Method and Device for Producing a Reinforced Concrete Component, and Concrete Component

Abstract

A method and an apparatus for producing a concrete component, comprising concrete and a textile reinforcement composed of a reinforcement fiber strand (28), wherein first a yarn (20) is saturated with a mineral suspension (35) and forms the at least one reinforcement fiber strand (28). According to the invention, the reinforcement fiber strand (28) is fed by means of a moving device, so that the reinforcement fiber strand (28) is placed in a concrete strand (4), placed on a concrete layer (2), or placed on a vertical side surface of a plurality of concrete layers placed on top of each other, so that a perpendicular reinforcement is produced when arranged on the outside, and wherein the reinforcement fiber strand (28) is further enclosed by the concrete immediately upon placement or subsequently before the mineral suspension (35) has cured. The invention also relates to a reinforced concrete component (1).

Claims

1. A method for producing a reinforced concrete component comprising a concrete matrix material and a textile reinforcement of at least one reinforcement fiber strand, wherein a yarn (20) is saturated with a mineral suspension (35) and is used to form the at least one reinforcement fiber strand (28), characterized in that the at least one reinforcement fiber strand (28) is dispensed from a moving device for dispensing the at least one reinforcement fiber strand (28), so that the at least one reinforcement fiber strand (28) is introduced into at least one concrete strand (4) according to a first embodiment, is placed on at least one concrete layer (2) according to a second embodiment or, according to a third embodiment, is placed on at least one vertical side surface of a plurality of superimposed concrete layers (2) of the concrete component (1) or is placed in the concrete strand (4) applied there, so that a perpendicular reinforcement (26) is produced which is arranged on the outside, and wherein the at least one reinforcement fiber strand (28) is further enclosed by the concrete immediately upon deposition or subsequently, before the mineral suspension (35) has cured.

2. The method according to claim 1, wherein the production of the concrete component (1) is carried out by means of a method for extrusion-based additive manufacturing, wherein the concrete layers (2) are formed by the at least one concrete strand (4) which is extruded from an extrusion nozzle (6), wherein for the production of each concrete layer (2) a relative movement between the extrusion nozzle (6) on the one hand and a substrate or the previously produced concrete layer (2) on the other hand takes place in the plane of the concrete layer (2) by means of a manipulation device, wherein the at least one reinforcement fiber strand (28) is placed in at least one of the concrete strands (4) or is placed on at least one of the concrete layers (2).

3. The method according to claim 2, wherein the at least one reinforcement fiber strand (28) is placed in at least one of the concrete layers (2) by means of the reinforcement fiber strand delivery unit (40) configured for direct integration of the reinforcement fiber strand (28) into the at least one concrete strand (4) exiting the extrusion nozzle (6), wherein the reinforcement fiber strand delivery unit (40) is arranged in an immobile manner with respect to the extrusion nozzle (6), wherein, for the production of each concrete layer (2), the reinforcement fiber strand delivery unit (40) and the extrusion nozzle (6), on the one hand, and the substrate or the previously produced concrete layer (2), on the other hand, are moved relative to one another in the plane of the concrete layer (2), and wherein the reinforcement fiber strand (28) is dispensed in an extrusion direction of the extrusion nozzle (6) and, at the same time, embedded in the concrete strand (4).

4. The method according to claim 2, wherein said at least one reinforcement fiber strand (28) is placed on at least one of said concrete layers (2) in that said reinforcement fiber strand delivery unit (50), configured for integration of said at least one reinforcement fiber strand (28) between said concrete layers (2), is moved in the plane of the concrete layer (2) relative to the substrate or to the previously produced concrete layer (2), dispenses the at least one reinforcement fiber strand (28) and the latter is covered by the subsequently placed concrete strand (4) forming a further concrete layer (2).

5. The method according to claim 2, wherein a flowable cement suspension or mortar is placed between the concrete layers (2) for improved adhesion between the reinforcement fiber strand (28) and the concrete layer (2).

6. The method according to claim 1, wherein the reinforcement fiber strand delivery unit (40, 50) arranged on a manipulation device comprises a strand preparation device (62, 72, 82) and an impregnation device (33), wherein, according to a first embodiment, the at least one reinforcement fiber strand (28) is formed stationarily in the strand preparation device (62, 72, 82) and transferred to the reinforcement fiber strand delivery unit (40, 50), wherein, according to a second embodiment, the at least one reinforcement fiber strand (28) is formed stationarily in the strand preparation device (62, 72, 82), is wound up into a strand coil (74), the strand coil (74) is connected to the reinforcement fiber strand delivery unit (40, 50) in such a way that the at least one reinforcement fiber strand (28) is fed from the strand coil (74) to the concrete component (1), wherein, according to a third embodiment, the reinforcement fiber strand delivery unit (40, 50) comprises a mobile strand preparation device (62, 72, 82) and the at least one reinforcement fiber strand (28) is formed in the reinforcement fiber strand delivery unit (40, 50).

7. The method according to claim 1, wherein the at least one reinforcement fiber strand (28) is formed by saturation with a mineral suspension (35) by performing the impregnation process with a padder; the squeezing off of excess suspension (35) as well as the shaping of the cross-section of the reinforcement fiber strand (28) being performed with the aid of a strand nozzle (34) which is conical or funnel-shaped in the dispensing direction.

8. The method according to claim 1, wherein the concrete layers (2) form a permanent formwork and flowable concrete is filled into the permanent formwork, wherein the entire formwork is filled at once or concrete layers (2) are formed which are provided with at least one reinforcement fiber strand (28) according to the method according to claim 4.

9. An apparatus for producing a reinforced concrete component (1), the concrete component (1) comprising a concrete matrix material and a reinforcement of at least one textile reinforcement fiber strand (28), wherein a reinforcement fiber strand delivery unit (40, 50) is provided as a device for dispensing the reinforcement fiber strand (28), comprising an impregnation device (33) forming from a yarn (20) the reinforcement fiber strand (28) saturated with a mineral suspension (35), characterized in that the reinforcement fiber strand delivery unit (40, 50) is movable relative to a substrate or a previously produced concrete layer (2) and is adapted to place the reinforcement fiber strand (28), according to a first embodiment, in a concrete strand (4) dispensed from an extrusion nozzle (6), to place it, according to a second embodiment, on a previously applied concrete layer (2), or to place it, according to a third embodiment, on a vertical side surface of a plurality of superimposed concrete layers (2) of the concrete component (1), or to place it in the concrete strand (4) to be applied thereon, so that, in each of the embodiments, immediate or subsequent enclosure of the reinforcement fiber strand (28) with concrete can take place before the mineral suspension (35) has cured.

10. The apparatus according to claim 9, configured for extrusion-based additive manufacturing of the concrete component (1), which is formed by at least one concrete strand (4) extruded from an extrusion nozzle (6) moved by means of a manipulation device for each concrete layer (2) in the plane of the concrete layer (2) relative to the substrate or the previously produced concrete layer (2).

11. The apparatus according to claim 9, wherein the reinforcement fiber strand delivery unit (40, 50) comprises a manipulation device configured as an articulated robot with three-dimensional mobility or as a gantry robot with at least two-dimensional in-plane mobility.

12. The apparatus according to claim 9, wherein a strand preparation device (62, 72, 82) comprises a yarn coil (21) accommodating a yarn (20), the impregnation device (33) configured as a padder or a two-roll padder, and further includes a strand nozzle (34) which is suitable for squeezing off excess suspension (35) as well as for shaping the cross-section of the at least one reinforcement fiber strand (28), is conical or funnel-shaped in the extrusion direction and has a constant or a variable outlet diameter.

13. The apparatus according to claim 12, wherein the strand preparation device (62, 72, 82) further includes an apparatus (32) for prewetting suitable for wetting the yarn (20) with water prior to the impregnation process.

14. The apparatus according to claim 12, wherein the strand preparation means (62, 72) is stationary and comprises a strand transferring means (64) for supplying the at least one reinforcement fiber strand (28) to the reinforcement fiber strand delivery unit (40, 50), or wherein a device for storing the at least one reinforcement fiber strand (28) on a strand coil (74) provided for supply to the reinforcement fiber strand delivery unit (40, 50) is comprised, or wherein the strand preparation device (82) is connected to the reinforcement fiber strand delivery unit (40, 50) so that the direct supply of the at least one reinforcement fiber strand (28) to the reinforcement fiber strand delivery unit (40, 50) can take place even during its movement.

15. The apparatus according to claim 12, wherein for direct integration of the at least one reinforcement fiber strand (28) into the concrete, the reinforcement fiber strand delivery unit (40) comprises an inlet device (41) and a first pair of drums (42) conveying the at least one reinforcement fiber strand (28), a second pair of drums (43) is provided for deflecting the at least one reinforcement fiber strand (28) in the direction of a horizontal orientation, a stripping device and a cutting device (44) are further provided, through which the at least one reinforcement fiber strand (28) is subsequently conveyed, a guiding device (46) being further provided, the at least one reinforcement fiber strand (28) being introduced directly into the extrusion nozzle (6) in the extrusion direction with the aid of the guiding device (46), so that the at least one reinforcement fiber strand (28) is integrated into the concrete strand (4) exiting the extrusion nozzle (6).

16. The apparatus according to claim 9, wherein a closing apparatus is further provided which can be closed during concrete extrusion without integration of the at least one reinforcement fiber strand (28) into the concrete strand (4) and is open during integration of the at least one reinforcement fiber strand (28) into the concrete strand (4), and which helps to prevent the extruded concrete from backing up into the guiding device (46).

17. The apparatus according to claim 9, wherein the extrusion nozzle (6) is configured such that the concrete to be extruded is divided into two partial strands and can be reunited directly behind an opening through which the at least one reinforcement fiber strand (28) is introduced between the two partial strands, to embed the at least one reinforcement fiber strand (28) in the concrete.

18. The apparatus according to claim 9, wherein the reinforcement fiber strand delivery unit (50) is configured to dispense the at least one reinforcement fiber strand (28) vertically downward.

19. A reinforced concrete component in which a permanent formwork is filled with flowable concrete or shotcrete, characterized in that the permanent formwork is formed of concrete layers (2) formed according to the method according to claim 1.

20. The reinforced concrete component according to claim 19, wherein the flowable concrete or shotcrete is filled in in layers and a reinforcement fiber strand (28) is placed on at least a part of the concrete layers (2) according to the method according to claim 4.

21. A reinforced concrete component (1) produced in an extrusion-based additive manner, comprising concrete layers (2) formed by at least one concrete strand (4) extruded from at least one extrusion nozzle (6), characterized in that the reinforcement provided is a yarn (20) which, for installation in the concrete strand (4) or between two concrete strands (4) or between two concrete layers (2), is saturated with a mineral suspension (35) to form at least one reinforcement fiber strand (28) which is completely enclosed with concrete in the concrete component (1), the installation and the enclosure having taken place before curing of the mineral suspension (35), the at least one reinforcement fiber strand (28) being provided as longitudinal reinforcement (22), transverse reinforcement (24) and/or vertical reinforcement (26).

22. The concrete component according to claim 21, obtainable by a method according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0089] FIG. 1: is a schematic representation of an embodiment of a concrete component according to the invention with introduced longitudinal reinforcement;

[0090] FIG. 2: is a schematic representation of an embodiment of a concrete component according to the invention with introduced transverse reinforcement;

[0091] FIG. 3: is a schematic representation of an embodiment of a concrete component according to the invention with introduced perpendicular reinforcement;

[0092] FIG. 4: is a schematic representation of an embodiment of an apparatus according to the invention for direct integration of a reinforcement fiber strand;

[0093] FIG. 5: is a schematic representation of an embodiment of an apparatus according to the invention for integrating a reinforcement fiber strand between concrete layers;

[0094] FIG. 6: is a schematic representation of an embodiment of an apparatus according to the invention for stationary-direct yarn delivery;

[0095] FIG. 7: is a schematic representation of an embodiment of an apparatus according to the invention for stationary-indirect yarn delivery, and

[0096] FIG. 8: is a schematic representation of an embodiment of an apparatus according to the invention for instationary-direct yarn delivery.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0097] FIG. 1 shows a schematic representation of an embodiment of a concrete component 1 according to the invention with introduced longitudinal reinforcement 22, configured as a reinforcement fiber strand 28. The reinforcement fiber strand 28 is embedded in a concrete strand 4. The concrete strand 4 is placed on the concrete layer 2 formed by a previously produced concrete strand 4, resulting in the additive, layer-by-layer production of the concrete component 1.

[0098] FIG. 2 shows a schematic representation of an embodiment of a concrete component 1 according to the invention with introduced transverse reinforcement 24, consisting of a reinforcement fiber strand 28. The transverse reinforcement 24 provides strength to the transverse struts laid out in a zigzag pattern inside the concrete component 1. Again, the reinforcement fiber strand 28 is embedded in the concrete strand 4.

[0099] FIG. 3 shows a schematic representation of an embodiment of a concrete component 1 according to the invention with introduced perpendicular reinforcement 26 by means of a reinforcement fiber strand 28. Once the production of the concrete component 1 or a section thereof as shown in FIGS. 1 and 2 is complete, the perpendicular reinforcement 26 is applied to the outer wall to provide the flexural load-bearing capacity in the horizontal loading direction. In the preferred embodiment, as shown, reinforcement 26 is also embedded in a concrete strand 4. This ensures optimum bonding to the concrete matrix and also protects the reinforcement fiber strand 28 from damage.

[0100] FIG. 4 shows a schematic representation of an embodiment of a reinforcement fiber strand delivery unit 40 according to the invention for direct integration of the reinforcement fiber strand 28 into the concrete strand 4. The reinforcement fiber strand delivery unit 40 for direct integration of the reinforcement fiber strand 28 is fixedly connected to the extrusion nozzle 6, since the dispensing direction of the reinforcement fiber strand 28 is fixed to the working direction of the extrusion nozzle 6. The reinforcement fiber strand 28 is fed to the reinforcement fiber strand delivery unit 40 for use as longitudinal reinforcement 22, transverse reinforcement 24, or perpendicular reinforcement 26, and enters the reinforcement fiber strand delivery unit 40 via the inlet device 41. First, the reinforcement fiber strand 28 is gripped by a first pair of drums 42. A second pair of drums 43 handles the deflection of the reinforcement fiber strand 28 in the working direction. The second pair of drums 43 is followed by a guillotine-type cutting device 44, which in turn is followed by a further guiding device, which is configured as a hose 46. Advantageously, the hose 46 has a closable opening that can be closed when no reinforcement fiber strand 28 is exiting and concrete ingress is to be prevented. The hose 46 opens into the extrusion nozzle 6, so that the reinforcement fiber strand 28 can be embedded directly in the concrete flowing through the extrusion nozzle 6 and exits the extrusion nozzle 6 together with it as an already “reinforced” concrete strand 4.

[0101] FIG. 5 shows a schematic representation of an embodiment of a reinforcement fiber strand delivery unit 50 according to the invention for integration of a reinforcement fiber strand 28 into an interlayer or space between two concrete strands 4 or two concrete layers 2. In this process, a first concrete strand 4 is applied first as a concrete layer 2 and the reinforcement fiber strand 28 is placed thereon as longitudinal reinforcement 22, transverse reinforcement 24 or vertical reinforcement 26. Then, another concrete strand 4 is applied via the extrusion nozzle 6, forming another concrete layer 2 immediately covering the reinforcement fiber strand 28 and thus embedding it in the concrete matrix.

[0102] In order that the application of the reinforcement fiber strand 28 can also take place independently of the working direction of the extrusion nozzle 6, which can be advantageous for covering the reinforcement, for example, the reinforcement fiber strand 28 is dispensed vertically downward from the reinforcement fiber strand delivery unit 50 via an outlet guiding device 56. Prior to this, the reinforcement fiber strand 28 passes through a first pair of drums 52, a second pair of drums 53, and a cutting device 54. The reinforcement fiber strand 28 enters the reinforcement fiber strand delivery unit 50 beforehand via an inlet device 51.

[0103] FIG. 6 shows a schematic representation of an embodiment of an apparatus 60 according to the invention for stationary-direct yarn delivery to the reinforcement fiber strand delivery unit 40 for direct integration into the concrete strand 4 even before it exits the extrusion nozzle 6 or to the reinforcement fiber strand delivery unit 50 for dispensing between two concrete strands 4.

[0104] Characteristic of this embodiment is that a strand preparation device 62 is provided which transfers the reinforcement fiber strand 28 to the reinforcement fiber strand delivery unit 40, 50 moving with the extrusion nozzle 6 by means of a strand transferring means 64, in the simple case configured as deflection points.

[0105] The strand preparation device 62 comprises a yarn coil 21 from which a multifilament yarn 20 is dispensed. From there, it passes through the prewetting apparatus 32, which in the preferred embodiment is configured as a kiss coater. From there, the preferably prewetted multifilament yarn reaches an impregnation device 33, which is preferably configured as a padder. The latter conveys the multifilament yarn 20 via three drums, allowing the mineral suspension 35 to penetrate between the filaments of the multifilament yarn 20 and ensure optimum impregnation. Finally, a strand nozzle 34 is used to strip off excess suspension 35 and give the reinforcement fiber strand 28 the desired cross-sectional shape. Thereafter, the reinforcement fiber strand 28 thus formed is withdrawn via the strand transferring means 64.

[0106] FIG. 7 shows a schematic representation of an embodiment of an apparatus 70 according to the invention for stationary-indirect yarn delivery, which also comprises a strand preparation device 72, but which has a further coil, i.e. the strand coil 74, downstream of the strand nozzle 34. The freshly formed reinforcement fiber strand 28 is wound onto this coil. The strand coil 74 is immediately thereafter taken to the reinforcement fiber strand delivery unit 40, 50 so that the mineral suspension used for impregnation does not cure in an undesirable manner. There, the reinforcement fiber strand 28 is fed into the reinforcement fiber strand delivery unit 40, 50 as previously described.

[0107] FIG. 8 shows a schematic representation of an embodiment of an apparatus 80 according to the invention for instationary-direct yarn delivery. In this case, the entire strand preparation device 82 is directly connected to the reinforcement fiber strand delivery unit 40, 50 and the extrusion nozzle 6 connected thereto. The entire assembly, consisting of extrusion nozzle 6, reinforcement fiber strand delivery unit 40, 50, and apparatus 80, is moved above the concrete component by a manipulation device to allow dispensing of the concrete strands 4. In this case, the strand preparation device 82 always outputs freshly produced fiber strands 28, the production of which is carried out in accordance with the manner illustrated in the description of FIGS. 6 and 7.

LIST OF REFERENCE NUMERALS

[0108] 1 concrete component [0109] 2 concrete layer [0110] 4 concrete strand [0111] 6 extrusion nozzle [0112] 20 yarn, multifilament yarn [0113] 21 yarn coil [0114] 22 longitudinal reinforcement [0115] 24 transverse reinforcement [0116] 26 perpendicular reinforcement [0117] 28 reinforcement fiber strand [0118] 32 prewetting apparatus (kiss coater) [0119] 33 impregnation device (padder) [0120] 34 strand nozzle [0121] 35 mineral suspension [0122] 40 reinforcement fiber strand delivery unit (for direct integration) [0123] 41 inlet device [0124] 42 first pair of drums [0125] 43 second pair of drums [0126] 44, 54 cutting device (guillotine) [0127] 46 guiding device (hose) [0128] 50 reinforcement fiber strand delivery unit (for interlayer) [0129] 51 inlet device [0130] 52 first pair of drums [0131] 53 second pair of drums [0132] 56 outlet guiding device [0133] 60 apparatus for stationary-direct yarn delivery [0134] 62 strand preparation device (with strand transferring means) [0135] 64 strand transferring means [0136] 70 apparatus for stationary-indirect yarn delivery [0137] 72 strand preparation device (with strand coil) [0138] 74 strand coil [0139] 80 apparatus for ins ationary-direct yarn delivery [0140] 82 strand preparation device (mobile)