FORMWORK FOR PRODUCING CONCRETE PRODUCTS

Abstract

Disclosed is a formwork for producing concrete products including at least one supporting beam with an axis of extension, at least one panel bendable around a transverse direction with respect to the axis and at least one adjustment device adapted to connect the panel to the beam and to vary the curvature of the panel between a flat undeformed condition and curved condition, where the outer surface is convex or, if necessary, concave, wherein the adjustment device is connected at least at one intermediate point of the panel and at least at one edge point, positioned at a lateral edge substantially parallel to the direction of curvature, in order to simultaneously move the points to vary the curvature of the outer surface of the panel.

Claims

1. Formwork (1) for producing concrete products comprising: at least one supporting beam (10) with an axis of extension (X); at least one panel (20) having an outer surface (23a) destined to come into contact with a concrete casting, said panel (20) being connected on an inner side (23b) to the beam and being bendable around a transverse direction (Y) with respect to the axis of extension (X) of said beam; at least one adjustment device (30) adapted to connect the panel (20) to the beam (10) and to vary the curvature of said panel (20) between a flat undeformed condition and curved condition where said outer surface (23a) is convex or, if necessary, concave; wherein said adjustment device (30) is connected at least at one intermediate point (24a, 24b) of the panel and at least at one edge point (25a, 25b), positioned at a lateral edge (22a, 22b) substantially parallel to the direction of curvature (Y), in order to simultaneously move said points to vary the curvature of the outer surface (23a) of said panel.

2. Formwork according to claim 1, wherein the adjustment device (30) comprises at least one drive mechanism (31, 31a, 31b, 41, 42) adapted to generate a movement of at least the intermediate point (24a, 24b) along a direction transverse to the axis of extension (X) of the beam (10), and of the edge point (25a, 25b) along a direction substantially parallel to or with at least one component parallel to said axis of extension.

3. Formwork (1) according to claim 2, wherein said drive mechanism (31, 31a, 31b, 41, 42) comprises mechanically interconnected elements adapted to cause the simultaneous movement of at least said intermediate point (24a, 24b) and said edge point (25a, 25b).

4. Formwork (1) according to claim 2, wherein said drive mechanism (31, 31a, 31b, 41, 42) comprises gears, an articulated system, or both.

5. Formwork (1) according to claim 2, wherein the adjustment device comprises a pair of adjustment mechanisms (31a, 31b, 41, 42), each acting on at least one intermediate point (24a, 24b) of the panel (20) and on at least one edge point (25a, 25b) of the respective opposite lateral edges (22a, 22b), said intermediate and edge points being symmetrical with respect to the centerline of the panel (20).

6. Formwork (1) according to claim 2, wherein the adjustment mechanism (31a, 31b, 41, 42) is connected to at least one intermediate point (24a, 24b) and to at least two edge points (25a, 25b), each at the opposite lateral edges (22a, 22b) of the panel.

7. Formwork (1) according to claim 2, wherein said drive mechanism (31, 31a, 31b, 41, 42) comprises a control member (38a, ?47) to which a force or a movement, or a torque or rotating movement or both, can be applied, the drive mechanism being configured to transfer said translation or rotation motion of the control member (38a, ?47), if necessary modulating or transforming it, at least to the intermediate point (24a, 24b) and to the edge point (25a, 25b).

8. Formwork (1) according to claim 1, wherein the panel (20), on the inner side (23a), is provided with struts (26a, 26b, 27a, 27b) arranged at least at said intermediate point (24a, 24b) and at said edge point (25a, 25b), the adjustment device (30) being connected to said struts.

9. Formwork (1) according to claim 7, wherein said drive mechanism (31a, 31b) comprises: at least a first slide (32), mounted sliding along a direction (Za) substantially perpendicular to the direction of extension (X) of the beam (10) and connected to the panel (20) at the intermediate point (24a, 24b); at least a second slide (33), sliding along a direction (Xa) substantially parallel to said axis of extension (X) of said beam (10) and connected to the panel (20) at an edge point (25a, 25b); said first slide (32) and said second slide (33) being connected by a transmission member.

10. Formwork (1) according to claim 9, wherein the transmission member comprises a first rack (34) and a second rack (35), associated respectively with the first slide (32) and with the second slide (33), and at least one gear wheel or one gear (36) that engages the aforesaid racks.

11. Formwork (1) according to claim 10, wherein the transmission member comprises a gear train (36a, 36b, 36c) interposed between the first rack (34) and the second rack (35).

12. Formwork (1) according to claim 9, wherein the first slide (32) is mounted rotatable around the direction of sliding (Za), said transmission member comprising: a first bevel gear wheel (39a) that rotates together with said first slide (32); a second bevel gear wheel (39b) that engages with the first gear wheel (39a); a threaded bar (39c) that rotates together with the second gear wheel (39b) and can be rotated about an axis parallel to the direction of movement (Xa) of the second slide (33); a lead screw (39d), mounted on the second slide (32), which engages said threaded bar (39c).

13. Formwork (1) according to claim 12, wherein said control member (38a) is connected to said first slide (32) or is integral therewith.

14. Formwork according to claim 2, wherein the drive mechanism (41, 42) comprises articulated rods (43, 44, 45) connected to a control element (47).

15. Formwork (1) according to claim 3, wherein said drive mechanism (31, 31a, 31b, 41, 42) comprises gears, an articulated system, or both.

16. Formwork (1) according to claim 3, wherein the adjustment device comprises a pair of adjustment mechanisms (31a, 31b, 41, 42), each acting on at least one intermediate point (24a, 24b) of the panel (20) and on at least one edge point (25a, 25b) of the respective opposite lateral edges (22a, 22b), said intermediate and edge points being symmetrical with respect to the centerline of the panel (20).

17. Formwork (1) according to claim 4, wherein the adjustment device comprises a pair of adjustment mechanisms (31a, 31b, 41, 42), each acting on at least one intermediate point (24a, 24b) of the panel (20) and on at least one edge point (25a, 25b) of the respective opposite lateral edges (22a, 22b), said intermediate and edge points being symmetrical with respect to the centerline of the panel (20).

18. Formwork (1) according to claim 3, wherein the adjustment mechanism (31a, 31b, 41, 42) is connected to at least one intermediate point (24a, 24b) and to at least two edge points (25a, 25b), each at the opposite lateral edges (22a, 22b) of the panel.

19. Formwork (1) according to claim 4, wherein the adjustment mechanism (31a, 31b, 41, 42) is connected to at least one intermediate point (24a, 24b) and to at least two edge points (25a, 25b), each at the opposite lateral edges (22a, 22b) of the panel.

20. Formwork (1) according to claim 3, wherein said drive mechanism (31, 31a, 31b, 41, 42) comprises a control member (38a, ?47) to which a force or a movement, or a torque or rotating movement or both, can be applied, the drive mechanism being configured to transfer said translation or rotation motion of the control member (38a, ?47), if necessary modulating or transforming it, at least to the intermediate point (24a, 24b) and to the edge point (25a, 25b).

Description

[0085] Further characteristics and advantages of the present invention will be more apparent from the description of an example of a preferred, but not exclusive, embodiment of a formwork as illustrated in the accompanying figures, wherein:

[0086] FIG. 1 is a front view of a formwork according to a variant of the invention, with the panel in flat or undeformed condition;

[0087] FIG. 2 is a view of the formwork of FIG. 1 with the panel curved;

[0088] FIG. 3 is a front view of a formwork according to another variant of the invention, with the panel in flat or undeformed condition;

[0089] FIG. 4 is a view of the formwork of FIG. 3 with the panel curved;

[0090] FIG. 5 is a front view of a formwork according to a further variant of the invention, with the panel in flat or undeformed condition;

[0091] FIG. 6 is a view of the formwork of FIG. 5 with the panel curved;

[0092] FIG. 7 is a front view of a formwork according to a further variant of the invention, with the panel curved;

[0093] FIG. 8 is a front view of a formwork according to a further variant of the invention, with the panel curved;

[0094] FIG. 9 is a front view of a formwork according to a further variant of the invention, with the panel curved;

[0095] FIG. 10 is a front view of a formwork according to a further variant of the invention, with the panel curved;

[0096] FIG. 11 is a front view of equipment for producing curved products comprising formworks according to the variant of FIG. 3.

[0097] With reference to the accompanying figures, the numeral 1 indicates as a whole a formwork for producing concrete products, or equivalent construction materials, having at least one curved surface.

[0098] The formwork 1 comprises at least one supporting beam 10 and at least one panel 20 that defines the shutter adapted to give said surface of the product its curved shape.

[0099] In the example illustrated, the beam 10 comprises a rectilinear profile that extends along a main axis X. Preferably, said profile has a constant section, for example with back-to-back double UPN profile, or other forms commonly used in mechanical engineering and construction.

[0100] In this way, it is possible to use off-the-shelf materials supplied by the majority of suppliers, limiting the production costs.

[0101] However, the beam can have any shape, for example partially or entirely curved or with one or more curved sides. In this case, the axis of extension X is positioned in the direction of the greatest dimension of the beam and is parallel to the panel 20, when this latter is flat.

[0102] Preferably, the beam 10 is made of metal or other metals suitable to support the stresses transmitted by the concrete casting to the panel. According to the arrangement of the formwork during use, these forces are generated by the hydrostatic thrust of the casting or, in the case of producing tunnel vaults or the like, also by its weight.

[0103] The panel 20 comprises a flat sheet having a thickness differing as a function of the material with which it is made. Typically, the panel is made of metal, for example steel, but can also be made of wood or laminated plastic materials. In any case, this thickness is such as to allow the panel to be used without being damaged and at the same time to withstand the pressure exerted by the casting without becoming deformed.

[0104] Typically, the panel 20 has a rectangular or square shape, with a front edge 21 and a rear edge, not visible in the figure, parallel to the axis X of the beam 10 and two lateral edges 22a, 22b substantially perpendicular to said axis X.

[0105] The dimensions of the panel 20 are variable according to requirements. Generally, the panel has a width, in the direction X, comprised between 0.3 meters and 3 meters, and a length comprised between 0.5 meters and 6 meters.

[0106] As a function of the length of the panel 20, the formwork 1 can comprise a single beam 10, for example at the center of the panel in the direction of length, two beams 10, respectively at the front and rear edges of the panel, or further beams 10 arranged between said front and rear edges.

[0107] The panel 20 is connected to the beam 10 at an inner surface 23b, the one facing downward in the accompanying figures. The outer surface 23 a is instead destined to come into contact with the concrete casting.

[0108] As already said previously, the panel 20 is connected to the beam 10 through an adjustment device, indicated as a whole with the number 30, which allows both variation of the curvature of said panel 20 around a transverse direction Y with respect to the axis X of the beam 10, and transfer of the forces applied by the casting to said beam.

[0109] In the example illustrated, the panel 20, starting from a flat or undeformed condition visible in FIGS. 1, 3, 5 and 7, can be bent so that the outer surface 23a is convex, as visible in FIGS. 2, 4, 6, 8, 9 and 10.

[0110] This curvature can be continuous or not and can involve all or part of said outer surface 23a.

[0111] According to an embodiment of the invention, illustrated in FIGS. 1 to 6, the adjustment device 30 comprises a first drive mechanism 31a and a second drive mechanism 31b.

[0112] Each drive mechanism comprises at least one first drive element 32, connected to the panel 20 at an intermediate point 24a, 24b and at least one second drive element 33, connected to the panel at an edge point 25a, 25b.

[0113] In a first variant of the invention, illustrated in FIGS. 1 and 2, the first drive element comprises a first slide 32, mounted in a guide 12 on the beam 10. Said guide 12 allows the slide 32 to slide along a direction Za substantially transverse, and preferably perpendicular, to the axis X of the beam 10.

[0114] The second drive element comprises a second slide 33 mounted in a respective guide 13 on the beam 10. The guide 13 allows the slide 33 to slide along a direction Xa substantially parallel to the axis X of the beam 10.

[0115] The movement of the slides 32, 33 is managed by a transmission member that includes two racks 34, 35, each associated with a slide, adapted to coact with a gear wheel 36 hinged on the beam 10. As the modulus of the rack and of said gear is identical, the two slides 32, 33 are constrained to carry out movements of the same amplitude in the respective directions Za, Xa.

[0116] Preferably, the first slide 32 has a lower portion 32a that projects from the lower side of the beam 10 and that can be connected to a control member, not illustrated in the figure, on which or by means of which a thrust is applied to the first slide 32. Said control member can comprise a portion of said slide, in the case in hand the lower end, or can be a separate element that coacts with said first slide.

[0117] Instead, the upper end 32b of the slide 32 rests on the inteimediate point 24a, 24b of the panel 20.

[0118] According to a preferred variant, struts 26a, 26b, 27a, 27b are fitted on the inner surface 23b of the panel 20, preferably extending for the whole of the length of the panel 20 between the front edge and the rear edge. Said struts can comprise profiles with a hollow, open or solid section, preferably made of metal or wood or other sufficiently strong materials.

[0119] According to the invention, said struts 26a, 26b, 27a, 27b are fixed to the panel at least at the respective intermediate points 24a, 24b and at the edge points 25a, 25b.

[0120] In the variant illustrated, an angular support 37 is fixed at the upper end 32b of the slide 32, adapted to contact and rest against the lower part of the strut 24a, 24b.

[0121] A screw 37b is mounted on said angular support 36 and is adjustable to project to a greater or lesser extent toward one side of the strut 26a, 26b in order to avoid any transverse movements of the panel 20.

[0122] Instead, the second slide 33 is hinged to the strut 27a, 27b at the edge points 25a, 25b.

[0123] When the first slide is translated in the direction Za toward the inner surface 23b of the panel 20, for example by applying a force on the lower end 32b, the intermediate point 24a, 24b is thrust away from the beam 10, upward in FIG. 2.

[0124] Simultaneously, the gear wheel 36, which engages both racks 34, 35, is rotated drawing the second slide 33 toward the centerline of the panel 20, which in turn moves the edge point 25a, 25b.

[0125] The effect obtained is a curvature of the panel 20 in which the outer surface 23a is convex.

[0126] When both the drive mechanisms 31a, 31b are operated in a coordinated manner, the movements of the intermediate and of the edge points are symmetrical with respect to the centerline of the panel, as in the example of FIG. 2.

[0127] By applying a force in an opposite direction on the first slides 32, said first and second slides are translated in respective opposite directions reducing the curvature of the panel 20.

[0128] In general, the panel is sufficiently elastic to allow a return to the undeformed or flat position when the force F is removed, as indicated in the figures.

[0129] For this reason, the drive mechanism 31a, 31b is preferably equipped with blocking means to constrain translation of at least the first slide 32 after reaching the desired curvature.

[0130] FIGS. 3 and 4 illustrate a variant of the formwork of FIGS. 1 and 2.

[0131] Operation of the drive mechanism is substantially identical to that described above.

[0132] In this case, however, the two racks are connected by a gear train 36a, 36b, 36c. A first gear 36a, hinged on the beam 10, is engaged with the rack 34 of the first slide 32. A second gear 36b is mounted coaxial and integral in rotation with said first gear 36a. A third gear 36c is engaged with said second gear 36b and with the rack 35 of the second slide 33.

[0133] The transmission ratio between the movement of the first and of the second slide, in this case, can be different to 1. As a function of the number of teeth of the various gears, it is possible to vary said ratio in order to obtain a curvature with a constant radius or, if desired, with a variable radius.

[0134] FIGS. 5 and 6 illustrate another preferred variant of the invention provided with a different transmission member.

[0135] In this variant, the drive mechanism 31a, 31b again comprises a first slide 32, sliding along a direction Za substantially transverse, and preferably perpendicular, to the axis X of the beam 10, and a second slide 33, sliding along a direction Xa substantially parallel to the axis X of the beam 10. The slides are connected respectively to the respective intermediate points 24a, 24b and edge points 25a, 25b.

[0136] In this variant, the first slide 32 is in the form of a splined shaft, or equivalent shape, rotatable about the axis Za. Said splined shaft rotates integrally with a first bevel gear wheel 39a and slides with respect to it along the axis Za. The first bevel gear wheel 39a is in turn engaged with a second bevel gear wheel 39b that rotates about an axis parallel to the direction of sliding Xa of the second slide 33. The second gear wheel 39b is connected to and rotates integrally with a threaded bar 39c which, in turn, is engaged in a lead screw 39d mounted on the second slide 33.

[0137] The lower end of the splined shaft 32 is connected to a threaded pin 38a, screwable into a respective seat 38b obtained on the beam or fitted thereto. Said threaded pin 38a acts as control member. Preferably, said threaded pin 38a rotates integrally with the splined shaft 32.

[0138] By rotating the threaded pin 38a in one direction, the splined shaft 32 is thus rotated both about the axis Za and thrust toward the inner surface of the panel. Rotation of the splined shaft is transmitted to the threaded bar 39c by means of the two bevel gear wheels 39a, 39b. This threaded bar 39c, in turn, coacting with the lead screw 39d, controls translation of the second slide 33 toward the centerline of the panel.

[0139] FIGS. 7 to 8 illustrate another variant of the formwork according to the invention.

[0140] In this variant, the drive mechanism 41, 42 comprises a first rod 43 hinged at one end 43 to the strut 26a, 26b and a second rod 44 hinged at one end 44 to the strut 27a, 27b. A third rod 45 is hinged at one end 45 to the beam 10 and at the opposite end 45 to the other end 44 of the second rod 44. Said third rod 45, in an intermediate point, is hinged to the end 43 of the first rod 43.

[0141] The ends 44 and 45 of the second rod and of the third rod are connected to a control member 47 comprising a threaded bar 47a screwable into a threaded sleeve 14 mounted rotatable on the beam 10.

[0142] Rotation of the sleeve 14 about an axis Xa, parallel to the axis X of the beam 10, causes the movement of the threaded bar 47a along said axis away from or toward the centerline of the panel 20.

[0143] This movement, in turn, moves the rods 43, 44, 45 varying the position of the intermediate points and of the edge points, bending the panel 20.

[0144] In the variant illustrated in FIGS. 7 and 8, the threaded bars 47a of both drive mechanisms 41, 42, are housed in the same sleeve 14. The rotation of said sleeve 14 causes the simultaneous translation of the threaded bars 47a in opposite directions to ensure a symmetrical curvature of the panel 20.

[0145] According to another variant, not illustrated, the control member can comprise a threaded block connected to the ends 44 and 45 of the second rod and of the third rod. The threaded bar 47a is instead housed in a support with the possibility of rotating about the axis Xa. According to this variant, rotation of the threaded bar 47a causes the movement of the threaded block, hence of the second rod 44 and of the third rod 45 and, consequently, of the first rod 43.

[0146] The movement of the threaded bars 47a can therefore be coordinated or independent, to obtain asymmetrical curvature profiles.

[0147] FIG. 9 illustrates another variant of the formwork 1 according to the invention. The adjustment device 30 comprises a single drive mechanism 31 connected to a strut 26a, at an intermediate point 24a, and to two struts 27a, 27b at respective edge points 25a, 25b.

[0148] In detail, the drive mechanism 31 comprises a first slide 32, mounted in a guide 12 on the beam 10, with the possibility of sliding along a direction Za substantially transverse, and preferably perpendicular, to the axis X of said beam 10. The drive mechanism further comprises a pair of second slides 33, each mounted in a respective guide 13 on the beam 10, and sliding along a direction Xa substantially parallel to the axis X of said beam 10.

[0149] The first slide 32 and the second slides 33 are connected respectively to the strut 26a and to the struts 27a, 27b.

[0150] Two racks 34, associated with the first slide 32, are connected by means of a pair of gears 36 to respective racks 35 on each second slide 33.

[0151] In this variant, the first slide 32 and the two second slides 33 are constrained to carry out movements of the same amplitude in the respective directions Za, Xa, the second slides 33 in opposite directions from each other.

[0152] With this variant, simpler with respect to the preceding variants, it is possible to obtain a complete and symmetrical curvature of the panel 20 by moving the first slide 32 in the direction Za.

[0153] The same variant can also be implemented equipping the drive mechanism 31 with a pair of gear trains in place of simple gears 36.

[0154] FIG. 10 illustrates a further simplified variant of the formwork 1 according to the present invention. In this variant the adjustment mechanism comprises a drive mechanism 31 connected to a strut 26a, at an intermediate point 24a, and more precisely at the centerline of the panel 20, and to a strut 27a at the edge point 25a.

[0155] The strut 27b, on the opposite edge point 25b, is instead hinged to the beam 10.

[0156] The drive mechanism 31 is substantially identical to that of the variant illustrated in FIGS. 1 and 2.

[0157] The first slide 32 and the second slide 33 are connected by a gear 36 or by a gear train, like those described previously.

[0158] Unlike the other variants, in this variant only one of the two edge points is connected to the drive mechanism 31, which acts by moving it along a direction Xa substantially parallel to the axis X of the beam 10. The hinge point between the strut 27b and the beam 10 instead remains fixed.

[0159] Deformation of the panel 20 therefore takes place by means of the thrust of the first slide 32 in the intermediate point 24a and simultaneously of the pull of the edge point 25a, by the second slide 33, toward the opposite edge of the panel 20.

[0160] FIG. 11 illustrates an example of equipment 100 for producing a product, in this case the lining R of a tunnel G, where this equipment 100 comprises several formworks 1, according to the variant of FIGS. 3 and 4, joined to one another. The equipment is made with formworks according to any one of the variants described.

[0161] The connection of two ends of adjacent formworks 1 is preferably implemented by means of plates 101. Said plates 101 are provided with at least one hole 102 and at least one slot 103 to allow the beams to be joined to one another in different angular positions and in any case allow adhesion of the lateral edges of adjacent panels 20, to create a continuous shutter with a uniform curvature.

[0162] The formworks 101, during the casting step, are supported by a supporting frame 104 of known type, shown schematically in the figure.

[0163] From the description above it can be seen that the formwork produced in accordance with the present invention allows simpler and faster adjustment of the curvature of the panel with respect to that of known manual systems.

[0164] Due to the simultaneous exertion of thrust and pulling actions in at least one intermediate point and at least one edge point, it is possible to reduce the manual control actions that an operator requires to carry out to place the formwork for a given work.

[0165] With the first two variants, FIGS. 1-4, it is sufficient to move both of the first slides 32 simultaneously, for example by means of a thrust or in another manner, to obtain a continuous and constant curvature of the panel on the whole of the outer surface.

[0166] The same operation can be carried out for the variants of FIGS. 9 and 10, moving the single first slide 32 to uniformly bend said outer surface of the panel.

[0167] This adjustment of the curvature can be carried out on the ground, before mounting the formworks on the supporting frame 104, or subsequently, before casting.

[0168] In the second case, the thrust on the slides 32 can if necessary be applied making use of moving elements provided in the frames and normally used to adapt said frames to the dimensions and to the shape of the tunnel.

[0169] Instead, in the variant of FIGS. 5 and 6, it is sufficient to act on the control member, i.e. rotate the threaded pins 38a, until reaching the desired curvature.

[0170] Also in the variant of FIGS. 7 and 8, it is possible to rotate the sleeve, to bend the panel until reaching the desired profile.

[0171] Advantageously, the drive mechanisms, in all the variants, can be provided with indices associated with the movable parts adapted to indicate the radius of curvature reached by the panel, if this is constant. This makes the use of the formwork even more practical and immediate.

[0172] Due to the fact that the formwork of the invention comprises completely mechanical devices, it is sturdy, reliable and inexpensive to produce.

[0173] Moreover, due to the drive mechanism, which acts simultaneously and in a coordinated manner on several points of the panel, the bending operation is simpler and faster to perform with respect to prior art formworks.

[0174] The invention has been described for illustrative and non-limiting purposes according to some preferred embodiments thereof. Those skilled in the art may find numerous other embodiments and variants, all falling within the scope of protection of the claims below.