Vacuum-sucker based uHPC gutter mold device

Abstract

The application relates to the technical field of gutter mold, in particular to a UHPC gutter mold device based on a vacuum chuck. The UHPC gutter mold device based on the vacuum chuck comprises a mold inner container, two end face sealing plates, two outer side plates and a bottom frame, and the two side plates are provided with hinge locking mechanisms; the mold inner container comprises a top plate and an inner side plate; the top plate is provided with a plurality of movable pull plates which can be pulled out. The UHPC gutter mold device based on the vacuum chuck has high rigidity, low adhesion characteristics and can realize rapid demolding, so as to meet the large-scale high-quality production requirement of the UHPC gutter.

Description

Technical Field

[0001] This application relates to the field of drainage ditch mold technology, and in particular to a UHPC drainage ditch mold device based on a vacuum suction cup. Background Technology

[0002] With the rapid development of urban infrastructure construction, ultra-high performance concrete (UHPC) has gradually become an ideal material for high-precision precast components such as drainage ditches due to its extremely high compressive strength (≥100MPa), durability, and impermeability. However, the traditional mold assembly and disassembly process in related technologies is complex, labor-intensive, and has low production efficiency, making it difficult to meet the needs of mass production. Moreover, existing molds for small precast components are mostly made of plastic, which lacks durability and is prone to deformation and damage after long-term use. The demolding process also relies heavily on manual removal of bolts, resulting in slow demolding speed, poor product dimensional consistency, and a potential impact on the dimensional accuracy and production efficiency of drainage ditches.

[0003] UHPC drainage gutter products possess ultra-high strength and high density, but their adhesion to the mold after curing is strong. Traditional mold technology and demolding processes present significant bottlenecks in terms of material strength, demolding efficiency, and finished product yield. Therefore, it is evident that existing molds for UHPC drainage gutters have significant shortcomings in related technologies. Utility Model Content

[0004] To overcome the shortcomings of related technologies, this application provides a vacuum suction cup-based UHPC drainage ditch mold device that combines high rigidity, low adhesion characteristics, and rapid demolding, in order to meet the needs of large-scale, high-quality UHPC drainage ditch production.

[0005] A UHPC drainage ditch mold device based on a vacuum suction cup includes a mold liner, two end sealing plates, two outer side plates, and a base frame. The outer wall of the mold liner and the inner wall of the outer side plates form an n-shaped casting space. The end sealing plates are used to seal both ends of the casting space. The bottom of the end sealing plates and the bottom of the mold liner are vertically hinged. The two outer side plates are equipped with hinge locking mechanisms. The mold liner includes a top plate and an inner side plate. The top plate is composed of multiple pull plates that can pull out the liner. Furthermore, the top of the UHPC drainage ditch mold device based on vacuum suction cups is also provided with a vacuum negative pressure suction cup structure, which has at least four suction cups.

[0006] Furthermore, the hinge locking mechanism includes a hinge component, a chain, a pull rod, and a screw.

[0007] Furthermore, the suction cup is made of silicone rubber, and its working surface has fine grooves and an internal reinforcing rib structure.

[0008] Furthermore, the second hinge component is provided with a limiting groove for engaging the pull rod.

[0009] Furthermore, the inner liner of the mold is designed as an inverted U-shape.

[0010] Furthermore, a fixing groove is provided on the top of the mold liner, which is pulled out in conjunction with the pull plate (24).

[0011] Furthermore, a handle groove is provided on the pull plate.

[0012] Furthermore, the outer side panel and the bottom of the mold liner are hinged.

[0013] This application has at least one of the following beneficial effects: 1. This application provides a vacuum suction cup-based UHPC drainage ditch mold device that combines high rigidity, low adhesion characteristics, and rapid demolding to meet the needs of large-scale, high-quality UHPC drainage ditch production.

[0014] 2. This application employs hinges for reinforcing and dismantling the template. This method effectively replaces the slow manual demolding process, thereby improving demolding efficiency and product dimensional accuracy, meeting the needs of industrial production. It simplifies the construction process, increases the frequency of mold use, and enhances demolding efficiency.

[0015] 3. This application solves the problems of short mold life, low demolding efficiency, easy damage to component surfaces, and large product size deviation in the prior art by optimizing the mold structure design and improving the demolding control method, so as to realize the high precision, high pass rate and industrial continuous production of UHPC drainage channels. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application.

[0017] Figure 2 This is a schematic diagram of the mold inner liner structure according to an embodiment of this application.

[0018] Figure 3 This is a schematic diagram of the end-face sealing plate structure according to an embodiment of this application.

[0019] Figure 4 This is a schematic diagram of the base frame structure according to an embodiment of this application.

[0020] Figure 5 This is a schematic diagram of the tie rod structure according to an embodiment of this application.

[0021] Figure 6 This is a schematic diagram of the suction cup structure according to an embodiment of this application.

[0022] Reference numerals: 1. Hinge locking mechanism; 2. Mold inner liner; 3. End face sealing plate; 4. Outer side plate; 5. Base frame; 14. Chain; 15. First hinge component; 16. Pull rod; 17. Screw; 18. Second hinge component; 21. Top plate; 22. Inner side plate; 23. Fixing groove; 24. Pull plate; 25. Handle groove; 28. Suction cup; 29. ​​End hinge; 30. Movable hinge. Detailed Implementation

[0023] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0024] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0025] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0026] The following is in conjunction with the appendix Figure 1-6 This application will be described in further detail.

[0027] Example 1 Reference Figure 1 , Figure 2 , Figure 3 and Figure 4A UHPC drainage ditch mold device based on a vacuum suction cup includes a mold liner 2, two end face sealing plates 3, two outer side plates 4, and a base frame 5. The outer wall of the mold liner 2 and the inner wall of the outer side plates 4 form a casting space with an n-shaped cross section. The end face sealing plates 3 are used to seal both ends of the casting space. The bottom of the end face sealing plates 3 and the bottom of the mold liner 2 are vertically hinged by end hinges 29. The two outer side plates are provided with hinge locking mechanisms 1. The mold liner 2 includes a top plate 21 and an inner side plate 22. The top plate 21 is composed of multiple pull plates 24 that can pull out the liner. The bottom outer side of the inner side plate 22 is provided with multiple movable hinges 30. The outer side plates 4 and the bottom of the mold liner 2 are hinged. The mold inner liner 2 is made of high-strength alloy steel, such as 42CrMo, and its dimensional tolerance is ensured to be ≤0.1mm through precision CNC machining. The base frame 5 is provided with a rectangular base plate, with square tubes on each of the four sides of the base plate, and multiple square tubes arranged parallel to each other between the two long sides of the base frame 5. Two end face sealing plates 3 are provided around the front and rear of the base frame 5, and multiple folded edges are provided on the end face sealing plates 3; two outer side plates 4 are provided on the left and right sides. The front end face sealing plate 3 and the rear end face sealing plate 3 are vertically hinged to the end hinges 29 provided at the bottom of the mold inner liner 2. The end hinges are divided into two halves, and the end face sealing plate 3 rotates around the first half, and is abutted by the second half after rotating to a certain angle. The front end face sealing plate 3 and the rear end face sealing plate 3 can be folded outward from vertically upward at a certain angle, preferably less than 45 degrees. Similarly, the two outer side plates 4 are hinged to multiple movable hinges 30 provided at the bottom of the inner side plate 22, and the two outer side plates 4 can be folded outward from vertically upward at a certain angle and are abutted by the movable hinges 30. The end hinges 29 and movable hinges 30 can also be used in conjunction with the square tubes on the base frame 5 to facilitate the movement of the mold inner liner 2 on the base frame 5.

[0028] The entire mold can simultaneously produce multiple drainage ditch components, separated by precision-machined partitions. In this embodiment, the structure of multiple pull plates 24 forming a top plate 21 is not limited to a single type. For example, the top of the mold inner liner 2 is provided with a fixing groove 23, and the two ends of the pull plates 24 are respectively drawn into the corresponding fixing grooves 23. Further details are omitted here. The top plate 21 is provided with movable pull plates 24 to facilitate non-sticking during vacuum adsorption demolding.

[0029] Reference Figure 1 and Figure 5The opening and closing angles of the two end face sealing plates 3 and two outer side plates 4 are designed according to the space required for construction, which can greatly reduce the labor intensity of workers opening and closing the mold while meeting construction conditions. The hinge locking mechanism 1 includes a first hinge component 15, a chain 14, a pull rod 16, a screw 17, and a second hinge component 18. Preferably, the pull rod 16 is a steel bar with a diameter of 16mm. The second hinge component 18 is fixedly installed on the left outer side plate 4. The second hinge component 18, screw 17, pull rod 16, chain 14, and first hinge component 15 are connected sequentially from left to right, surrounding the front end face sealing plate 3. The second hinge component 18 is provided with a limit groove for clamping the pull rod 16 with a nut and a washer. The screw 17 and the nut move relative to each other through the engagement of the threads. Similarly, the rear end face sealing plate 3 is also provided with a hinge locking mechanism 1 for locking. The two end-face sealing plates 3 and two outer side plates 4 are implemented through a quick-release mold hinge design. The mold opening and closing is achieved via hinges, abandoning the traditional mold screw design concept, greatly improving production efficiency and reducing worker labor intensity. This application, through innovative mold design, completely abandons the traditional concept of securing molds with screws or clips, significantly reducing the labor intensity of construction workers and improving construction efficiency. The mold disassembly and assembly time is reduced from 4 minutes per set to 30 seconds; worker labor intensity is reduced by 70%. The optimized mold structure design improves the strength and durability of the mold material. It solves the problems of easy deformation and wear in traditional molds, increasing mold turnover and cycle time tenfold.

[0030] Reference Figure 6 The UHPC drainage ditch mold device based on vacuum suction cups is also equipped with a vacuum negative pressure suction cup structure on its top. This structure uses a truss-driven pneumatic-hydraulic vacuum suction cup for demolding. Demolding utilizes the principle of vacuum negative pressure to lift the component from the mold, reducing the need for manual labor and equipment compared to traditional demolding methods. The vacuum negative pressure suction cup structure has multiple suction cups 28. Furthermore, the structure employs intelligent stacking by a robotic arm, which can intelligently stack components according to their size and shape, further reducing manual labor and equipment requirements. Demolding is performed using the vacuum negative pressure principle through the truss suction cups. During demolding, the suction cups 28 are first attached to the surface of the drainage ditch component, then a vacuum is applied between them. A hydraulic device then lifts the drainage ditch component upwards, separating it from the mold. This achieves unmanned construction and better ensures the integrity of the component.

[0031] The vacuum negative pressure suction cup structure has at least four suction cups 28, which are made of highly elastic and wear-resistant silicone rubber. The suction cups 28 are generally circular or square. Their working surfaces have fine annular or radial grooves, which effectively expel air when in contact with the UHPC drainage ditch component surface and increase friction with the component surface, ensuring a firm adhesion. Internal reinforcing ribs enhance the strength of the suction cups 28 under negative pressure, preventing deformation and breakage.

[0032] The drainage channel is integrally molded from UHPC material on the outer side of the mold inner liner 2, the end face sealing plate 3, and the inner side of the outer side plate 4, featuring high strength and high durability. The drainage channel body is inverted U-shaped with uniform and relatively thin walls to reduce weight while ensuring structural strength. The top or side surfaces of the drainage channel that need to contact the suction cup 28 are designed with smooth, flat adsorption areas to reduce air leakage caused by uneven surfaces and improve the reliability of vacuum adsorption. Inside the drainage channel components, steel fiber reinforcement is arranged according to mechanical design requirements to enhance the overall load-bearing capacity of the components, enabling them to withstand the adsorption force of the suction cup 28 during demolding and various stresses during lifting.

[0033] The working principle of this application embodiment: Quick demolding process steps: (1) Step 1: Spraying the release agent: Before pouring concrete, spray a layer of oil-based release agent onto the mold. The oil-based release agent is mainly composed of mineral oil, fatty acid esters, and organosilicon. Then spray a layer of nano-coating release agent. The nano-coating release agent uses water as the dispersion medium and adds nanomaterials such as nano-silica and nano-zinc oxide, as well as water-based film-forming agents, surfactants, and other additives. The combination of oil-based release agent and nano-material water-based release agent adopts a layered application method: When treating the mold surface, first spray a layer of oil-based release agent evenly, and use its good adhesion to the mold to form a basic isolation layer. After the oil-based release agent dries, spray the nano-material water-based release agent on its surface. Due to the small size effect and high surface activity of nanomaterials, the nanoparticles in the water-based release agent can fill the microscopic gaps in the oil-based release agent layer, further improving the density and release performance of the release agent layer, while giving the release agent some special properties, such as better wear resistance and corrosion resistance. The combination of oil-based release agent and water-based release agent made of nanomaterials can reduce the adhesion friction between the component and the formwork, enhance the surface strength and gloss of the concrete, and reduce air bubbles.

[0034] (2) Step 2: Use a pry bar to pry the hinge and quickly close the mold through the hinge locking mechanism 1.

[0035] (3) Step 3: The components are cured with low-temperature steam. By using steam curing, the demolding time is shortened from 8-10 hours to 4-6 hours, thus improving production efficiency.

[0036] (4) Step 4: Pull the pull plate 24 out of the top plate 21 by pulling the handle groove 25.

[0037] (5) Step 5: Use a pry bar to pry the hinge and quickly disassemble the mold through the hinge locking mechanism 1.

[0038] (6) Step 6: Use the truss vacuum negative pressure suction cup to lift the component out of the mold as a whole.

[0039] (7) Step 7: Use a robotic arm to grab, flip and transfer the components to achieve non-destructive demolding and stacking of the drainage ditch components.

[0040] In summary, this application employs a hinge locking mechanism 1 for fastening, abandoning the traditional bolt or clip fastening methods for molds. This significantly reduces the labor intensity of construction workers and improves construction efficiency, reducing the time for disassembling and assembling molds from 4 minutes per set to 30 seconds; reducing worker labor intensity by 70%. Furthermore, the top plate 21 of the mold inner liner 2 of this application is equipped with multiple movable pull plates 24, which possess high rigidity, low adhesion characteristics, and enable rapid demolding, preventing the drainage ditch components from sticking to the mold inner liner 2. This reduces the adhesion friction between the drainage ditch components and the formwork, enhances the surface strength and gloss of the concrete, and reduces air bubbles. It also reduces adhesion forces during demolding, avoiding damage to the component surface.

[0041] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A UHPC drainage ditch mold device based on a vacuum suction cup, characterized in that, The mold includes an inner liner (2), two end face sealing plates (3), two outer side plates (4) and a base frame (5). The outer wall of the inner liner (2) and the inner wall of the outer side plate (4) form a casting space with an n-shaped cross section. The end face sealing plates (3) are used to seal the two ends of the casting space. The bottom of the end face sealing plates (3) and the bottom of the mold inner liner (2) are vertically hinged by end hinges (29). The two outer side plates are provided with hinge locking mechanisms (1). The mold inner liner (2) includes a top plate (21) and an inner side plate (22). The top plate (21) is composed of multiple pull plates (24) that can pull out the inner liner.

2. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The top of the UHPC drainage ditch mold device based on vacuum suction cups is also provided with a vacuum negative pressure suction cup structure, which has at least four suction cups (28).

3. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The hinge locking mechanism (1) includes a first hinge component (15), a chain (14), a pull rod (16), a screw (17), and a second hinge component (18).

4. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 2, characterized in that, The suction cup (28) is made of silicone rubber, and its working surface has fine grooves and a reinforcing rib structure inside.

5. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 3, characterized in that, The second hinge component (18) is provided with a limit groove for engaging with the pull rod (16).

6. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The inner liner of the mold (2) is set as an inverted U-shape.

7. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The top of the mold liner (2) is provided with a fixing groove (23), which is pulled out in conjunction with the pull plate (24).

8. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The pull plate (24) is provided with a handle groove (25).

9. The UHPC drainage ditch mold device based on a vacuum suction cup according to claim 1, characterized in that, The outer side plate (4) and the bottom of the mold inner liner (2) are hinged.

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