PROCESS FOR PRODUCING DOUBLE SLABS, AND A DEVICE SUITABLE FOR REALIZING SAID PROCESS

Abstract: The invention concerns a process to produce and obtain double slabs, and also a device to obtain double slabs, whereby the double slabs are advantageously suitable for building use and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are embedded, and whereby said layers are separated from each other by trellis elements (26) which are advantageously flat trellises, said device being suitable to carry out the process of the preceding claim and comprising in mutual cooperation and coordination: - table means (I4) to form the first slab (30), equipped with vibrating means (I5), - mould means (20) with combs and with means (I125-I29) to retain conglomerate and with at least one end bar (I8) for positioning and handling purposes having means (34) for its detachment, - supporting surface means (33) with positioning means (I9) and adjustable means (32), whereby said supporting means (33) are independent and able to uphold means with combs (20), and whereby there are vibrating means (I5), - withdrawal table means (I2) with substantially horizontal withdrawal means (I3) together with means (II2-37-I37) to sustain and possibly to guide said mould means with combs (20).

Description: Description of the invention entitled: "Process to obtain double slabs, and a device suitable for. realizing said process in the name of hNDREA PITTINI at Gemona del Friuli. Submitted on under No. This invention concerns a process to obtain double slabs and therefore also concerns a device suitable for realizing said process. To be more exact, this invention concerns a process suitable for obtaining double slabs by making use atv-ant- ageously of flat trellises able to support and position reciprocally and temporarily the electnca.lly welded wire mesh which is thereafter contained and embedded in the castings which constitute the two plane-parallel slabs forming the double slab. Double slabs are knows which are typically composed of an element with a continuous or semi-continuous surface coop erating with another substentially similar element, both elements consisting advantageously of cemented conglomerate, whereby metallic elements having stiffening and distancing. characteristics are interposed between the two slabs. Double slabs are also known in which insulating and/. or sound-proofing elements are made to cooperate. Our invention concerns a new process to obtain said /. :i double slabs and also concerns a new device suitable for realizing said process. In the known art there is, for instance, patent applieation IT I974IA/77 in the name of Sartorio, wherein the structure and the processes for making arld applying buil- ding element are described. Said building elements are made vzth automatic equip. ment working vqith a continuous cycle. Said automatic equipment comprises a movable working surface consisting of an endless mat of plastic material moved by suitable rollers. Parallel rings of a suitable section are also envisaged as delimiting the side zones of formation of said building element. This device involves many drawbacks in that its continuous movement makes it impossible to vary, as washed, the structure of the panels thus made, and moreover it is not suited to the diverse operations which have to be carried out to nake said building elenent. Furthermore, if working is carried out rvith a discontinuous cycle, a plurality of interferences begins to take place among the various operations or functions performed on the same working surface. ifjoreover, the patent does not say how the working sutG face is limited in its lengshwise direction, nor does it indicate any other functional elements required. Patent application IT 23223A/77, also in the name of Sartorio, describes some presumed improvements to the preceding patent. This patent application shows in a fanciful tvay a new method to obtain double slabs; this method envis- ages the descent from above of both the zaire mesh and the distancing and separating elements into mass of cemented conglomerate that is still not solidified. Besides being substantially fanciful, as we said, this device too requires a very liquefied concrete nass with very long drying and hardening times and involves many drawbacks and shortcomings which make it substantially impossible to apply. There is also patent application IT 25325A/77, again in the. name of Sartorio, wherein a system is substantially visualised for a bond been neighbouring panels with a double slab; a special panel is also envisaged which repeats substantially an old patent of Sartorio, namely IT 713072. Moreover, a further patent in the name of Sartorio has been set. .forth wherein the realization of double slabs is envisaged by .means of a system of crosswise supports coopt erating with sound-proofing elements. This process is described in IT 27620A/78 and can also be deemed to be essentially fanciful in that the elements cooperating with the distancing. trellises comprise special conformations which cannot be readily handled on a building site. In any event this patent foresees rather imaginary and unreal solutions in view of normal working methods. An application also exists in-the name of Impianti Industriali, which was submitted under No. 83345A/78 and deals with a system for realizing double slabs by withdrawal from above of the mould forming the empty-spaces. This patent deals with a particularly advantageous de device which, however, has inborn limitations because of the height of the shed which it assumes to be available. Our present invention aims at the realization of two- slab panels with a device which is in itself simple and by the employment of a process which can also be applied to the normal existing tables for making slabs. This invention, therefore, enables double slabs to be made even in cooperation with and on tables already suitable for producing single slabs. According to the invention arrangements are made to lay on a suitable table an electrically welded wire mesh and advantageously to apply the flat trellises, after which it is arranged to pour the concrete mass and create a homogeneous with vibrations, this phase being substantially the same as that normally employed for flat slabs. On this layer a mould with combs is applied, of which the upper surface forms the lower inner surface of the upper slab constituting the double slab, whereby the mould is suitable for not interfering lengthwise with the intermed iate trellises. The upper surface of the mould with combs is positioned v7ith suitable distancing shims, which thereby regulate the thickness of the double slab; said distancing shims cooper ate with appropriate supports not connected to the vibrating surface on which the first slab has been predisposed and ob tained. On the mould with combs an intermediate layer of insul awing and/or sound-proofing material can be spread out or deposited. This intermediate layer can consist of a plurality of elements made of sound-proofing and/or insulating material, on w-hich an electrically welded wire mesh is advantageously .laid and anchored to the flat vertical protruding elements. then the electrically welded cire mesh has been predisposed, arrangements are made to cast the concrete and vibrate the upper slab; the vibration tykes place independgently of that of the lower slab since the mould with combs receives its vibration either from independent supports or. direct and discharges said vibration onto independent sup ports. Vnlen vibration has taken place or earlier, the surface of the upper slab is finished with a levelling board, which may perhaps vibrate, the purpose being to obtain diverse finishes for the usage phase of the slab. Next, steps are taken to anchor the mould with combs to a crane and to hoist it in a substantially horizontal position, thereby also lifting the double slab in which the mould with combs is/ lodged. The double slab, with the mould with combs lodged in- side it, is rested on an appropriate table. During this phase the mould with combs detaches itself independently, owing to the force of its ovn weight, from the upper slab and rests on the lower slab, thus being ready to be with drawn. iMlen one end of the mould with combs has been removed, it is possible to apply to the other end a-suitable towingmeans, which may be a winch. By means of this towing means steps are then taken to withdraw the mould with combs from the double slab on a sub stantially horizontal surface. According to the invention the weight of the mould during withdrawal is advantageously borne not by the slab but on appropriate rollers positioned on the table itself and on a possible plurality of bearings solidly fixed to the mould with combs and running on appropriate guides. The double slab thus formea can be left on the vith- drawal table for final hardening or can be rested on suit able surfaces; the double slab is normally transported with a bridge crane or lift truck. According to a variant of the invention the mould with combs is suitable for the circulation of a hot substance able to speed up the drying and hardening process. According to another variant said hot substance will advantageously be hot air and/or steam and perhaps will be allowed to flow between the mould and the double slab so as to improve the drying and hardening action. The device suitable for carrying out this process, therefore, is envisaged as having a moulding surface with vibration means, whereby said surface and said means can be the same as those required now to make a single slab. The use of a lifting means and of auxiliary means to position the mould with combs is also envisaged. Independ ent supporting and/or vibrating means cooperating with the mould with combs are also envisaged. According to a variant said mould means are suitable for the circulation and distribution of hot substances and advantageously of steam. In cooperation with the forming table a withdrawal table is envisaged as hiving substantially horizontal towing means, the mould means being advantageously guided and sup ported thereon. The invention is therefore embodied in a process for manufacturing and obtaining double slabs, whereby the double slabs are advantageously suitable for building purposes and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically weld ed wire mesh elements are embedded; said plane-parallel layers are kept apart from each other by trellis elements advantageously consisting of a flat trellis; said process is characterized by the fact that an electrically welded wire mesh cooperating vdth advantageously flat trellises is put in a knows manner on a forming surface; thereafter conglomerate is cast in a known manner and is vibrated, and then, after suitable distancing means have been regulated, a mould with combs is predisposed, on which a layer of in insulating and/or sound-proofing material is perhaps laid and on which is placed an electrically welded wire mesh anchored to the protruding trellises; next, a mass of cemented conglomerate is cast and vibrated independently; the whole is. then lifted and moved onto a substantially horizontal with- drawl surface, where the mould with combs is withdrawn axi allyq Furthermore, the invention is embodied in a device to obtain double slabs, whereby the slabs are advantageously suitable for building purposes and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are em- bedded, and whereby said plane-parallel layers are kept apart from each other by trellis elements advantageously consisting of a flat trellis, said device being character- ized by comprising in mutual cooperation and coordination: - - vibrating surface means to form the first slab, - mould means with combs having circumferential means to retain the conglonaerate, and at least one removahle end for positioning and handling purposes, - independent adjustable means to support the mould means with combs, there also being vibrating means, - substantially horizontal surface means with means to us- tain and possibly to guide the mould means with combs, - and means to withdraw the mould means .v4th combs. With the help of the attached tables, which have been given as an illustrative but not restrictive example, let - us now look at a preferential solution of-the invention. The tables are as follows: Fig. I shows from above a plant with two forming tables and two withdrawal tables; Fig. 2 gives a side view of the plant of Fig. I; Pig. 3 gives a three-dimensional view ofwthe forming ta ble with the mould with combs in the process of- being positioned; Fig. 4 shows the plant with the mould with combs in pos ition and the electrically welded wire mesh fitted; Fig. 5 shows the plant of Fig. 4 with the second slab be ing cast; Fig. 6 shows a successive phase of levelling and vibrat ing the second layer; ; Fig. 7 shows the mould/double slab assembly being removed with a winch; Fig. 8 shows a double slab positioned on the supporting table, While the mould with combs is already con nected to the winch and has been partially with- drawn; Fig. 9 shows the mould with combs fully viithdrawn from the double slab; Fig. 10 gives an example of the combs of the mould means. With reference to the figures, we have as follows: According to the example shown in the figures the forming table 14 is supported by one or more beams I6 resting on independent legs II7,vzhich in this instance are anchored to the floor. The forming table I4 has in a position beneath - itself some vibrators I5 which cooperate with the table I4 itself. On its upper side the forming table I4 has the ability to anchor some suitable movable and shaped side boards 29, which can be fixed with locking pins 28 or other means. These movable side boards 29 serse to conform the edge of the lower slab 30 and at the same time to contain the cast concrete. In cooperation with the forming table 14 and at the sides thereof there are supports 33 which are independent of the forming table I4 and which cooperate with the legs 17 and have vibrating elements II5. The independent sup ports with bearing surface 33 comprise an alignment pin I9 and possible variable shims 32 for the vertical positioning of the mould with combs 20. Instead of the variable shims 32 other means to adjust height could be employed. A vibrator I5 which is suitable for transmitting the vibration desired to the mould means with combs 20 and only to said mould means 20 cooperates with the supporting sur- face 33. Between the supporting surface 33 and the legs I7 vi bration-damping means 31 may be envisaged which do not let the vibrations of the vibrator 15 pass on. The forming of the double slab takes place substantial ly as follows: the forming table I4 is made ready before hand, and on it the movable side boards 29 are positioned and secured with suitable means 28 so as to limit circum- - ferentially in a desired manner the slab to be obtained. Within the perimeter formed by these side boards 29 is laid an electrically welded wire mesh, to which are anchored in our example, by means of the hooks 27 some trellises 26 - for connecting and distancing purposes. Said trellises 26 are advantageously flat and are char acterized by suitable hooks 27 which enable a trellis to be anchored to the electrically welded wire mesh by a simple sideways displacement of-the trellis 26 in respect of the wire mesh. Other trellises 26, however, can be employed which are substantially suitable for use but have no hooks 27. Within the perimeter formed by the movable side boards 29 the conglomerate, which may be a cemented conglomerate, is then poured until the thickness desired for the lower - slab 30 has been reached. Next, the whole is vibrated with - the vibrators I5 cooperating with the forming table I40 - - When the first layer or first slab 30 has been obtain ed, steps are taken to position the mould means with combs - 20 by making use of a crane 24 with slings 23 cooperating with appropriate hook holes 22 in the frontal connection bars 18. The frontal bars I8 position between themselves the combs I20 of the mould means 20 and are anchored to the mould by connecting pins 34 able to be inserted wherever needed. The frontal bars I8 comprise at their ends at 21 some appropriate holes able to cooperate with the positioning means or pins I9 present on the supporting surface 33. Thus, the mould with combs rests on separate and auxil iary structures I7-33 which do not cooperate directly with the forming table I4. This makes it possible to use already existing forming tables 14 too and merely to add legs 17 and supporting sur - faces 33 like those shown. The frontal bars I8 include at their end some guide - - bearing means II8 which are suitable, during the withdrawal phase for cooperating with the lateral guide I37 of the withdrawal group 13. The frontal bars 18 secure the combs I20 of the mould means 20. The combs 120 and frontal bars 18 are fixed to each - other, for instance, with pins 34, so that by removing the pins 34 it is possible to remove the frontal bars I8. Arrangements are then made to position the mould means 20 in such a way that the combs 120 are disposed alongside the trellises 26 and lengthwise thereto so that the corres ponging spaces 25 cooperate with the trellises 26 themselves. The spaces 25 are closed upwardly advantageously by elastic means I25 which prevent the conglomerate from pass - ing through and enable a moulding surface I14 to be obtained. The combs I20 can be conformed in any desired manner. Vihen positioning the frontal bars I8, care should be taken to ensure that the holes 2I in said frontal bars I8 coincide with the positioning means or pins 19 so as to permit both a suitable anchorage and a coordinated seat on the surface 33. With the mould means 20 in position the plant is ready to make the second layer. To regulate the interspace which has to be kept between the upper and lower layers, steps are taken to predispose shims 32 of various sizes until the required height is rear ched. Instead of the shims 32 means of another type to regal ate the height can be envisaged. A layer of insulating and/or sound-proofing material is placed on the mould means 20 on the new forming surface II9, or nothing is placed thereon, depending on the specific requirements. Electrical and/or hydraulic circuits can also be predisposed together with possible junction boxes or sockets, thus enabling the various electrical, hydraulic and intercom circuits, etc. to be obtained or making it possible to obtain spaces which are equipped or can be equipped, - such as windows or doors and the like while the double slab is being made. The electrically welded wire mesh 42 is put on the - mould with combs 20 and possibly on the possible layer of insulating material when so predisposed, and is anchored to the trellises 26. then the electrically welded wire mesh has been anchored to the trellises 26, the plant is ready to make the sec- ond slab 43. As said earlier, the trellises 26 are made to pass through the mould means 20 by making use of lengthwise slits 25, which are closed lengthwise 25 to the passage of con crete material by means 125 made of an elastic material. - Around the mould means 20 and on its upper side, suitable movable side boards I29 are provided and fixed to the mould means itself 20 and to the bars 18 and serve to linut and delimit the second slab 43. When the upper surface I14 too has been made ready, steps are taken to pour and level the conglomerate, as shove in Figs. 4, 5 and 6 as an example. Levelling can be done with a levelling board 4I, which may be motorized or not and which can cooperate with vibrator means 215. As soon as the upper surface has been levelled and the product has been hardened enough, arrangements are made to - lift with the crane 24 the whole assembly consisting of the double slab 30-43 and the mould means with combs 20, as shown in Fig. 7 as an example. The mould neans 20 can be provided vith suitable ducts through which steam or hot air or another heating means can pass so as to dry and normalise the double slabs more quick- ly. According to P variant the combs I20 include a plurality of holes 220 which permit the the coordinated outgoing of steam and/or hot air which comes into contact with the - conglomerate and speeds up drying. Said holes 220 can be of any desired type and shape and can be located anyvzhere. The double slab 30-43 and mould means 20 are lifted together and the whole is rested on the withdrawal table I2, care being taken that the rear end bar 18 cooperating with the rear end of the mould means 20 cooperates advantageously with the pins II9 on the withdrawal table 12. MMen the double slab 30-43 and the mould means 20 are - rested on the withdrav-al table I2, the mould means 20 de taches itself from the upper slab 43 owing to the action of its own weight and rests on the lower slab 30, thus freeing itself. On the withdrawal table 12 the double slab can be rest ed advantageously on the supports II2 covered with wood or with an elastic material. Next, the end bar i8 present at the front of the mould means 20 is anchored to the winch means 35 with a carriage - or carriages with a towing wire 36. The rear end bar I8 cooperating with the pins I19 is - then detached by removing the connections consisting of the connection pins 34, if existent; the mould means 20 is thus left with only the front end bar 18. By using the winch 35, the mould means 20 is caused to leave by being pulled out from the double slab and is advantageously made to slide on the supporting rollers 37 so that said mould means 20 does not press on the lower slab - 30 and thereby create stresses or breakage. To reduce the pressure still further, the bar I8 combs prises bearing means I18 that slide on the lateral guides - 137 and are sustained thereby. then the whole mould means 20 has been withdrawn, the - slab is available for transfer to any desired place. Ledge means 234 can be emvisaged which are able to permit the mould means to continue to be supported both by the bearing means II8 (at its front) and by the roller or rollers 37 (at its rear). As soon as it has been withdrawn, the mould means 20 - is cleaned and re-assembled, and the end bar 18 which was - tenporarily detached is mounted again thereon; the mould means 20 is used again for the next cycle of moulding double - slabs, said cycle beginning with the time of use of the mould means 20 itself. In fact, the forming table 14 has been cleaned in the meanwhile, the electrically welded wire mesh has been pre- disposed, the trellises 26 have been predisposed, the first casting of conglomerate has been carried out and vibrating has been done. This makes available the instalment of the mould means 20 which has been withiránn just now from the double slab 30-43. A plant II according to the invention can include one or more forming tables I4, perhaps aligned, and one or more withdrawal tables I2-I3 with one or more winch means 35, depending on the production rate. We have described here a preferential solution of the invention, but variants are possible. Thus the proportions times, sizes and lay-outs can be varied; it is possible to conform the mould means 20 in any desired way; the invent- - ion can be combined with forming tables I4 already existing, etc. These and other variants are all possible for a technic ian in this field.

Claims: C L A I M S I. Process to produce and obtain double slabs, whereby the slabs are advantageously suitable for building uses and consist of two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are embedded, andereby said parallel surfaces are separated from each other by trellis elements which are advantageously flat trellises, said process being character- ized by the fact that on one forming surface (14) is placed in a knonn manner an electrically welded wire mesh (42) co- operating with trellises (26) which are avantageously flat, and that a casting of conglomerate is then carried out in a known manner and is next vibrated to obtain the first surface (30), and that, after regulation with suitable distancing means (32), a mould means with combs (20) is predisposed on which a layer of insulating and/or sound-profing material is possibly laid and over which an electrically welded wire mesh (42) is placed and anchored to said protruding trellises (26), and that a mass of cemented conglomerate is then poured which is vibrated independently, -the second surface (43) being thus obtained, whereby the whole (23-24) is then lifted and moved onto a substantially horizontal withdrawal surface (12), where said mould means with combs (20) is with drawn axially (35-37). 2. Device to obtain double slabs, whereby the double - slabs are advantageously suitable for building uses and consist of at least two substantially plane-parallel layers of cemented conglomerate in which electrically welded wire mesh elements are embedded, and whereby said parallel surfaces are separated from each'other by trellis elements (26) which are advantageously flat trellises and the device is suitable for embodying the process of the Claim hereinbeforer, said device being characterized by comprising in mutual co operation and coordination: : - table means (14) to form the first slab (30), equipped with vibrating means (15), - mould means with combs (20) together with means to retain the conglomerate (125-I29) with at least one end bar (I8) to obtain positioning ánd handling, - supporting surface means (33) with positioning means (I9) and adjustable means (32), said supporting means (33) being independent and able to sustain mould means with combs (20), there being vibrating means (I5)t - withdrawal table means (12) with substantially horizontal withdrawal means (13) together with means (II2-37-137) to support and possibly to guide the mould means with combs (20). 3. Device to obtain double slabs, as in Claim 2, characterized by the fact that the supporting means (33) bear positioning means (I9) and means to regulate thickness (32) and are upheld by independent legs (17), whereby there are advantageously vibration-damping means (31) and whereby - vibrator means (15) are present. 4. Device to obtain double slabs, as in Claims 2 and 3, characberized by the fact that the mould means (20) comprises a plurality of interspaced (25) combs (I20), whereby said plurality of combs (I20) is positioned by end bar means - (18) and at least one of said end bar means is removable, - and whereby said spaces (25) between said combs (120) in- crude elastic means (125) to retain conglomerate at least at their upper side. - 5. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims thereafter, characterized by the fact that the end bar means (;8) include holes (21) to cooperate with positioning means (19) and bearing means (118) to copperate with guide means (I37), whereby there are advantageously means to anchor side boards (I29) and - book means (22). 6. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims thereafter, characterized by - the fact that the combs (120) include means to receive and convey hot substances (ir-and/or steam), whereby distri bution means (22Q) are advantageously present. 7. Device to obtain double slabs as in Claim 2 and in one or another of the Claims thereafter, characterized by - the fact the the withdrawal table means (I2) with withdraw- al means comprise a supporting surface (I2) for the double- slab (30-43)/mould means (20) assemblage and, at their front, toping means (35-36) and guiding (I37) and supporting (37) means and possibly a stop (234). 8. Device to obtain double slabs, as in Claim 2 and in one or another of the Claims thereafter, characterized by the fact that the supporting surface means (I2) has support ing surfaces (II2) covered with soft materials (wood, rubber, etc.). etc.). 9. Device to obtain double slabs, as in Claim 2 and it one or another of the Claims thereafter, characterized by the fact that the towing means (35-36) consist of winch means (35) cooperating with a cable (36) anchored to the end bar (I8) solidly fixed to the plurality of combs (120).- 10. Process to produce and obtain double slabs advantageously suitable for building uses, and device to realize said process, as described and shown and for the purposes allowed.

Inventors: PITTINI, ANDREA
Applicants: PITTINI, ANDREA
Application year: 1981
Main classification: B28B23
IPC codes: B28B23