MODULAR FORMWORK SYSTEM FOR PRODUCING CONCRETE ELEMENTS

Abstract

The invention relates to a modular formwork system (1) for producing concrete elements (20), consisting of a plurality of individual moulds (2), said individual moulds (2) being produced at least on the surface (3) which faces the concrete, which is made of a plastic (4) that is cured layer by layer. The invention also relates to a method for producing the formwork system, and to a washer device for washing same.

Claims

1. A modular formwork system for producing concrete elements comprising: a plurality of individual molds, wherein the individual molds are produced, at least on the surface facing the concrete elements, from a plastic with a high-resolution surface that is cured in layers in an additive manufacturing process, and wherein the individual molds additionally have a printed or foamed layer with a lower resolution that adjoins the high-resolution surface.

2. The modular formwork system as recited in claim 1, characterized in that the formwork system includes at least one device for fixing the individual molds.

3. The modular formwork system as claimed in claim 1, characterized in that the individual mold or a component connected thereto includes a memory on which information on the individual mold is stored.

4. The modular formwork system as claimed in claim 1, characterized in that the individual molds are manufactured from a recyclable base carrier and a releasable plastic which can be recycled for reuse in 3D printing.

5. The modular formwork system as recited in claim 1, characterized in that the plurality of individual molds comprise at least one layer of cured foam.

6. The modular formwork system as recited in claim 1, characterized in that the plurality of individual molds are at least partially built up from honeycomb structures.

7. The modular formwork system as recited in claim 1, further comprising at least one mold core which is connected to at least one individual mold of the plurality of individual molds via plastic which is cured in layers.

8. The modular formwork system as recited in claim 7, characterized in that the mold core is at least partially formed from a water-soluble plastic.

9. The modular formwork system as recited in claim 8, characterized in that at least one washing duct is provided in the region of the water-soluble plastic.

10. The modular formwork system as recited in claim 9, characterized in that the washing duct comprises water-soluble supporting structures in its interior.

11. The modular formwork system as recited in claim 5, characterized in that at least one individual mold of the plurality of individual molds includes a device for the water-guiding fastening of a washer device.

12. A method for producing a formwork system for concrete construction, comprising the following steps of: determining the size and geometry of a plurality of individual molds from which the formwork system is assembled; printing at least one high-resolution surface, which faces the concrete elements, of at least one individual mold through an additive manufacturing technology from plastic cured in layers; printing or foaming a layer with lower resolution that adjoins the high-resolution surface; and assembling and filling the formwork system.

13. The modular framework system as recited in claim 4, characterized in that the surface facing the concrete elements is produced from a recyclable plastic material.

14. The modular framework system as recited in claim 4, characterized in that the plurality of individual molds are formed from a recyclable base carrier on which a surface facing the concrete is printed through an additive manufacturing technology, the surface being detachable for reuse of the base carrier.

15. The modular framework system as recited in claim 14, characterized in that the surface facing the concrete element is at least partially printed from a water-soluble plastic.

Description

IN THE DRAWINGS

[0053] FIG. 1 shows the digital workflow for determining the individual molds,

[0054] FIG. 2 shows the printing of the individual molds,

[0055] FIG. 3 shows the building site mounting and concrete casting,

[0056] FIG. 4 shows the comminution and the recycling,

[0057] FIG. 5 shows devices for fixing the individual elements,

[0058] FIG. 6 shows a pillar-shaped formwork system,

[0059] FIG. 7 shows individual molds of different stability,

[0060] FIG. 8 shows a honeycomb structure,

[0061] FIG. 9 shows a plastic cured in layers,

[0062] FIG. 10 shows components particularly predestined for the formwork system,

[0063] FIG. 11 shows a concrete element having a water-soluble mold core,

[0064] FIG. 12 shows the concrete element from FIG. 11 without mold core,

[0065] FIG. 13 shows an overview of the method steps for an implementation of the invention,

[0066] FIG. 14a shows two individual molds which have different structure densities in cross section,

[0067] FIG. 14b shows the individual molds from FIG. 14a which are placed on base carriers.

[0068] FIG. 1 shows the digital workflow which is executed according to one embodiment of the invention in order to produce the individual molds 2.

[0069] Here, a model for the required wall thicknesses of the concrete object is computed from the computer-aided computer program to map three-dimensional objects. From this model there is calculated an overall mold which is ultimately subdivided into the individual molds 2.

[0070] FIG. 2 shows the way in which the individual molds 2 are produced. According to the embodiment shown here, use is made of base carriers 6 which are preferably designed to be moved in a manufacturing line for 3D printing. For this purpose, the base carriers 6 preferably have memories on which information from the manufacturing line for 3D printing can be stored. In addition, markings for sensors of the manufacturing line are preferably fastened on the base carrier. The recyclable plastics are then printed onto the base carrier, as has previously been computed. The base carrier 6 forms, together with the printed-on plastic, the respective individual mold 2. In a further step, a post treatment of the mold by means of, for example, application of a lubricant (formwork grease) or the removal of overhangs can be provided.

[0071] FIG. 3 shows how the individual molds 2 are brought into position on the building site. In a manner not shown here, the fitter here uses the information stored on the memory unit of the base carriers 6 and a suitable information playback unit, such as, for instance, a graphic/virtual display of the construction that is to be carried out in space. After the individual molds have been positioned and fixed, the formwork system 1 is filled with concrete. After curing, the individual molds 2 are removed and the concrete object 10 is completed.

[0072] FIG. 4 shows that, after the concrete casting, the plastics 7 applied to the base carrier 6 are released from the base carrier 6, comminuted, melted and then reprocessed again to form a filament which can be used for further printing.

[0073] FIG. 5 shows an individual mold 2 which has devices for fixing on its base carrier 6. As illustrated here, use is made of clamping straps. However, other types of connection can also be chosen.

[0074] FIG. 6 shows a cuboidal formwork system 1. By virtue of its height and the expected hydrostatic forces, it has been decided in this case to configure the individual molds 2 to have different strengths. Here, different rib structures have been used, as is shown in FIG. 7.

[0075] FIG. 8 shows a honeycomb structure 8. In the context of the invention, the term honeycomb is preferably to be interpreted in broad terms and preferably refers not only to the structure illustrated here but to all structures having regular bridges and spaces formed thereby. According to a further embodiment, irregular bridges and the spaces formed thereby also together count among such structures.

[0076] FIG. 9 shows a plastic 4 cured in layers. The honeycomb structure from FIG. 8 is also built up in layers. However, in this figure, the grain can be clearly seen and patterns the concrete mold.

[0077] FIG. 10 shows particularly predestined objects for the formwork system 1 according to the invention. A: Large-area concrete components (walls, supports, ceilings, facade components). The formwork system consists of a material: PLA (biodegradable, recyclable) and can be chipped after use in order to be printed again.

[0078] B: Large-area concrete components (walls, supports, ceilings). The formwork system consists of two materials: Basic structure consisting of PLA (biodegradable, recyclable), only the formwork surface consists of PVA (biodegradable, water-soluble, recyclable) and can be washed out after use and be printed on again for the next component.

[0079] C: Large-area concrete components (walls, supports, ceilings, facade components) having integrated, complex undercuts and cavities. The formwork system is a hybrid of PVA (biodegradable, recyclable) and PLA (biodegradable, water-soluble, recyclable). After the concrete has cured, the cavities provided are washed out with water.

[0080] D, E: Node componentsthe formwork system as hybrid of PLA (biodegradable, recyclable) and PVA (biodegradable, water-soluble). New nodes can be created at any time in that the surface-relevant.

[0081] FIGS. 11 and 12 show a concrete element 10 having a water-soluble plastic 9 which here forms a mold core.

[0082] FIG. 13 shows once again a particularly preferred embodiment of the method according to the invention.

[0083] If a concrete component, for example a column or a pillar, is intended to be cast, first of all a design is then preferably created on the PC. The dimensions are determined as the next step. The individual formwork elements/individual molds 2 are then computed and passed onto a 3D printer. This prints the individual molds 2 either directly with fastening elements, for example cutouts in which devices for fixing 5 can engage, or onto base carriers 6 which for their part have fastening elements. A memory in which information on the individual mold 2 and, where appropriate, its position in the formwork system 1 is automatically stored is preferably mounted on an individual mold 2.

[0084] The individual molds are then assembled on the building site to form the formwork system 1 while taking account of the information stored on the memory.

[0085] In the assembled state, the correct positioning of the individual molds can also be checked once again via the stored information. Here, according to one embodiment, the individual memories of the adjoining individual molds 2 of the formwork system 1 can be read in succession. If two individual molds 2 lie next to one another that should not lie next to one another, a warning signal is emitted.

[0086] After determining the correct assembly of the formwork system 1, the latter is filled.

[0087] According to a variant (not shown here), a washing device is then connected to two or more points of the formwork system 1, the formwork system 1 being designed to receive said device in a sealing manner. Soluble parts of the individual molds 2, if present, are subsequently washed out.

[0088] The formwork system 1 is removed thereafter. The individual molds are subsequently shredded, recycled and the material resulting therefrom reused.

[0089] FIGS. 14a and 14b show two different solutions as to how there can be achieved a quick production rate of the individual molds 2 in spite of high resolution of the surface facing the concrete. One possibility consists in printing the outer surfaces of the individual mold 2, with the result that an interior is enclosed, and, during the printing or after the printing of the outer surfaces, to fill the interior of the individual mold with a self-curing foam by spraying. Here, the foam can be applied with a second printing head, or the foam is injected through an opening after printing the outer surfaces. This operation leads in short time to an individual mold 2 which has a high resolution, which is necessary for face concrete, of the surface facing the concrete and is dimensionally stable at the same time in order to be able to take up the forces necessary for the operation. There can also be provision that the interior provided for filling by spraying with the self-curing foam is not formed by the individual mold 2 itself but by the individual mold 2 together with the base carrier 6. Here, for example, a peripheral side wall of the individual mold can engage in a peripheral side wall of the base carrier, resulting in a sealed interior.

[0090] Another solution consists, instead of foaming, in selecting a printing method in the interior of the individual mold, which has a smaller resolution than the outer surfaces of the individual mold 2. For this purpose, use can be made, for example, of honeycomb structures 8 which are applied with a second printing head. Whether foaming or printing, a layer adjoining the high-resolution layer has a lower resolution in both cases. It is shown in FIG. 14b how these individual molds 2 are placed on the base carriers 6. This can occur, for example, by a clip connection or adhesive connection (not shown here). The base carrier 2 is, preferably for weight reduction, also not configured to be solid but comprises supporting structures in its interior.

LIST OF REFERENCE SIGNS

[0091] 1 Formwork system

[0092] 2 Individual molds

[0093] 3 Surface facing the concrete

[0094] 4 Plastic cured in layers

[0095] 5 Device for fixing

[0096] 6 Base carrier

[0097] 7 Recyclable plastic

[0098] 8 Honeycomb structures

[0099] 9 Water-soluble plastic

[0100] 10 Concrete element