Impact-resistant transparent special-shaped cast-in-place structure shaping mold

Abstract

The invention relates to the technical field of building construction, and provides an anti-impact transparent special-shaped cast-in-place structure shaping mold. In the mold, an inner-layer base plate and an outer-layer base plate are arranged in parallel, a bonding layer is arranged between the inner-layer base plate and the outer-layer base plate, the bonding layer is attached to the inner-layer base plate and the outer-layer base plate through transparent synthetic glue, the inner-layer base plate and the outer-layer base plate are both made of transparent materials, and a middle layer is a prestress braid layer coated with an epoxy coating. Therefore, the prestressed braid layer coated with the epoxy coating is adhered to the double surfaces of the inner-layer base plate and the outer-layer base plate to form a transparent integral mold, so that common quality problems such as honeycombs, pitted surfaces and rotten roots on the surface of concrete can be observed in real time in the concrete pouring construction process, and measures can be conveniently taken in time to solve the common quality problems; and meanwhile, the overall structural strength of the mold is effectively enhanced through the prestress braid layer, the forming quality in the concrete pouring process can be guaranteed, and the mold erecting efficiency is effectively improved.

Description

Technical Field

[0001] This application relates to the field of building construction technology, and in particular to a shaping mold for impact-resistant transparent irregular-shaped cast-in-place structures. Background Technology

[0002] In current construction, traditional formwork is complex to assemble, time-consuming, and leads to excessive consumption of manpower and resources. Furthermore, traditional formwork cannot provide real-time monitoring of concrete pouring quality or allow for targeted repairs during construction. These problems not only affect construction efficiency but can also lead to common quality defects on the concrete surface such as honeycomb, pitting, and root defects. Therefore, there is an urgent need for a technical solution that addresses the shortcomings of existing technologies. Summary of the Invention

[0003] The purpose of this application is to provide an impact-resistant, transparent, irregularly shaped cast-in-place structure molding die to solve or alleviate the problems existing in the prior art.

[0004] To achieve the above objectives, this application provides the following technical solution: This application provides an impact-resistant transparent irregular-shaped cast-in-place structure shaping mold, comprising: an inner substrate, an outer substrate, and an intermediate layer; the inner substrate and the outer substrate are arranged in parallel, the intermediate layer is located between the inner substrate and the outer substrate, and is bonded to the inner substrate and the outer substrate by a transparent synthetic adhesive; both the inner substrate and the outer substrate are made of transparent material, and the intermediate layer is a prestressed braided layer coated with an epoxy coating.

[0005] Preferably, the transparent synthetic adhesive is a transparent weather-resistant adhesive and contains steel fibers.

[0006] Preferably, the transparent synthetic adhesive is an AB-component acrylic structural adhesive, and the ratio of component A, component B and the steel fiber in the transparent synthetic adhesive is 20:2:1; the steel fiber is 20 mm long and 0.3 mm in diameter.

[0007] Preferably, the thickness of the inner substrate is not less than 6 mm, the thickness of the outer substrate is less than the thickness of the inner substrate and not less than 4 mm, and the thickness of the intermediate layer is not less than 3 mm.

[0008] Preferably, the prestressed braided layer of the intermediate layer is It is woven from tensioned steel strands, among which, It is a positive integer.

[0009] Preferably, each of the steel strands is provided with multiple anti-deformation blocking pins.

[0010] Preferably, each of the steel strands is provided with prestressed anchors at both ends for adjusting the tension stress of the steel strands.

[0011] Preferably, it further includes: a mounting frame, wherein the mounting frame is provided with a lock mounting hole and a substrate mounting groove, the lock mounting hole is used to install the prestressed anchor, and the substrate mounting groove is used to install the inner substrate and the outer substrate.

[0012] Preferably, the mounting frame is a snap-fit ​​assembly structure, and the lock mounting hole and the base plate mounting groove are provided at the snap-fit ​​joint surface; an adjustment through hole communicating with the lock mounting hole is provided on the outer side wall of the mounting frame, so as to adjust the tensioning prestress of the prestressed anchor on the steel strand through the adjustment through hole; a flared pull hole is also provided on the inner side wall of the mounting frame, and the pull hole communicates with the lock mounting hole. Preferably, the intermediate layer is bonded to the inner substrate and the outer substrate by a transparent synthetic adhesive. The bonding process should be carried out in an ambient temperature and 50% humidity environment for at least 72 hours.

[0013] Beneficial effects: In the impact-resistant transparent irregular-shaped cast-in-place structure mold provided in this application embodiment, the inner substrate and the outer substrate are arranged side by side in parallel. An adhesive layer is arranged between the inner substrate and the outer substrate. The adhesive layer is bonded to the inner substrate and the outer substrate with transparent synthetic adhesive. Both the inner substrate and the outer substrate are made of transparent material, and the middle layer is a prestressed braided layer coated with epoxy. Thus, by bonding the epoxy-coated prestressed braided layer to both the inner substrate and the outer substrate on both sides, a transparent integral mold is formed. This allows for real-time observation of common quality defects such as honeycomb, pitting, and rotten roots on the concrete surface during concrete pouring, facilitating timely intervention and improving concrete pouring quality and construction efficiency. Simultaneously, the prestressed braided layer effectively enhances the overall structural strength of the mold, ensuring not only the forming quality during concrete pouring but also significantly improving formwork efficiency. Attached Figure Description

[0014] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. Wherein: Figure 1 This is a schematic diagram of a shaping mold for an impact-resistant, transparent, irregularly shaped cast-in-place structure according to an embodiment of this application; Figure 2 for Figure 1 The diagram shown is a schematic representation of the assembly of the inner substrate and the prestressed braided layer in the embodiment shown. Figure 3 This is a structural schematic diagram of a shaping mold for an impact-resistant transparent irregular-shaped cast-in-place structure according to another embodiment of this application; Figure 4 for Figure 3 A schematic diagram of the assembly of the half-frame and the prestressed anchor in the embodiment shown; Figure 5 for Figure 3 The schematic diagram of the half-frame structure in the embodiment shown; Figure 6 This is an exploded view of a prestressed anchorage provided according to some embodiments of this application; Figure 7 for Figure 6 The diagram shows the assembly of the prestressed anchorage. Figure 8 for Figure 6 A sectional view of the prestressed anchor shown; Figure 9 This is a schematic diagram of the structure of an anti-deformation blocking pin provided according to some embodiments of this application; Figure 10 for Figure 9 The diagram shows a partial structural diagram of the interlocking anti-deformation blocking pins. Figure 11 for Figure 9 The diagram shows another part of the structure of the anti-deformation blocking pins in mutual cooperation.

[0015] Explanation of reference numerals in the attached figures: 100. Prestressed anchorage; 200. Installation frame; 101. Outer base; 102. Connecting seat; 103. Tie body; 104. Tightening pin; 201. Lock mounting hole; 202. Adjustment through hole; 203. Filling hole; 204. Pull wire hole; 205. Base plate mounting groove. Detailed Implementation

[0016] The present application will now be described in detail with reference to the accompanying drawings and embodiments. Various examples are provided by way of explanation and not by way of limitation. In fact, those skilled in the art will understand that modifications and variations can be made to the present application without departing from the scope or spirit of the present application. For example, a feature shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention should fall within the scope of protection of the embodiments of the present invention.

[0017] To address the challenges of complex mold assembly and the inability to address real-time, targeted repairs of pouring quality issues arising during traditional formwork construction, this application proposes an impact-resistant, transparent, irregularly shaped cast-in-place structure mold. The inner and outer layers utilize impact-resistant polycarbonate sheets as substrates, while the middle layer is a prestressed woven layer coated with an epoxy layer. Both sides are bonded and solidified using transparent synthetic adhesive to form a transparent, integrated structure. This, combined with the steel frame's outer keel and assembly pins, enables rapid assembly. Furthermore, during pouring, the concrete surface can be observed in real-time for issues such as honeycombing, pitting, and root defects. The prestressed woven layer effectively enhances the overall structural strength of the mold, ensuring not only the quality of concrete pouring but also significantly improving formwork efficiency.

[0018] like Figures 1 to 7 As shown, in this impact-resistant transparent irregular-shaped cast-in-place structure forming mold, the inner substrate and the outer substrate are arranged side by side and are both made of transparent material. The thickness of the inner substrate is not less than 6 mm, and the thickness of the outer substrate is less than the thickness of the inner substrate, but not less than 4 mm. Specifically, both the inner and outer substrates are made of transparent impact-resistant polycarbonate sheets to allow for real-time observation of common quality defects such as honeycomb and pitting during concrete pouring, enabling timely adjustments and treatments to ensure the forming quality of the concrete surface.

[0019] A prestressed braided layer coated with an epoxy layer is disposed between the inner and outer substrates. The intermediate layer has a thickness of not less than 3 mm and contains a prestressed steel strand braided mesh; that is, the prestressed braided layer of the intermediate layer is… ( It is woven from (positive integer) tensioned steel strands, with multiple anti-deformation blocking pins evenly distributed on each hot-dip galvanized steel strand.

[0020] Specifically, 1.2 mm hot-dip galvanized steel strands are arranged in a crisscross pattern, with a uniform spacing of 20 mm, and the hot-dip galvanized steel strands are subjected to a 75% tension load. This effectively enhances the overall structural strength of the mold. After the inner substrate withstands the impact force from the concrete, the impact force is transferred to the middle layer, where the steel strand mesh further disperses the impact force, effectively improving the overall impact resistance of the mold.

[0021] Multiple anti-deformation blocking pins are evenly distributed on the hot-dip galvanized steel strands to ensure the strands are positioned between the inner and outer substrates, preventing potential twisting or tangling. Each anti-deformation blocking pin is a columnar structure with a through-hole in its central radial direction; it can be integrally formed or a modular assembly. In the modular assembly type, the two mating parts are threaded together, and symmetrical semi-circular holes are provided at the connection points to form the through-holes.

[0022] In another specific example, the edges of both the inner and outer substrates are provided with... The tensioned steel strand is compatible with A prestressed anchor 100. The prestressed anchor 100 includes: an outer base 101, a connecting seat 102, a tie body 103, and a tightening pin 104; wherein, the outer base 101 is located in the tie mounting holes provided on the circumferential sidewalls of the inner and outer substrates, and the outer base 101 has an internally threaded blind hole along the axial direction; the connecting seat 102 is a barrel-shaped structure with an open top, and an external connecting thread adapted to the internally threaded blind hole of the outer base 101 is provided on its outer sidewall; the outer base 101 and the connecting seat 102 are threadedly connected through the internally threaded blind hole and the external connecting thread. Specifically, a tightening slot is provided radially downward at the open end of the barrel-shaped structure of the connecting seat 102, so that a tightening tool can be inserted into the tightening slot to thread-tighten the connecting seat 102 and the outer base 101.

[0023] The tie-up body 103 is a cylindrical structure that slides axially within the barrel-shaped structure of the connecting seat 102. A tightening threaded hole is radially provided in the center of the tie-up body 103, and a tightening pin 104 is threaded into the tightening threaded hole. Here, coaxial prestressing threaded holes are provided on the outer base 101, connecting seat 102, and tie-up body 103, and the tightening threaded hole of the tie-up body 103 extends to the prestressing threaded hole. Thus, after the end of the hot-dip galvanized steel strand passes sequentially through the prestressing threaded holes on the outer base 101, connecting seat 102, and tie-up body 103 from the lower part of the outer base 101, a 75% tension load is applied to the hot-dip galvanized steel strand, and the tightening pin 104 in the tightening threaded hole is tightened, causing the end of the tightening pin 104 to press against the hot-dip galvanized steel strand in the prestressing threaded hole.

[0024] In one specific embodiment, the inner and outer substrates are provided with tie-in grooves that are adapted to and directly opposite the outer base 101. The tie-in grooves on the inner and outer substrates together form the tie-in mounting groove of the outer base 101. After the end of the top-tightening pin 104 presses the hot-dip galvanized steel strand in the prestressed wire hole, the prestressed anchor 100 is placed into the tie-in mounting groove. After the prestressed anchor 100 is placed into the tie-in mounting groove, the steel strand stretched in the prestressed braided layer is cut along the edges of the inner and outer substrates, so that the steel strand shrinks into the prestressed anchor 100. At the same time, it is ensured that the end face of the prestressed anchor 100 does not exceed the end face of the inner and outer substrates to ensure that the edge of the mold is smooth.

[0025] After the prestressed anchor 100 is placed into the tie-in installation groove, a transparent weather-resistant adhesive mixed with steel fibers is poured inward from the edges of the inner and outer substrates. The transparent synthetic adhesive then covers the steel strand mesh and simultaneously bonds it to the inner and outer substrates, ensuring proper adhesion. The inner substrate, outer substrate and prestressed braided layer are bonded and solidified to form a whole in an ambient temperature and 50% humidity environment for at least 72 hours.

[0026] It should be noted that before the inner and outer substrates are fitted with the steel strand braiding mesh, each steel strand in the mesh is coated with an epoxy coating. First, the steel strands undergo deep cleaning treatment to ensure a surface cleanliness of over 95% and the absence of chlorides, with a surface roughness of 0.04~0.10. Then, an epoxy coating (resin powder applied via electrostatic spraying) is applied to the cleaned steel strand surface, with the interval between the deep cleaning treatment and the epoxy coating application not exceeding 3 hours. After the epoxy coating is applied, the steel strand surface must not show any oxidation. Finally, the epoxy coating is cured using medium-frequency heating, and after water cooling, the cores are stranded together using a splitter to form a steel strand with the epoxy coating. The thickness of the epoxy coating on the steel strand surface is 120μm~200μm. This effectively ensures that the epoxy coating adheres uniformly and firmly to the steel strand, providing excellent corrosion protection.

[0027] In another specific example, the prestressed anchor 100, the inner substrate, and the outer substrate are all installed within the mounting frame 200. The mounting frame has a locking mounting hole 201 and a substrate mounting groove 205. The prestressed anchor 100 is installed in the locking mounting hole 201, and the inner and outer substrates are installed in the substrate mounting groove 205. Here, the mounting frame 200 adopts a snap-fit ​​assembly structure, that is, it is formed by combining two interlocking half-frames. The locking mounting hole 201 and the substrate mounting groove are provided at the snap-fit ​​joint surface of the mounting frame 200. An adjustment through hole 202 communicating with the locking mounting hole 201 is provided on the outer wall of the mounting frame 200, allowing adjustment of the prestress of the prestressed anchor 100 on the steel strand. A trumpet-shaped pull hole 204 communicating with the locking mounting hole 201 is also provided on the inner wall of the mounting frame 200.

[0028] In other words, a lock mounting hole 201 and a base plate mounting groove are provided on the interlocking surface of the half frame. During the installation process, the inner base plate (or outer base plate) is first placed in the base plate mounting groove of the half frame. Then, the prestressed anchor 100 is placed in the lock mounting hole 201 of the half frame. Steel strands are then threaded through the two corresponding prestressed anchors 100 on both sides of the half frame, and the hot-dip galvanized steel strands in the prestressed wire hole are pressed by pressing the end of the top pin 104.

[0029] Next, the outer base layer (or the corresponding inner base layer) is installed in the base plate mounting groove 205 of the other half frame, and is then snapped together with the half frame on which the prestressed lock is installed. The two half frames are then pressed together by the bolt group connecting them to form the mounting frame 200. Then, a tightening tool is passed through the adjustment through hole 202 provided on the outer wall of the mounting frame 200 and inserted into the tightening slot provided on the connecting seat 102 of the prestressed lock in the lock mounting hole 201. The connecting seat 102 is rotated using the tightening tool, causing it to rotate outward relative to the outer base 101 along the axial direction of the adjustment through hole 202, thereby adjusting the tension prestress of the corresponding steel strand.

[0030] In this embodiment, an injection hole 203 is also provided on the outer wall of the mounting frame 200, and the injection hole 203 is located between the inner substrate and the outer substrate. After the inner substrate, the outer substrate, and the prestressed anchor 100 are installed on the mounting frame 200, a transparent weather-resistant adhesive mixed with steel fibers is injected into the space between the inner substrate and the outer substrate through the injection hole 203. The transparent synthetic adhesive covers the steel strand braided mesh and simultaneously adheres it to the inner substrate and the outer substrate, ensuring that... The inner substrate, outer substrate and prestressed braided layer are bonded and solidified to form a whole in an ambient temperature and 50% humidity environment for at least 72 hours.

[0031] In this application, the prestressed braided layer is double-sided bonded to the inner and outer substrates using a transparent synthetic adhesive. The transparent synthetic adhesive is a transparent, weather-resistant adhesive incorporating steel fibers. Specifically, the transparent synthetic adhesive is an AB-component acrylic structural adhesive, with the volume ratio of component A, component B, and steel fibers in the transparent synthetic adhesive being 20:2:1. The steel fibers are 20 mm long and 0.3 mm in diameter.

[0032] In a specific example, the inner substrate is a polycarbonate sheet with a thickness of not less than 6 mm, and the outer substrate is a polycarbonate sheet with a thickness not less than that of the inner substrate. The inner and outer substrates are connected by SS811 deketoxime type transparent weather-resistant adhesive mixed with fibers. Tie grooves with an equal number of hot-dip galvanized steel strands are left on the four sides of the inner and outer substrates and in the prestressed steel strand braided mesh to maintain the tension of the hot-dip galvanized steel strands and ensure that the prestressed steel strand braided mesh is evenly distributed and firmly fixed.

[0033] A transparent, limiting synthetic adhesive is used to bond the double-sided polycarbonate sheets together, ensuring that... After bonding for at least 72 hours at an ambient temperature and 50% humidity, the slab and prestressed steel strands are bonded and solidified to form an integral structure. The tensioned prestressed steel strands are cut along the edge of the slab, and the strands are shrunken to be fixed in the prestressed anchors 100mm apart. The edges are then sealed with waterproof welding adhesive (a mixture of silicone adhesive and oil-based AB adhesive with 6% waterproof powder, in the following ratio: silicone adhesive: oil-based AB adhesive: waterproof powder = 65%: 29%: 6%).

[0034] During mold application, after mold installation, pressure sensors can be installed on the mold surface (outer surface of the outer substrate) at five points (four corners and center) without damaging the installation surface, so as to monitor the stress on the mold in real time during concrete pouring.

[0035] By bonding the prestressed woven layer coated with epoxy to both the inner and outer substrates, a transparent integral mold is formed. This allows for real-time monitoring of common quality defects such as honeycomb, pitting, and rotten roots on the concrete surface during the concrete pouring process. This facilitates timely intervention and reduces the occurrence of quality problems, lowers maintenance and rework costs, and improves concrete pouring quality and construction efficiency. At the same time, the prestressed woven layer effectively enhances the overall structural strength of the mold, ensuring not only the molding quality during concrete pouring but also significantly improving formwork efficiency.

[0036] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0038] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0039] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0040] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0041] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A shaping mold for impact-resistant transparent irregular-shaped cast-in-place structures, characterized in that, include: An inner substrate, an outer substrate, and an intermediate layer; the inner substrate and the outer substrate are arranged side by side in parallel, and the intermediate layer is located between the inner substrate and the outer substrate, and is bonded to the inner substrate and the outer substrate by a transparent synthetic adhesive; Both the inner and outer substrates are made of transparent material, and the intermediate layer is a prestressed braided layer coated with an epoxy coating.

2. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 1, characterized in that, The transparent synthetic adhesive is a transparent, weather-resistant adhesive and contains steel fibers.

3. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 1, characterized in that, The transparent synthetic adhesive is an AB component acrylic structural adhesive, and the ratio of component A, component B and steel fiber in the transparent synthetic adhesive is 20:2:

1. The steel fiber is 20 mm long and 0.3 mm in diameter.

4. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 1, characterized in that, The thickness of the inner substrate is not less than 6 mm, the thickness of the outer substrate is less than the thickness of the inner substrate and not less than 4 mm, and the thickness of the intermediate layer is not less than 3 mm.

5. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 1, characterized in that, The prestressed braided layer of the intermediate layer is woven from N tensioned steel strands, where N is a positive integer.

6. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 5, characterized in that, Each of the steel strands is evenly distributed with multiple anti-deformation blocking pins.

7. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 5, characterized in that, Each of the steel strands is provided with prestressed anchors at both ends for adjusting the tension stress of the steel strands.

8. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 7, characterized in that, Also includes: The mounting frame is provided with lock mounting holes and substrate mounting grooves. The lock mounting holes are used to install the prestressed anchors, and the substrate mounting grooves are used to install the inner substrate and the outer substrate.

9. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 8, characterized in that, The mounting frame is a snap-fit ​​assembly structure, and the lock mounting hole and the base plate mounting groove are provided at the snap-fit ​​mating surface. An adjustment through hole communicating with the lock mounting hole is provided on the outer side wall of the mounting frame, so as to adjust the tensioning prestress of the steel strand by the prestressed anchor through the adjustment through hole; The inner wall of the mounting frame is also provided with a flared pull cable hole, which is connected to the lock mounting hole.

10. The impact-resistant transparent irregular-shaped cast-in-place structure shaping mold according to claim 1, characterized in that, The intermediate layer is bonded to the inner substrate and the outer substrate by means of transparent synthetic adhesive in an environment of 25°C to 35°C and 50% humidity for at least 72 hours.

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