Block press machine and method for producing molded articles

Abstract

A block press machine (1) for producing molded articles (7) and a method for producing molded articles (7) are provided. The block press machine (1) has a frame (2), a pressing device (4) movable relative to the frame (2), a mold device (3) movable relative to the frame (2), a counter-pressing means (5) and a synchronization device (6). The synchronization device (6) is configured to synchronize a movement of the mold device (3) and the pressing device (4) by establishing a temporarily fixed connection between the pressing device (4) and the mold device (3), so that the pressing device 4 and the mold device (3) can be moved synchronously by a common moving means.

Description

[0001] Block press machine and method for producing molded articles

[0002] The present invention relates to a block press machine and to a method for producing molded articles with a block press machine.

[0003] Block press machine are generally known from the state of the art. They are used for producing molded articles for the manufacture of artificial stones of various kinds, such as paving stones, bricks, masonry stones, curbstones or also stones for the manufacture of pipelines, etc. Within the meaning of the present invention, a molded article is thus to be understood as a product manufactured from a material suitable for the production of artificial stones with the aid of a mold and pressure. The material is usually a granular mixture of different starting materials, such as a ready-mixed, fresh but not yet hardened concrete, a material mixture suitable for the production of fired bricks or even just a finegrained granulate that hardens without the addition of cement. In principle, this can be an intermediate product that is subsequently fed to further production steps such as firing or curing, for example. However, it can also be a product that no longer needs to be fired or subjected to a special curing procedure with the addition of heat, e.g. in an autoclave.

[0004] In known block press machines, the at least one material is inserted into a mold device and then compressed under pressure by a pressing device and / or by vibration in order to produce at least one molded article in the mold. As a rule, several molded articles are produced simultaneously in one work step in such a mold device. For this purpose, the pressing device has a plunger that matches the shape of the mold device, which plunges into the mold in order to compress the material in the mold using pressure. For this purpose, known block press machines have a counter-pressing means against which the pressure of the plunger, which is usually applied from above, can act. The mold itself is correspondingly open at the top and bottom. When the mold rests on the counter-pressing means, the counter-pressing means closes the mold from below and the at least one material is inserted into the mold from above. The plunger then also plunges into the mold from above in order to compress the material in the mold under pressure.

[0005] After the material has been fully compressed, i.e. the molded article has been produced, the molded article still has to be demolded from the mold. This demolding is carried out either upwards or downwards out of the mold in known block press machines. When demolding upwards, a second plunger acts as a counter-pressing means from below, which presses the molded articles upwards out of the mold after they have been pressed by the first plunger. The molded articles can then be gripped above the mold with a gripping tool for further transport. When demolding downwards, a transport pallet acts as a counter-pressing means from below. For demolding "downwards", the plunger is held in position after pressing and the mold is lifted upwards until the molded articles are no longer in the mold and can be transported further by the transport pallet. In the known "demolding downwards" process, the molded articles do not move downwards out of the mold, but the mold moves away upwards.

[0006] The emergence of new methods for the production of artificial stones has created new challenges for the known machines used to manufacture them. These new manufacturing processes use particularly fine-grained materials that have to be pressed into molded articles under particularly high pressure before being fed into further manufacturing steps. These particularly fine-grained materials, in turn, are generally not suitable for compression by vibration, as is common in the production of concrete blocks.

[0007] In addition, the two known variants described above for demolding and further transport are in principle ruled out for molded articles that are pressed from particularly fine-grained materials under particularly high pressure. For demolding upwards and subsequent transport such molded articles are not suitable because they are still so fragile after pressing and before the further manufacturing steps that gripping and lifting them using pincer grippers or similar devices can very easily damage the molded articles or destroy them completely.

[0008] However, these molded articles are also not suitable for direct pressing with a transport pallet as a counter-pressing means and demolding downwards by lifting the mold. The pressures to be applied to produce the molded articles are so high that the transport pallets normally used cannot withstand the necessary pressure and therefore cannot be used as a counter-pressing means.

[0009] Against this background, it is an object of the present invention to be able to reliably produce and transport molded articles made of particularly fine-grained material.

[0010] This object is achieved with a block press machine for producing molded articles according to the invention. The block press machine has a frame, a mold device movable relative to the frame, a pressing device movable relative to the frame, a counter-pressing means and a synchronization device. It is configured in such a way that at least one molded article can be produced in the mold device by interaction of the pressing device, the mold device and the counter-pressing means. For its part, the synchronization device is configured in such a way that it can synchronize the movement of the mold device and the pressing device relative to the frame.

[0011] In the block press machine according to the invention, the mold device and the pressing device are therefore each separately movable relative to the frame. Therefore, they can in principle also be moved relative to each other. This is necessary for the different movement sequences during the production of the molded articles. However, the synchronization device according to the invention now synchronizes the movement of the mold device and the pressing device relative to the frame, in particular when demolding is to take place. This means that the synchronization device ensures a uniform joint movement of the mold device and the pressing device. In other words, the synchronization device allows the mold device and the pressing device to be moved together relative to the frame, essentially without relative movement to each other. The synchronization device enables this synchronous movement of the mold device and the pressing device, for example by a common moving means.

[0012] With the synchronization device, it is therefore possible to lift the pressing device and the mold device synchronously with the at least one molded article located in the mold after the at least one molded article has been produced within the mold device under the pressure of the pressing device on the counter-pressing means. Synchronous is to be understood here as a joint movement of the two devices, in which there is practically no relative movement of the two devices with respect to one another. This is the only way to ensure that the freshly pressed molded articles are not damaged. This is because even if the at least one molded article is produced under high pressure and initially retains its shape by itself, it is still very sensitive to vibrations. The synchronization device therefore allows the synchronous lifting of the mold device, the pressing device and the at least one molded article located in the mold device from the counter-pressing means. This makes it possible to demold the at least one molded article downwards onto a separate transport means previously inserted into the machine and to transport it for further processing without damaging the at least one molded article.

[0013] In principle, the block press machine should be configured in such a way that relatively high pressures can be achieved during the production of the molded articles. For example, the pressure for pressing the at least one molded article should be at least 200 bar. However, pressures of around 300 bar are particularly suitable.

[0014] Advantageously, the synchronization device is configured to establish a temporarily fixed connection between the mold device and the pressing device, so that the mold device and the pressing device are movable synchronously relative to the frame. A temporarily fixed connection is to be understood as a releasable connection which is established at least between a part of the mold device and a part of the pressing device in such a way that a movement of the part of the mold device or a movement of the part of the pressing device is transmitted to the respective counterpart. Thus, when the temporarily fixed connection between a part of the mold device and a part of the pressing device is established, a movement of the part of the pressing device synchronously causes the same movement of the part of the mold device and vice versa. In other words, the synchronization device temporarily prevents a relative movement between the mold device and the pressing device. When the temporarily fixed connection between the mold device and the pressing device is released again, the two devices can move relative to each other again. This achieves reliable synchronization of the movements of the mold device and the pressing device. It is useful if the synchronization device is a mechanical synchronization device. This means that the synchronization device synchronizes the movement of the mold device and the pressing device mechanically. In principle, synchronization of the movement of the mold device and the pressing device by other means is also conceivable, for example electromagnetic, hydraulic or electronic synchronization. However, it has been found that mechanical synchronization is particularly reliable.

[0015] Preferably, the synchronization device has at least one first synchronization means and at least one second synchronization means. The first synchronization means is configured to establish a temporarily fixed connection with the at least one second synchronization means. The at least one first synchronization means is therefore an active synchronization means and the at least one second synchronization means is a passive synchronization means. A relative movement between the first synchronization means and the second synchronization means is possible as long as the temporarily fixed connection is not established by the first synchronization means, and is not possible as soon as the temporarily fixed connection is established by the first synchronization means. The division of the synchronization device into at least two separate synchronization means permits a large degree of design freedom in the arrangement of the synchronization device in the block press machine according to the invention.

[0016] Further, the at least one first synchronization means is provided on the pressing device and the at least one second synchronization means is provided on the mold device. Alternatively, the at least one first synchronization means is provided on the mold device and the at least one second synchronization means is provided on the pressing device. By providing the at least one first synchronization means on the pressing device or on the mold device and providing the at least one second synchronization means on the respective other device, reliable synchronization of the movement of the mold device and the pressing device is achieved.

[0017] Advantageously, the at least one first synchronization means comprises at least one locking brake and the at least one second synchronization means comprises at least one clamping rod. The clamping rod can move through the locking brake as long as the locking brake is not active. As soon as the locking brake is active, the locking brake establishes a temporarily fixed connection with the clamping rod and the movement of the clamping rod relative to the locking brake is blocked. Thus, a relative movement of the mold device and the pressing device with respect to each other is also effectively blocked by the at least one clamping rod being attached to the one device and the at least one locking brake being attached to the other device.

[0018] Advantageously, the mold device has a mold carrier, at least one mold moving means and a block mold. The at least one mold moving means is configured to move the mold carrier with the block mold relative to the frame. The block mold is preferably interchangeable. In particular, therefore, the mold carrier and the block mold of the mold device attached to the mold carrier are movable by the at least one mold moving means of the mold device. A mold carrier is also understood here to mean mold carrier structures comprising several components which are fixedly connected to one another to form a mold carrier frame.

[0019] Advantageously, the pressing device has a plunger carrier, at least one plunger moving means and a plunger. The at least one plunger moving means is configured to move the plunger carrier with the plunger relative to the frame. The plunger is preferably interchangeable.

[0020] In particular, the plunger carrier of the pressing device and the plunger of the pressing device attached to the plunger carrier are therefore movable by the at least one plunger moving means. A plunger carrier is also understood here to mean plunger carrier structures comprising several components which are, for example, fixedly connected to one another to form a plunger carrier frame. Preferably, the plunger moving means is exactly one plunger moving means. Providing the block mold to be interchangeable further allows the block press machine to be converted to other molded articles or a damaged block mold to be replaced.

[0021] Preferably, the at least one plunger moving means is configured to move the plunger carrier with the plunger and the mold carrier with the block mold synchronously relative to the frame by interacting with the synchronization device. In this way, the plunger carrier with the plunger attached thereto, the mold carrier with the block mold attached thereto and the at least one molded article produced in the block mold can be lifted synchronously from the counter-pressing means without the at least one molded article being damaged.

[0022] Further, at least one mold moving means and / or at least one plunger moving means has at least one hydraulic, electrical and / or mechanical drive.

[0023] The use of one or more hydraulic mold lifting cylinders as a hydraulic drive is advantageous, as precise movements can be realized via hydraulic cylinders. Particularly preferably, four hydraulic mold lifting cylinders are provided, which are connected to four corners of the mold carrier in order to ensure a particularly precise and uniform movement of the mold carrier and the block mold attached to the mold carrier. In principle, other moving means such as electrical, mechanical, pneumatic or electromagnetic drives are also conceivable as mold moving means.

[0024] In the block press machine according to the invention, the plunger moving means applies the greatest forces, namely pressure forces of up to 300 bar. A hydraulic drive, e.g. in the form of a hydraulic cylinder, is particularly suitable for this purpose. It is therefore advantageous to implement the synchronized movement of the mold device and the pressing device with only a single plunger moving means as a common moving means of the mold device and the pressing device. Using exactly one moving means as a common moving means simplifies the synchronization of the movement and makes it particularly precise. The at least one plunger moving means therefore preferably comprises at least one hydraulic plunger cylinder.

[0025] It is preferable if the block press machine also has at least one material insertion device, preferably a filling carriage, which is configured to insert at least one material into the mold device. Preferably, the block press machine has a first material insertion device, in particular a first filling carriage, and a second material insertion device, in particular a second filling carriage, wherein the first material device is configured to insert at least a first material, in particular a core material, into the mold device, in particular into the block mold, and the second material insertion device is configured to insert at least a second material, in particular a second material and a third material, into the mold device, in particular into the block mold. As a result, the block press machine is able to produce molded articles from at least one material and, depending on requirements, also from several materials.

[0026] Preferably, the counter-pressing means comprises a matrix that is fixedly attached to the frame. This can be a solid plate or block made of a metal, such as steel. However, solutions in which the matrix is made of stone, ceramic and / or another pressure-resistant material are also conceivable. The matrix should also preferably be interchangeably attached to the frame. By fixedly attaching the matrix to the frame, the matrix can be mounted in such a way that it can absorb the large forces from the pressing device during the production of the at least one molded article particularly well and transfer them to the frame. A steel plate is particularly well suited as a counterpart for producing the at least one molded article due to the high pressure exerted by the pressing device. Providing the matrix to be interchangeable allows the block press machine to be converted to other molded articles or a damaged matrix to be replaced.

[0027] It is useful if the block press machine further has a transport device fortransporting a transport means, preferably a pallet. In particular, the transport means is a separate element from the counter-pressing means. In this way, the block press machine can further transport the at least one produced molded article using conventional transport means and feed it, for example, to a downstream manufacturing step.

[0028] Preferably, the transport device is configured to move the transport means between the counterpressing means and the mold device, wherein the block press machine is configured to demold the at least one molded article from the mold device onto the transport means. Preferably, the block press machine is configured to synchronously set down the mold device, the pressing device and the at least one molded article on the transport means, to cancel the synchronization of the movement of the mold device and the pressing device and to lift the mold device off the transport means again, while the pressing device remains in position, in order to demold the at least one molded article from the mold device onto the transport means. This allows the intended production and undamaged transportation of the at least one molded article in a particularly advantageous manner.

[0029] Advantageously, the frame has at least one guide element which guides both the movement of the mold device and the movement of the pressing device, wherein the at least one guide element preferably comprises at least one tension rod. The frame of the block press machine according to the invention must withstand high pressure loads from the pressing device attached to it. Accordingly, it is advantageous if the frame has tension rods for stabilization. These tension rods are well suited as common guide elements for the mold device and the pressing device. In principle, it is advantageous to guide the movements of the mold device and the pressing device on at least one common guide element. This additionally supports the synchronization of the movement of the mold device and the pressing device.

[0030] Furthermore, the object is achieved by a method for producing molded articles with a block press machine according to the invention. The block press machine has a frame, a mold device movable relative to the frame, a pressing device movable relative to the frame, a counter-pressing means, at least one material insertion device and a transport device for transporting a transport means. The method comprises the following steps: inserting at least one material into the mold device by the at least one material insertion device; pressing the at least one material to form at least one molded article by interaction of the pressing device, the mold device and the counter-pressing means; synchronous lifting of the pressing device, the mold device and the at least one molded article located in the mold device; moving the transport means between the counter-pressing means and the mold device; and demolding the at least one molded article from the mold device onto the transport means.

[0031] Using the method according to the invention, molded articles made of particularly fine-grained material can be reliably produced in the block press machine and transported out of the block press machine without damaging the molded articles. Due to the synchronous lifting of the pressing device, the mold device and the produced molded article, only minimal forces act on the at least one molded article during lifting from the counter-pressing means.

[0032] It is advantageous if the synchronous lifting of the pressing device, the mold device and the at least one molded article located in the mold device is performed by a common moving means. This simplifies the synchronous lifting and achieves a particularly precise joint movement.

[0033] Advantageously, the method comprises the following steps: synchronously lowering the pressing device, the mold device and the at least one molded article located in the mold device onto the transport means; and demolding the at least one molded article onto the transport means by lifting the mold device.

[0034] This enables precise depositing and demolding of the at least one molded article onto the transport means.

[0035] Advantageously, the procedure comprises the following steps: inserting a first material, preferably a core material, into the mold device by a first material insertion device; pre-pressing the first material by interaction of the pressing device, the mold device and the counter-pressing means; inserting a second material, preferably a header material, into the mold device by a second material insertion device; pressing the first material and the second material to form at least one molded article by interaction of the pressing device, the mold device and the counter-pressing means.

[0036] Thus, the method according to the invention can be used to produce molded articles from different material compositions.

[0037] Preferably, the method comprises the following steps: inserting a third material into the mold device by the second material insertion device; and pressing the first material, the second material and the third material to form at least one molded article by interaction of the pressing device, the mold device and the counter-pressing means.

[0038] Thus, the method according to the invention can be used to produce molded articles from up to three different materials, which provides even greater variability in the application of the method.

[0039] It is advantageous if the method is performed with a block press machine as described above. This way, the block press machine according to the invention and the method according to the invention can interact in a particularly advantageous manner in order to produce and transport molded articles made of particularly fine-grained material.

[0040] The present invention is explained in more detail below using the example of one embodiment. The figures schematically show:

[0041] Fig. 1 a perspective view of a block press machine according to the invention; Fig. 2 a top view of the block press machine shown in Fig. 1 ;

[0042] Fig. 3 a sectional view of the block press machine along line A - B in Fig. 2;

[0043] Fig. 4 a sectional view of a part of the block press machine along line C - D in Fig. 2;

[0044] Fig. 5 a sectional view of a part of the block press machine along line E - F in Fig. 8;

[0045] Fig. 6 a sectional view of a part of the block press machine along the line G - H in Fig. 4;

[0046] Fig. 7 a side view of the block press machine during a pressing process;

[0047] Fig. 8 a side view of the block press machine with mold device and pressing device synchronously lifted;

[0048] Fig. 9 a side view of the block press machine with mold device and pressing device synchronously placed on a transport means;

[0049] Fig. 10 a side view of the block press machine during demolding; and

[0050] Fig. 11 a side view of the block press machine during a transport of molded articles.

[0051] The block press machine 1 has a frame 2, a mold device 3 movable relative to the frame, a pressing device 4 movable relative to the frame, a counter-pressing means 5 and a synchronization device 6. The block press machine 1 is configured to produce at least one molded article 7 in the mold device 3 by interaction of the pressing device 4, the mold device 3 and the counter-pressing means 5. The synchronization device 6 is configured to synchronize a movement of the mold device 3 and the pressing device 4 relative to the frame 2.

[0052] Furthermore, the block press machine 1 of the illustrated embodiment has a transport device 8 and two material insertion devices 9. The transport device 8 is configured to transport pallets 10 into the block press machine 1 and out of the block press machine 1 in the direction indicated by arrows in Fig. 1 . In the embodiment shown, the two material insertion devices 9 are configured as a first filling carriage 11 and a second filling carriage 12. The first filling carriage 11 and the second filling carriage 12 are movable into and out of the block press machine 1 in the directions indicated by arrows in Fig. 1 in order to insert materials for producing the molded articles 7 into the mold device 3.

[0053] In the embodiment shown, the frame 2 comprises an upper frame 13, a lower frame 14, four pressure supports 15 and four tension rods 16. An anvil 17 is mounted on the lower frame 14, on which the counter-pressing means 5 is in turn interchangeably mounted. In this case, the counter-pressing means 5 is a matrix 18 in the form of a steel plate. The tension rods 16 clamp the upper frame 13 and the lower frame 14 together by means of clamping nuts 19 via the pressure supports 15.

[0054] In the sectional views in Figs. 3 and 4, the details of the mold device 3 and the pressing device 4 of the present embodiment are clearly recognizable.

[0055] The mold device 3 has a mold carrier 20, four mold moving means 21 and a block mold 22. The four mold moving means 21 are configured to move the mold carrier 20 with the block mold 22 relative to the frame 2. Here, the four mold moving means 21 are configured as four hydraulic mold lifting cylinders 23, which are configured to move the mold carrier 20 with the block mold 22 interchangeably attached thereto up and down in the vertical direction as seen in Fig. 3. The mold carrier 20 is configured as a mold carrier frame, which is made up of several interconnected components. For clarification, some of the components are provided with the reference sign 20 of the mold carrier in Fig. 3.

[0056] The pressing device 4 has a plunger carrier 24, a plunger moving means 25 and a plunger 26. The plunger moving means 25 is configured to move the plunger carrier 24 with the plunger 26 relative to the frame. In the present case, the plunger moving means 25 is configured as a hydraulic plunger cylinder 27, which is mounted centrally on the upper frame 13 and is configured to move the plunger carrier 24 with the plunger 26 interchangeably attached thereto up and down in the vertical direction as seen in Fig. 3. The plunger carrier 24 is also made up of several components in the present case.

[0057] The four hydraulic mold lifting cylinders 23 are connected to the mold carrier 20 in such a way that they can move the mold carrier 20 and the block mold 22 attached thereto up and down relative to the frame 2 and relative to the pressing device 4. The hydraulic plunger cylinder 27 is connected to the plunger carrier 24 in such a way that it can move the plunger carrier 24 and the plunger 26 attached thereto up and down relative to the frame 2 and relative to the mold device 3. The pressing device 4 and the mold device 3 can therefore basically be moved up and down independently of each other. Both the mold carrier 20 and the plunger carrier 24 are guided on the tension rods 16. The tension rods 16 are therefore guide elements for the mold carrier 20 and the plunger carrier 24. The mold carrier 20 has two guide points on each tension rod 16, as can be seen in Fig. 4. The plunger carrier 24 has one guide point on each tension rod 16 between the two guide points of the mold carrier 20. In the present embodiment, the plunger carrier 24 is thus guided in the vertical direction between two sections of the mold carrier 20.

[0058] The synchronization device 6 of the illustrated embodiment is a mechanical synchronization device 6. The synchronization device 6 in the present case has four first synchronization means 28 and four second synchronization means 29. Each first synchronization means 28 is configured to establish a temporarily fixed connection with one of the second synchronization means 29. In the present case, the first synchronization means 28 is configured as a locking brake 30 and the second synchronization means 29 is configured as a clamping rod 31 .

[0059] As can be seen in Figs. 4 and 6, each of the clamping rods 31 is fixedly connected to the mold carrier 20 via a clamping rod bearing 32. Fig. 4 clearly shows that the clamping rod 31 extends vertically from the clamping rod bearing 32 upwards through the locking brake 30 attached to the plunger carrier 24, the plunger carrier 24, an upper section of the mold carrier 20 and the upper frame 13. On the upper frame 13, the clamping rod 31 is equipped with a fall protection 33.

[0060] As can be seen in Figs. 4 and 5, each locking brake 30 is attached to the plunger carrier 24. The clamping rod 31 runs through the locking brake 30. As long as the locking brake 30 is not in the braking position, the clamping rod 31 and the locking brake 30 can move freely relative to each other. As soon as the locking brake 30 is brought into the braking position, it clamps the clamping rod 31 in such a way that a temporarily fixed connection is established between the locking brake 30 and the clamping rod 31 . The locking brake 30 and the clamping rod 31 can then no longer move relative to each other. The same applies to the mold carrier 20, to which the four clamping rods 31 are attached, and the plunger carrier 24, to which the four locking brakes 30 are attached. As soon as the four locking brakes 30 fix the clamping rods 31 , a temporarily fixed connection is established between the mold carrier 20 and the plunger carrier 24. In this state, the mold carrier 20 and the plunger carrier 24 can no longer move relative to each other. In this state, the mold carrier 20 and the plunger carrier 24 can be moved via a common moving means.

[0061] In the embodiment shown, in the state in which the locking brakes 30 are active, the four hydraulic mold lifting cylinders 23 can be switched to freewheeling. This means that the piston in each of the four hydraulic mold lifting cylinders 23 is free to move up or down, since no hydraulic pressure acts on the piston from above or below. In this state, the hydraulic plunger cylinder 27 can act as a common moving means for the mold carrier 20 and the plunger carrier 24 and move the mold carrier and the plunger carrier 24 up and down synchronously relative to the frame 2 in the vertical direction. In this way, the locking brakes 30 as the first synchronization means 28 of the synchronization device 6 and the clamping rods 31 as the second synchronization means 29 of the synchronization device 6 synchronize the movement of the mold device 3 and the pressing device 4.

[0062] As shown in Fig. 11 , the block press machine 1 of the present embodiment also has a first filling device 34 in the form of a first filling funnel and a second filling device 35 in the form of a second filling funnel. Via the first filling device 34, a first material, in particular a particularly fine-grained core material, for producing the molded articles 7 can be filled into the first filling carriage 11 . A second material, in particular a header material, for producing the molded articles 7 can be filled into the second filling carriage 12 via the second filling device 35. In addition, a third material, for example sand, for producing the molded articles 7 can be filled into the second filling carriage 12 via the second filling device 35. The first filling carriage 11 is configured to move in the direction shown by a double arrow in Fig. 1 over the block mold 22 and back to its starting position shown in Fig. 1 and to insert the first material into cavities 36 of the block mold 22. In the process, the first filling carriage 11 inserts the first material into the cavities 36 as it passes over the block mold 22 and scrapes off excess material again as it returns to its starting position. The cavities 36 of the block mold 22 are shown in an empty state, for example in Fig. 3. The second filling carriage 12 is configured to move in the direction shown by a double arrow in Fig. 1 over the block mold 22 and back to its starting position shown in Fig. 1 and to apply the second material and potentially the third material to the material previously filled into the cavities 36 of the block mold 22. In the process, the second filling carriage 12 inserts the second material into the cavities 36 as it passes over the block mold 22 and, when returning to its starting position, potentially inserts the third material onto the material located in the cavities 36 and brushes off excess material. The first material, the second material and possibly the third material form a raw material 37, from which the at least one molded article 7 is produced under the pressure of the plunger 26. In Fig. 4, the raw material 37 is arranged in the cavities 36 of the block mold 22 before the plunger 26 presses the raw material 37 from above to form the molded articles 7. The raw material 37 can also be only the first material that is inserted by the first filling carriage 11 . In general, the raw material 37 thus comprises at least the first material and / or the second material and / or the third material.

[0063] In the following, the method for producing molded articles according to the invention is described using the block press machine 1 as an example.

[0064] In a first step, at least one material is inserted into the mold device 3 by at least one material insertion device 9. The starting position of the individual components before the first step is carried out can be seen in Fig. 3, for example. In the present embodiment, in the first step, the first filling carriage 11 inserts the core material as the first material into the block mold 22 of the mold device 3, which rests on the matrix 18. The matrix 18 thereby forms a lower base for the cavities 36 of the block mold 22, so that the core material does not emerge downwards from the cavities 36. To insert the core material, the filling carriage 11 moves over the block mold 22 into the block press machine 1 and inserts the core material into the cavities 36. The filling carriage 11 then moves out of block press machine 1 again and removes excess core material from block mold 22. In an intermediate step, the hydraulic plunger cylinder 27 moves the plunger carrier 24 with the plunger 26 downwards so that the plunger 26 plunges into the cavities 36 of the block mold 22 in order to pre-press the core material. This creates space in the cavities 36 for further material. The hydraulic plunger cylinder 27 then moves the plunger carrier 24 with the plunger 26 back into a lifted position so that the second filling carriage 12 can move into the block press machine 1 in order to insert the header material and potentially a third material into the cavities 36 of the block mold 22. The second filling carriage 12 then moves back to its starting position shown in Fig. 1 . This means that the raw material 37 is now in the cavities 36 of the block mold 22, which rests on the matrix 18, as can be seen in Fig. 4, for example. In a second step, the block press machine 1 presses at least one molded article 7 from the raw material 37 by interaction of the pressing device 4, the mold device 3 and the counter-pressing means 5. In the present embodiment, the plunger 26 thus moves into the block mold 22 and presses under high pressure onto the raw material 37, as can be seen, for example, in Fig. 7. In this way, the molded articles 7 are produced between the plunger 26, the block mold 22 and the matrix 18 in the cavities 36. The hydraulic plunger cylinder 27 applies a pressure of at least 200 bar and up to 300 bar via the plunger carrier 24 and the plunger 26. After the pressure required to produce the molded articles 7 from the raw material 37 has been maintained for a sufficiently long time, the hydraulic plunger cylinder 27 relieves the plunger 26 again, but does not lift it from the molded articles 7 located in the block mold 22.

[0065] In a third step, the block press machine 1 now synchronously lifts the pressing device 4, the mold device 3 and the molded articles 7 located in the mold device 3. For this purpose, the synchronization device 6 establishes a temporarily fixed connection between the pressing device 4 and the mold device 3. In the present embodiment, the locking brakes 30 block the clamping rods 31 in order to establish a temporarily fixed connection between the mold carrier 20 and the plunger carrier 24. The hydraulic mold lifting cylinders 23 are switched to freewheeling, i.e. the pistons of the hydraulic mold lifting cylinders 23 are relieved on both sides. The hydraulic plunger cylinder 27 then acts as a common moving means for the pressing device 4 and the mold device 3. The hydraulic plunger cylinder 27 lifts the plunger carrier 24 with the plunger 26, whereby the mold carrier 20 with the block mold 22 and the molded articles 7 located in the block mold 22 are lifted synchronously via the temporarily fixed connection between the locking clamps 30 and the clamping rods 31 . Since the molded articles 7 have been formed under high pressure in the block mold 22, the molded articles 7 adhere easily to the block mold 22 during lifting, although the matrix 18 no longer acts as a base for the molded articles 7 from below. The arrangement of the individual components of the present embodiment after the synchronous lifting of the plunger 26, the block mold 22 and the molded articles 7 located in the block mold 22 from the matrix 18 is shown, for example, in Fig. 8.

[0066] In a fourth step, the transport device 8 moves a transport means 10, configured for example in the form of a pallet, between the counter-pressing means 5 and the mold device 3. In the present embodiment, the transport device 8 moves the transport means 10 between the matrix 18 and the block mold 22, as can be seen in Fig. 8.

[0067] In a fifth step, the molded articles 7 are demolded from the mold device 3 onto the transport means 10. In the present embodiment, the hydraulic plunger cylinder 27 lowers the pressing device 4 and the mold device 3 synchronously onto the transport means 10 in an intermediate step. More precisely, the hydraulic plunger cylinder 27 lowers the plunger carrier 24 with the plunger 26, the mold carrier 20 with the block mold 22 and the molded articles 7 located in the block mold 22 until the block mold 22 and the molded articles 7 located in the block mold 22 rest on the transport means 10, as can be seen in Fig. 9. For the actual demolding, the synchronization device 6 releases the temporarily fixed connection between the mold device 3 and the pressing device 4. In the present embodiment, the hydraulic mold lifting cylinders 23 are first pressurized again so that they are no longer in freewheel mode. The locking brakes 30 then release their temporarily fixed connection with the clamping rods 31 , so that the mold carrier 20 and the plunger carrier 24 are once again movable relative to each other. Now the hydraulic mold lifting cylinders 23 lift the mold carrier 20 with the block mold 22. Meanwhile, the plunger 26 remains in its position, so that the block mold 22 moves upwards relative to the plunger 26 and thus the molded articles 7 are demolded from the block mold 22 onto the transport means 10, as can be seen in Fig. 10. When the molded articles 7 have completely left the block mold 22, the hydraulic plunger cylinder 27 also moves the plunger carrier 24 with the plunger 26 upwards, so that the molded articles 7 are now only in contact with the transport means 10, as shown in Fig. 11 .

[0068] In principle, it would also be conceivable, instead of synchronously lowering the mold device 3 and the pressing device 4 onto the transport means 10, to demold the molded articles 7 from the block mold 22 by the plunger 26 pressing the molded articles 7 out of the block mold 22 onto the transport means 10 located at a certain distance below the block mold 22. However, for molded articles 7 of the present embodiment, which contain the particularly fine-grained core material, this entails too great a risk of damage to the molded articles 7.

[0069] In a sixth step, the transport device 8 transports the transport means 10 with the at least one molded article 7 out of the block press machine 1 to a next manufacturing step. Fig. 1 shows, for example, a transport means 10 with several finished molded articles 7 that have already left the interior of the block press machine 1 .

[0070] REFERENCE SIGNS block press machine frame mold device pressing device counter-pressing means synchronization device molded article transport device material insertion device transport means first filling carriage second filling carriage upper frame lower frame pressure support tension rod anvil matrix clamping nut mold carrier mold moving means block mold hydraulic mold lifting cylinder plunger carrier plunger moving means plunger hydraulic plunger cylinder first synchronization means second synchronization means locking brake clamping rod clamping rod bearing fall protection first filling device second filling device cavity raw material

Claims

CLAIMS1 . Block press machine (1) for producing molded articles (7), wherein the block press machine (1) has a frame (2), a mold device (3) movable relative to the frame (2), a pressing device (4) movable relative to the frame (2), a counter-pressing means (5) and a synchronization device (6), wherein the block press machine (1) is configured to produce at least one molded article (7) in the mold device (3) by interaction of the pressing device (4), the mold device (3) and the counter-pressing means (5), wherein the synchronization device (6) is configured to synchronize a movement of the mold device (3) and the pressing device (4) relative to the frame (2).

2. Block press machine (1) according to claim 1 , characterized in that the synchronization device (6) is configured to establish a temporarily fixed connection between the mold device (3) and the pressing device (4), so that the mold device (3) and the pressing device (4) are movable synchronously relative to the frame (2).

3. Block press machine (1) according to claim 1 or 2, characterized in that the synchronization device (6) is a mechanical synchronization device (6).

4. Block press machine (1) according to any one of the preceding claims, characterized in that the synchronization device (6) has at least one first synchronization means (28) and at least one second synchronization means (29), wherein the first synchronization means (28) is configured to establish a temporarily fixed connection with the at least one second synchronization means (29).

5. Block press machine (1) according to claim 4, characterized in that the at least one first synchronization means (28) is provided on the pressing device (4) and the at least one second synchronization means (29) is provided on the mold device(3).

6. Block press machine (1) according to claim 4, characterized in that the at least one first synchronization means (28) is provided on the mold device (3) and the at least one second synchronization means (29) is provided on the pressing device(4).

7. Block press machine (1) according to any one of claims 4 to 6, characterized in that the at least one first synchronization means (28) comprises at least one locking brake (30) and the at least one second synchronization means (29) comprises at least one clamping rod (31).

8. Block press machine (1) according to any one of the preceding claims, characterized in that the mold device (3) has a mold carrier (20), at least one mold moving means (21) and a block mold (22), wherein the at least one mold moving means (21) is configured to move the mold carrier (20) with the block mold (22) relative to the frame (2), wherein the block mold (22) is preferably interchangeable.

9. Block press machine (1) according to any one of the preceding claims, characterized in that the pressing device (4) has a plunger carrier (24), at least one plunger moving means (25) and a plunger (26), wherein the at least one plunger moving means (25) is configured to move the plunger carrier (24) with the plunger (26) relative to the frame (2), and wherein the plunger (26) is preferably interchangeable.

10. Block press machine (1) according to any one of the preceding claims 8 or 9, characterized in that at least one mold moving means (21) and / or at least one plunger moving means (25) has at least one hydraulic (23, 27), electrical and / or mechanical drive.11 . Block press machine (1) according to any one of the preceding claims 9 to 10, characterized in that the at least one plunger moving means (25) is configured to move the plunger carrier (24) with the plunger (26) and the mold carrier (20) with the block mold (22) synchronously relative to the frame (2) by interacting with the synchronization device (6).

12. Block press machine (1) according to any one of the preceding claims, characterized in that the block press machine (1) further has at least one material insertion device (9), preferably a filling carriage (11 , 12), which is configured to insert at least one material into the mold device (3).

13. Block press machine (1) according to any one of the preceding claims, characterized in that the counter-pressing means (5) comprises a matrix (18) which is attached to the frame (2).

14. Block press machine (1) according to any one of the preceding claims, characterized in that the block press machine (1) further has a transport device (8) for transporting a transport means (10), which is preferably configured as a pallet.

15. Block press machine (1) according to claim 14, characterized in that the transport device (8) is configured to move the transport means (10) between the counter-pressing means (5) and the mold device (3), wherein the block press machine (1) is configured to demold the at least one molded article (7) from the mold device (3) onto the transport means (10).

16. Block press machine (1) according to any one of the preceding claims, characterized in that the frame (2) has at least one guide element which guides both the movement of the mold device (3) and the movement of the pressing device (4), wherein the at least one guide element preferably comprises at least one tension rod (16).

17. Method for producing molded articles (7) with a block press machine (1), wherein the block press machine (1) has a frame (2), a mold device (3) movable relative to the frame (2), a pressing device (4) movable relative to the frame (2), a counter-pressing means (5), at least one material insertion device (9) and a transport device (8) for transporting a transport means (10), wherein the method comprises the following steps:- inserting at least one material into the mold device (3) by the at least one material insertion device (9);- pressing the at least one material to form at least one molded article (7) by interaction of the pressing device (4), the mold device (3) and the counter-pressing means (5);- synchronous lifting of the pressing device (4), the mold device (3) and the at least one molded article (7) located in the mold device (3);- moving the transport means (10) between the counter-pressing means (5) and the mold device (3); and- demolding the at least one molded article (7) from the mold device (3) onto the transport means (10).

18. Method according to claim 17, characterized in that the synchronous lifting of the pressing device (4), the mold device (3) and the at least one molded article (7) located in the mold device (3) is performed by a common moving means.

19. Method according to claim 17 or 18, characterized in that the method comprises the following steps:- synchronously lowering the pressing device (4), the mold device (3) and the at least one molded article (7) located in the mold device (3) onto the transport means (10); and- demolding the at least one molded article (7) onto the transport means (10) by lifting the mold device (3).

20. Method according to any one of claims 17 to 19, characterized in that the method comprises the following steps:- inserting a first material, preferably a core material, into the mold device (3) by a first material insertion device (11);- pre-pressing the first material by interaction of the pressing device (4), the mold device (3) and the counter-pressing means (5);- inserting a second material, preferably a header material, into the mold device (3) by a second material insertion device (12);- pressing the first material and the second material to form at least one molded article (7) by interaction of the pressing device (4), the mold device (3) and the counter-pressing means (5).21 . Method according to any one of claims 17 to 20, characterized in that the method comprises the following steps:- inserting a third material into the mold device (3) by the second material insertion device (12); and- pressing the first material, the second material and the third material to form at least one molded article (7) by interaction of the pressing device (4), the mold device (3) and the counter-pressing means (5).

22. Method according to any one of claims 17 to 21 , characterized in that the method is performed with a block press machine (1) according to any one of claims 1 to 16.

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