METHOD OF AND DEVICE FOR PRODUCING CONCRETE BLOCKS

Abstract

A method of producing concrete blocks for creating a surface covering, wherein each concrete block comprises a multiple-layer concrete block body with at least one level concrete block underside and, opposite the at least one level concrete black underside, an essentially flat concrete block upper side, wherein the multi-layer concrete block body comprises a first concrete block layer designed as a facing concrete layer and forming the concrete block upper surface, at least one second concrete block layer designed as a core concrete layer, as well as at least one third concrete block layer forming the concrete block underside. In the method at least one formwork is provided.

Claims

1. A method of producing concrete blocks, wherein each concrete block comprises a multiple-layer concrete block body with at least one even concrete block underside and, opposite the at least one even concrete block underside, an essentially flat concrete block upper side, wherein the multiple-layer concrete block body comprises a first concrete block layer designed as a facing concrete layer and forming the concrete block upper side, at least one second concrete block layer designed as a core concrete layer, as well as at least one third concrete block layer forming the concrete block underside, wherein at least one formwork is provided, and the method comprises the steps of: producing the second concrete block layer as the core concrete layer, wherein a core concrete is introduced into the formwork by a first filling device; wherein after introducing the core concrete, producing the first concrete block layer as the facing concrete layer, whereby a face concrete is subsequently filled into the formwork and wherein the core concrete introduced into the formwork is then compacted and hardened; and wherein before introducing the core concrete, in an initial step of the method to produce the third concrete block layer, a concrete material for the third concrete block layer is introduced into the formwork by a first dosing device.

2. The method according to claim 1, wherein the concrete material for the third concrete block layer is introduced into the formwork in a volumetrically-dosed manner.

3. The method according to claim 1, wherein the concrete material for the third concrete block layer is introduced into the formwork by a dosing device configured as a cellular wheel sluice or comprising a cellular wheel sluice.

4. The method according to claim 3, wherein, for introduction into the formwork by a dosing device of the concrete material for the third concrete block layer, a rotating cellular wheel of the cellular wheel sluice is driven in a controlled manner and a rotation speed of the rotating cellular wheel is set in a controlled manner.

5. The method according to claim 4, wherein the dosing device is moved in at least one direction of travel running in a direction along a longitudinal axis of the formwork with a controlled set advancing speed and, through this, the concrete material is evenly supplied, at least in relation to a longitudinal direction of the formwork.

6. The method according to claim 5, wherein the controlled set advancing speed of the dosing device is moved in the direction of travel and the rotation speed of the cellular wheel are matched to each other in a controlled manner and, more particularly, are adapted and matched to each other as a function of a type of concrete material used for the third concrete block layer and/or a desired layer thickness of the third concrete block layer.

7. The method according to claim 6, wherein at least the controlled set advancing speed of the dosing device is moved in a direction of travel is controlled as a function of a shape of the formwork.

8. The method according to claim 1, wherein a formwork with a plurality of mould recesses is provided and a plurality of concrete blocks corresponding to a number of mould recesses are produced at the same time, wherein the concrete material for the third concrete block layer is preferably introduced into each of the plurality of mould recesses of the formwork in a volumetrically-dosed manner.

9. The method according to claim 1, wherein before filling the core concrete and/or before subsequently filling the face concrete, at least one further concrete material is filled into the formwork and thereby at least one further concrete block layer is produced, wherein the further concrete block layer is arranged between the second and third concrete block layer or between the first and second concrete block layer.

10. The method according to claim 9, wherein the at least one further concrete material for the further concrete block layer is introduced into the formwork in a volumetrically-dosed manner, more particularly by the first dosing device, or by a second dosing device configured as a cellular wheel sluice or comprising a cellular wheel sluice.

11. The method according to claim 1, wherein the concrete material introduced into the formwork for the third concrete block layer and/or the introduced core concrete and/or the introduced face concrete is/are evenly spread.

12. The method according to claim 1, wherein in an intermediate step, the concrete material introduced into the formwork for the third concrete block layer is pre-compacted before introduction of the core concrete and/or in that in an intermediate step the core concrete introduced into the formwork is pre-compacted before introduction of facing concrete.

13. The method according to claim 1, wherein the third concrete block layer is produced with a layer thickness which is between 2% and 20% of a total height of the multiple-layer concrete block body.

14. The method according to claim 1, wherein gravel and/or sand-rich concrete is used as core concrete material for producing the third concrete block layer and/or a porous concrete is used as core concrete for producing the second concrete block layer.

15. The method according to claim 1, wherein a concrete with a water/cement ratio in a range of 0.25 to 0.4 is used as concrete material for producing the third concrete block layer.

16. A device for producing concrete blocks comprising at least one formwork with at least one or more mould recesses and at least one first filling device for introducing concrete into the formwork, wherein the device also comprises at least one first dosing device, wherein the at least one first dosing device is designed for introducing concrete material into the formwork in a volumetrically-dosed manner.

17. The device according to claim 16, wherein the at least one first dosing device is formed by a cellular wheel sluice or comprises at least one cellular wheel sluice.

18. The device according to claim 16, wherein the at least one first dosing device is movably mounted and can be moved in a driven manner, in at least one first direction of travel in a direction running along a longitudinal axis of the formwork.

19. The device according to claim 16, wherein the at least one first filling device is designed in the form of a filling hopper that can be moved in a direction along a longitudinal axis of the formwork.

20. The device according to claim 16, wherein a control and/or regulating unit communicating with the at least one first filling device and the at least one first dosing device is provided, and introduction of concrete material into the formwork can be adjusted in a programme-controlled manner by way of at least one control routine executed in a control and/or a regulating unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] The invention will be described below with the aid of examples of embodiment in connection with the drawings. In these:

[0062] FIG. 1 shows a roughly schematic and greatly simplified view of a section of a form of embodiment of a device for manufacturing a concrete block in a state during the introduction of concrete material into a formwork;

[0063] FIG. 2 shows a roughly schematic and greatly simplified view of a section of a form of embodiment of the device for manufacturing the concrete block in a state during the introduction of core concrete into a formwork;

[0064] FIG. 3 shows a roughly schematic and greatly simplified view of a section of a form of embodiment of the device for manufacturing the concrete block in a state during the introduction of face concrete into a formwork;

[0065] FIG. 4 shows a roughly schematic and greatly simplified view of a section of a form of embodiment of the device for manufacturing the concrete block in a state during the compacting of the concrete;

[0066] FIG. 5 shows a very simplified and roughly schematically outlined perspective view of a form of embodiment of a dosing device and a formwork to be filled;

[0067] FIG. 6 shows the dosing device in FIG. 5 with a partially opened housing;

[0068] FIG. 7 shows a very simplified and roughly schematically illustrated perspective view of a form of embodiment of a three-layer concrete block;

[0069] FIG. 8 shows a very simplified and roughly schematically illustrated perspective view of a form of embodiment of a four-layer concrete block; and

[0070] FIG. 9 shows a very simplified and roughly schematically illustrated side view of a form of embodiment of a multiple-layer concrete block.

DETAILED DESCRIPTION OF THE INVENTION

[0071] For the same elements of the invention or those acting in the same way, identical reference numbers are used in the figures. Furthermore, for the sake of clarity, in the individual figures, only reference numbers are used that are required for the description of the respective figure.

[0072] The present method of manufacturing multiple-layer concrete blocks 1 (not clearly seen in FIGS. 1 to 4; for this see FIGS. 7 to 9) is described by way of example with reference to FIGS. 1 to 4. Purely as an example, FIGS. 1 to 4 set out individual, selected procedural steps and show, in each case greatly simplified and only roughly schematic, views or partial views, of respective sections of a device 10 for manufacturing the concrete blocks 1 as it can be used for implementing the method. Shown in the figures are individual units or fittings comprised by the device that have been selected for the respective figure.

[0073] With the present method, the concrete blocks 1 are produced as multiple-layer concrete blocks 1, each with a multiple-layer concrete block body 2, which comprises a first concrete block layer 2a made of a facing concrete and designed as a facing layer, a second concrete block layer 2b made of a core concrete and designed as a core concrete layer and at least one third concrete block layer 2c. The first concrete block layer 2a designed as a facing concrete layer forms a concrete block layer upper side 2.1 of the concrete block body 2 and thus also the surface of the concrete block 1, namely in the used condition, in which several concrete blocks 1 laid in conjunction with each other form a surface covering, the visible and walkable or drivable surface or traffic surface. The third concrete block layer 2c forms a concrete block underside which is opposite the concrete block layer upper side 2.1 and is envisaged for placing on a bedding layer.

[0074] In the present method, to manufacture the concrete blocks 1, a formwork 4 is initially provided, which in the examples in FIGS. 1 to 4, solely for reasons of simplified illustration, is shown as a single mould for one ground cover element, i.e. as a formwork 4 with just one mould recess 4a to take up the concrete material. However, it goes without saying that the formwork 4 can of course also be a formwork 4 for the simultaneous production, particularly in layers, of several concrete blocks 1, which then accordingly has several mould recesses 4a and each mould recess 4a is designed to mould one concrete block 1 each.

[0075] In the present method, in an initial procedural step outlined in FIG. 1, which is essentially the first step in producing the concrete block layers 2a, 2b, 2c of the multiple-layer concrete block body 2, a concrete material for the third concrete block layer 2c is introduced into the formwork 4 and thereby the third concrete block layer 2c is produced. The concrete material for the third concrete block layer 2c is thus introduced before the introduction of the core concrete and the facing concrete.

[0076] In the method, the concrete material for the third concrete block layer 2c is introduced by means of a first dosing device 13 into the formwork 4 in a volumetrically-dosed manner. In the shown example, the first dosing device 13 comprises a cellular wheel sluice 14 for the volume-related dosing of the concrete material. The dosing device 13 with the cellular wheel sluice 14 is, in relation to the formwork 4, arranged above the latter and is preferably borne in a moveable manner relative to the formwork 4.

[0077] This step of introducing the concrete material for the third concrete block layer 2c into the formwork 4, namely the feed of the concrete material to the mould recess 4a or the dosing in or additional dosing is described in more detail further below in the text relating to FIGS. 5 and 6.

[0078] In the example of FIG. 1, the concrete material for the third concrete block layer 2c is introduced into the mould recess 4a in a quantity such that a continuous, complete and even third concrete block layer 2c is formed. The concrete material for the third concrete block layer 2c in the shown example, is a coarse gravel and/or sand-rich concrete, which at least in parts is permeable to water.

[0079] For example, the concrete material for the third concrete block layer 2c is selected in such a way that the third concrete block layer 2c is configured to draw water up from the bedding layer in a capillary manner in order to increase the evaporation of water via the surface of the concrete block 1.

[0080] After the step of forming the third concrete block layer 2c, according to this method, as shown in FIG. 2, for example, the core concrete is introduced into the formwork 4 in order to produce the second concrete block layer 2b. Here, the core concrete is subsequently filled onto the concrete material or the previously formed third concrete block layer 2c and the concrete block layer is formed.

[0081] The step of filling the core concrete into the formwork 4, which can also be understood as pouring in or casting the core concrete, takes place by way of a first filling device 11, via which the core concrete is taken from a corresponding storage container and supplied to the formwork 4, for example using suitable pumps or by other suitable conveying means known to a person skilled in the art. In the shown example, the first filling device 11 is designed as a filling hopper, which can be moved relative to the formwork 4 and, indeed, is height adjustable and further displaceable, namely displaceable both in an x-direction and y-direction in relation to a plane taking up the formwork 4, so that even filling of the formwork 4 can be facilitated or ensured.

[0082] The first filling device 11 can preferably comprise a filling tube that extends into the formwork 4 so that the core concrete can be filled with as little splashing and as cleanly as possible. The filling device 11 can, for example, comprise a funnel-shaped filling container which bears the filling tube. The filling container and/or the filling tube can, for example, be connected via a flexible connection piece, for example, via a hose, to other units of the filling device 11 and/or, in particular, connected to a concrete reserve.

[0083] In a next step of the method, which is outlined in the greatly simplified illustration of FIG. 3, a facing concrete is subsequently filled onto the prepared second concrete block layer 2b and through this a first concrete block layer 2a forming the facing concrete layer is produced. Introduction of the facing concrete into the formwork 4 takes place by means of a second filling device 12, which can be designed similarly to the first filling device 11 and is preferably also displaceable and therefore movable relative to the formwork 4.

[0084] In a further next step of the manufacturing process, the concrete filled into the formwork 4 is compacted, as shown in a roughly schematic manner in FIG. 4. For this, a compacting device is used, for example, which more particularly comprises a press or a punch 15. Alternatively or additionally, compacting of the concrete can also take place by shaking and/or vibration. After compacting, the concrete is finally hardened, through which the concrete block body 2 is completed.

[0085] With reference to FIGS. 5 and 6, the volumetrically-dosed introduction of the concrete material for the third concrete block layer 2c by way of the first dosing device 13 is described in more detail. As has already been mentioned above in connection with FIG. 1, the dosing device 13 in the shown example, is a cellular wheel sluice 14, which in the figures is only shown partially and very roughly schematically.

[0086] The example cellular wheel sluice 14 is designed and fitted out in such a way that the introduction of concrete material into a formwork 4 provided with several mould recesses 4a can take place in an optimal and effective manner and the concrete material is volumetrically-dosed into each of the mould recesses 4a.

[0087] In the example shown in FIG. 5, the formwork 4, which in terms of its length extends along a longitudinal axis LA and in the direction perpendicular to the longitudinal axis A has a mould width BF, has nine mould recesses 4a, wherein it is expressly emphasised that the shown number and arrangement of the mould recesses 4a is only given as an example and, of course, different numbers and arrangements are conceivable without departing from the inventive idea.

[0088] The cellular wheel sluice 14, which, for the sake of clarity, is shown again in FIG. 6 isolated from the formwork 4 and in a partially covered state, has an operational width AB, which corresponds or approximately corresponds to the mould width BF of the formwork 4 so that the concrete material is given off or discharged over the entire mould width BF of the formwork 4.

[0089] On the inlet side, in an area of the inlet 14.1, the cellular wheel sluice 14 is supplied with concrete material via a supply or delivery unit which is not shown in the figures. The cellular wheel sluice 14 also comprises an intermediate storage unit, not shown in the figures, which is provided in the area of an inlet 14.1 and is connected therewith in such a way that concrete material held in the intermediate storage unit can be supplied to a sluice or dosage space 14a of the cellular wheel sluice 14. The concrete material thus reaches the sluice or dosage space 14a, which can also be designated as the sluice or dosage chamber, and is at least in sections delimited by a casing wall or chamber wall.

[0090] Arranged in the sluice or dosing space 14a is the driven cellular wheel 16 which is provided with a (not shown) drive and rotates about an axis of rotation RA in direction of rotation DR. The cellular wheel 16 comprises a long or elongated axial body or rotor body 17, extending in terms of its length along the axis of rotation RA and arranged on which is a plurality of rotor blades 18 which are also long or elongated and again in terms of their respective length, extend in the direction of the axis of rotation RA. The cellular wheel 16 has a cellular wheel length LZ approximately corresponding to the operational width AB.

[0091] The rotor blades 18, which in the shown example are four in number, but this can also be departed from, essentially project radially outwards from the rotor body 17. The cellular wheel 16, in particular an outer circumference of the cellular wheel 16, is dimensioned in such a way that the cellular wheel 16 fits, more particularly precisely fits into the housing of the sluice or dosing space 14a and can rotate freely. Here, the rotor blades 18 are arranged with their respective outwardly directed free longitudinal sides as close as possible to the housing walls, but at the same time at a sufficient distance that clogging or blocking or caking with concrete material is prevented.

[0092] The rotor blades 18 are evenly distributed around the circumference of the rotor body 17, wherein between respective adjacent rotor blades 18 a cell is formed in each case. Between respective adjacent rotor blades 18 the same angular distance is always maintained so that all the cells of the cellular wheel 16 are essentially the same size. During rotation of the cellular wheel 16 about the axis of rotation RA, each cell takes up a defined quantity of concrete material in the area of the inlet 14.1 of the cellular wheel sluice 14 and discharges it in the area of an outlet 14.2, from where the concrete material falls or is introduced into the formwork 4 arranged underneath it.

[0093] In the example cellular wheel sluice 14, in the area of the outlet 14.2, a dosing aid 19 is provided, which can also be designated as a distribution and/or output aid, and in the shown example is designed as a dosing plate, which in turn can be designated as a distributing plate. The dosing plate 19 of the shown example is an arched metal sheet provided with a plurality of apertures, for example an arched perforated plate or an arched, perforated metal sheet. The dosing plate 19 of the shown example is essentially a bowl-shaped or partially cylindrical perforated metal sheet. When the concrete material is discharged at the outlet 14.2, the concrete material passes from the respective cells of the cellular wheel 16, through the holes in the perforated metal plate and into the formwork 4. By means of the dosing plate 19 the concrete material is evenly distributed in relation to the area of the formwork 4.

[0094] The exemplary dosing device 13 with cellular wheel sluice 14 is borne movable, for example in a displaceable manner on a frame, not shown in the figures, and has a drive, also not shown in the figures, so that the dosing device 13 with cellular wheel sluice 14 can be moved, more particularly displaced, in a driven manner in a direction of travel FR along the longitudinal axis LA of the formwork 4. The direction of travel FR is essentially perpendicular to the operating width AB of the cellular wheel sluice 14.

[0095] To fill the concrete material into the formwork 4, the cellular wheel sluice 14 is moved from an initial position (as indicated in FIG. 5) relative to the formwork 4 and above it in direction of travel FR, wherein the cellular wheel 16 is rotated at the same time. When the cellular wheel 16 is in operation, the cellular wheel sluice 14 travels over the formwork 4. Through this, all mould recesses 4a can be evenly filled. It goes without saying that the dosing device 13 with cellular wheel sluice 14 can be moved back into its initial position by means of a restoring movement opposite to the direction of travel FR.

[0096] With reference to FIGS. 7 to 9, various embodiments of example concrete blocks 1 produced by means of the present method are described. FIGS. 7 and 8 each show a greatly simplified and rough schematic perspective view and FIG. 9 shows a side view of a respective concrete block 1.

[0097] As has already been stated above in connection with the manufacturing method, the concrete blocks 1 are of multiple-layer, namely at least three-layer design, and each has a multiple-layer, in the example in the figures essentially cuboid, concrete block body 2 with at least one first, second and third concrete block layer 2a, 2b, 2c. FIG. 7 shows such a three-layer concrete block 1. FIG. 8 shows an alternative, four-layer variant, the concrete block body 2 of which, in addition to the first to third concrete block layer 2a, 2b, 2c, comprises a further concrete block layer 2n and FIG. 9 shows a many-layer variant.

[0098] Each concrete block 1 or the concrete block body 2 has a predetermined format with a block length SL and block width SB and comprises at least one concrete block underside 2.1 suitable for laying on a bedding layer of a substrate, and opposite site, a concrete block upper side 2.2 along which an upper surface of the concrete block 1 extends.

[0099] On the lateral surfaces of the concrete block 1, projections 3, for example rib or nose-like projections 3, can be provided which act as spacers or spacing noses and when laying the concrete blocks 1 in conjunction with each other ensure that, in the laid surface assembly, a minimum distance between the respective adjacent concrete blocks 1 is maintained and thereby joints with a predetermined minimum width are produced.

[0100] The first concrete block layer 2a defining the upper side and designed as a facing layer, is made of a face concrete, which is, for example, a structurally dense concrete. Depending on the purpose of use, the first concrete block layer 2a can be designed as an at least partially water-permeable or water-permeable but also as a water-impermeable layer.

[0101] Adjoining the first concrete block layer 2a is the second concrete block layer 2b, which in the shown examples directly adjoins the first concrete block layer 2a. The second concrete block layer 2b is made of a no-fines core concrete with a large proportion of fine and micro-pores. This no-fines concrete block layer 2b supports the uptake and storage of water and thus enables water to penetrate in via the lateral surface of the concrete block layer into the second concrete block layer 2b. Under thermal conditions that promote evaporation of water, the temporarily stored water in the second concrete block layer 2b can again be given off to outside, namely in the form of water vapour again via the lateral surfaces and/or in the case of a water-permeable design of the first concrete block layer 2a can escape or be given off via this to the atmosphere from the concrete block 1.

[0102] In FIG. 7, the third concrete block layer 2c directly adjoining the second concrete block layer 2b, is water-permeable and made of a gravel and/or sand-rich concrete material which exhibits at least moderate water permeability. The gravel and/or sand portion can be fine or coarse, or a mixture of fine-grain sand and coarse-grain gravel can be added. Also, due to the capillary effect produced in the third concrete block layer 2c, a supply of moisture from the bedding layer or the substrate into the second concrete block layer 2b is possible, through which the evaporation properties of the concrete block 1 are improved further, and, in particular, the evaporation rate is increased.

[0103] In the example shown in FIG. 8, formed between the second and the third concrete block layer 2b, 2c is an additional further concrete block layer 2n, through which the concrete block 1 can be even better adapted to desired purposes of use. For example, the third concrete block layer 2c is produced here as a stabilisation layer or strengthening layer which gives the concrete block 1 greater stability and strength. The further concrete block layer 2n is designed as a water-permeable layer in order, for example, to support controlled water permeability and/or storage.

[0104] In the manufacturing of the concrete block 1 shown in FIG. 8, both the concrete material for the third concrete block layer 2c as well as the further concrete material for the further concrete block layer 2n is introduced into the formwork 4 in a volumetrically-dosed manner, wherein to introduce the further concrete material for the further concrete block layer 2n a second dosing device is provided. Both in terms of design and function, the second dosing device is similar to the first dosing device 13 or is identical thereto.

[0105] FIG. 9 shows a side view of a further, alternative form of embodiment of the concrete block 1. Here, between the third concrete block layer 2c and the second concrete block layer 2b, the concrete block body 2 comprises a plurality of further concrete block layers 2n with a total layer thickness Dn. The plurality of further concrete block layers 2n is made up of many individual further concrete block layers 2n which are each very thin in design and have very small layer thicknesses. Through this, in a particularly precise and defined way, layers of different concrete material, for example, can be combined in such a way that in the concrete block body 2, a specially desired property thereof, can be set in a predetermined, defined manner, such as the desired water permeability, particular density or strength values or suchlike.

[0106] For example, it is also possible to vary and, for instance, gradually change said properties in relation to a height of the concrete block body 2 over a period of time. In doing so, one of said properties, such as the water permeability, water storage, strength or density, for example, can define a “transition” so that the plurality of further concrete block layers 2n can also be understood as a common transition layer. Alternatively, it would also be conceivable to successively alternate the individual thin, further concrete block layers 2n, so that alternating water-permeable and water-impermeable concrete block layers and/or dense and less dense concrete block layers and/or coarse and fine concrete block layers are layered on top of each other.

[0107] Preferably, for the manufacturing of a variant of an embodiment of the concrete block 1 shown as an example in FIG. 9, a first dosing device 13 and a second dosing device, in particular, each with a cellular wheel sluice 14 is used, wherein the two cellular wheel sluices 14 operate alternatingly, and each consecutively introduces a respective concrete material into the formwork 4 in a volumetrically-dosed manner. Between the respective dosing steps by the two cellular wheel sluices 14, steps can also be carried out, for example, for compacting or punching the concrete material introduced in a respective dosing step.

LIST OF REFERENCE NUMBERS

[0108] 1 Concrete block [0109] 2 Concrete block body [0110] 2.1 Concrete block underside [0111] 2.2 Concrete block upper side [0112] 2a First concrete block layer [0113] 2b Second concrete block layer [0114] 2c Third concrete block layer [0115] 2n Further concrete block layer [0116] 3 Projection [0117] 4 Formwork [0118] 4a Mould recess [0119] 10 Device for producing concrete blocks [0120] 11 First filling device [0121] 12 Second filling device [0122] 13 First dosing device [0123] 14 Cellular wheel sluice [0124] 14.1 Inlet [0125] 14.2 Outlet [0126] 14a Sluice and/or dosing space [0127] 15 Press or punch [0128] 16 Cellular wheel [0129] 17 Axle or rotor body [0130] 18 Rotor blades [0131] 19 Dosing aid [0132] AB Working width [0133] BF Mould width [0134] DR Direction of rotation [0135] Dc Layer thickness of the third concrete block layer [0136] Dn Total layer thickness of the further concrete block layers [0137] FR Direction of travel [0138] LA Longitudinal axis of the formwork [0139] LZ Cellular wheel length [0140] RA Axis of rotation [0141] SB Width of the concrete block [0142] SL Length of the concrete block