0072] Step 2: Assemble the mold. Hang the outer bottom template 10 at the top center position of the cross-shaped sliding bracket 3. Adjust the position of the outer bottom template 10 through the measuring instrument to ensure that the outer bottom template 10 is located at the top center position of the cross-shaped sliding bracket 3. After the adjustment is completed, fix it by welding.

[0073] The inner mold 2 is assembled simultaneously, with the four inner vertical molds 21 fixed to the top of the inner bottom mold 20, and the joints sealed with sealing strips. A reinforcement steel beam 5 is installed on top of the inner vertical molds 21 using high-strength bolts. Adjustable supports 6 are then installed within the inner cavity of the inner mold 2 to provide internal support.

[0074] Nylon blocks 15 are bolted to the outer bottom of the inner mold 2. Doorway forms 4 and multiple cavity molds 7 are installed on the outer side of the inner mold 2, and the joints are sealed with sealing strips. After installation, the inner mold 2 is hoisted entirely above the outer bottom form 10 using lifting equipment, positioning and reinforcing steel beams 5. This height is higher than the casting position to facilitate mold closing.

[0075] The outer vertical formwork 11 and the outer special formwork 12 are slidably installed on the cross-shaped sliding bracket 3 via the pulley 32. The outer vertical formwork 11 and the outer special formwork 12 are slid to the edge of the outer bottom formwork 10 and fixed with high-strength bolts. The connection position is sealed with sealing strips to complete the installation of the outer formwork 1. The positioning reinforcement steel beam 5 is then fixedly connected to the top of the outer formwork 1 to complete the mold closing.

[0076] Step three, casting and forming, grouting is performed in the casting cavity through the bottom grouting port 8. During the grouting, the grouting condition is observed through the observation port 9 and the top opening of the casting space. After the grouting is completed, a thin-walled concrete bathroom structure 16 is formed.

[0077] Step 4: Mold removal: After the thin-walled concrete bathroom structure 16 reaches the designed strength, the mold is removed. First, remove the top bolts connecting the positioning reinforcement steel beam 5 to the outer mold 1, enter the inner cavity of the inner mold 2 through the door template 4, and remove the adjustable support 6.

[0078] Then remove the connecting bolts of the inner mold 2, outer mold 1 and door template 4 at the same time. When removing, first remove the vertical connecting template 41, horizontal connecting template and inner connecting template 211, and then remove the door corner mold 40 and inner corner mold 210.

[0079] Then, the outer vertical formwork 11 and outer dedicated formwork 12 are slid outward, the inner bottom formwork 20, cavity mold 7, and nylon block 15 are removed, and the thin-walled concrete bathroom structure 16 is transported to the designated location. The removed molds are cleaned and maintained. Once one thin-walled concrete bathroom structure 16 is poured, the above steps are repeated for the next thin-walled concrete bathroom structure 16.

[0080] like Figure 20 and Figure 21The product formed by a production method shown is a thin-walled concrete toilet structure 16. The thin-walled concrete toilet structure 16 includes a base 162, four wall panels 160 integrally arranged circumferentially above the base 162, vertical ribs 161 integrally arranged on the outer sides of the wall panels 160, transverse ribs 163 integrally arranged on the outer sides of the wall panels 160, drainage ditches 164 provided on the base 162, water outlets 165 provided within the drainage ditches 164, and a base return platform 166 provided on the base 162. The water outlet 165 is provided on the side of the base to communicate with the outside for draining water. The transverse ribs 163 are integrally connected to the vertical ribs 161, and corner ribs are provided at the corners of two adjacent wall panels 160.

[0081] The reserved holes for electromechanical pipelines on the wall panel 160 are fixed to the outer vertical template 11 with nylon rods 167 by bolts before the outer vertical template 11 is closed. Figure 24 shown.

[0082] The above embodiments are merely some explanations of the concept and implementation of the present invention, and are not intended to limit the same. Under the concept of the present invention, technical solutions that have not been substantially changed are still within the scope of protection.

Claims

1. A mold for integrally forming a thin-walled concrete bathroom structure, comprising an outer mold and an inner mold disposed within the outer mold, wherein a casting cavity with an open top is formed between the outer mold and the inner mold, characterized in that: The outer formwork is installed on a cross-shaped sliding bracket; the outer formwork includes an outer bottom formwork, three outer vertical formworks vertically arranged on the outside of the outer bottom formwork and an outer special formwork, and the outer bottom formwork is fixedly installed on the cross-shaped sliding bracket; door openings corresponding to the positions are set on the outer special formwork and the inner formwork, and the doorway formwork is detachably installed at the door opening, and the inner cavity of the inner formwork can be entered through the door opening; positioning and reinforcement steel beams are detachably installed on the top of the outer formwork and the inner formwork; multiple adjustable support members are installed inside the inner formwork; the inner formwork includes an inner bottom formwork and four inner vertical formworks fixedly installed on the top of the inner bottom formwork, and the inner bottom formwork includes an inner bottom middle plate and multiple inner bottom edge plates installed on the outer circumference of the inner bottom middle plate; multiple cavity molds are installed on the inner vertical formwork, and the gap between two adjacent cavity molds forms a reinforcing rib; a bottom grouting port is set on the inner bottom middle plate, and an observation port is set on the outer vertical formwork; a thin-walled concrete bathroom structure is formed by grouting from bottom to top through the bottom grouting port; The doorway template includes door corner templates arranged at the four corners of a rectangle and a vertical connecting template or a horizontal connecting template fixedly installed between two adjacent door corner templates; wedge-shaped connecting parts are provided at the ends of the vertical connecting template and the horizontal connecting template, and connecting plates are provided at the ends of the door corner templates, and the connecting plates are detachably connected to the corresponding wedge-shaped connecting parts; The positioning and reinforcement steel beams include two first steel beams arranged in parallel and spaced apart and two second steel beams arranged perpendicular to the first steel beams. Connectors are fixedly installed at the bottoms of both ends of the first steel beams and the second steel beams, and the connectors are connected to the tops of the outer mold and the inner mold. The inner vertical template includes inner corner templates arranged at the four corners of the rectangle and an inner connecting template fixedly installed between two adjacent inner corner templates. A connecting inclined plate is arranged at the position where the inner connecting template and the inner corner template are connected.

2. The mold for integrally forming a thin-walled concrete bathroom structure according to claim 1, characterized in that: A slide groove is provided on the cross-shaped sliding bracket; a reinforcement bracket is fixedly installed on the outer side of the outer vertical template and the outer special template, a pulley is installed at the bottom of the reinforcement bracket, and the pulley is slidably installed in the slide groove.

3. The mold for integrally forming a thin-walled concrete bathroom structure according to claim 1 or 2, characterized in that: The length of the outer dedicated template is the same as the length of the side corresponding to the outer bottom template; the length of the outer vertical template is greater than the length of the side corresponding to the outer bottom template.

4. The mold for integrally forming a thin-walled concrete bathroom structure according to claim 3, characterized in that: The adjustable support member includes a threaded sleeve, two adjusting screws installed at both ends of the threaded sleeve through threads, and a support seat installed at the ends of the adjusting screws. The support seat is fixedly installed inside the inner mold; the threads at both ends of the threaded sleeve have opposite rotation directions.

5. The mold for integrally forming a thin-walled concrete bathroom structure according to claim 4, characterized in that: Nylon blocks are installed on the outer sides of the inner bottom side plates; six inner bottom side plates are provided, and two adjacent inner bottom side plates are connected via inner bottom inclined plates.

6. The mold for integrally forming a thin-walled concrete bathroom structure according to claim 1, 2, 4 or 5, characterized in that: An operating platform is provided on the outer side of the outer mold, and a staircase is provided on one side of the operating platform.

7. A method for producing a mold for integrally forming a thin-walled concrete bathroom structure according to any one of claims 1 to 6, characterized in that: The production method comprises the following steps, Step 1: Prepare the foundation. Level the ground in the mold installation area. Ensure the surface flatness deviation is no more than 1mm. Then, hoist the cross-shaped sliding bracket onto the installation area and secure it with expansion bolts. Step 2: Assemble the mold. Fix the outer bottom template at the top center of the cross-shaped sliding bracket; assemble the inner mold simultaneously, fix the four inner vertical templates on the top of the inner bottom template, install the positioning reinforcement steel beam on the top of the inner vertical template, and then install the adjustable support in the inner cavity of the inner mold to provide internal support for the inner mold; install nylon blocks on the outer bottom of the inner mold; install the door template and multiple cavity molds on the outer side of the inner mold. After the installation is completed, use the lifting equipment to lift the inner mold as a whole to the top of the outer bottom template through the positioning reinforcement steel beam; slide the outer vertical template and the outer special template on the cross-shaped sliding bracket, slide the outer vertical template and the outer special template to the edge of the outer bottom template and fix them to complete the installation of the outer mold; then fix the positioning reinforcement steel beam to the top of the outer mold; Step 3: Casting and forming. Grouting is performed in the casting cavity through the bottom grouting port. The grouting condition is observed through the observation port and the top opening during grouting. After the grouting is completed, a thin-walled concrete bathroom structure is formed. Step 4: Mould removal. After the thin-walled concrete bathroom structure reaches the designed strength, the mould is removed. First, remove the top connection bolts between the positioning reinforcement steel beam and the outer mould, and remove the adjustable support. Then, remove the inner mould, outer mould and door mould at the same time, and then slide the outer vertical mould and the outer special mould outward. Remove the inner bottom mould and cavity mould, and transport the thin-walled concrete bathroom structure to the designated location. Clean and maintain the removed mould.

8. A product formed by the production method according to claim 7, characterized in that: The product is a thin-walled concrete bathroom structure, which includes a chassis, four wall panels integrally arranged on the upper circumference of the chassis, vertical ribs integrally arranged on the wall panels, transverse ribs integrally arranged on the wall panels, drainage ditches arranged on the chassis, water outlets arranged in the drainage ditches and a chassis return platform arranged on the chassis. The water outlet is arranged on the side of the chassis and connected to the outside, and several electromechanical pipeline holes are reserved on the upper part of the wall panels to connect to external pipelines.

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