A prefabricated laminated slab production mold and prefabricated laminated slab

Abstract

The utility model provides a kind of mold and prefabricated composite slab for prefabricated composite slab production, including flat plate mould platform, end mould, side mould, clamping component and compacting mould frame;End mould and side mould are placed on the flat plate mould platform, and the flat plate mould platform, end mould and side mould constitute the mould cavity of upper open;End module is installed on the end mould, for the clamping groove of the both ends of prefabricated composite slab formed;Side edge module is installed on the side mould, for the step of the both sides of prefabricated composite slab formed;Clamping component is installed on end mould, and by clamping component, side mould is tightly attached with end mould;Compact mould frame is installed between two side moulds, and it is located above mould cavity, for limiting the light core material inside prefabricated composite slab to float or shift during pouring process.The utility model limits the light core material inside prefabricated composite slab to float or shift during pouring process, ensure that the internal structure of composite slab meets design requirements, improve product pass rate.

Description

Technical Field

[0001] This utility model relates to the field of prestressed concrete precast components, and in particular to a mold for producing precast composite slabs and a precast composite slab. Background Technology

[0002] Traditional cast-in-place composite slabs require on-site formwork, a process that is extremely time-consuming and significantly reduces construction efficiency. Furthermore, the on-site formwork process and subsequent construction phases inevitably cause serious environmental pollution. The generation of large amounts of construction waste, dust pollution, and noise pollution negatively impacts the living environment of nearby residents. In addition, the construction cycle for traditional cast-in-place slabs is lengthy; each step, from formwork and pouring to curing, requires substantial time. This becomes a key factor restricting the overall progress of projects with strict schedule requirements.

[0003] Traditional composite board molds are usually fixed in size or have a limited range of adjustment. Producing boards of different widths requires replacing the entire set of side molds or molds, which is costly, inefficient, and occupies a large area.

[0004] Existing adjustable molds often have complex adjustment mechanisms (such as lead screw adjustment), which are cumbersome, time-consuming, and difficult to guarantee positioning accuracy. Furthermore, locking is not convenient or reliable enough. When producing laminated plates with surface features (such as grooves, ribs, etc.), it is usually necessary to make a special upper mold or a complex detachable module, which has poor versatility.

[0005] During concrete pouring, lightweight filling materials (such as polystyrene blocks, hollow boxes, etc.) inside the mold are prone to floating and shifting due to concrete flow and vibration, affecting product quality and structural performance. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a mold and precast composite slab for production. Through modular end and side module design, precast composite slabs can be formed simply by changing the shape and size of the end and side modules, significantly reducing the labor intensity of operators and adapting to small-batch production of multiple specifications. By changing the end mold, side mold, end modules, and side modules, composite slabs of various lengths, end shapes, and surfaces can be produced, reducing mold investment costs.

[0007] This utility model achieves the above-mentioned technical objectives through the following technical means.

[0008] A mold for producing precast composite slabs includes a flat mold platform, end molds, side molds, clamping components, and a pressing mold frame. The end molds and side molds are placed on the flat mold platform, and the flat mold platform, end molds, and side molds form an open upper mold cavity. End modules are installed on the end molds for forming grooves at both ends of the precast composite slab. Side modules are installed on the side molds for forming steps on both sides of the precast composite slab. The clamping components are installed on the end molds to ensure that the side molds are tightly attached to the end molds. The pressing mold frame is installed between the two side molds and above the mold cavity to restrict the floating or displacement of the lightweight core material in the precast composite slab during casting.

[0009] Furthermore, a triangular strip is provided on one side of the side mold, and a triangular groove is provided on the end mold to match the triangular strip of the side mold for positioning the side mold and the end mold.

[0010] Furthermore, the upper part of the end mold is provided with a reinforcing tube, and the mating part of the reinforcing tube and the clamping component is respectively provided with a first waist-shaped hole. The first waist-shaped hole of the clamping component and the first waist-shaped hole of the reinforcing tube are tightly fitted by a wedge pin. Under the action of external force, the inclined surface of the wedge pin pushes the clamping component to move towards the reinforcing tube, so that the side mold and the end mold are tightly fitted.

[0011] Furthermore, the end mold and side mold are respectively installed on the flat mold table via quick-release latches, and sealing structures are provided between the end mold and the flat mold table, between the side mold and the flat mold table, and between the end mold and the side mold.

[0012] Furthermore, the clamping mold frame includes a mold frame structure, mold frame pin sleeves, and clamping mechanisms; the mold frame structure is a frame structure component, and several mold frame pin sleeves are respectively provided on both sides of the mold frame structure for positioning with the side mold; several adjustable-height clamping mechanisms are installed at the bottom of the mold frame structure, and the clamping mechanisms are located above the mold cavity. By adjusting the height of the clamping mechanisms, the clamping mechanisms are used to clamp the lightweight core material.

[0013] Furthermore, the upper surface of the side mold is provided with several side mold bottom pins, and the mold frame pin sleeve is sleeved on the side mold bottom pins. The mold frame pin sleeve and the side mold bottom pin are respectively provided with a second waist-shaped hole and a third waist-shaped hole. The second waist-shaped hole of the mold frame pin sleeve and the third waist-shaped hole of the side mold bottom pin are tightly fitted by a wedge pin. Under the action of external force, the inclined surface of the wedge pin pushes the pressing mold frame to move towards the side mold, so that the side mold and the pressing mold frame are tightly fitted.

[0014] Furthermore, the side mold bottom pin is eccentrically positioned on the upper end face of the side mold, and the eccentricity between the side mold bottom pin and the center line of the side mold is 100mm-200mm.

[0015] Furthermore, the length of the second oblong hole of the mold frame pin sleeve is greater than the length of the third oblong hole of the side mold bottom pin.

[0016] Furthermore, the clamping mechanism includes a pressure plate, an adjusting bolt, and a tightening nut. The bottom of the mold frame structure is provided with a threaded sleeve. The two pressure plates are connected by a crossbeam. The crossbeam is installed inside the sleeve by an adjusting bolt. A tightening nut is provided between the crossbeam and the sleeve.

[0017] Furthermore, the pressure plate is a steel grating, and the width of the pressing mechanism matches the width of the lightweight core material.

[0018] A prefabricated composite slab, which is produced using a mold for producing the prefabricated composite slab.

[0019] Furthermore, the lightweight core material is one or a combination of two of EPS, foam, sponge, and XPS.

[0020] The beneficial effects of this utility model are as follows:

[0021] 1. The mold for producing precast composite slabs according to this utility model utilizes a flat mold platform, end molds, and side molds to form an open upper mold cavity. End modules are installed on the end molds for forming the slots at both ends of the precast composite slab. Side modules are installed on the side molds for forming the steps on both sides of the precast composite slab. The modular design of the end and side modules allows for the forming of precast composite slabs simply by changing their shape and size, significantly reducing the labor intensity of operators and adapting to small-batch production of multiple specifications. By changing the end molds, side molds, end modules, and side modules, composite slabs of various lengths, end shapes, and surface types can be produced, reducing mold investment costs.

[0022] 2. The mold for producing precast composite slabs according to this utility model, wherein the clamping mold frame is installed between two side molds and located above the mold cavity, is used to restrict the floating or displacement of the lightweight core material in the precast composite slab during the casting process, to ensure that the internal structure of the composite slab meets the design requirements, and to improve the product qualification rate.

[0023] 3. In the mold for producing precast composite slabs described in this utility model, the first waist-shaped hole of the clamping component and the first waist-shaped hole of the reinforcing tube are tightly fitted by a wedge pin. Under the action of external force, the inclined surface of the wedge pin pushes the clamping component to move towards the reinforcing tube, so that the side mold and the end mold are tightly fitted to achieve quick insertion and locking.

[0024] 4. The precast composite slab production method of the mold for producing precast composite slabs described in this utility model forms the base plate of the precast composite slab through the first concrete pouring and the inverted conical ribs on the precast composite slab through the second concrete pouring. It can realize the production of precast composite slabs with inverted conical ribs without the need for a special upper mold or a complex detachable module. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are some embodiments of this utility model. For those skilled in the art, it is obvious that other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a three-dimensional exploded view of the mold used for producing precast composite slabs according to this utility model.

[0027] Figure 2 This is a schematic diagram of the assembled structure of the mold for producing prefabricated composite slabs according to this utility model.

[0028] Figure 3 This is a schematic diagram of the installation of the side mold and the clamping mold frame described in this utility model.

[0029] Figure 4 This is a schematic diagram of the installation of the end mold and side mold described in this utility model.

[0030] Figure 5 This is a partially enlarged schematic diagram of the clamping hook described in this utility model.

[0031] Figure 6 This is a front view of the clamping mold frame described in this utility model.

[0032] Figure 7 This is a three-dimensional partial view of the clamping mold frame described in this utility model.

[0033] Figure 8 This is a three-dimensional view of the prefabricated composite slab described in this utility model.

[0034] Figure 9 This is a cross-sectional view of the prefabricated composite slab described in this utility model.

[0035] In the picture:

[0036] 1-Flat mold table; 2-Precast composite slab; 201-Base plate; 202-Inverted conical rib; 203-Lightweight core material; 3-End mold; 301-Reinforcing tube; 4-End module; 5-Side module; 6-Side mold; 7-Clamping hook; 8-Wedge pin; 9-Pressure mold frame; 601-Side mold bottom pin; 602-Triangular strip; 9-Pressure mold frame; 901-Mold frame pin sleeve; 902-Tightening nut; 903-Adjusting bolt; 904-Pressure plate. Detailed Implementation

[0037] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0038] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "axial," "radial," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. 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 indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0039] In this utility model, 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 connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0040] like Figure 1 and Figure 2 As shown, the mold for producing precast composite slabs according to this utility model includes a flat mold base 1, an end mold 3, a side mold 6, a clamping component, and a pressing mold frame 9. The end mold 3 and the side mold 6 are placed on the flat mold base 1, and the flat mold base 1, the end mold 3, and the side mold 6 form an open mold cavity at the top. Multiple end modules 4 are installed on the end mold 3 at intervals for forming the slots at both ends of the precast composite slab. Side modules 5 are installed on the side mold 6 for forming the steps on both sides of the precast composite slab. The clamping component is installed on the end mold 3, and the side mold 6 is pressed tightly against the end mold 3. The pressing mold frame 9 is installed between the two side molds 6 and located above the mold cavity, for limiting the floating or displacement of the lightweight core material 203 in the precast composite slab during the casting process.

[0041] like Figure 4 and Figure 5 As shown, a triangular strip 602 is provided on one side of the side mold 6, and a triangular groove adapted to the triangular strip 602 of the side mold 6 is provided on the end mold 3 for positioning the side mold 6 and the end mold 3. The upper part of the end mold 3 is provided with a reinforcing tube, and the clamping component is a clamping hook 7. One end of the clamping hook 7 presses against the outside of the side mold 6, and the other end is inserted into the reinforcing tube at the upper part of the end mold. The mating parts of the reinforcing tube and the clamping hook 7 are respectively provided with a first waist-shaped hole. The first waist-shaped hole of the clamping hook 7 and the first waist-shaped hole of the reinforcing tube are tightly fitted by a wedge pin 8. Since there is a certain distance between the edge of the first waist-shaped hole of the clamping hook 7 and the edge of the first waist-shaped hole of the reinforcing tube, when the wedge pin 8 is inserted into the waist hole and is wedge-tightened by a hammer, the inclined surface of the wedge pin 8 pushes the clamping component to move towards the reinforcing tube 301 under the action of external force. It will press against the edge of the first waist-shaped hole of the clamping hook 7 and move towards the waist-shaped hole of the reinforcing tube until the clamping hook 7 pulls the side mold 6 and the end mold together without gap, and the wedge pin 8 is in place. This makes the side mold 6 and the end mold 3 fit tightly.

[0042] The end mold 3 and the side mold 6 are respectively installed on the flat mold table 1 by quick-release buckles, quick bolts or fasteners. There are sealing structures between the end mold 3 and the flat mold table 1, between the side mold 6 and the flat mold table 1, and between the end mold 3 and the side mold 6. Generally, the seams of the end mold 3 and the side mold 6 are filled with rubber strips.

[0043] like Figure 3 As shown, the clamping mold frame 9 includes a mold frame structure, mold frame pin sleeves 901, and clamping mechanisms; the mold frame structure is a frame structure component, and several mold frame pin sleeves 901 are respectively provided on both sides of the mold frame structure for positioning with the side mold 6; several adjustable-height clamping mechanisms are installed at the bottom of the mold frame structure, and the clamping mechanisms are located above the mold cavity. By adjusting the height of the clamping mechanisms, the clamping mechanisms are used to clamp the lightweight core material 203.

[0044] A plurality of side mold bottom pins 601 are provided on the upper end face of the side mold 6. The side mold bottom pins 601 are equidistantly arranged on the side mold 6 at 500mm intervals, and usually 5-8 are provided. The side mold bottom pins 601 are eccentrically arranged on the upper end face of the side mold 6, that is, the side mold bottom pins are not centered on the side mold 6. The eccentricity between the side mold bottom pins 601 and the center line of the side mold 6 is 100mm-200mm.

[0045] Three sets of pin sleeves are arranged equidistantly at 1000mm intervals on both sides of the clamping mold frame 9. The mold frame pin sleeve 901 is fitted onto the side mold bottom pin 601. The mating points of the mold frame pin sleeve 901 and the side mold bottom pin 601 are respectively provided with a second oblong hole and a third oblong hole. The second oblong hole of the mold frame pin sleeve 901 and the third oblong hole of the side mold bottom pin 601 are tightly fitted by a wedge pin 8. Under the action of external force, the inclined surface of the wedge pin 8 pushes the clamping mold frame 9 towards the side mold 6, making the side mold 6 and the clamping mold frame 9 tightly fitted. The length of the second oblong hole of the mold frame pin sleeve 901 is greater than the length of the third oblong hole of the side mold bottom pin 601. The lower edge of the second oblong hole of the mold frame pin sleeve 901 is higher than the lower edge of the third oblong hole of the side mold bottom pin 601 by a certain distance, and the upper edge of the second oblong hole of the mold frame pin sleeve 901 is higher than the upper edge of the third oblong hole of the side mold bottom pin 601 by a certain distance. When the wedge pin 8 is inserted into the oblong hole and is gently wedged with a hammer, the inclined surface of the wedge pin 8 will press against the upper edge of the third oblong hole of the side mold bottom pin 601 under the push of external force, pressing the mold frame pin sleeve 901 downward until the mold frame pin sleeve 901 and the side mold bottom pin 601 are pulled tight without gap, the wedge pin 8 is in place, and the clamping mold frame 9 and the side mold 6 are fixed.

[0046] like Figure 6 and Figure 7 As shown, the clamping mechanism includes a pressure plate 904, an adjusting bolt 903, and a tightening nut 902. A threaded sleeve is provided at the bottom of the mold frame structure. Two pressure plates 904 are connected by a crossbeam. The crossbeam is installed inside the sleeve by the adjusting bolt 903, and a tightening nut 902 is provided between the crossbeam and the sleeve. The pressure plate is a steel grating, and the width of the clamping mechanism matches the width of the lightweight core material 203. The height of the pressure plate 904 relative to the upper surface of the side mold 6 is changed by rotating the adjusting bolt 903 to ensure that all pressure plates 904 are pressed down at equal distances, ensuring uniform downward pressure. Then, the adjusting bolt 903 is tightened using the tightening nut 902 to fix the height of the pressure plate 904. Bolts are installed in groups, hoisted at intervals of 500 / 1000mm. Each set of pressure plates is arranged at equal intervals of 600mm width.

[0047] The joints between the side mold, end mold, and bottom mold, as well as the joints between them, are sealed with sealing strips that are pressed tightly to cover the edges.

[0048] A method for producing precast composite slabs using the aforementioned mold for producing precast composite slabs includes the following steps:

[0049] Determine the dimensions: Based on the required width and length of the precast composite slab 2 to be produced, and according to the product width requirements in the drawings, using 600mm as the base, assemble the mold cavity using the flat mold table 1, end mold 3 and side mold 6;

[0050] First concrete pour: The reinforcing bars are placed and positioned in the mold cavity. The first concrete pour and vibration are carried out in the mold cavity to form the bottom plate 201 of the precast composite slab 2. During the first concrete pour, the concrete is poured onto the upper edge plane of the triangular strip of the side mold 6 and the surface is smoothed.

[0051] After the initial setting of the concrete in the base slab 201, a lightweight core material 203 is placed on top of the base slab 201; end modules 4 and side modules 5 are respectively installed on the end molds 3 and side molds 6 around the mold cavity; a clamping mold frame 9 is installed between the two side molds 6 to clamp the lightweight core material 203; the lightweight core material 203 is one or a combination of two of EPS, foam, sponge, and XPS. The EPS board is expandable polystyrene foam board, and the XPS board is extruded polystyrene foam board.

[0052] The second concrete pouring and vibration operation is carried out inside the mold cavity to form the inverted conical ribs 202 on the precast composite slab 2, such as... Figure 8 As shown. The 904 pressure plate ensures that lightweight materials do not float or shift.

[0053] Demolding: After the concrete reaches its strength, disassemble in reverse order: first loosen and remove the pressure plate 904, loosen and remove the clamping parts of the side mold 6, remove the end mold 3, remove the end module 4 and the side module 5, and finally lift out the formed precast composite slab 2.

[0054] like Figure 8 and Figure 9 As shown, the prefabricated composite slab of this utility model is a prefabricated composite slab produced using the mold for producing the prefabricated composite slab.

[0055] It should be understood that although this specification is described according to various embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

[0056] The detailed descriptions listed above are merely specific descriptions of feasible embodiments of the present utility model, and are not intended to limit the scope of protection of the present utility model. All equivalent embodiments or modifications made without departing from the spirit of the present utility model should be included within the scope of protection of the present utility model.

Claims

1. A mold for producing precast composite slabs, characterized in that, The system includes a flat mold base (1), an end mold (3), a side mold (6), a clamping component, and a pressing mold frame (9). The end mold (3) and the side mold (6) are placed on the flat mold base (1), and the flat mold base (1), the end mold (3), and the side mold (6) form an open upper mold cavity. An end module (4) is installed on the end mold (3) for forming the slots at both ends of the precast composite slab. A side module (5) is installed on the side mold (6) for forming the steps on both sides of the precast composite slab. The clamping component is installed on the end mold (3) to make the side mold (6) fit tightly against the end mold (3). The pressing mold frame (9) is installed between the two side molds (6) and above the mold cavity to restrict the floating or displacement of the lightweight core material in the precast composite slab during the casting process.

2. The mold for producing precast composite slabs according to claim 1, characterized in that, The side mold (6) is provided with a triangular strip (602) on one side, and the end mold (3) is provided with a triangular groove that matches the triangular strip (602) of the side mold (6) for positioning the side mold (6) and the end mold (3).

3. The mold for producing precast composite slabs according to claim 1, characterized in that, The end mold (3) is provided with a reinforcing tube on its upper part. The reinforcing tube and the clamping component are respectively provided with a first waist-shaped hole. The first waist-shaped hole of the clamping component and the first waist-shaped hole of the reinforcing tube are tightly fitted by a wedge pin (8). The inclined surface of the wedge pin (8) pushes the clamping component to move towards the reinforcing tube (301) under the action of external force, so that the side mold (6) and the end mold (3) are tightly fitted.

4. The mold for producing precast composite slabs according to claim 1, characterized in that, The end mold (3) and side mold (6) are respectively installed on the flat mold table (1) by quick-release buckles. A sealing structure is provided between the end mold (3) and the flat mold table (1), between the side mold (6) and the flat mold table (1), and between the end mold (3) and the side mold (6).

5. The mold for producing precast composite slabs according to claim 1, characterized in that, The clamping mold frame (9) includes a mold frame structure, mold frame pin sleeves (901), and clamping mechanisms; the mold frame structure is a frame structure component, and several mold frame pin sleeves (901) are provided on both sides of the mold frame structure for positioning with the side mold (6); several adjustable-height clamping mechanisms are installed at the bottom of the mold frame structure, and the clamping mechanisms are located above the mold cavity. By adjusting the height of the clamping mechanisms, the clamping mechanisms are used to clamp the lightweight core material.

6. The mold for producing precast composite slabs according to claim 5, characterized in that, The upper surface of the side mold (6) is provided with several side mold bottom pins (601), and the mold frame pin sleeve (901) is sleeved on the side mold bottom pins (601). The mold frame pin sleeve (901) and the side mold bottom pin (601) are respectively provided with a second waist-shaped hole and a third waist-shaped hole. The second waist-shaped hole of the mold frame pin sleeve (901) and the third waist-shaped hole of the side mold bottom pin (601) are tightly fitted by a wedge pin (8). Under the action of external force, the inclined surface of the wedge pin (8) pushes the clamping mold frame (9) to move towards the side mold (6), so that the side mold (6) and the clamping mold frame (9) are tightly fitted.

7. The mold for producing precast composite slabs according to claim 6, characterized in that, The side mold bottom pin (601) is eccentrically set on the upper end face of the side mold (6), and the eccentric distance between the side mold bottom pin (601) and the center line of the side mold (6) is 100mm-200mm.

8. The mold for producing precast composite slabs according to claim 6, characterized in that, The length of the second oblong hole of the mold base pin sleeve (901) is greater than the length of the third oblong hole of the side mold bottom pin (601).

9. The mold for producing precast composite slabs according to claim 5, characterized in that, The clamping mechanism includes a pressure plate (904), an adjusting bolt (903), and a tightening nut (902). The bottom of the mold frame structure is provided with a threaded sleeve. The two pressure plates (904) are connected by a crossbeam. The crossbeam is installed in the sleeve by the adjusting bolt (903). A tightening nut (902) is provided between the crossbeam and the sleeve.

10. The mold for producing precast composite slabs according to claim 5, characterized in that, The pressure plate is a steel grating, and the width of the pressing mechanism matches the width of the lightweight core material.

11. A precast composite slab, characterized in that, Precast composite slabs produced using the molds for producing precast composite slabs as described in any one of claims 1-10.

12. The prefabricated composite slab according to claim 11, characterized in that, The lightweight core material is one or a combination of two of EPS, foam, sponge, and XPS.

Images