Method of manufacturing articles with interconnecting voids using a concrete mixture

Abstract

The invention relates to the field of construction. A method of manufacturing articles with interconnecting voids using a concrete mixture comprises: charging a mold with void-forming bodies made of ice such as to provide for contact between said bodies; feeding water at a temperature of 1°С - 10°С into the mold to wet the surface of the bodies until they become joined to one another; continuing to feed in water to increase the contact surface between the bodies by crystallization of the water; removing the remaining non-crystallized water from the mold; feeding a concrete mixture into the mold to fill the voids between the bodies; holding the molded article until it is ready to be released, and then thawing the mold and extracting the article therefrom. The invention makes it possible to increase the number of voids in an article and to enlarge the cross-section of the channels connecting the voids.

Description

[0001] A METHOD FOR PRODUCING PRODUCTS WITH CONNECTED VOIDS FROM A CONCRETE MIXTURE

[0002] Field of technology

[0003] The invention relates to the field of construction, and more specifically to the technology of producing concrete products with voids or cavities communicating with each other, which allows them to be used both in architectural design as decorative products of various shapes and sizes, for example, monolithic panels with the voids formed in them filled with nutrient soil for various types of vegetation, and as blanks for the further production of building products, for example, heat-insulating or sound-insulating when filling the voids with the appropriate material, as well as in a combination of these forms, without being limited to them.

[0004] Prior art

[0005] The use of crushed ice in the production of concrete products is known. Specifically, a portion of the water required for the concrete mix is ​​added to the mixture in the form of crushed ice, which is pre-cooled to low temperatures using a cryogenic coolant; for example, crystalline ice is cooled with liquid nitrogen. (EP 0124724A1, November 14, 1984) This method is used to prevent stress and cracks in large structures, as eliminating them is often impossible without additional cooling. This is due to the need to consider not only the heat input from the environment but also the heat generated during the concrete hardening process, which leads to an increase in the temperature of the freshly placed concrete.

[0006] Also known is a method for producing a panel for architectural design, which comprises placing a plurality of objects in a mold, each having a shape and size corresponding to the desired shape and size of a plurality of voids, placing a curable material in the mold together with the objects, and removing the objects from the mold after the curable material placed in the mold has cured. In this case, at least one of the following is used as objects - a plurality of balloons or a plurality of balls, and the objects are destroyed upon removal from the mold (WO 03018274A1, 06.03.2003). This invention is a matrix for panels used in architectural design, such as for exterior architectural panels, panels for interior partitions or space delimiters, wall or ceiling architectural panels, tables, shelves, etc.Specifically, the panel used in architectural design contains a matrix with numerous voids arranged in a seemingly random pattern. Some voids communicate with the outer surface of the panel, while others may communicate with each other, giving the panels a perforated, sponge-like appearance. Furthermore, the use of balloons or balls is not technologically feasible when placing them in a mold and subsequently removing them from the finished product. Furthermore, the spherical shape does not provide a wide variety of designs.

[0007] The closest known technical solution is the one disclosed in the published application (RU 96110163 A, 20.08.1998), namely, a method for producing lightweight large-cell concrete, including the preparation of a binder solution, after which large ice granules, which are a temporary filler and have a temperature of no more than -5 °C, are placed in a mold for a concrete product, then the voids between the granules are filled with a binder solution with a temperature of no more than +5 °C using vibration compaction, and after the initial setting of the concrete, the products are removed from the mold, its temperature is increased to +80 - 95 °C for 20 - 24 hours and maintained at the specified temperature until the voids formed by the ice granules are completely free of water. To produce lightweight large-cell concrete, a mixture containing cement, gypsum and sand is used, and large granules of chilled ice and soap shavings are used as temporary filler in the following ratio of components, wt.%: cement (20-25), gypsum (2-3), sand (15-20), soap shavings (0.5-1), granulated ice (55-60).

[0008] The known method does not provide the required variability in the shape and voidage of concrete products, since, as a rule, contact between granules occurs over a small area—in the case of spherical granules, contact occurs at the point of contact, while for other granule shapes, contact occurs along a line. This determines the cross-sectional area of ​​the channel connecting adjacent voids.

[0009] Disclosure of invention

[0010] The objective of this technical solution is to produce concrete products with increased void volume, interconnected by channels of increased cross-section. This will also expand the product's variability in shape and its range of applications.

[0011] The technical result of this solution is to increase the voidness of the product and to increase the cross-section of the channels by means of which the voids of the product are connected to each other.This is achieved by the fact that in the method for producing articles with interconnected voids from a concrete mixture, which includes loading void-forming bodies previously made of ice into a mold, feeding the concrete mixture into the mold, holding the article in the mold and removing the molded article, the void-forming bodies are loaded into the mold, ensuring their contact with each other, after loading the void-forming bodies into the mold, water with a temperature of 1 °C - 10 °C is fed into it, wetting the surface of the void-forming bodies until they are connected to each other, and the supply of water is continued to increase the contact surface between the void-forming bodies by crystallization of water, the water remaining in a non-crystallized state is removed from the mold and concrete mixture is fed into the mold, ensuring that the voids between the void-forming bodies are filled with it, the molded article is held until it can be stripped and removed from the mold.In this case, void-forming bodies with an initial negative temperature in the range of -1 °C... -20 °C of regular geometric shapes, including spherical and / or tetrahedrons and / or hexahedrons and / or octahedrons and / or dodecahedrons and / or icosahedra, or void-forming bodies with an initial negative temperature in the range of -1 °C... -20 °C in the shape of an ellipsoid and / or spherical shape are loaded into the mold, while void-forming bodies of the same size or volume are loaded into the mold, or void-forming bodies of different sizes or volumes are loaded into the mold. In this case, a metal mold can be used, on the inner surface of which, during the process of feeding water, the void-forming bodies in contact with it are fixed by freezing, wherein the metal mold can be cooled before and / or after loading the void-forming bodies into it, to a temperature below the crystallization of water.Some of the void-forming bodies loaded into the mold can be fixed to the mold's inner surface in their design positions before water is added. Water can be supplied to the mold from above, evenly distributing it within the open area of ​​the mold. Water can also be supplied from below or from the side, filling the voids between the void-forming bodies. The mold bottom can be heated to facilitate the removal of uncrystallized water. Additionally, design elements can be placed in the mold, such as decorative objects and / or products and / or lighting fixtures and / or irrigation systems and / or elements containing plant soil. These design elements can be pre-frozen, at least partially, into the void-forming bodies made of ice.At least some of the design elements may communicate with each other and / or with the space outside the product by forming openings in void-forming bodies containing the design elements and introducing into these openings means of communication of the design elements with each other and / or with the space outside the product, made in the form of pipelines and / or electrical wires.

[0012] Brief description of the drawings

[0013] The invention is illustrated by figures 1-3 (a, b), which show various forms of products made from concrete mixture using the proposed method with interconnected voids.

[0014] Figure 4 reflects the geometric principle of splicing of void-forming bodies applied in this invention, where:

[0015] 1 - Ice pieces after loading, the area of ​​the mating surfaces a is minimal and is reduced to contact points A. The free volume of the form p is maximum.

[0016] 2 - Ice structure after the first irrigation with water. The resulting ice crust a' increases the cross-section of the ice pieces from point A to segment B. At the same time, the free volume of the form decreases from p to p'.

[0017] 3 - Ice structure after the second irrigation. The resulting ice crust a" increases the cross-section of the ice pieces from segment B to segment C. At the same time, the free volume of the form decreases from p' to P".

[0018] Implementation of the invention

[0019] Example 1 - Simple rectangular product

[0020] 1. A rectangular plywood form measuring 300*150*50 cm with an open top surface is placed in a chamber with a base temperature of -10°C.

[0021] 2. Using a crusher, drum and screening, rounded pieces (granules) of void-forming ice measuring 5-25 cm are produced.

[0022] 3. The void-forming ice is loaded into the mold with an indentation of 10-15 cm from the upper edge of the mold.

[0023] 4. Water at a temperature of +5...+10 °C is supplied to the mold. The water is supplied in a uniform spray across the entire open area of ​​the mold.

[0024] 5. When the water level reaches the upper level of the void-forming bodies, the water supply stops.

[0025] 6. The water is held in the mold for 10 minutes and then removed by pumping it out. Removal is accomplished using a flexible hose running between the void-forming bodies to the bottom of the mold.

[0026] 7. After removing the water, the void-forming filler, warmed by the water, is cooled to its initial temperature of -10°C. 8. The water irrigation procedure (steps 4-7) to increase the accumulative volume of ice at the points of contact between the bodies can be repeated three times. With each irrigation, the contact area between the void-forming bodies increases due to the formation of a new layer of ice on the surface of the void-forming bodies.

[0027] 9. After completion of the irrigation procedures, the void-forming bodies are cooled to the base temperature.

[0028] 10. The form is filled with concrete mixture.

[0029] 11. After the concrete has set and been cured to the stripping strength at the base temperature, the form is defrosted and the formed product is removed. In the places where the void-forming bodies are located, interconnected voids of an increased size due to the freezing of ice are created in this way, and the size of the cross-section of the channels communicating the voids is also increased.

[0030] Example 2 - A serial rectangular product (metal mold)

[0031] 1. A rectangular metal mold measuring 300 x 150 x 50 cm with an open top surface is placed in a chamber with a base temperature of -10°C. The mold has the following features: the bottom surface of the mold has a heating device that covers its entire surface and is equipped with an inlet / outlet for connecting a hose.

[0032] 2. By cutting ice, hollow-forming bodies in the shape of hexahedrons with a side size of 25 cm are produced.

[0033] 3. The void-forming bodies are loaded into the mold with an indentation of 10-15 cm from the upper edge of the mold.

[0034] 4. Water at a temperature of +5...+10°C is fed into the mold using a reversible pump. Water enters the mold through inlet / outlet openings on the bottom of the mold, while the surface of the mold bottom and the hoses leading to the openings are heated to a temperature of +5°C.

[0035] 5. When the water level reaches the upper level of the void-forming bodies, the water supply is stopped.

[0036] 6. Water for freezing ice (for a given volume of the mold) is kept in the mold for 10 minutes and after this time it is removed from the mold by pumping it out with a reversible pump through the drain holes.

[0037] 7. After removing the water, the void-forming filler, heated by water, cools to a base temperature of -10 °C.

[0038] 8. The form is filled with concrete mix. 9. After the concrete has set and cured to stripping strength at base temperature, the form is defrosted and the formed product is removed. In the locations of the void-forming bodies, interconnected voids of increased size due to the freezing of ice are thus created, and the cross-sectional size of the channels connecting the voids is also increased.

[0039] Example 3 - A product of arbitrary geometry

[0040] 1. A metal mold of arbitrary geometry and overall dimensions of 300*150*150 cm with an open top surface is placed in a chamber with a base temperature of -10 °C.

[0041] 2. Using a crusher, drum and sieve, rounded pieces of hollow-forming ice measuring 15-20 cm are produced.

[0042] 3. The void-forming ice is loaded into the mold with an indentation of 10-15 cm from the upper edge of the mold.

[0043] 4. Water at a temperature of +5...+10°C is fed into the mold using a reversible pump. The water enters the mold through inlet / outlet openings on the bottom of the mold, while the surface of the bottom of the mold and the hoses leading to the openings can be heated to a temperature of +5°C to prevent them from freezing.

[0044] 5. When the water level reaches the upper level of the void-forming bodies, the water supply is stopped.

[0045] 6. The water is kept in the mold for 12 minutes and after this time it is removed from the mold by pumping it out with a reversible pump through the drain holes.

[0046] 7. After removing the water, the void-forming filler, heated by water, cools to its initial temperature of -10 °C.

[0047] 8. The water irrigation procedure (steps 4-7) can be repeated 2-4 times. With each irrigation, the contact area between the void-forming bodies increases due to the formation of a new layer of ice on the surface of the void-forming bodies.

[0048] 9. After irrigation is complete and the void-forming bodies have cooled to the base temperature, the form is filled with concrete mixture.

[0049] 10. After the concrete has set and cured to stripping strength at base temperature, the mold is defrosted and the molded part is removed. Interconnected voids of increased size due to ice formation are thus created at the locations of the void-forming bodies, and the cross-sectional area of ​​the channels connecting the voids is also increased.

[0050] Example 4 - Cylindrical Product 1. A cylindrical metal mold measuring 300 x 60 cm is placed in a chamber with a base temperature of -10°C. The ends of the mold have the following structure: the upper end of the mold has a circular opening with a diameter of 50 cm along the axis of the cylinder, and the lower end of the mold has a sealed bottom with a heating device operating over the entire surface of the end, and an inlet / outlet opening for connecting a hose.

[0051] 2. Using a crusher, drum and sieve, rounded pieces of hollow-forming ice measuring 5-15 cm are produced.

[0052] 3. Void-forming ice is loaded into a vertically installed form with an indentation of 10-15 cm from the upper edge of the form.

[0053] 4. The mold loaded with void-forming ice is placed horizontally on rollers for axial rotation; water at a temperature of +5...+10 °C is supplied to the mold up to a level of 5 cm from the bottom of its volume.

[0054] 5. Using rollers and an electric motor, the mold is rotated at a speed of 30 revolutions per minute, while the water, flowing evenly over the surface of the cylinder, forms a layer of ice on its wall.

[0055] 6. After the water has crystallized, the mold is placed vertically.

[0056] 7. Water at a temperature of +1...+5°C is fed into the mold using a reversible pump. Water enters the mold through inlet / outlet openings on the bottom of the mold, while the surface of the mold bottom and the hoses leading to the openings are heated to a temperature of +5°C, preventing the risk of complete freezing.

[0057] 8. When the water level reaches the upper level of the void-forming bodies, the water supply is stopped.

[0058] 9. The water is kept in the mold for 8 minutes and after this time it is removed from the mold by pumping it out with a reversible pump through the drain holes.

[0059] 10. After removing the water, the void-forming filler, heated by water, is cooled to a base temperature of -10 °C.

[0060] 11. The form is filled with concrete mixture, preserving the resulting structure of the connection of void-forming bodies.

[0061] 12. After the concrete has set and cured to stripping strength at base temperature, the mold is defrosted and the molded part is removed. Interconnected voids of increased size due to ice formation are thus created at the locations of the void-forming bodies, and the cross-sectional area of ​​the channels connecting the voids is also increased.

[0062] Example 5 - A product with embedded irrigation elements. 1. A rectangular plywood form measuring 300 x 150 x 50 cm with an open top surface is placed in a chamber with a base temperature of -10°C.

[0063] 2. Using a crusher, drum and sieve, rounded pieces of void-forming bodies measuring 5-15 cm are produced from ice.

[0064] 3. The void-forming ice is loaded into the mold to a level of 10 cm from the bottom of the mold.

[0065] 4. Hoses are laid between the ice void-forming bodies, with the inlets of the hoses leading out through openings in the vertical walls of the form, and the outlets of the hoses placed in 2-3 cm deep holes drilled in the void-forming bodies.

[0066] 5. The void-forming ice is loaded into the mold to a level of 10-15 cm from the top edge of the mold.

[0067] 6. Water at a temperature of +2...+8 °C is added to the mold. The water is applied in a uniform spray across the entire open area of ​​the mold.

[0068] 7. When the water level reaches the upper level of the void-forming bodies, the water supply is stopped.

[0069] 8. The water is held in the mold for 11 minutes and then removed by pumping it out. Removal is accomplished using a flexible hose running between the void-forming bodies to the bottom of the mold.

[0070] 9. After removing the water, the void-forming bodies, heated by water, are cooled to the initial temperature of -10 °C.

[0071] 10. The water irrigation procedure (steps 4-7) is repeated twice. With each irrigation, the contact area between the void-forming bodies increases due to the formation of a new layer of ice on the surface of the void-forming bodies.

[0072] 11. After irrigation is complete, the void-forming bodies are cooled to the base temperature.

[0073] 12. The form is filled with concrete mixture.

[0074] 13. After the concrete has set and cured to stripping strength at base temperature, the mold is defrosted and the molded part is removed. Interconnected voids of increased size due to ice formation are thus created at the locations of the void-forming bodies, and the cross-sectional area of ​​the channels connecting the voids is also increased.

[0075] The parameters of water temperature, initial temperature, and number of irrigation repetitions specified in the examples are characteristics of the method for producing concrete products with interconnected voids, tied to the specific dimensions of the mold and its material. The purpose of the examples was to confirm the feasibility of achieving a technical result consisting of increasing the degree of voidage in a concrete product and increasing the cross-section of the channels through which the product's voids are interconnected.

Claims

CLAUSES OF THE INVENTION 1. A method for producing articles with interconnected voids from a concrete mixture, which comprises loading void-forming bodies previously made of ice into a mould, feeding concrete mixture into the mould, holding the article in the mould and removing the moulded article, characterized in that the void-forming bodies are loaded into the mould ensuring their contact with each other, after loading the void-forming bodies into the mould, water at a temperature of 1 °C - 10 °C is fed into it, wetting the surface of the void-forming bodies until they are connected to each other, and continuing to feed water to increase the contact surface between the void-forming bodies by crystallization of water, the water remaining in a non-crystallized state is removed from the mould and concrete mixture is fed into the mould ensuring that the voids between the void-forming bodies are filled with it, the moulded article is held until it can be removed from the mould, followed by defrosting of the mould and removal of the article from the mould.

2. The method according to claim 1, characterized in that void-forming bodies with an initial negative temperature in the range of -1 °C... -20 °C of regular geometric shapes, including spherical and / or tetrahedrons and / or hexahedrons and / or octahedrons and / or dodecahedrons and / or icosahedra, are loaded into the mold, or void-forming bodies with an initial negative temperature in the range of -1 °C... -20 °C, having an ellipsoidal and / or spherical shape, are loaded into the mold, while void-forming bodies of the same size or volume are loaded into the mold, or void-forming bodies of different sizes or volumes are loaded into the mold.

3. The method according to paragraph 1, characterized in that a metal mold is used, on the inner surface of which, during the process of supplying water, void-forming bodies in contact with it are fixed by freezing.

4. The method according to paragraph 3, characterized in that the metal mold is cooled before and / or after loading the void-forming bodies into it, to a temperature below the crystallization of water.

5. The method according to paragraph 1, characterized in that part of the void-forming bodies loaded into the mold are fixed on the inner surface of the mold in the design position before water is supplied to it.

6. The method according to item 1, characterized in that water is supplied to the mold from above onto the void-forming bodies by uniformly distributing it within the open area of ​​the mold, or water is supplied to the mold from below or from the side, ensuring that the voids between the void-forming bodies are filled.

7. The method according to claim 1, characterized in that the bottom of the mold is heated to intensify the removal of non-crystallized water.

8. The method according to paragraph 1, characterized in that additionally, design elements in the form of decorative objects and / or products and / or lighting fixtures and / or irrigation systems and / or elements containing plant soil are placed in the form.

9. The method according to item 8, characterized in that the design elements are first, at least partially, frozen into void-forming bodies made of ice.

10. The method according to item 8 or 9, characterized in that at least some of the design elements communicate with each other and / or with the space outside the product by forming openings in void-forming bodies containing the design elements and introducing into these openings means of communication of the design elements with each other and / or with the space outside the product, made in the form of pipelines and / or electrical wires. and

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