Method for manufacturing a concrete masonry block calibrated to a given height, and compacting device ensuring that such a masonry block is obtained

Abstract

The invention relates to a method for manufacturing a concrete masonry block calibrated to a given height and a compacting device (1) for manufacturing such a masonry block, said masonry block comprising a lower face, an upper face, side faces as well as cells opening out on the upper face, the compacting device (1) comprising an arrangement of rams (3) driven by first jacks (4) in a vertical translational movement and an arrangement of reservations (5), of a shape complementary to the cells to be formed, driven by second jacks (6) in a vertical translational movement, said reservations being controlled to adjust the pressure exerted on the concrete composition 2 as a function of that applied by the rams (7). Figure to be published with the abstract: Fig. 1

Description

Title of the invention: Method for manufacturing a concrete masonry block calibrated to a given height, and compacting device ensuring that such a masonry block is obtained. TECHNICAL FIELD OF THE INVENTION

[0001] The present invention relates to the field of manufacturing concrete masonry blocks (concrete blocks).

[0002] The invention relates more particularly to a method for manufacturing a concrete masonry block calibrated to a determined height, comprising a step of filling a mold with a fresh concrete composition and a step of compacting this concrete composition, as well as a compacting device for producing such a masonry block.

[0003] The manufacturing method and the compacting device according to the invention are intended in particular, but not exclusively, for the manufacturing of blocks to be coated and of facing blocks to be glued. STATE OF THE ART

[0004] Concrete masonry blocks commonly have numerous surface irregularities due to burrs caused during their manufacture, heterogeneity in the filling of the mold cells during the filling phase and uncontrollable pre-vibration or due to the presence of more or less large aggregate particles. Such irregularities prevent satisfactory parallelism of the lower and upper faces of the masonry blocks from being obtained. However, certain techniques for laying concrete masonry blocks, and in particular the thin-joint technique for laying concrete blocks, require precise dimensioning, in particular a precise height measurement. This need for precise height dimensioning imposes dimensional manufacturing tolerances.

[0005] To achieve certain masonry block tolerance classes, mechanical methods of material removal by "rectification" are used after molding and steaming the masonry block. These methods consist of removing material by machining or polishing to achieve the desired height and flatness.

[0006] These material removal methods, however, present a risk which is the alteration or weakening of the concrete masonry blocks obtained. Furthermore, depending on the surface condition of the masonry blocks and their irregularities, it may prove relatively difficult to obtain, with this type of method, low dimensional tolerances. In addition, the use of material removal methods slows down the manufacturing cycle of the concrete blocks, which generates a cost of significant production, the latter being all the more important as the desired tolerance values ​​are low (the machining phases are in fact longer and slower than for wider tolerance values).

[0007] The use of removal methods to calibrate the height of concrete masonry blocks therefore constitutes a significant problem in the manufacture of concrete masonry blocks using current techniques.

[0008] Another problem encountered during the manufacture of masonry blocks is linked to the compacting operation. This, commonly carried out using a compacting device (press) comprising one or more rammers, has the disadvantage of not being homogeneous over the entire height, the volume closest to the piston being more compacted than that close to the bottom of the mold. This then leads to the production of masonry blocks having a density gradient over their height.

[0009] Another problem encountered with current techniques for manufacturing concrete masonry blocks is the injection of foam or any other insulation into the cells of the blocks. Indeed, since the blocks in their fresh state once demolded collapse in most cases, the integration of insulation into the cells is generally carried out in the hardened state. Therefore, according to current techniques, the masonry blocks undergo, once formed, a first passage in the oven followed by an exit to be filled with an insulating material to then be subjected to a second phase of baking. Such back and forth to the oven have the disadvantage of considerably slowing down the production line.

[0010] The invention aims to remedy these problems by proposing a method for manufacturing a concrete masonry block as well as an associated device making it possible to obtain a height-calibrated concrete building block simply, quickly and precisely.

[0011] The method and the device according to the invention also aim to obtain a concrete masonry block having a reduced height density gradient compared to that present in masonry blocks manufactured using current techniques.

[0012] The method and device according to the invention also aim to manufacture masonry blocks containing an insulating material in a simple and rapid manner. OBJECT OF THE INVENTION

[0013] To this end, and according to a first aspect, the invention proposes a method for manufacturing a concrete masonry block calibrated to a given height, said masonry block comprising a lower face, an upper face, side faces as well as cells opening onto the upper face, the method comprising the following steps consisting of pouring a predetermined quantity of a concrete composition to the fresh state in a mold defining a container having a volume corresponding to the shape of the masonry block to be manufactured, and shaping the concrete composition by means of a compacting device comprising an arrangement of rams driven by first jacks in a vertical translational movement and an arrangement of reservations, of a shape complementary to the cells to be formed, driven by second jacks in a vertical translational movement, the shaping being carried out (i) by pushing the reservations into the concrete composition contained in the mold to a depth not exceeding a defined maximum depth, a portion of the concrete composition rising towards the top of the mold when the reservations are pushed in, (ii) by compacting the concrete composition by applying the rams to the portions of the concrete composition having risen and surrounding the reservations,the height of the raised parts being adjusted during compaction to the height of the masonry block targeted by adjusting the sinking of the reservations according to the pressure exerted on the concrete composition by the rammers, (iii) by removing the reservations from the mold, the location of the reservations forming the cells of the masonry block.

[0014] Thus, thanks to the adjustment of the sinking of the reservations during the compaction phase as a function of the pressure exerted by the rammers on the concrete composition compared to that applied by the reservations, the target height between the lower face and the upper face is respected.

[0015] Advantageously, it may be provided to position the piles within the mold at a height corresponding to the height of the masonry block targeted prior to the sinking of the reservations into the concrete composition.

[0016] Advantageously, in the event of a pressure exerted by the reservations on the concrete composition greater than a limit pressure corresponding to a pressure greater than or equal to that exerted by the rammers on the raised part of the concrete composition, the reservations are raised until the pressure exerted by the reservations on the concrete composition is less than or equal to the pressure exerted by the rammers.

[0017] Advantageously, the maximum depth of insertion of the reservations is defined to establish a distance of at least 5 millimeters between the underside of the reservations and the bottom of the mold.

[0018] Advantageously, the mold is subjected to vibration as soon as the reservations come into contact with the concrete composition contained in the mold.

[0019] Advantageously, the method comprises a step of injecting an insulating material into the cells formed after removal of the reservations and before removal of the mold.

[0020] The invention also relates to a device for compacting a concrete composition for the manufacture of a calibrated concrete masonry block at a height given said masonry block comprising a lower face, an upper face, side faces as well as cells opening on the upper face, the compacting device comprising an arrangement of rams driven by first jacks in a vertical linear movement, the compacting device being remarkable in that it comprises an arrangement of reservations, of a shape complementary to the cells to be formed, driven by second jacks in a vertical translation movement, said reservations being controlled to adjust the pressure exerted on the concrete composition according to that applied by the rams.

[0021] Advantageously, the compacting device comprises means ensuring that the reservations are placed in abutment in a determined position relative to the rammers.

[0022] Advantageously, the first and second cylinders are powered by a common hydraulic or pneumatic circuit.

[0023] The invention also relates to a device for compacting a concrete composition for the manufacture of a concrete masonry block calibrated to a given height according to the manufacturing method described above.

[0024] The invention also relates to a concrete masonry block calibrated to a given height obtained according to the manufacturing method described above. BRIEF DESCRIPTION OF THE FIGURES

[0025] Other characteristics and advantages of the invention will emerge from the detailed description of the invention which follows, given by way of example and with reference to the appended figures in which:

[0026] [Fig.l] [Fig.l] represents a schematic sectional view of a device for compacting a concrete composition according to the invention for the manufacture of a masonry block, the compacting device being illustrated implemented with a concrete composition contained in a mold;

[0027] [Fig.2] [Fig.2] shows schematically the process of shaping a concrete composition using the compacting device of [Fig.l]. DETAILED DESCRIPTION OF THE INVENTION

[0028] In relation to Figures 1 and 2, a device 1 for compacting a concrete composition 2 is described for manufacturing a concrete masonry block calibrated to a given height as well as the step of compacting the concrete composition for the purpose of manufacturing the masonry block.

[0029] The masonry block intended to be manufactured in the example illustrated, of parallelepiped shape, is a block comprising a lower face, an upper face, lateral faces as well as cells delimited by internal walls, said cells extending vertically between the upper and lower faces and being open on the upper face and not open on the lower face.

[0030] In a known manner, the compacting device 1 is part of an assembly also comprising a mold 7 placed on a vibrating table (not shown) as well as distribution means for supplying the mold 7 with fresh product to be molded. In the illustrated embodiment, the mold 7 has a box body defining a container of volume 70 corresponding to the shape of the masonry block to be manufactured. The box body, open at the top and bottom, is placed on a board 8 advantageously instrumented, itself arranged on the vibrating table. The instrumented board 8 comprises sensors for diagnosing the operation of the vibrating table during a production cycle. This is of course an exemplary embodiment, the mold 7 being able to include a bottom wall and be placed directly on the vibrating table.

[0031] The compacting device 1 according to the invention comprises an arrangement of rams 3 driven by first jacks (housed in the example described in the block referenced 4) according to a vertical translation movement and an arrangement of reservations 5, of a shape complementary to the cells to be formed, driven by second jacks 6 according to a vertical translation movement.

[0032] The reservations 5 are controlled to be moved downwards, in the direction of the mold, to sink into the concrete composition 2 contained in a mold 7 and proceed to shape the masonry block, and upwards, in the direction opposite to the mold 7 to allow either an adjustment of the height of the reservations within the mold 7 as a function of the compacting pressure exerted by the rammers, or a removal of the reservations 5 from the concrete composition 2. As will be seen later, the adjustment of the height of the reservations within the mold 7 is carried out when the reservations 5 exert on the concrete composition 2 a pressure greater than or equal to that exerted by the rammers 3 on the concrete composition 2.

[0033] According to a preferred embodiment, the second cylinders 6 are hydraulic or pneumatic cylinders which are powered by the hydraulic or pneumatic circuit powering the first cylinders 4.

[0034] Advantageously, the compacting device 1 comprises stops 50 ensuring that the reservations 5 are placed in abutment in a determined position relative to the rammers 3. In the example illustrated, the stops 50 are carried by the reservations 5 and are arranged to come into abutment on the end feet 30 of the rammers 3. This is of course an exemplary embodiment, any other means for placing the reservations 5 in abutment on the rammers 3 being able to be implemented without departing from the scope of the invention. In addition to the stops 50, the compacting device 1 also comprises stops (not shown) allowing the rammers 3 to be placed in abutment at a compaction level corresponding to the desired height of the masonry block.

[0035] Compaction of a concrete composition by means of the compaction device just described is carried out in the following manner ([Fig.2]).

[0036] First of all, a predetermined quantity of a fresh concrete composition 2 is poured into the mold 7. By predetermined quantity, we mean the quantity necessary to produce the masonry block.

[0037] The piles 3 are then lowered to be positioned within the mold 7 at a height corresponding to the height of the targeted masonry block.

[0038] The masonry block is then shaped by lowering the reservations 5 and pushing them into the concrete composition 2 contained in the mold 7 ([Fig.2], diagram (a)). In order to ensure a minimum thickness of the laying wall (part of the concrete composition 2 located at the bottom of the mold 7, on the underside of the reservations 5), the driving in of the reservations 5 is limited to a depth not exceeding a defined maximum depth. Preferably, the maximum driving depth of the reservations 5 is defined to establish a distance of at least 5 millimeters between the underside of the reservations 5 and the bottom of the mold 7. It is of course obvious that a different maximum depth can be defined without departing from the scope of the invention. Advantageously, the mold 7 is subjected to vibration as soon as the reservations 5 come into contact with the concrete composition 2 contained in the mold 7.

[0039] When the reservations 5 are driven in, a part of the concrete composition 2 rises towards the top of the mold 7 to form the faces and spacers of the masonry block ([Fig.2], diagrams (b) and (c)).

[0040] When the quantity of concrete composition 2 poured into the mold 7 is adequate (no overfilling), the rammers 3, arranged at the target height of the masonry block, come into contact with the parts of the concrete composition 2 having risen and extending around the reservations 5, thus compacting the composition. By touching the concrete composition, the rammers 3 create an overpressure by the thrust of the concrete composition on the jacks of the reservations 5. The reservations 5 then tend to rise. In this case, and for each type of block (or each mold 7), a maximum pressure is programmed not to be exceeded which allows (via a non-return valve) the reservations 5 to rise. Thus, in the event of overfilling, the reservations 5 are raised, allowing the composition to move towards the bottom of the mold, thus creating an excess thickness of the laying veil.Thus, thanks to the transfer of part of the composition to the bottom of the mold, the target height of the concrete composition in the mold, and therefore that of the final product, is respected.

[0041] Once the block has been shaped, the reservations 5 and the pins 7 are removed from the mold 7, the location of the reservations 5 then forming the cells of the masonry block.

[0042] During these withdrawals, the reservations 5 and the pounding pins 3 are braked, and a decom- pressure, with a partial rise of 5 mm maximum of the mold 7 (height corresponding to the minimum thickness of the laying veil), is observed. The reservations are then completely raised, followed by the raising of the rams.

[0043] Once the reservations 5 and the pins 7 have been removed, the manufactured masonry block is still in the box of the mold 7, which prevents it from collapsing. It is then possible to inject foam or any other insulation into the cells without risking damaging the block. To do this, the equipment for injecting insulation into the cells is positioned above the mold 7 of the press, the injection is carried out and then the equipment is removed.

[0044] The final demolding is then carried out by reassembling the mold 7.

[0045] The invention is described in the above by way of example. It is understood that a person skilled in the art is able to carry out different variant embodiments of the invention without departing from the scope of the invention.

Claims

Claims

1. A method of manufacturing a concrete masonry block calibrated to a given height, said masonry block comprising a lower face, an upper face, side faces and cells opening out on the upper face, the method comprising the following steps consisting of pouring a predetermined quantity of a concrete composition (2) in the fresh state into a mold (7) defining a container having a volume corresponding to the shape of the masonry block to be manufactured and shaping the concrete composition by means of a compacting device (1) comprising an arrangement of rams (3) by first jacks (4) in a vertical translational movement and an arrangement of reservations (5), of a shape complementary to the cells to be formed, driven by second jacks (6) in a vertical translational movement,the shaping being carried out: - by pushing the reservations (5) into the concrete composition (2) contained in the mold (7) to a depth not exceeding a defined maximum depth, a part of the concrete composition (2) rising towards the top of the mold (7) when pushing in the reservations (5) to form the faces and spacers of the masonry block, - by compacting the concrete composition (2) by applying the rammers (3) to the parts of the concrete composition (2) having risen and surrounding the reservations (5), the height of the raised parts being adjusted during compaction to the height of the masonry block targeted by adjusting the depression of the reservations (5), - then, by removing the reservations (5) from the mold (7), the location of the reservations (5) forming the cells of the masonry block.

2. Method for manufacturing a concrete masonry block according to claim 1, characterized in that, prior to driving the reservations (5) into the concrete composition (2), the piles (3) are positioned within the mold (7) at a height corresponding to the height of the intended masonry block.

3. A method of manufacturing a concrete masonry block according to claim indication 1 or claim 2, characterized in that in the event of a pressure exerted by the reservations (5) on the concrete composition (2) greater than a limit pressure corresponding to a pressure greater than or equal to that exerted by the rammers (3) on the raised part of the concrete composition (2), the reservations (5) are raised until the pressure exerted by the reservations (5) on the concrete composition (2) is less than or equal to the pressure exerted by the rammers (3).

4. Method for manufacturing a concrete masonry block according to any one of claims 1 to 3, characterized in that the maximum depth of insertion of the reservations (5) is defined to establish a distance of at least 5 millimeters between the underside of the reservations (5) and the bottom of the mold (7).

5. Method for manufacturing a concrete masonry block according to any one of claims 1 to 4, characterized in that the mold (7) is subjected to vibration as soon as the reservations (5) come into contact with the concrete composition (2) contained in the mold (7).

6. Method for manufacturing a concrete masonry block according to any one of claims 1 to 5, characterized in that it comprises a step of injecting an insulating material into the cells formed after removal of the reservations (5) and before removal of the mold (7).

7. Device (1) for compacting a concrete composition (2) for the manufacture of a concrete masonry block calibrated to a given height, said masonry block comprising a lower face, an upper face, side faces as well as cells delimited by at least one internal wall and opening on the upper face, the compacting device (1) comprising an arrangement of rams (3) driven by first jacks (4) in a vertical linear movement, characterized in that it comprises an arrangement of reservations (5), of a shape complementary to the cells to be formed, driven by second jacks (6) in a vertical translation movement, said reservations being controlled to adjust the pressure exerted on the concrete composition (2) as a function of that applied by the rams (7).

8. Compacting device (1) according to claim 7, characterized in that it comprises means (50) ensuring that the reservations (5) are placed in abutment in a determined position relative to the rammers (3).

9. Compacting device (1) according to claim 7 or claim 8, characterized in that the first and second cylinders (4, 6) are powered by a common hydraulic or pneumatic circuit.

10. Concrete masonry block calibrated to a given height obtained according to the manufacturing method according to any one of claims 1 to 6.

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