METHOD OF MANUFACTURING A MOLD INSERT FOR THE PRODUCTION OF MOLDINGS, AND MOLD INSERT AND ITS USE

Abstract

A method of manufacturing a mold insert for the production of moldings, in particular blocks or slabs, in which a plurality of strips that form wall elements of the mold insert to be manufactured are interlocked by connecting elements and the interlocked strips are soldered to each other. There is also described a mold insert for producing moldings and to its use.

Claims

1-15. (canceled)

16. A method for manufacturing a mold insert for producing shaped bodies, the method comprising: fitting together multiple strips, which are configured to form wall elements of the mold insert to be manufactured, using connecting elements; and soldering the fitted-together strips to one another.

17. The method according to claim 16, which comprises soldering the fitted-together strips to one another using a vacuum soldering method.

18. The method according to claim 17, which comprises soldering with a high-temperature vacuum brazing method.

19. The method according to claim 16, which comprises, after the strips have been soldered to one another, allowing the strips to cool down to ambient temperature without the soldered-together strips having been quenched beforehand in a liquid coolant.

20. The method according to claim 16, which comprises forming a wear-protection layer on the strips after fitting the strips to one another.

21. The method according to claim 19, which comprises applying a hard material to the fitted-together strips before the soldering step, and, subsequent to soldering the strips to one another, forming the wear-protection layer on the strips from the applied hard material.

22. The method according to claim 21, wherein the hard material is a carbide.

23. The method according to claim 22, wherein the hard material is a carbide selected from the group consisting of tungsten carbide, titanium carbide, and chromium carbide.

24. The method according to claim 21, which comprises applying the hard material to the strips as a constituent part of a hard material and solder suspension.

25. The method according to claim 24, which comprises applying the hard material and solder suspension by spraying the suspension onto the strips and, subsequent to spraying, allowing the suspension to dry in air or in another gas atmosphere.

26. The method according to claim 16, which comprises producing the mold insert for forming blocks or slabs.

27. A mold insert for producing shaped bodies, the mold insert comprising: a plurality of strips fitted to one another with connecting elements and soldered to one another to form wall elements of the mold insert.

28. The mold insert according to claim 27, which comprises a wear-protection layer disposed on said strips.

29. The mold insert according to claim 28, wherein said wear-protection layer contains a hard material.

30. The mold insert according to claim 27, wherein strips are formed with openings configured to receive said connecting elements and said connecting elements are inserted in said openings formed in said strips.

31. The mold insert according to claim 27, wherein at least one of said strips is a metal strip.

32. The mold insert according to claim 31, wherein said at least one metal strip is a steel strip.

33. The mold insert according to claim 27, wherein at least one of said strips is a metallized ceramic strip.

34. The mold insert according to claim 27, wherein at least one of said strips is fabricated from a different material than other ones of said strips.

35. A method of forming blocks or slabs, the method comprising: providing a mold insert according to claim 27 and forming shaped bodies formed as blocks or slabs in the mold inserts.

Description

[0056] In the figures:

[0057] FIG. 1 shows a perspective illustration of an exemplary embodiment of a mold insert according to the invention;

[0058] FIG. 2 shows a perspective illustration of the mold insert from FIG. 1 in a non-finished state;

[0059] FIG. 3 shows a schematic method sequence of an exemplary embodiment of a method according to the invention for the manufacture of the mold insert from FIG. 1.

[0060] FIG. 1 shows a perspective illustration of a mold insert 1 for producing shaped bodies, in particular concrete blocks, in an oblique view from above.

[0061] The mold insert 1 comprises multiple strips 2, more specifically multiple longitudinal strips 2a that are arranged parallel to one another and multiple transverse strips 2b that are arranged at right angles to the longitudinal strips 2a. The strips 2 of the mold insert 1 form the wall elements of said mold insert. All of the strips 2 of the mold insert 1 have the same thickness d, for example a thickness of 12 mm.

[0062] As can be seen from FIG. 1, each of the two end faces of each of the transverse strips 2b adjoins one of the longitudinal strips 2a of the mold insert 1.

[0063] Furthermore, the mold insert 1 comprises multiple cuboidal mold impressions 3, which are delimited by the strips 2 and serve to receive a molding compound. The mold insert 1 from FIG. 1 comprises by way of example four longitudinal strips 2a, nine transverse strips 2b and six mold impressions 3. In principle, the mold insert 1 may comprise a different number of longitudinal strips 2a, transverse strips 2b and mold impressions 3.

[0064] If appropriate, the strips 2 may have, on their surfaces that delimit the mold impressions 3, one or more respective grooves (not illustrated in the figures) for forming projections on the shaped bodies to be manufactured.

[0065] The mold insert 1 further comprises multiple pin-shaped connecting elements 4, by means of which the strips 2 are fitted together. In addition, the strips 2 of the mold insert 1 are soldered to one another and covered with a wear-protection layer containing a hard material, in particular with a wear-protection layer containing chromium carbide, titanium carbide or tungsten carbide.

[0066] The strips 2 of the mold insert 1 may be metallized ceramic strips, for example. As an alternative, the strips 2 of the mold insert 1 may be steel strips, for example. In the latter case, it may be provided in particular that some of the strips 2 consist of a steel of a different steel grade than the other strips 2. For example, the longitudinal strips 2a may consist of a steel of a first steel grade, while the transverse strips 2b consist of a steel of a second steel grade.

[0067] Said connecting elements 4 are inserted in openings in the strips 2, which openings are provided for receiving the connecting elements 4, each of the connecting elements 4 engaging in two openings of two adjacent strips 2. In the case of the transverse strips 2b, the openings provided for receiving the connecting elements 4 are located in the end faces of said transverse strips. In the case of the longitudinal strips 2a, the openings provided for receiving the connecting elements 4 are located in the front and rear sides of said longitudinal strips, specifically in the present exemplary embodiment in the center and in the two ends of the respective longitudinal strip 2a.

[0068] FIG. 2 shows a perspective illustration of the mold insert 1 from FIG. 1 in an oblique view from above, the mold insert 1 being illustrated in a not-yet-finished state.

[0069] More precisely, FIG. 2 shows the mold insert 1 in a state in which the wear-protection layer has not yet been formed on the strips 2 and multiple, but not all, strips 2 of the mold insert 1 are fitted together, and therefore it is not yet the case that all of the mold impressions 3 of the mold insert 1 have been formed.

[0070] Multiple connecting elements 4, which protrude from two of the transverse strips 2b or from one of the longitudinal strips 2a, can be seen in FIG. 2.

[0071] FIG. 3 shows a schematic method sequence of a method for manufacturing the mold insert 1 from FIG. 1.

[0072] The method comprises five method steps that follow one another (method steps S1 to S5).

[0073] First of all, the longitudinal strips 2a and transverse strips 2b are fitted together using the connecting elements 4 (method step S1).

[0074] A hard material/solder suspension is then applied to, in particular sprayed onto, the fitted-together strips 2 (method step S2).

[0075] Then, the hard material/solder suspension applied to the strips 2 is allowed to dry in air or in another gas atmosphere (method step S3).

[0076] After this, the strips 2 are soldered to one another in a vacuum furnace using a vacuum soldering method, a wear-protection layer being formed on the strips 2 from the hard material applied to the strips 2 (method step S4). The soldering method in the present case is a high-temperature vacuum soldering method in which the strips 2 are heated to a temperature of approx. 1150° C., for example. The process duration for the combined soldering of the strips 2 and the formation of the wear-protection layer is preferably between 10 and 15 hours.

[0077] After the strips 2 have been soldered together, the strips 2 are allowed to cool down slowly, in the course of which the strips 2 cool down to ambient temperature, without the soldered-together strips 2 having been quenched beforehand in a liquid coolant (method step S5).

[0078] In principle, it is possible to apply the hard material/solder suspension to the strips 2 and to allow the hard material/solder suspension to dry before the strips 2 are fitted together. That is to say, method steps S2 and S3 may in principle be carried out before method step S1.

[0079] The invention has been described in detail on the basis of the exemplary embodiment illustrated. However, the invention is not restricted to or by the example disclosed. A person skilled in the art will be able to derive other variants from this exemplary embodiment without deviating from the concepts on which the invention is based.

LIST OF REFERENCE SIGNS

[0080] 1 Mold insert [0081] 2 Strip [0082] 2a Longitudinal strip [0083] 2b Transverse strip [0084] 3 Mold impression [0085] 4 Connecting element [0086] d Thickness [0087] S1 Method step—fitting the strips together [0088] S2 Method step—applying a hard material/solder suspension to the strips [0089] S3 Method step—allowing the hard material/solder suspension to dry [0090] S4 Method step—soldering the strips together using a vacuum soldering method and forming a wear-protection layer [0091] S5 Method step—allowing the strips to cool down to ambient temperature