Die for integrally forming thin-wall concrete toilet structure

Abstract

The utility model discloses a mould for integrally forming a thin-wall concrete toilet structure, which relates to the field of buildings and comprises an outer mould and an inner mould, and the outer mould is mounted on a cross-shaped sliding support; the outer mold comprises an outer bottom template, an outer vertical template and an outer special template; mounting a doorway template on the inner mold; positioning and reinforcing steel beams are mounted at the tops of the outer mold and the inner mold; an adjustable supporting piece is installed in the inner mold; the inner mold comprises an inner bottom mold plate and an inner vertical mold plate, and the inner bottom mold plate comprises an inner bottom middle plate and a plurality of inner bottom edge plates installed in the circumferential direction of the outer side of the inner bottom middle plate; a cavity mold is mounted on the inner vertical mold plate; a bottom grouting opening is formed in the inner bottom middle plate. According to the mold, the thin-wall concrete toilet structure can be integrally poured, operation is easy and convenient, the size adjusting capacity is achieved, universality is good, pouring uniformity is high, and the assembling cost is saved.

Description

Technical Field

[0001] This utility model relates to the field of building technology, specifically to a mold for integral molding of thin-walled concrete bathroom structures. Background Technology

[0002] The common method for forming thin-walled concrete bathroom structures is to use flat molds to produce wall panels and a base, which are then connected using mortise and tenon joints. The flat mold production process involves first producing the wall panels and base components, and then assembling them. Because the wall panels and base components are produced separately, the complexity of individual component molds is relatively low. The molds for both the base and wall panels consist of core molds and edge molds. The flat mold process requires consideration of the assembly of the base and wall panel components. The mold design must account for the precision of numerous assembly nodes between wall panels and between wall panels and the base to avoid conflicts during assembly. Therefore, although the construction of a single mold is simple, the large number of nodes that need to be controlled for the entire bathroom structure can easily lead to assembly failures or node damage, resulting in higher component processing costs. Furthermore, structural adhesive needs to be injected into the gaps between the base and wall panels, and between wall panels themselves, which is costly. For a single bathroom, one base mold and four wall panel molds are required, resulting in a large mold footprint. To address the aforementioned pain points, there is an urgent need to develop a new vertical mold production process to eliminate the glue injection process for assembling gaps between wall panels and between wall panels and chassis, thereby improving the overall prefabrication rate of thin-walled concrete bathroom structures. Utility Model Content

[0003] The purpose of this utility model is to provide a mold for integral molding of thin-walled concrete bathroom structures. This mold can integrally cast thin-walled concrete bathroom structures, is simple and convenient to operate, has size adjustment capability, good versatility, and strong casting uniformity, thus saving assembly costs.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A mold for integral molding of thin-walled concrete bathroom structures includes an outer mold and an inner mold disposed inside the outer mold. A casting cavity with a top opening is formed between the outer mold and the inner mold. The outer mold is mounted on a cross-shaped sliding bracket. The outer mold includes an outer bottom template, three outer vertical templates arranged vertically outside the outer bottom template, and an outer special template. The outer bottom template is fixedly mounted on the cross-shaped sliding bracket. Door openings are provided in corresponding positions on the outer special template and the inner mold. Doorway templates can be detachably installed at the door openings, allowing access to the inner cavity of the inner mold. Positioning and reinforcing steel beams are detachably installed at the top of the outer mold and the inner mold. Multiple adjustable support members are installed inside the inner mold. The inner mold includes an inner bottom template and four inner vertical templates fixedly installed on the top of the inner bottom template. The inner bottom template includes an inner bottom middle plate and multiple inner bottom side plates installed circumferentially outside the inner bottom middle plate. A bottom grouting port is provided on the inner bottom middle plate. Grout is injected from bottom to top through the bottom grouting port to form the thin-walled concrete bathroom structure.

[0006] Preferably, a sliding groove is provided on the cross-shaped sliding bracket; a reinforcing bracket is fixedly installed on the outside of the outer vertical template and the outer special template, and a pulley is installed at the bottom of the reinforcing bracket, the pulley being slidably installed in the sliding groove.

[0007] Preferably, the length of the outer special 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 corner molds arranged at the four corners of a rectangle and vertical or horizontal connecting templates fixedly installed between two adjacent corner molds; wedge-shaped connecting parts are provided at the ends of the vertical and horizontal connecting templates, and connecting plates are provided at the ends of the corner molds, wherein the connecting plates are detachably connected to the corresponding wedge-shaped connecting parts.

[0009] Preferably, the positioning and reinforcing steel beam includes two first steel beams arranged in parallel intervals and two second steel beams arranged perpendicular to the first steel beams. Connecting members are fixedly installed at the bottom of both ends of the first steel beams and the second steel beams, and the connecting members are connected to the top of the outer mold and the inner mold.

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

[0011] Preferably, the inner vertical template includes inner corner molds located at the four corners of the rectangle and an inner connecting template fixedly installed between two adjacent inner corner molds, with a connecting slant plate provided at the connection between the inner connecting template and the inner corner mold.

[0012] Preferably, a nylon block is installed on the outer side of the inner bottom edge plate, the width of the nylon block being less than the thickness of the inner bottom template; six inner bottom edge plates are provided, and adjacent inner bottom edge 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] Preferably, multiple cavity molds are installed on the inner vertical template, and the gap between two adjacent cavity molds forms a reinforcing rib.

[0015] In this invention, the outer mold side is assembled from three outer vertical templates and one outer special template. The three outer vertical templates are relatively large, accommodating molds for bathrooms of different sizes. When the size changes, only the outer special template and the outer bottom template need to be replaced, reducing production costs and demonstrating strong versatility. The outer vertical templates and the outer special template are slidably mounted on a cross-shaped sliding bracket, facilitating mold disassembly and assembly operations.

[0016] After the outer vertical template on the opposite side of the outer special template is removed, it can be completely removed to allow the finished product to be lifted horizontally from that side after demolding. This greatly reduces the requirement of vertically lifting the finished product to the top of the mold and then lifting it horizontally, which would occupy a lot of the overhead crane height.

[0017] The inner bottom formwork consists of an inner bottom middle plate and multiple inner bottom edge plates installed on the outer perimeter of the inner bottom middle plate. This minimizes the impact on cracking of the thin-walled concrete bathroom chassis during demolding. Adjacent inner bottom edge plates are connected by inner bottom inclined plates, which ensures structural strength and reduces disturbance to the thin-walled concrete bathroom chassis during demolding.

[0018] The doorway formwork is designed to form a bathroom doorway in one continuous pour, eliminating the need for subsequent doorway cutting. The hollow mold provides integrated reinforcing ribs, increasing structural strength. The nylon blocks, once removed, can form drainage ditches or decorative surface mounting platforms, avoiding secondary construction. The open design of the doorway formwork allows operators easy access to the inner cavity of the mold from the outside, and also facilitates observation of the grouting process. The doorway formwork consists of four corner molds and vertical or horizontal connecting molds fixed between adjacent corner molds, allowing for easy assembly, disassembly, and dimensional adjustment.

[0019] The bottom grouting port is located on the inner bottom plate, and the grouting method is from bottom to top. This avoids the problems of incomplete gas removal and uneven pouring caused by traditional top-down grouting, and ensures the uniformity of the overall structure pouring.

[0020] The positioning and reinforcing steel beams not only strengthen the overall structural strength of the inner and outer molds after installation, but also restrict and fix their relative positions, ensuring consistency in the thickness of each side wall. They also facilitate the overall hoisting of the inner mold, making this a multi-functional device. The adjustable supports provide vertical support at different positions of the inner mold, preventing bulging.

[0021] The three-sided operating platform facilitates grouting operations and mold assembly and disassembly for operators, and also allows operators to observe the grouting process from the top.

[0022] This mold enables the one-piece fabrication of thin-walled concrete bathroom structures with reinforcing ribs, reducing wall thickness to as low as 1cm. This reduces concrete material usage, lowers overall weight, and avoids the drawbacks of high costs and large production footprint associated with assembled concrete bathrooms. It also saves on the cost of grouting at assembly joints. The one-piece casting method addresses the high strength requirements of the base and wall panel concrete in weak tensile and shear areas of structural connection joints, allowing for a more appropriate reduction in the structural strength of thin-walled concrete bathrooms. Furthermore, it significantly improves the cleanliness and orderliness of construction practices within the production plant. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0024] Figure 2 This is a schematic diagram of the present invention without the operating platform installed.

[0025] Figure 3 This is a schematic diagram of the external vertical template structure of this utility model;

[0026] Figure 4 This is a partial structural diagram of the cross-shaped sliding bracket of this utility model;

[0027] Figure 5 This is a schematic diagram of the positioning and reinforcement steel beam structure of this utility model;

[0028] Figure 6 This is a schematic diagram of the inner mold structure of this utility model;

[0029] Figure 7 This is a schematic diagram of the internal vertical template structure of this utility model;

[0030] Figure 8 This is a schematic diagram of the doorway template structure of this utility model;

[0031] Figure 9 This is a schematic diagram of the adjustable support structure of this utility model;

[0032] Figure 10 This is a schematic diagram of the inner bottom template structure of this utility model;

[0033] Figure 11 This is a schematic diagram of the AA cross-section of this utility model;

[0034] Figure 12 This is a schematic diagram of the outer bottom template structure of this utility model;

[0035] In the diagram: 1. Outer mold; 2. Inner mold; 3. Cross-shaped sliding bracket; 4. Doorway formwork; 5. Positioning and reinforcing steel beam; 6. Adjustable support component; 7. Cavity mold; 8. Bottom grouting port; 9. Observation port; 10. Outer bottom formwork; 11. Outer vertical formwork; 12. Outer special formwork; 13. Operating platform; 14. Staircase; 15. Nylon block; 20. Inner bottom formwork; 21. Inner vertical formwork; 30. Slide groove; 31. Reinforcement 32. Bracket; 40. Door corner mold; 41. Vertical connecting template; 42. Horizontal connecting template; 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 base; 200. Inner bottom middle plate; 201. Inner bottom side plate; 210. Inner corner mold; 211. Inner connecting template; 212. Connecting inclined plate. Detailed Implementation

[0036] The present invention will be further described below with reference to the accompanying drawings:

[0037] like Figures 1 to 12 The mold shown is for integral molding of thin-walled concrete bathroom structures. It includes an outer mold 1, which comprises an outer bottom template 10, three outer vertical templates 11 arranged vertically outside the outer bottom template 10, and one outer special template 12. The length of the outer special template 12 is the same as the length of the corresponding side of the outer bottom template 10; the length of the outer vertical template 11 is greater than the length of the corresponding side of the outer bottom template 10. When the size of the outer mold 1 needs to be adjusted, only the corresponding size outer bottom template 10 and outer special template 12 need to be replaced; the three outer vertical templates 11 are universal. Sealing elements are installed at the connection points between the outer bottom template 10, outer special template 12, and outer vertical template 11 to seal the joints.

[0038] Specifically, the outer vertical template 11 is composed of a steel plate and stiffening ribs arranged longitudinally and transversely on the back of the steel plate. Bolt holes adjacent to the outer bottom template 10 are provided at the bottom of the steel plate. Multiple bolt holes are also provided on the stiffening ribs arranged circumferentially on the steel plate. Multiple triangular stiffening ribs are fixedly provided between the top stiffening ribs and the steel plate. Lifting lugs are fixedly installed above the top stiffening ribs.

[0039] The outer bottom template 10 consists of a steel plate and channel steel or I-beams fixedly installed on the back of the steel plate. A connecting plate is fixedly installed circumferentially at the bottom of the steel plate, and bolt holes are provided on the connecting plate. It is adjacent to the outer vertical template 11 by high-strength bolts.

[0040] The external special template 12 is composed of a steel plate and stiffening ribs arranged longitudinally and transversely on the back of the steel plate. Bolt holes adjacent to the outer bottom template 10 are provided at the bottom of the steel plate. Multiple bolt holes are also provided on the stiffening ribs arranged circumferentially on the steel plate. Multiple triangular stiffening ribs are fixedly installed between the top stiffening ribs and the steel plate. Lifting lugs are fixedly installed above the top stiffening ribs.

[0041] The outer mold 1 is mounted on the cross-shaped sliding bracket 3. Specifically, the outer bottom mold 10 is fixedly mounted on the cross-shaped sliding bracket 3 by welding. Multiple sliding grooves 30 are provided on the cross-shaped sliding bracket 3. Reinforcing brackets 31 are fixedly installed on the outer sides of the outer vertical mold 11 and the outer special mold 12. Pulleys 32 are installed at the bottom of the reinforcing brackets 31, and the pulleys 32 slide within the sliding grooves 30. A set of pulleys 32 is installed on each side of the reinforcing bracket 31, allowing the outer vertical mold 11 or the outer special mold 12 to slide stably. The cross-shaped sliding bracket 3 includes a steel frame arranged in a cross shape, a reinforcing scissor support frame fixedly mounted on the steel frame, and multiple embedded plates mounted on the steel frame. The cross-shaped sliding bracket 3 is fixedly mounted using these embedded plates.

[0042] An operating platform 13 is provided on the outside of the outer mold 1 by fasteners or welding. Specifically, one operating platform 13 is provided on each of the outer vertical templates 11. A staircase 14 is provided on one side of the operating platform 13 opposite the outer special template 12. The operator can climb to the operating platform 13 to carry out the work by climbing the staircase 14.

[0043] An inner mold 2 is installed inside the outer mold 1, forming a casting cavity with a top opening between the outer mold 1 and the inner mold 2. Concrete is poured into the casting cavity to form a concrete bathroom structure.

[0044] The inner formwork 2 includes an inner bottom template 20 and four inner vertical templates 21 fixed to the top of the inner bottom template 20 by high-strength bolts. Sealing elements are installed at the connections between the inner bottom template 20 and the inner vertical templates 21, and at the connections between adjacent inner vertical templates 21, to seal the joints. The inner bottom template 20 includes an inner bottom middle plate 200 and multiple inner bottom edge plates 201 fixedly installed circumferentially on the outer side of the inner bottom middle plate 200. Specifically, six inner bottom edge plates 200 are provided, and adjacent inner bottom edge plates 200 are connected by inner bottom inclined plates. This increases the area of ​​the connection surface and reduces disturbance to the thin-walled concrete bathroom chassis during demolding, thus reducing the impact on cracking of the thin-walled concrete bathroom chassis during demolding.

[0045] The inner vertical formwork 21 includes inner corner molds 210 located at the four corners of the rectangle and inner connecting formwork 211 fixedly installed between two adjacent inner corner molds 210. Connecting inclined plates 212 are installed at the connection points between the inner connecting formwork 211 and the inner corner molds 210. Because the wall panels of the thin-walled bathroom are relatively thin, using the connecting inclined plates 212 reduces the impact on cracking of the thin-walled concrete bathroom wall panels during demolding. The frictional stress during demolding using the connecting inclined plates 212 is significantly reduced compared to using straight plate connections. During demolding, the inner connecting formwork 211 is removed first, followed by the inner corner molds 210. Following this order minimizes the disturbance to the thin-walled wall panels caused by the frictional stress at the connection between adjacent inner vertical formwork 21s.

[0046] Nylon blocks 15 are installed on the outside of the inner bottom edge plate 201. The width of the nylon blocks 15 is less than the thickness of the inner bottom template 20. After the nylon blocks 15 are removed, they can form a drainage ditch or a decorative surface installation platform, avoiding subsequent secondary construction.

[0047] Multiple cavity molds 7 are installed on the inner vertical template 21. The gap between two adjacent cavity molds forms a reinforcing rib, which can increase the structural strength of the wall panel. Space is reserved in the cavity between the reinforcing ribs for laying internal pipelines. The cavity molds 7 are made of thin plastic shell products and are bolted to the inner vertical template 21 for easy removal.

[0048] Door openings are provided on the outer special template 12 and the inner mold 2, and door template 4 is detachably installed at the door openings by bolts. The hollow open structure of door template 4 allows access to the inner cavity of the inner mold 2 through the door openings and door template 4, making it convenient for operators to enter the inner cavity of the inner mold 2 from the outside. The fixedly installed door template 4 can form a bathroom door opening in one piece, avoiding subsequent door opening cutting operations.

[0049] The doorway template 4 includes corner templates 40 arranged at the four corners of a rectangle and vertical connecting templates 41 or horizontal connecting templates 42 fixedly installed between two adjacent corner templates 40. Wedge-shaped connecting parts 43 are provided at the ends of both the vertical connecting templates 41 and the horizontal connecting templates 42. A connecting plate 44 is provided at the end of the corner template 40. The connecting plate 44 and the corresponding wedge-shaped connecting part 43 are detachably connected by bolts for easy assembly and disassembly. The corner templates 40 are inclinedly connected to the vertical connecting templates 41 or the horizontal connecting templates 42 to avoid disturbing the wall panel during demolding and reduce the risk of damaging the wall panel.

[0050] A bottom grouting port 8 is set on the inner bottom plate 200, and an observation port 9 is set 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 a thin-walled concrete bathroom structure. The bottom-up grouting method avoids the problems of incomplete gas removal and uneven pouring caused by traditional top-down grouting, ensuring the uniformity of the overall structure pouring. During grouting, the grouting situation on different sides can be observed through the observation port 9, allowing construction personnel to have a more comprehensive understanding of the pouring process.

[0051] Positioning and reinforcing steel beams 5 are detachably installed on the top of the outer mold 1 and the inner mold 2 using bolts. The positioning and reinforcing steel beams 5 include two parallel, spaced-apart first steel beams 50 and two second steel beams 51 perpendicular to the first steel beams 50. Connecting pieces 52 are fixedly installed at the bottom of both ends of the first steel beams 50 and the second steel beams 51, and the connecting pieces 52 are bolted to the top of the outer mold 1 and the inner mold 2. The positioning and reinforcing steel beams 5, on the one hand, strengthen the overall structural strength of the inner mold 2 and the outer mold 1 after installation, restrict and fix the relative position between the inner mold 2 and the outer mold 1, ensuring the consistency of the thickness of the four wall panels; on the other hand, they facilitate the overall hoisting of the inner mold 2.

[0052] Multiple adjustable support members 6 are installed inside the inner mold 2. These support members 6 provide vertical support at different positions of the inner mold 2, preventing mold bulging. Each adjustable support member 6 includes a threaded sleeve 60, two adjusting screws 61 threaded to both ends of the threaded sleeve 60, and a support seat 62 installed at the end of each adjusting screw 61. The support seat 62 is fixed inside the inner mold 2 by bolts or welding. The threads at both ends of the threaded sleeve 60 have opposite directions. During adjustment, rotating the threaded sleeve 60 causes the two adjusting screws 61 to extend or retract synchronously. Nuts are installed on the adjusting screws 61. After the threaded sleeve 60 has been adjusted for reinforcement, the nuts secure the threaded sleeve 60 to the adjusting screws 61, ensuring the stability of the support reinforcement.

[0053] The above embodiments are merely illustrative of the concept and implementation of this utility model, and are not intended to limit it. Under the concept of this utility model, the technical solutions without substantial changes are still within the scope of protection.

Claims

1. A mold for integrally molding a thin-walled concrete toilet structure, comprising an outer mold and an inner mold disposed inside the outer mold, a casting cavity with an open top being formed between the outer mold and the inner mold, characterized in that: The outer mold is installed on the cross-shaped sliding support; the outer mold comprises an outer bottom mold plate, three outer vertical mold plates arranged vertically in sequence outside the outer bottom mold plate, and an outer special mold plate; the outer bottom mold plate is fixedly installed on the cross-shaped sliding support; a door hole corresponding in position is arranged on the outer special mold plate and the inner mold; a door opening mold plate is detachably installed at the door hole; the inner cavity of the inner mold can be accessed through the door hole; a positioning and reinforcing steel beam is detachably installed at the top of the outer mold and the inner mold; a plurality of adjustable supporting members are installed inside the inner mold; the inner mold comprises an inner bottom mold plate and four inner vertical mold plates fixedly installed on the top of the inner bottom mold plate; the inner bottom mold plate comprises an inner bottom middle plate and a plurality of inner bottom edge plates installed circumferentially outside the inner bottom middle plate; a bottom grouting port is arranged on the inner bottom middle plate; thin-walled concrete bathroom structure is formed by grouting from bottom to top through the bottom grouting port.

2. The mold for integrally molding a thin-wall concrete toilet structure according to claim 1, characterized in that: A sliding groove is arranged on the cross-shaped sliding support; reinforcing supports are fixedly installed outside the outer vertical mold plates and the outer special mold plate; pulleys are installed at the bottom of the reinforcing supports and slidably installed in the sliding groove.

3. The mold for integrally molding a thin-wall concrete toilet structure according to claim 1 or 2, characterized in that: The length of the outer special mold plate is the same as the length of the corresponding side of the outer bottom mold plate; the length of the outer vertical mold plate is greater than the length of the corresponding side of the outer bottom mold plate.

4. The mold for integrally molding a thin-wall concrete toilet structure according to claim 3, characterized in that: The door opening mold plate comprises door corner molds arranged at the four corners of a rectangle and vertical connecting mold plates or horizontal connecting mold plates fixedly installed between adjacent two door corner molds; wedge-shaped connecting portions are arranged at the ends of the vertical connecting mold plates and the horizontal connecting mold plates; connecting plates are arranged at the ends of the door corner molds and detachably connected with the corresponding wedge-shaped connecting portions.

5. The mold for integrally molding a thin-wall concrete toilet structure according to claim 1, 2 or 4, wherein: The positioning and reinforcing steel beam comprises two first steel beams arranged in parallel and at intervals and two second steel beams arranged vertically to the first steel beams; connecting members are fixedly installed at the two ends and the bottom of the first steel beams and the second steel beams; the connecting members are connected to the top of the outer mold and the inner mold.

6. The mold for integrally molding a thin-wall concrete toilet structure according to claim 5, wherein: The adjustable supporting member comprises a threaded sleeve, two adjusting screws threadedly installed at the two ends of the threaded sleeve, and a supporting seat installed at the end of the adjusting screw; the supporting seat is fixedly installed inside the inner mold; the threads at the two ends of the threaded sleeve are opposite in rotation direction.

7. The mold for integrally molding a thin-wall concrete toilet structure according to claim 1, 2, 4 or 6, characterized in that: The inner vertical mold plate comprises inner corner molds arranged at the four corners of a rectangle and inner connecting mold plates fixedly installed between adjacent two inner corner molds; connecting inclined plates are arranged at the connecting portions of the inner connecting mold plates and the inner corner molds.

8. The mold for integrally molding a thin-wall concrete toilet structure according to claim 7, characterized in that: Nylon blocks are installed outside the inner bottom edge plates; there are six inner bottom edge plates, and adjacent two inner bottom edge plates are connected through inner bottom inclined plates.

9. A mold for integrally molding a thin-wall concrete toilet structure according to claim 1, 2, 4, 6 or 8, characterized in that: An operation platform is arranged outside the outer mold; a staircase is arranged on one side of the operation platform.

10. The mold for integrally molding a thin-wall concrete toilet structure according to claim 9, characterized in that: A plurality of cavity molds are installed on the inner vertical mold plate; gaps are formed between adjacent two cavity molds to form reinforcing ribs.

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