Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
     Not Applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to a method and apparatus for the molding of a four or five sided, monolithic, seamless, concrete casting. 
     2. Related Art 
     A wide variety of molding techniques exist for the purpose of creating a monolithic concrete unit used in water systems and the like. What is desired is an apparatus that will greatly reduce the likelihood of damage to the product, particularly interior corners. The usual way of removing corner-forming mold sections is to retract them inwardly in a horizontal direction. It has been found that such movement may cause the fracturing of the casting due to misalignment and lack of coordination between the corner-forming sections and side panels. 
     BRIEF SUMMARY OF THE INVENTION 
     In one aspect of the present.invention there is provided an apparatus for integrally casting a multi-sided monolithically poured concrete module having a plurality of side walls comprising a pallet for defining the cross-sectional shape and thickness of the side walls, an inside mold core disposed interiorly of the pallet and including a plurality of interior panels having opposite end portions for molding inside surfaces of the side walls. A plurality of corner forming sections are included with each being located between respective opposite end portions of two adjacent interior panels for molding inside surfaces of side walls and corners formed thereby of a concrete module. There are means for moving the interior panels inwardly and the corner forming sections outwardly and upwardly, and inwardly and downwardly between a closed casting position and an open release position. The inside mold core abuts against the pallet in the closed casting position and is movable to the open release position. Alignment means are attached between an adjacent interior panels and adjacent corner forming section in alignment during movement of the corner forming section. An outside mold jacket is disposed outwardly of the pallet and includes a plurality of exterior panel members cooperatively arranged to generally envelope the pallet and the inside mold core for molding outside surfaces of side walls of a concrete module. Means are included for moving each exterior panel member between a closed casting position abutting the pallet and an open release position away from the pallet, the outside mold jacket and the inside mold core defining a mold cavity therebetween for receiving the concrete when the mold core and the mold jacket are in the closed casting positions. 
     In other aspects of the present invention each forming section includes a movable corner member for forming an interior concrete corner, the means for moving the interior panels and the corner forming section including means for moving the corner member substantially vertically upward to the closed casting position and substantially vertically downwardly to the open release position. The means for moving the corner member includes a hydraulic cylinder attached between the corner member and another part of the apparatus. The corner forming section also includes means for movably attaching the corner forming section to each adjacent interior panels. Means for moving the interior panels and the corner forming sections includes means for moving each corner forming section substantially vertically upwardly and outwardly to a closed casting position and substantially vertically downwardly and inwardly to an open release position. 
     Further advantages of the present invention are seen by each of the movable corner forming sections having a movable wedge-shaped element with an upper apex portion and a lower base portion with a width greater than the apex portion and two slanted edges and a pair of connection plate members each having a slanted edge portion adjacent one slanted edge portion of the element and another substantially vertical edge portion attached to one end portion of one interior panel. Engaging means are provided for slideably connecting one slanted edge portion of one connection plate member for causing the interior panels attached to the connection plate to the moved inwardly when the element is moved substantially vertically downwardly to the open release position and for causing the interior panels to be moved outwardly when the element is moved substantially vertically upwardly to the closed casting position. The alignment means includes an elongated bar member having opposite end portions and means for movably mounting each end portion of the bar member to a respective interior panel, the bar member being mounted generally horizontally. The means for movably mounting includes a pair of generally horizontally extending slots and cooperating fixed bolts located through the slots. The engaging means includes at least one elongated slot in one slanted edge portion and at least one or more bolt extending through the slot and movably therealong. The means for moving the interior panels and the corner forming sections includes lubricating means for lubricating between the corner forming sections and the respective opposite end portions of the adjacent interior panels and particularly for lubricating between the slanted edge portions of the element and the connection plate. There is also sealing means attached between the slanted edge portion of one element and the slanted edge portion of the respective connection plate to inhibit grout and debris entering the engaging means. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     The novel features which are believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in which: 
     FIG. 1 is a top view of the casting apparatus in accord with the present invention in the closed casting position and without a lid; 
     FIG. 2 is a top view of the casting apparatus of FIG. 1 in the open release position; 
     FIG. 3 is a pictorial view of a corner framing section of the apparatus of FIGS. 1 and 2; 
     FIG. 4 is a partial side view of the inside and outside forming jackets and the base and roller guide. 
     FIG. 4A is a top view of the pallet used in FIGS. 1 and 2; 
     FIG. 5 is a cross-section of the pallet taken on the line  5 — 5  of FIG. 4A; 
     FIG. 6 is a cross section of the system taken on the line  6 — 6  of FIG. 1; 
     FIG. 7 is a top view of the corner forming section of the apparatus of FIGS. 1 and 2; 
     FIG. 8 is a side elevation view of a portion of the corner forming section of FIGS. 1-3, and  7 ; and 
     FIG. 9 is a partial cross-section of the apparatus of FIGS. 1 and 2 illustrating the pallet support apparatus. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With respect now to the drawings, the mold system in accord with the present invention is shown generally at  10  in FIGS. 1 and 2, mold cavity  11  is formed to hold concrete casting or module  12  by interior core mold apparatus  13  and exterior mold jacket apparatus  14  which includes a plurality of securing means such as latches  15  (only one shown in FIG.  2 ). Interior mold  13  includes four corner sections  16  whose location is shown in FIGS. 1 and 2. The exterior jacket apparatus  14  includes end exterior walers  17  and side exterior walers  18  held in place by exterior columns  31 . End exterior forming panels  19  and side exterior forming panels  20  provide the exterior support for casting  12 . 
     In FIG. 1 the mold  10  is shown in the closed or forming position. In FIG. 2 the mold  10  is in the opened or released position. Inside mold apparatus  13  includes end interior walers  21  and side interior walers  22  with corresponding end and side interior forming panels  24  and  23  respectively. The entire apparatus  10  is shown as rectangular mold. The mold may also be square if desired. 
     A plurality of interior support members  25  include horizontal braces  26  with end brackets  27  that are bolted via holes  28  and bolts  30 . Side-mounted bolts  29  fit in slightly elongated holes and are loosened to allow the length of a support member  25  to shorten slightly when the interior mold apparatus  13  is contracted to release the mold. When the apparatus  10  is closed for molding the support members  25  push outwardly against side interior walers  23  and are rigid to hold the mold closed when vibrators to settle concrete  12  are used. The specific construction and number of members  25  employed depends upon the size of the mold and associated casting. The specific construction details of interior core apparatus  13  and exterior jacket apparatus  14  may vary depending on the size of the mold being made. Latches  15  may be replaced with a nut and bolted flange in the case of a high (8′ or more) molding in order to provide greater holding force. 
     In FIGS. 3,  7  and  8 , a corner forming sliding section  16  is illustrated. The present invention provides a corner section  16  that moves downwardly and away from the cast product when the mold  10  is opened. The resultant shearing process is fast and greatly reduces the risk of damage to the concrete mold  12 . 
     Grease rail  32  is mounted on top of side connection plate  33  and support beam  54  (FIG. 6) to provide for placing a lid  53  having chamfer  56  on the apparatus to mold top  55 . A slide angle plate  34  with spaced slotted holes  43  is connected to slide bar  35  which has spaced holes  42  into which are inserted slide nut and bolt fasteners  73 ,  74 . The jacket stiffener bars  36  are used to provide for structural rigidity of ear side skin plates  44 . Cross tie squaring bar  37  supports hydraulic (or pneumatic) cylinder assembly  39  via bolts  40  and  40 ′ and is mounted to apparatus base  50  in the case of short molds via any appropriate apparatus  78 . Clevis pin bracket  38  and  38 ′ connects double-acting cylinder assembly  39  between base and slide skin plate  41  to which it is welded at the corner flat bar  45  at points  77  and allows for slight inward and outward movement of section  16 . Holes  46  and bolts and nuts  75  are used to connect plates  33  to interior forming panels  21  and  22 , which are supported above base  50  and freely movable during contraction and expansion of the mold  13 . 
     Slide skin plate  41  is welded to slide angle plate  34 , which overlaps the junction between plates  41  and  44  to assist in keeping grout out of the apparatus and specifically to inhibit grout from entering between sliding plates  34  and  35 . Slide skin plate  41  is moved upwardly to be placed in position to form a concrete mold and pulled downwardly to release or strip the mold. As shown in FIGS. 3 and 8, the downward movement of plates  34  and  41  from arrow A to arrow B will cause the side connection plate and attached interior panels  21  and  22  to be pulled inward toward the corner section  16  because the skin plate  41  gets wider at the lower end. The angle  69  as seen in FIG. 8, determines the amount of inward contraction movement. This action results because plates  34  and  35  are movably secured together via bolts  73  and Teflon coated nuts  74 . As plate  34  moves downwardly it will encounter the end of slot  43  which functions as a travel limit. 
     The movement downwardly of corner section plates  34  and  41  will result in inward movement of interior panels  21  and  22  as they are pulled closer to corner section  16  which also moves inwardly with them. The overall result is an open position of the interior mold  13  resulting from the overall “shrinkage” of the perimeter around panels  21 , and  22  as shown in FIG.  2 . This result occurs because all interior panels  21 ,  22  are connected to respective outside edges of a corner section  16 . Corner sections  16  are also moved inwardly thereby releasing (or “stripping”) the interior mold  13  from the concrete casting  12 . The opposite result occurs when plates  34  and  41  are moved upwardly to the closed casting position. 
     The length of slot  43  is about  12 ″ with the result that plates  35  and panels  21 ,  22  will be pulled towards the corner and inwardly about 1 ⅜″ if all four corners have corner sections  16  that are lowered simultaneously. If only two diagonal corner sections  16  are employed, with the other diagonal corners being integral with respective end and side walls, the “shrinkage” or inward motion of interior mold apparatus  13  will be about {fraction (11/16)}″. The number of holes  42 , slots  43 , and fasteners  43 ′ used depend upon the height of the mold apparatus  10 . This distance can be anywhere from about 2 feet to over 12 feet as necessary. Slots  72  in cross tie  37  (FIG. 3) permit bolts  71  to slide therein and such slots  72  are horizontally elongated slightly to accommodate the expansion and shrinkage of the mold during raising or lowering respectively of a corner section  16 . 
     FIGS. 4 and 6 illustrate a cross-section showing base  50  having inspection manhole  76  (FIG. 1) upon which the interior portions of the mold rest and the roller guide  49  and roller  48  that allow the outside or exterior mold jacket  14  on exterior base apparatus  50 ′ to be moved to the right in preparation for casing. Any appropriate apparatus indicated by arrows  70  including manual means, which is preferable, can be used against exterior walers  17  to push jacket  14  into position. 
     FIGS. 4A and 5 illustrate the pallet  47  which can be rectangular as shown or square depending on the mold desired. The pallet  47  is comprised of a top flat bar  57  and bottom flat bar  58 . Steel side walls  59  define interior space  62  and support four flanges  61  that enclose gaskets  50  that extend beyond the edge of plates  57  and  58  about {fraction (1/16)}″ to provide for sealing the pallet  47  against grout. The pallet  47  is shown having a flat top surface but it is to be understood that other cross-sectional shapes may be desired. 
     FIG. 9 illustrates the pallet  47  and its associated operating assembly. A clamping assembly  63  includes brackets  64  and  66  welded to base  50  and  50 ′ and associated welded nuts  64 ′,  66 ′ that support threaded rod  65  which may be turned via handle  68 . Flange  67  will raise or lower pallet  47  as the handle  67  is turned to position one or the other end of flange  67  into place to adjust for a different wall height of the casting  12 . 
     In small castings only two corner sections  16  normally would be “live”, that is, have a sliding skin plate  41 . These sections  16  would be positioned opposite and diagonally across the apparatus  10 . In larger applications, all four corners will have “live” corner sections  16  to provide greater control and movement of the interior apparatus  13  during opening and closing of the assembly  10 . 
     Referring to FIG. 3, cross tie squaring bar  37  provides for proper alignment of skin plates  44  during upward or downward movement of corner assembly  16 . This prevents one of the interior forming panels  21  and  22  from moving independently and possibly damaging the casting  12  and otherwise causing jamming of the sliding plates  34  and  41  during movement. More than one bar  37  can be used if necessary in very large molds, i.e., a casting that has tall side walls. 
     Another aspect of the present invention that assists in alignment and the prevention of jamming is the offset or overlapping positions of the connection or interface  79  between respective plates  41  and plates  44  as seen in FIG.  3 . Plate  34  extends over the interface  79  of plates  41  and  44  to prevent grout from leaking into the interface  79  and possibly jamming the apparatus in and around slots  43  and bolt holes  42 . 
     Teflon-coated nuts  74  used with bolts  73  (FIG. 8) also contribute to low friction movement of plate  41  and thereby contributes to maintaining alignment and jam-free operation. In addition, slots  43  are accurately machined rather than being “burned in” by torch and thus provide for smoother operation and extended life of the apparatus. 
     Lubricating system  80  for convenience is shown in FIG. 8 as being supported between mounting bars  86  attached to stiffening members  36 . However, since supply  83  is periodically replaced, the same may be centrally located on base  50  as would be apparent to those skilled in the art. Lubricating system  80  includes feeder block  81  to supply grease via a plurality of hoses  82  from the pump and supply system shown generally at  83  which is well known in the lubricating art. Grease is supplied via fittings  85  to grease ports  84  for corner forming section  16 . The block  81  also supplies grease to ports  87  (FIG.3) in grease rail  32  upon which lid  53  rests. This grease forms a seal between the removable lid  53  and grease rails  32  which assists in excluding grout intrusion. 
     Pump system  80  may provide grease to the entire assembly or only to one or more sections  16 . Hydraulic plant  88  (shown only in FIG. 1) is standard as understood in the art and operates each of double-acting hydraulic cylinders  39  via lines  89  in a conventional manner. The plant  88  may be mounted on base  50  or elsewhere as desired. 
     Also, as understood in the art, a pneumatic system may be used for control of the movement of corner sections  16 , but it is preferred to use a hydraulic system particularly for large casting mold system. 
     While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.

Technology Category: 7