A prefabricated building pouring mold

Abstract

The present application provides a kind of prefabricated building pouring mold, for pouring the house unit with wall and roof.The mold includes inner mold component, outer mold component and top mold component, and the inner mold component and outer mold component define wall pouring chamber, and the top mold component defines top pouring chamber, and they are communicated to form closed pouring chamber.The top of wall pouring chamber has detachable upper forming plate, and is provided with exhaust hole and first mechanical connector.The mold is provided with grouting port below, and is connected with cement pouring pump by stop valve.The outer mold and inner mold component are spliced by modular components, and are connected to top mold component by inclined support rod, and the size of house unit can be changed by the adjustment frame of top mold component bottom frame.Horizontal pull rod increases the connection strength between outer mold component and inner mold component.The mold improves pouring precision and building performance, optimizes mold structure, enhances universality, controls pouring accurately, and is convenient to assemble and disassemble.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, specifically to a mold for casting prefabricated buildings, and more particularly to a mold structure and casting process for casting house units with walls and roofs, which has the advantages of high positioning accuracy, convenient assembly, and high structural strength. Background Technology

[0002] Prefabricated buildings, with their advantages of high construction efficiency, strong quality control, and outstanding environmental performance, have become the core direction of modern building industrialization. Among them, prefabricated modular concrete houses, as a key carrier for upgrading prefabricated buildings to high integration and fully industrialized manufacturing, have component molding quality and production efficiency that directly depend on the structural design accuracy and process adaptability of the mold system.

[0003] The current mainstream production process for prefabricated concrete modular houses faces the following technical bottlenecks:

[0004] (1) Defects of the prefabricated modular splicing method: The process of prefabricating the roof and wall panels separately and then casting them together results in a long process chain (requiring multiple stages such as independent prefabrication, positioning and assembly, and joint casting), high equipment investment costs, and long production cycles. More importantly, the cumulative dimensional error of the prefabricated modular components (usually ±5mm or more) requires remedial processes such as grouting sleeves or secondary formwork casting during splicing and positioning. This not only reduces construction efficiency but also creates structural weaknesses, affecting the overall seismic performance and airtightness of the building.

[0005] (2) Defects of the open-top casting process: The current mold adopts an open-top casting scheme, which lacks effective control over the concrete flow direction and venting path, resulting in significant dimensional deviations at the top of the components (measured flatness error > 3mm / m). This defect directly causes two major problems: ① The forming quality of the concave-convex connection positioning grooves on the roof or wall bottom is poor, the positioning is inaccurate, and the connection of steel bars is difficult, making it impossible to use high-efficiency precision mechanical connectors; ② Stepped joints are generated during component assembly, forcing the use of high-cost injection filling technology on site; ③ A redundant gap of more than 2cm needs to be reserved at the joint surface between the roof and the wall panel, which greatly reduces the structural force transmission efficiency. According to statistics, the rework rate caused by this is as high as 12%, which significantly weakens the cost advantage of industrialized construction.

[0006] (3) Structural defects of the mold system: The existing mold adopts a rigid connection of the outer mold frame and the integral inner mold combination design, which has three major contradictions: ① The modular expansion capability is weak, and the mold components need to be reconstructed when different house types are converted; ② The demolding process is time-consuming and the frequent disassembly and assembly leads to wear of the positioning pin holes; ③ There are nodes with sudden stiffness changes in the inner mold support system, which cause local mold expansion (deformation > 1.5mm) during the casting process, directly affecting the assembly tolerance of the wall panel joint surface.

[0007] The aforementioned technological bottlenecks overlap, forming an impossible triangle of "precision-efficiency-cost" that restricts the industry's development. Existing improvement solutions mostly focus on single problems but fail to overcome the fundamental contradictions in mold system design, resulting in a modular building application rate of less than 15% in high-rise buildings. Therefore, there is an urgent need for a new mold system with topology-optimized structure, innovative casting process, and rapid assembly characteristics to fundamentally reconstruct the industrial production paradigm of integrated concrete modular housing. Summary of the Invention

[0008] The purpose of this invention is to provide a mold for casting prefabricated buildings, so as to solve the problems of uneven cement slurry filling, complex assembly and disassembly, and poor versatility of existing molds when casting house units with walls and roofs, thereby improving the molding quality and production efficiency of house units and reducing production costs.

[0009] To achieve the above objectives, this application adopts the following technical solution:

[0010] The present invention provides a mold for casting prefabricated buildings, used for casting housing units having walls and roofs, comprising an inner mold assembly, an outer mold assembly, and a top mold assembly. A wall casting chamber for forming the walls is defined between the inner mold assembly and the outer mold assembly, and a top casting chamber for forming the roof is defined within the top mold assembly; the wall casting chamber and the top casting chamber are interconnected.

[0011] During the pouring operation, the top mold assembly is positioned on the operating platform with support. The inner mold assembly and the outer mold assembly are both arranged above the top mold assembly and extend upward from the edge area of ​​the top mold assembly. Furthermore, the top pouring chamber and the wall pouring chamber are combined to form a closed pouring chamber. The cement slurry gradually rises after filling the top pouring chamber until it fills the wall pouring chamber.

[0012] Furthermore, the top of the wall casting chamber has an upper molding plate adapted to form a predetermined shape on the bottom surface of the wall. The upper molding plate is fixed between the inner mold assembly and the outer mold assembly, and closes the top opening of the wall casting chamber. The top of the wall casting chamber is equipped with vent holes to allow gas to escape during the casting process and prevent air bubbles from remaining. The upper molding plate is detachably fitted with a first mechanical connector adapted to be embedded into the bottom of the wall. The predetermined shapes formed by the upper and lower molding plates can be mutually adapted for subsequent modular assembly of housing units.

[0013] The mold also includes a grouting port located below the mold, which is directly connected to the top grouting chamber. The grouting port is connected to a cement injection pump via a shut-off valve to precisely control the injection volume of cement grout. The shut-off valve is detachably fixed to the outer mold assembly or the top mold assembly so that it can be removed before the cement grout injected into the grouting chamber solidifies, preventing the valve from becoming stuck after the cement grout has solidified.

[0014] The outer mold assembly comprises multiple outer mold components laid along the outer wall surface. Adjacent outer mold components are joined together via tongue and groove joints, specifically L-shaped or other shaped joint designs. The outer mold components positioned at wall corners are first assembled into an outer mold frame for constructing the outer mold assembly. Then, outer mold components located within the wall's interior are filled into this frame to complete the outer mold assembly. The outer mold components positioned at wall corners are connected to the top mold assembly via diagonally arranged outer mold support rods. The bottom of each outer mold component is fixed to the top mold assembly.

[0015] The outer mold components are equipped with transparent observation ports to observe the flow of cement slurry and the height of the liquid level inside the mold. The injection speed of the cement injection pump and the opening of the shut-off valve are adjusted in a timely manner to accurately control the injection volume of cement slurry and avoid over- or under-injection.

[0016] The inner mold assembly has multiple inner mold components laid along the inner wall surface of the wall, with adjacent inner mold components joined together via inner mold tongue and groove joints. Inner mold components positioned at wall corners are connected by at least one corner brace, which spans the corner area and connects to two inner mold components at its two ends. The inner mold assembly is connected to the top mold assembly via multiple inner mold supports, which are arranged obliquely. The upper end of the inner mold assembly is fixed to the outer mold assembly via connecting members.

[0017] It also includes a plurality of horizontal tie rods passing through the outer mold tongue and the inner mold tongue in a horizontal direction. The horizontal tie rods are configured to lock the outer mold tongue and the inner mold tongue in a horizontal direction respectively, thereby increasing the overall connection strength of the outer mold assembly and the inner mold assembly. The portion of the horizontal tie rod located in the wall grouting chamber is sleeved in a tube to facilitate the separation of the horizontal tie rod within the cured wall.

[0018] The top mold assembly includes a base frame and a top frame, defining a top grouting chamber between the base frame and the top frame. The top frame is fixed to the inner mold assembly, and the base frame is fixed to the outer mold assembly. The top frame is fixed to the inner mold assembly via a connecting member, the surface of which on the grouting chamber side is configured as a transition surface, facilitating the flow of cement slurry and increasing the structural strength of the structure. The base frame includes a support frame and an adjusting frame movably mounted on the support frame. The outer mold assembly is fixed to the adjusting frame. Changing the position of the adjusting frame allows for alteration of the length and width dimensions of the housing unit, improving the mold's versatility.

[0019] The prefabricated building casting mold of this invention brings significant technical benefits in many aspects, greatly promoting the development of the prefabricated building field. Regarding improved casting accuracy and building performance, traditional molds, due to their modular prefabrication and open-top casting process, suffer from problems such as dimensional deviations, difficult splicing, and decreased building performance. This mold, through its unique integrated design, connects the top casting chamber and the wall casting chamber, forming a closed casting cavity. Cement slurry fills each cavity in an orderly manner, fundamentally avoiding accumulated dimensional errors, reducing complex remedial processes during splicing and positioning, and greatly improving construction efficiency. Simultaneously, this design significantly enhances the building's seismic performance, airtightness, and structural force transmission efficiency, providing a solid guarantee for building quality.

[0020] Regarding mold structure optimization and versatility enhancement, existing mold structures suffer from drawbacks such as weak modular expansion capabilities, difficulty in demolding, wear of locating pin holes, and localized mold bulging. This mold features an innovative design for both the outer and inner mold components, employing modular assembly and obliquely connected to the top mold component via support rods. This structure not only enhances modular expansion capabilities but also adapts to different housing unit requirements. The adjustable frame of the top mold component base allows for flexible changes in housing unit dimensions, improving mold versatility. Furthermore, it reduces demolding time, lowers the risk of locating pin hole wear, effectively avoids localized mold bulging, and improves production efficiency and mold lifespan.

[0021] Regarding the ease of grouting control and assembly / disassembly, traditional molds suffer from inaccurate control over the amount of cement grout injected, and the assembly / disassembly process is cumbersome. This mold features a grouting port at the bottom that leads directly to the top grouting chamber. Connected to the cement injection pump via a shut-off valve, it allows for precise control of the injection volume. Furthermore, the shut-off valve can be easily removed, avoiding difficulties in separation after curing. The horizontal tie rod design increases the connection strength between the outer and inner mold components and facilitates separation within the wall, making mold assembly and disassembly more convenient and faster, further improving production efficiency and construction convenience. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1;

[0023] Figure 2 yes Figure 1 Enlarged view of point A in the middle;

[0024] Figure 3 yes Figure 1 Enlarged view of point B in the middle;

[0025] Figure 4 This is a schematic diagram of the specific structure of Embodiment 1.

[0026] Explanation of the reference numerals in the figure:

[0027] 100. Outer mold assembly; 101. Outer mold component; 102. Outer mold tongue and groove; 200. Inner mold assembly; 201. Inner mold component; 202. Inner mold tongue and groove; 300. Top mold assembly; 301. Base frame; 302. Top frame; 303. Connecting component; 400. Outer mold support rod; 500. Corner support rod; 600. Inner mold support rod; 700. Positioning ruler; 800. Horizontal tie rod; 900a. Upper forming plate; 900b. Lower forming plate. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0029] In the description of this application, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. For ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0030] Example 1:

[0031] like Figure 1-4 As shown, the prefabricated building casting mold in this embodiment is mainly used for casting house units with walls and roofs, and its overall structure is as follows. Figure 1The mold consists of an inner mold assembly 200, an outer mold assembly 100, and a top mold assembly 300. The inner mold assembly 200 and the outer mold assembly 100 define a wall grouting chamber for forming the walls, while the top mold assembly 300 defines a top grouting chamber for forming the roof. The wall grouting chamber and the top grouting chamber are interconnected, forming a closed grouting cavity. This closed structure offers significant advantages, maintaining the dimensional stability of the building units. During pouring, the cement grout is evenly filled within the closed grouting chamber, ensuring precise dimensional accuracy of the walls and roof, especially guaranteeing the installation and positioning accuracy of mechanical connectors. This provides precise connection and positioning dimensions for the subsequent modular assembly of multiple building units, ensuring accurate alignment of mechanical connectors during modular assembly, thereby improving the efficiency and quality of modular assembly. On the bottom surface of the wall, the upper molding plate 900a is precisely fixed between the inner mold component 200 and the outer mold component 100. Its constructed shape is compatible with the lower molding plate 900b and provides precise connection and positioning dimensions for the modular assembly of multiple house units in the later stage.

[0032] like Figure 1 As shown, this embodiment employs an inverted mold casting method, where both the inner mold assembly 200 and the outer mold assembly 100 are positioned above the top mold assembly 300 and extend upwards from the edge area of ​​the top mold assembly 300. During casting, the top mold assembly 300 is supported and positioned on the work platform. Cement grout first fills the top casting chamber, and then the liquid level gradually rises until it fills the wall casting chamber. This casting method improves the density of the building product, enhances structural strength, and prevents defects such as hollow areas.

[0033] like Figure 3 and Figure 4 As shown, a detachable upper forming plate 900a is installed on the top of the wall grouting chamber. This upper forming plate is precisely positioned with the outer mold assembly 100 and the inner mold assembly 200 by means of positioning pins. This precise positioning method is highly effective, and can strictly control the error of the pre-embedded position of the mechanical connector within ±1.0mm. Under optimal conditions, the error can be controlled within ±0.5mm.

[0034] The bottom of the wall grouting chamber integrates a lower forming plate 900b, on which second mechanical connectors are distributed. These second mechanical connectors can be securely connected to the first mechanical connectors of the upper forming plate. In practical applications of prefabricated buildings, when upper and lower building units are stacked, the tight connection between the second and first mechanical connectors enables modular assembly with millimeter-level precision. This feature is particularly suitable for the rapid assembly of upper and lower floors in prefabricated buildings, greatly improving construction efficiency and quality. Furthermore, the upper forming plate 900a and the lower forming plate 900b form a mortise and tenon joint in their structural shape. This ingenious design greatly facilitates the assembly positioning between upper and lower floors, making the assembly process more accurate and efficient.

[0035] Furthermore, to meet the horizontal assembly requirements of prefabricated buildings, this embodiment further incorporates mechanical connectors on the outer formwork assembly 100. These mechanical connectors enable the horizontal assembly of housing units, enhancing the flexibility and versatility of unit combinations. For housing units assembled horizontally, considering actual functional and structural requirements, four complete walls are not always necessary. In most cases, a three-wall design suffices. In some cases, door or window frames may even be embedded in one wall to facilitate later installation of doors and windows, making prefabricated buildings more aligned with actual usage scenarios and user needs.

[0036] The outer formwork assembly 100 is composed of multiple outer formwork components 101 laid along the outer wall surface. Adjacent outer formwork components 101 are joined using an overlapping tongue-and-groove joint. In this embodiment, the inner outer formwork components are joined using... Figure 3 The L-shaped tongue and groove in the middle form the outer mold frame, and the outer mold components are joined together by the T-shaped tongue and groove.

[0037] like Figure 1 and Figure 3 As shown, the following steps must be followed when assembling the outer mold assembly 100. First, select an appropriate number and shape of outer mold components 101 according to the angle of the wall corner and assemble them to build the outer mold frame of the outer mold assembly 100. Taking a 90-degree corner as an example, two mutually perpendicular outer mold components 101 can be spliced ​​together to form an L-shaped frame. The two outer mold components 101 at the corner are tightly joined together through tongue and groove joints. After the outer mold frame is completed, the outer mold components 101 located in the inner area of ​​the wall are filled into the outer mold frame to build the complete outer mold assembly 100.

[0038] In terms of connection and fixation, the bottom of the outer mold component 101 is firmly fixed to the top mold assembly 300 by bolts or snap-fits, specifically fixed to the base frame 301. For the outer mold component 101 located in the corner area of ​​the wall, it is also additionally connected to the top mold assembly 300 at an angle by an outer mold support rod 400. This connection method not only enhances the connection stability between the outer mold component 100 and the top mold assembly 300, but also provides effective support for the outer mold component 100, preventing deformation of the outer mold component 100 due to the pressure of cement slurry during the pouring process, thus ensuring the smooth progress of the pouring operation and the stability of the mold structure.

[0039] It should be noted that, in this embodiment, the outer mold components used to assemble the outer mold frame and the outer mold components filling the spaces between the outer mold frames may differ in terms of splicing tongues and grooves and other structural aspects. However, for the sake of simplicity, they will be uniformly referred to as outer mold components in this document, but this does not mean that all outer mold components have the same structure.

[0040] In addition, such as Figure 3 and Figure 4 As shown, the tongue-and-groove connection design of the inner and outer mold components is unique, consisting of two tongue-and-groove units interlocking to form a fixed surface. The main purpose of this design is to reduce or even eliminate the need for transverse horizontal beam support. Specifically, the interlocking surfaces of the outer mold tongue-and-groove 102 and the inner mold tongue-and-groove 202 can fully ensure the connection stability between adjacent mold components. In this way, the mold does not need to rely excessively on transverse horizontal beam support during assembly and casting, greatly simplifying the mold structure and effectively reducing mold costs.

[0041] At the same time, such as Figure 4 As shown, the mold is also equipped with multiple horizontal tie rods 800. These horizontal tie rods pass horizontally through the outer mold tongue-and-groove 102 and the inner mold tongue-and-groove 202, and are evenly distributed vertically. The function of the horizontal tie rods 800 is to lock the outer mold tongue-and-groove 102 and the inner mold tongue-and-groove 202 horizontally, thereby significantly increasing the overall connection strength of the outer mold assembly 100 and the inner mold assembly 200. It is worth mentioning that the portion of the horizontal tie rod 800 located in the wall grouting chamber is fitted inside a tapered sleeve. This design facilitates the easy separation of the horizontal tie rod 800 and the tapered sleeve after the wall has cured, allowing the hole to be sealed without causing any adverse effects on the wall structure.

[0042] However, because the horizontal tie rod 800 needs to pass through both the inner and outer mold grooves simultaneously, its installation is relatively complex and costly. To further optimize the mold design, simplify the installation process, and reduce costs, while ensuring that the tension of the horizontal tie rod 800 meets the mold's anti-bulging requirements, ordinary bolts can be used to fix some inner mold components or some outer mold components together. Specifically, bolts with the same diameter as the horizontal tie rod 800 can be used instead. These bolts only need to pass through either the inner or outer mold groove, unlike the horizontal tie rod 800 which needs to pass through both grooves simultaneously. This alternative solution effectively reduces installation difficulty and cost while ensuring mold connection stability.

[0043] like Figure 4 As shown, to further improve the dimensional accuracy of the housing units, positioning rulers are used for precise positioning and assembly of the internal components of the inner mold assembly 200, outer mold assembly 100, and top mold assembly 300. Positioning rulers ensure accurate positioning of each component during assembly, reducing dimensional deviations and thus guaranteeing high dimensional accuracy of the final cast housing units. Specifically, positioning rulers 700 are used to connect and fix the outer mold components of the outer mold assembly 100. Simultaneously, the single upper forming plate 900a on the top of the wall casting chamber is precisely positioned with adjacent outer mold assembly 100 and inner mold assembly 200 using two positioning pins, further improving the forming accuracy of the wall bottom surface and providing a more precise foundation for the subsequent modular assembly of the housing units.

[0044] The inner mold assembly 200 consists of multiple inner mold components 201 laid along the inner wall surface, with adjacent inner mold components 201 also joined together by an L-shaped tongue and groove joint (inner mold tongue and groove joint 202). Figure 3 and Figure 4 As shown, the inner mold component 201, located in the corner area of ​​the wall, is connected by at least one corner brace 500. The corner brace 500 spans the corner area, and its two ends are respectively connected to two inner mold components 201 to enhance the stability of the inner mold assembly 200 in the corner area and ensure that the inner mold assembly 200 will not be displaced or deformed due to the pressure of cement slurry during the pouring process. The inner mold assembly 200 is connected to the top frame 302 of the top mold assembly 300 by multiple obliquely arranged inner mold support rods 600. The inner mold support rods 600 can better distribute the pressure borne by the inner mold assembly 200 and improve the connection strength between the inner mold assembly 200 and the top mold assembly 300. The upper end of the inner mold assembly 200 is fixed to the outer mold assembly 100 by the upper forming plate 900a to ensure the relative position stability between the inner mold assembly 200 and the outer mold assembly 100, which together define the wall pouring chamber. The mechanisms of both the inner and outer mold support rods can be designed with reference to the adjustable diagonal brace disclosed in Chinese Patent CN221021556U.

[0045] It is particularly important to emphasize that, in this embodiment, the outer mold support rods are only installed at the outer mold frame in the corner area of ​​the outer mold, while the inner mold support rods are evenly distributed along the circumference of the inner mold. This arrangement not only fully meets the structural strength requirements but also significantly reduces structural costs, makes mold assembly easier, and improves construction efficiency.

[0046] The top formwork assembly 300 includes a base frame 301 and a top frame 302, defining a top grouting chamber between the base frame 301 and the top frame 302. The top frame 302 is fixed to the inner formwork assembly 200 via a connecting member 303. The surface of the connecting member 303 on the grouting chamber side is configured as a transition surface, which can be arc-shaped or inclined. This facilitates the flow of cement grout and increases the strength of the precast components, preventing eddies or air bubbles from forming during the flow of cement grout. This ensures that the cement grout can be uniformly filled into the top grouting chamber and the wall grouting chamber. It also forms an arc or oblique angle at the junction of the top and bottom of the wall, improving the structural strength of the building. The top frame 302 is fixed to the inner formwork assembly 200, and the base frame 301 is fixed to the outer formwork assembly 100. Support legs are also provided between the top frame 302 and the base frame 301 to provide more stable support for the base frame 302 and the inner formwork assembly 200, and to more accurately define the thickness of the top grouting chamber.

[0047] The top of the wall casting chamber has an upper molding plate 900a, which is fixed between the inner mold assembly 200 and the outer mold assembly 100. Specifically, it can be fixed using two locating pins and a through bolt in the middle, precisely positioning the structure to close the top opening of the wall casting chamber and facilitating the construction of a predetermined shape on the bottom surface of the wall. The upper molding plate 900a is detachably fitted with a first mechanical connector suitable for embedding into the bottom of the wall. The bottom of the wall casting chamber has a lower molding plate 900b, which is detachably fitted with a second mechanical connector suitable for embedding into the top of the wall. The predetermined shapes constructed by the upper molding plate 900a and the lower molding plate 900b can be mutually adapted, specifically through mortise and tenon joints. Simultaneously, the stacked house units are connected to the first mechanical connector via the second mechanical connector, enabling modular assembly of the house units and improving the construction efficiency and overall quality of prefabricated buildings. The top of the wall grouting chamber is also equipped with an exhaust vent, which is specifically located on an exhaust pipe. The exhaust pipe is approximately 300-800mm higher than the upper forming plate 900a. This helps to enhance the compactness of the concrete on the top surface, allowing gas to escape during the pouring process and preventing air bubbles from remaining. Specifically, the exhaust pipe is fixed to the upper forming plate 900a.

[0048] The base frame 301 includes a base frame placed on the working platform, serving as the supporting foundation for the entire top formwork assembly 300; a first guide rail extending in a first direction is attached to the base frame. The adjusting frame includes a pair of first adjusting frames defining the pouring range of the roof in the first direction. The first adjusting frames slide against the first guide rails to adjust the spacing between the pair of first adjusting frames; this sliding engagement makes the adjustment process smoother and more accurate. The pair of first adjusting frames are spaced apart in the first direction, and the spacing between the pair of first adjusting frames is determined by a first positioning ruler. The first positioning ruler is configured to achieve modular positioning between the pair of first adjusting frames for precise spacing adjustment. The first positioning ruler has multiple positioning holes, with the spacing between adjacent positioning holes being a module m. A connector passes through the positioning holes and is partially embedded in the first adjusting frame to determine the spacing between the pair of first adjusting frames. This positioning method is simple and reliable, improving positioning accuracy and efficiency.

[0049] Furthermore, a first filler frame is installed between the pair of first adjusting frames, and the length of the first filler frame in the first direction is set to a module m. Thus, the spacing between the first adjusting frames can be easily adjusted by increasing or decreasing the number of first filler frames. The top height of the first filler frame is approximately the same as that of the second adjusting frame.

[0050] To further improve the flexibility and accuracy of adjustment, a first adjustment mechanism is connected between the base frame and the first adjustment frame. The first adjustment mechanism includes a first screw operable by the user and a first nut that engages with the first screw. The first screw and the first nut are optionally mounted on either the base frame or the first adjustment frame for pitch adjustment.

[0051] The base frame 301 also includes two pairs of second adjusting frames that define the pouring range of the roof in a second direction. Each second adjusting frame is coupled with a second guide rail extending in the second direction, which is mounted on the first adjusting frame. The second adjusting frames slide against the second guide rails to accommodate adjustment of the spacing between the pair of second adjusting frames. This sliding fit improves the flexibility and accuracy of adjustment. The pair of second adjusting frames are spaced apart in the second direction, and the spacing between them is determined by a second positioning ruler. The second positioning ruler is also configured to provide modular positioning between the pair of second adjusting frames. The second positioning ruler also has multiple positioning holes, with the spacing between adjacent holes being a module n. A connector passes through the positioning holes and partially embeds itself into the second adjusting frame to determine the spacing between the pair of second adjusting frames. The modules n and m can be equal or unequal to meet the needs of different roof sizes.

[0052] Similarly, a second filling frame is installed between a pair of second adjusting frames, and the length of the second filling frame in the second direction is set to a module n. The top height of the second filling frame is approximately the same as that of the second adjusting frame.

[0053] A second adjustment mechanism is connected between the first and second adjustment frames. The second adjustment mechanism includes a second screw operable by the user and a second nut cooperating with the second screw. The second screw and the second nut are selectively mounted on either the first or second adjustment frame to adjust and fix the position of the second adjustment frame.

[0054] The first adjusting frame, the second adjusting frame, the first filling frame, and the second filling frame are all covered with base plates to form a complete casting mold surface. In this way, during the casting process, the concrete can be evenly distributed on the top formwork component 300, ensuring the casting quality of the roof.

[0055] The first and second directions are perpendicular to each other, allowing for the definition and adjustment of the roof pouring area in both perpendicular directions. Changing the position of the adjustment frames (first and second adjustment frames) can alter the length and width dimensions of the house unit, improving the mold's versatility. For example, when pouring house units of different sizes, simply adjusting the position of the adjustment frames on the base frame allows for adjustment of the outer mold assembly 100's dimensions, thereby changing the size of the house unit without requiring mold redesign and manufacturing, significantly reducing production costs.

[0056] Meanwhile, detachable sealing strips (not individually marked in the figure) are installed at various connection points of the mold. These sealing strips prevent cement slurry leakage and are also easy to disassemble and replace. When the sealing strips become worn or aged, they can be replaced with new ones in a timely manner to ensure the sealing performance of the mold.

[0057] The mold is equipped with a grouting port that is directly connected to the top grouting chamber and linked to a cement grouting pump via a shut-off valve for precise control of the cement grout injection volume. The shut-off valve and grouting pump are controlled by a liquid metering control system, enabling intelligent grouting. Bottom grouting allows the cement grout to gradually fill from the bottom upwards, facilitating the removal of air from the grouting chamber and reducing bubble formation. In cases of high walls, a second grouting port can be added at the top to ensure uniform filling of the wall grouting chamber, employing a layered grouting method. Layered grouting allows for staged injection of cement grout according to the wall height and structural characteristics, reducing pressure on the side molds, ensuring thorough filling of each section, and improving component quality. In other embodiments, one or more grouting ports can be provided, located on the side molds or the bottom mold. This flexible grouting method allows the mold of this invention to adapt to the casting needs of housing units of different sizes and shapes.

[0058] Before pouring, close the shut-off valve, assemble the mold, and position it on the operating table. Then, start the cement grouting pump and open the shut-off valve, allowing the cement grout to flow into the top grouting chamber from the grouting port. Since the top grouting chamber and the wall grouting chamber are interconnected, the liquid level will gradually rise as the top grouting chamber fills with cement grout, and the cement grout will flow upwards along the wall grouting chamber until it is completely filled. During the pouring process, the flow of the cement grout and the height of the liquid level inside the mold can be observed through the transparent observation port on the outer mold components. The pouring speed of the cement grouting pump and the opening of the shut-off valve can be adjusted in a timely manner to precisely control the amount of cement grout poured, avoiding over- or under-pouring. Once the cement grout has filled the entire mold cavity and reached a certain height at the top transparent vent pipe, close the shut-off valve and the cement grouting pump, and wait for the cement grout to solidify and form. The grouting components, such as the shut-off valve, are detachably installed on the outer mold assembly 100 or the bottom mold assembly 300 so that after the cement enters the final setting stage, it has a small amount of hardening strength to separate the grouting components from the mold, preventing the grouting components from being unable to separate from the mold after the cement has cured in the later stage.

[0059] After the cement grout has solidified, remove the connecting components, outer mold support rod 400, inner mold support rod 600 and other connecting parts. First, remove the inner mold assembly 200 from the house unit, then remove the outer mold assembly 100 from the outside of the house unit, and finally separate the top mold assembly 300 from the formed house unit to complete the pouring operation of the house unit.

[0060] Example 2

[0061] This embodiment is basically the same as Embodiment 1, except for the tongue and groove shape of the outer mold assembly and the inner mold assembly. In this embodiment, the outer mold tongue and groove 102 and the inner mold tongue and groove 202 adopt a trapezoidal tongue and groove. Compared with the L-shaped tongue and groove, the trapezoidal tongue and groove has a larger contact area, which can enhance the connection strength and sealing between adjacent outer mold components 101 or inner mold components 201, and reduce the leakage of cement slurry at the tongue and groove.

[0062] When assembling the outer mold assembly 100 and the inner mold assembly 200, the outer mold component 101 or inner mold component 201 in the corner area is first assembled into a frame, and then the outer mold component 101 or inner mold component 201 in the inner area is filled. Due to the special shape of the trapezoidal tongue and groove, the position of each component needs to be adjusted more precisely during assembly to ensure that the tongue and groove can fit tightly. However, after assembly, the overall stability and sealing of the mold will be significantly improved.

[0063] Example 3

[0064] This embodiment, based on Embodiment 1, adds heating and heat preservation functions to the mold. Heating wires (not separately marked in the figure) are installed in the base frame 301 and top frame 302 of the top mold assembly 300. The heating wires are connected to an external power supply through a temperature control system. In winter or when the ambient temperature is low, the heating wires can be turned on to heat the mold, thereby improving the setting speed and quality of the cement slurry.

[0065] Meanwhile, an insulation material (not separately marked in the image) is wrapped around the outside of the mold. This insulation material reduces heat exchange between the mold and the surrounding environment, maintaining a stable temperature inside the mold. After pouring, the insulation material also prevents cracks from forming in the house units due to sudden temperature changes, thus improving the quality of the house units.

[0066] In summary, the prefabricated building casting mold of the present invention demonstrates its different structural designs and functional characteristics through multiple embodiments. These embodiments not only solve the problems existing in the cement slurry filling, assembly and disassembly, and versatility of existing molds, but also improve the performance and service life of the mold by adding functions such as heating and heat preservation. In practical applications, appropriate embodiments can be selected according to specific needs to achieve efficient and high-quality casting of prefabricated building components.

[0067] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A mold for casting prefabricated buildings, used for casting housing units having walls and roofs, comprising an inner mold assembly, an outer mold assembly, and a top mold assembly, wherein a wall casting chamber for forming the walls is defined between the inner mold assembly and the outer mold assembly, and a top casting chamber for forming the roof is defined within the top mold assembly; characterized in that, During the pouring operation: The top mold assembly is supported and positioned on the operating table. The inner mold assembly and outer mold assembly are both positioned above the top mold assembly and extend upwards from the edge region of the top mold assembly. The top grouting chamber and the wall grouting chamber are interconnected and together form a closed casting chamber. The cement grout gradually rises in level after filling the top grouting chamber until it fills the wall grouting chamber.

2. The mold for prefabricated building casting according to claim 1, characterized in that, The top of the wall injection chamber has an upper molding plate adapted to form a predetermined shape on the bottom surface of the wall. The upper molding plate is fixed between the inner mold assembly and the outer mold assembly and closes the top opening of the wall injection chamber.

3. The mold for prefabricated building casting according to claim 2, characterized in that, The top of the wall grouting chamber is equipped with an exhaust vent.

4. The mold for prefabricated building casting according to claim 1, 2, or 3, characterized in that, The upper forming plate is detachably fitted with a first mechanical connector suitable for embedding into the bottom of the wall.

5. The mold for prefabricated building casting according to claim 4, characterized in that, The bottom of the wall injection chamber has a lower forming plate adapted to form a set shape on the top surface of the wall. The lower forming plate is detachably installed with a second mechanical connector adapted to be embedded in the top of the wall. The modular assembly of the house units can be achieved by connecting the stacked house units with the first mechanical connector through the connection between the second mechanical connector and the first mechanical connector.

6. The mold for prefabricated building casting according to claim 1, characterized in that, It also includes at least one grouting port configured in the mold, the grouting port being directly connected to the top grouting chamber.

7. The mold for prefabricated building casting according to claim 6, characterized in that, The grouting port is connected to the cement injection pump via a shut-off valve, which is detachably fixed to the outer mold assembly or the bottom mold assembly so that the shut-off valve can be removed before the cement grout injected into the grouting chamber solidifies.

8. The mold for prefabricated building casting according to claim 1, characterized in that, The outer mold assembly has multiple outer mold components laid along the outer wall surface of the wall, and adjacent outer mold components are joined together by an outer mold tongue and groove joint.

9. The mold for prefabricated building casting according to claim 8, characterized in that, The outer mold components located at the corner of the wall are first assembled into an outer mold frame for building the outer mold assembly. Then, the outer mold components located in the inner area of ​​the wall are filled into the outer mold frame to build the outer mold assembly.

10. The mold for prefabricated building casting according to claim 8, characterized in that, The outer formwork component, located in the corner area of ​​the wall, is connected to the top formwork assembly via an outer formwork support rod, which is arranged obliquely.

11. The mold for prefabricated building casting according to claim 8, 9, or 10, characterized in that, The bottom of the outer mold component is fixed to the base frame of the top mold assembly; preferably, the inner mold assembly has multiple inner mold components laid along the inner wall surface of the wall, and adjacent inner mold components are joined together by an inner mold tongue and groove joint; preferably, it also includes multiple horizontal tie rods that pass through the outer mold tongue and groove joint and the inner mold tongue and groove joint in the horizontal direction, and the horizontal tie rods are configured to lock the outer mold tongue and groove joint and the inner mold tongue and groove joint in the horizontal direction respectively, so as to increase the overall connection strength of the outer mold assembly and the inner mold assembly; preferably, the portion of the horizontal tie rod located in the wall grouting chamber is sleeved in a sleeve to facilitate the removal of the horizontal tie rod from the wall after curing; preferably, the inner mold components arranged in the corner area of ​​the wall are connected by at least one corner brace, and the corner brace crosses... The corner area is connected to two inner mold components at both ends; preferably, the inner mold component is connected to the top frame of the top mold component by multiple inner mold support rods, the inner mold support rods being arranged obliquely; preferably, the top mold component includes a base frame and a top frame, the base frame and the top frame defining a top injection chamber, the inner mold component being fixed to the top frame, and the outer mold component being fixed to the base frame; preferably, the inner mold component is fixed to the top frame by a connecting member, the surface of the connecting member on the injection chamber side being configured as a transition surface; preferably, the base frame includes a support frame and an adjusting frame movably disposed on the support frame, the outer mold component being fixed to the adjusting frame, and changing the position of the adjusting frame can change the length and width dimensions of the housing unit.

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