EP4137284B1 - Shaping system - Google Patents

Description

The present invention relates to a molding system with at least one molded part.

Forming systems are used, among other things, in the construction industry, particularly in the production of precast concrete elements. For example, it is known that fresh concrete can be poured into permanent formwork to create a foundation and cured there. Such formwork cannot be reused, as it remains in the structure with the cured foundation. This has the advantage that the formwork lining no longer needs to be removed and cleaned, and it saves costs for return transport. However, even such permanent formwork is associated with considerable manufacturing effort.

A special formwork for the construction of foundations is described in the publication DE 32 15 579 A1 This formwork consists of plate-shaped, pluggable components. This offers the advantage that these components are easy to transport and can be assembled on site. This formwork is also not reusable and has only limited stability.

From the printed publication US 2006/0016150 A1 A molded body is known that has walls made of honeycomb cardboard. Honeycomb cardboard does not allow for a biaxial curvature of the molded body's inner wall. Accordingly, the honeycomb cardboard is flat on its inner side facing the concrete part to be produced.

The printed matter EP 2 128 357 A1 proposes a foldable support structure using honeycomb cardboard. Here, closure elements are attached to the openings of the honeycomb cardboard using tuck-in tabs, to which a molding surface is then applied. While this allows for more variable shapes, the labor and time required to manufacture such a support structure are immense.

The printed matter DE 198 23 610 A1 proposes a computer-controlled, adjustable formwork table. The formwork table has a flexible, bidirectionally bendable formwork panel, the size of the elements to be constructed, with a substructure in the form of a grating, which is computer-controlled and deformed into the desired surface geometry. With this formwork, the adjustability of the curvature of the grating is severely limited by the grating itself. Furthermore, the specific design of the adjustment elements is not explained.

The printed matter EP 1 629 951 A2 Describes a concrete manhole base with a molded-in channel formed using sliding steel pins, rubber heads, and a resilient cover. This formwork system is also complex and expensive.

Concrete components can also be manufactured as precast elements directly in a production facility using formwork. This allows the concrete components to be manufactured with high precision and reproducibility. However, this approach involves high transport requirements and corresponding costs.

Furthermore, formwork that is at least partially reusable is used to produce concrete components. For example, fresh concrete is placed in the formwork, and after it has hardened, the finished concrete component is removed from the formwork.

Due to the precast elements often adhering to the inside of such formwork, partial or even complete destruction of the formwork and damage to the concrete part often occur during the required demolding process.

Formwork is also used to decorate exposed concrete, for example on ceilings and columns of buildings. In the publication DE 1684 231 For this purpose, a wood grain, for example, is transferred to the prefabricated part using formwork by embossing. The key disadvantage of this is that a new formwork with the corresponding embossing must be produced for each new grain.

For the production of concrete components with curved surfaces, a flexible formwork skin in the form of a tailored membrane skin can be used. The disadvantage However, the disadvantage of this formwork method is that the formwork often deforms during the pouring of concrete. After the precast element has hardened, the precast element takes on the shape of the deformed formwork.

Precast concrete elements with high precision and a wide variety of shapes can also be created by milling formwork systems made of solid material, such as polystyrene. The disadvantages of this method are the high labor intensity and the large amount of material residue generated by milling.

Formwork systems made of sand and/or wax can still be used to produce precast concrete elements. After milling out a highly compacted sand bed or wax bed, the remaining material can be reused. However, for a new formwork, the sand and/or wax formwork must be completely crushed or melted, which represents additional effort.

From the printed publication DE 1 908 884 A1 , which discloses the preamble of claim 1, a permanent formwork for forming concrete components is known. The formwork comprises a plasterboard panel with interconnected cardboard ribs arranged perpendicular to the panel. The ribs are connected to each other by being inserted into notches formed therein. An outer skin is applied to the edges of the ribs.

The printed matter WO 00/11281 A1 discloses a cavity mold for the formation of concrete structures. The cavity mold has a chamber defined by side walls, for example, made of cardboard, and an outwardly projecting spacer. A grid-shaped reinforcement element, for example, made of cardboard, is provided in the chamber.

The printed matter US 2005/0011152 A1 Describes a cavity form made of degradable material, such as cardboard, for forming a cavity in a concrete component. The cavity form can be composed of interlocking strips with a lid placed on top.

It is therefore the object of the present invention to provide a shaping system which is inexpensive to implement, at least partially reusable and dimensionally stable and enables a wide variety of shapes.

This object is achieved according to the invention by a shaping system with at least one shaped part, wherein the shaped part comprises a shaping part which has a plurality of individual cardboard shaped elements, wherein upper edges and/or upper sides of the cardboard shaped elements together form a contour, the cardboard shaped elements are inserted into one another and through openings are formed between the cardboard shaped elements, and at least one shaping mat arranged on the shaping part and lying against the contour, wherein the shaping part stands on a carrier which is coupled to a lifting system.

In the forming system according to the invention, a surface contour of the component to be formed is predefined by the contour of the forming part. The forming mat applied to the forming part connects the upper edges or upper sides of the cardboard forming elements of the forming part to form a closed surface that corresponds to a negative contour of the respective component to be formed. This means that the forming part predetermines the positive contour to be formed of a component produced with the forming system according to the invention.

According to the invention, the forming part is formed from several individual cardboard forming elements. The upper edges and/or upper sides of the cardboard forming elements form the contour of the forming part.

Despite its construction from cardboard form elements, the forming part can be used for any number of formwork processes, as it is protected from moisture from the concrete by the form mat.

Despite the fact that the forming part is made of cardboard, it is extremely stable. The cardboard forming elements can be formed in such a way that they form a highly mechanically stable arrangement. To achieve this, the cardboard forming elements in the present invention are inserted into each other.

The use of cardboard preforms, i.e., preforms made of cardboard, for the formation of the molded part results in a wide variety of design options for the surface contour of the molded part. Cardboard can be easily cut and/or punched, thus creating the desired shape. The surface contour of the molded part can thus be completely or partially flat, convex or concave, stepped, wavy, trapezoidal, and/or conical—in other words, it can be designed in a variety of ways.

Accordingly, the top sides and/or upper edges of the cardboard preforms can be easily designed such that the top sides and/or upper edges of the cardboard preforms, which form the top side of the finished preform, together form the contour of the preform. The contour of the preform results from the plane spanned by the top sides and/or upper edges of the cardboard preforms. This plane is flat, curved, or otherwise structured depending on the respective height of the cardboard preforms.

Cardboard also has the advantage of being not only inexpensive but also lightweight. Therefore, the elements of the molding part can be can be easily transported to a construction site and used there without complex transport technology.

A further advantage of the molding system according to the invention is that the molded part can be assembled directly on-site from individual elements, the cardboard molding elements. This eliminates the need to transport a bulky, complete structure to the construction site. Instead, the individual, preferably prefabricated cardboard molding elements can be transported to the construction site in a space-saving and efficient manner and assembled there.

The cardboard preforms used to form the molded part are inserted into one another to form a lattice structure with hollow spaces between them. This results in significantly lower weight for the assembled cardboard preforms compared to compact formwork.

Preferably, the individual cardboard preform elements are connected to one another in such a way that the distances between the cardboard preform elements are of a similar size, so that when the form mat is subsequently applied to the upper sides and/or upper edges of the cardboard preform elements, the form mat lies evenly on these and, in particular, when a concrete mass is later applied to the form mat, does not sink too much into the free spaces between the cardboard preform elements in isolated cases.

In the present invention, the top surfaces and/or top edges of the cardboard forming elements form a surface representing the contour of the forming part onto which the forming mat can be placed.

In order to be able to form a curved or stepped contour of the shaping part, the cardboard preforms have at least partially different heights and/or top edge shapes. The height and/or top edge shape of some or all of the cardboard preforms can vary along their length and/or the height and/or top edge shape of the cardboard preforms can vary from cardboard preform to cardboard preform. It is also possible for at least two of the cardboard preforms to have the same height or the same height profile. The height of the individual cardboard preforms can be reduced, for example, by cutting off a lower region of the respective cardboard preform.

The cardboard elements are preferably made of solid cardboard, but can also be made of corrugated cardboard. The cardboard elements can each be made of one or more cardboard layers.

At least one forming mat lies on the forming part. In the present invention, the forming part with the at least one forming mat placed thereon forms the formed part. Preferably, a single forming mat is placed on the forming part, but in certain embodiments of the invention, such as with complicated shapes, it may also be expedient to apply several forming mats to the forming part. The respective forming mat largely conforms to the contour of the forming part, although edges, corners, or points of the contour located beneath the forming mat tend to be rounded off or tapered by the forming mat, so that the shape of the forming mat is determined by the contour but does not have to correspond exactly to the contour and, in particular, does not correspond to a contour of the forming part that has edges, corners, or points.

When using the molding system according to the invention, a hardenable material, such as concrete, is applied to the mold mat, which, after hardening and removal of the formwork, forms a finished part. The surface of the finished part formed on the mold mat then has a positive contour that results from the surface contour of the molded part.

The at least one mold mat preferably consists of a stable, moisture-impermeable material, so that the cardboard mold elements are protected by the mold mat lying on top during the production of finished parts.

The respective form mat can have different thicknesses depending on the application. A thin form mat adapts particularly well to the contour defined by the forming part. For example, this allows the form mat to adhere better to corners and/or edges. However, the mat thickness must be selected so that the form mat has sufficient stability for the manufacturing process of a precast part, for example, to prevent it from tearing during the application of the moist, heavy concrete mass.

It is particularly advantageous if the cardboard preforms have a hydrophobic coating. This leads to increased mechanical strength of the molded part formed from the cardboard preforms.

In an advantageous embodiment of the present invention, the cardboard preforms are plate-shaped. This has the advantage that the cardboard preforms can be easily layered or stacked on top of one another, for example, for storage or transport.

For example, slots or gaps can be easily incorporated into the respective plate-shaped cardboard preforms to allow them to be assembled with minimal effort. This allows the forming part to be formed, for example, as a grid formed by the plate-shaped cardboard preforms inserted into one another.

The carrier can be plate-, frame-, or grid-shaped, for example. The carrier holds the molding part formed from the cardboard preforms. The molding part can simply be placed on the carrier. The carrier can be made of metal, such as aluminum, or plastic, such as polycarbonate, or a composite material.

Because the support is coupled to the lifting system, it, and thus also the forming part, is height-adjustable. For example, the forming part placed on the support can be moved upwards using the lifting system to easily place and secure the forming mat onto the surface of the cardboard preforms. The forming part can then be moved back down using the lifting system to easily apply a molding compound, such as concrete, to the forming mat.

Advantageous functionality combined with good stability of the lifting system is achieved when the lifting system has four lifting columns, each arranged in the corner areas of the support. The stroke of the lifting system preferably ranges from 300 to 800 mm, particularly preferably from 600 mm. A feed speed of the lifting system in a range of 4 to 12 mm/s, preferably 8 mm/s, has proven particularly advantageous. The lifting system preferably has a compressive load capacity of at least 3 kN, preferably at least 4.5 kN. It is also advantageous if the lifting system has a synchronous control. To prevent damage to the lifting system's drive, horizontal compensating plates can be installed between the lifting columns and the support.

In a preferred embodiment of the present invention, the carrier is designed as a carrier grid, wherein a fixed base is arranged beneath the carrier and cardboard blocks are placed on the base, passing through through-openings in the shaping part and the carrier grid. The carrier grid can, for example, consist of crossed narrow rods or strips that are firmly connected to one another. The resulting grid structure has grid openings that are preferably square. This allows the cardboard blocks to be guided through these grid openings, which serve as through-openings. The cardboard blocks stand on the base, which is not coupled to the lifting system and therefore cannot be moved up and down.

This design has the advantage that the grid-shaped support can be lowered along the cardboard blocks by the lifting system, whereby the cardboard blocks protrude through the grid openings of the support grid and, with their upper edges and/or upper sides, form a preferably flat support surface initially located above the support grid. The forming mat can be easily placed onto this support surface.

In a preferred embodiment of the invention, the base consists of a plate with grid-shaped retaining grooves adapted to the support grid. The cardboard blocks can advantageously be placed in the retaining grooves so that their position is defined and they can remain securely upright on the base. The cardboard blocks stand upright on the base, in the retaining grooves. The retaining grooves are preferably elongated depressions made in a surface of the base. The retaining grooves can have various cross-sections, but they should be arranged so that the support with its grid structure is positioned over the retaining grooves. The preferably hollow cardboard blocks can thus be inserted into the retaining grooves with their openings facing downwards and stand securely on the base. The formation of the Retaining grooves in the surface of the plate can be created, for example, by punching or milling. The plate can be made of metal, ceramic, or plastic, preferably a multiplex board.

In a preferred embodiment of the invention, the cardboard blocks are each folded from a single cardboard layer. The respective flat cardboard layers can thus be stacked or layered on top of each other, saving space when transported to the construction site, and then easily folded on-site into the respective cardboard blocks, similar to a packaging box. The cardboard blocks are preferably made of solid cardboard, but can also be made of corrugated cardboard.

In an advantageous embodiment of the present invention, a frame is arranged on the respective mold mat. The frame preferably runs along an outer edge of the mold mat, but rests on it. The frame must rest firmly on the mold mat or be seamlessly connected to the mold mat to prevent the mold mat from slipping during the component's curing process.

The frame can, for example, consist of several frame elements that are positively connected to one another. It is advantageous if the frame has a high level of rigidity. This rigidity enables the frame to withstand the pressure of the wet concrete mass. The frame can, for example, be made of metal, plastic, wood or a composite material. However, the material should be chosen such that the cured component can be easily removed from the frame without leaving any noticeable traces of residue. The frame can, for example, be made of polyurethane with a Shore A hardness in the range of 40 to 70, preferably 65. The frame can, for example, have a width in the range of 20 to 40 mm and a height in the range of 20 to 40 mm.

In a preferred embodiment of the invention, the frame is formed from four strips, wherein at least two of the strips each have a receptacle on at least one side, in which an adjacent strip of the four strips is received. The respective receptacle can be designed as a passage or as a lateral recess in the respective strip. The respective receptacle allows the strips to be moved relative to one another, thereby providing the frame with optimal Shape can be given. In this position of the strips relative to each other, they can then be fixed together, for example with screws.

The frame is preferably attached to the at least one mold mat in a material-to-material manner, for example with double-sided adhesive tape or silicone.

In a particularly practical embodiment of the present invention, at least one of the at least one molding mat is formed from bands connected in a plain weave. This results in sufficient flexibility of the molding mat while simultaneously maintaining high mechanical strength.

In a specific embodiment of the present invention, the at least one mold mat is formed from two polyurethane mats and a silicone mat located therebetween.

In order to give the molded part a decorative and/or functional surface during casting, it has proven particularly advantageous if at least one mold mat has a structured surface on at least one side.

Figur 1

schematisch einen Teil einer Ausführungsform eines erfindungsgemäßen Formgebungssystems in einer ersten Sockelhöhe in einer perspektivischen Ansicht zeigt;

Figur 2

schematisch den Teil des Formgebungssystem aus Figur 1 mit auf einen Sockel aufgestellten Pappquadern in einer anderen Sockelhöhe in einer anderen perspektivischen Ansicht zeigt;

Figur 3

schematisch eine mögliche Ausbildung einer bei dem erfindungsgemäßen Formgebungssystem einsetzbaren Formmatte in einer Draufsicht zeigt;

Figur 4

schematisch einen als Trägergitter ausgebildeten Träger einer Ausführungsform des erfindungsgemäßen Formgebungssystems mit durch das Trägergitter führenden Pappquadern in einer perspektivischen Draufsicht zeigt;

Figur 5

schematisch eine Ausbildung eines Sockels zur Aufnahme von Pappquadern einer Ausführungsform des erfindungsgemäßen Formgebungssystems in einer perspektivischen Draufsicht zeigt;

Figur 6

schematisch einen Teil eines Hubsystems mit darauf angeordnetem Sockel einer Ausführungsform des erfindungsgemäßen Formgebungssystems in einer perspektivischen Ansicht von unten zeigt;

Figur 7

schematisch eine mögliche Ausbildung eines Zuschnitts zur Ausbildung eines bei einer Ausführungsform des erfindungsgemäßen Formgebungssystems einsetzbaren Pappformquaders in einer Draufsicht zeigt;

Figur 8

schematisch einen aus dem Zuschnitt von Figur 6 ausgebildeten Pappquaders in einer perspektivischen Ansicht zeigt;

Figur 9

schematisch eine perspektivische Draufsicht auf einen Sockel mit darauf auf gesetzten Pappquadern gemäß einer Ausführungsform des erfindungsgemäßen Formgebungssystems zeigt;

Figur 10

schematisch einen oberen Teil einer Ausführungsform des erfindungsgemäßen Formgebungssystems mit Blick auf eine Formmatte mit Klebeband zur Befestigung eines Rahmens auf der Formmatte in einer perspektivischen Draufsicht zeigt;

Figur 11

schematisch die Formmatte aus Figur 10 mit darauf aufgebrachtem Rahmen in einer perspektivischen Draufsicht zeigt;

Figur 12

schematisch eine mögliche Ausbildung eines Rahmenelementes des Rahmens in einer Seitenansicht zeigt; und

Figur 13

schematisch eine Seitenansicht einer möglichen Ausbildung von Pappformelementen mit darauf aufgebrachter Formmatte einer Ausführungs- form des erfindungsgemäßen Formgebungssystems mit einem darauf ausgebildeten Betonfertigteil zeigt.

Preferred embodiments of the present invention, their structure, function and advantages are explained in more detail below with reference to figures, wherein

Figure 1

schematically shows a part of an embodiment of a forming system according to the invention at a first base height in a perspective view;

Figure 2

schematically the part of the forming system Figure 1 with cardboard blocks placed on a base at a different base height in a different perspective view;

Figure 3

schematically shows a possible design of a forming mat usable in the forming system according to the invention in a plan view;

Figure 4

schematically a support designed as a support grid of an embodiment of the shaping system according to the invention with shows a perspective top view of the cardboard blocks leading to the support grid;

Figure 5

schematically shows a design of a base for receiving cardboard blocks of an embodiment of the forming system according to the invention in a perspective top view;

Figure 6

schematically shows a part of a lifting system with a base arranged thereon of an embodiment of the forming system according to the invention in a perspective view from below;

Figure 7

schematically shows a possible design of a blank for forming a cardboard block usable in an embodiment of the forming system according to the invention in a plan view;

Figure 8

schematically a cut from Figure 6 formed cardboard cuboid in a perspective view;

Figure 9

schematically shows a perspective top view of a base with cardboard blocks placed thereon according to an embodiment of the forming system according to the invention;

Figure 10

schematically shows an upper part of an embodiment of the forming system according to the invention with a view of a forming mat with adhesive tape for attaching a frame to the forming mat in a perspective top view;

Figure 11

schematically the mold mat from Figure 10 with the frame applied to it in a perspective top view;

Figure 12

schematically shows a possible design of a frame element of the frame in a side view; and

Figure 13

schematically a side view of a possible design of cardboard form elements with a form mat applied thereon of an embodiment form of the forming system according to the invention with a precast concrete part formed thereon.

Figure 1 shows schematically a part of an embodiment of a shaping system 1 according to the invention in a perspective view.

The forming system 1 comprises a molded part which has a Figure 1 visible shaping part 2 and at least one, for example in Figure 3 shown forming mat 3 to be applied to the forming part 2.

On this construction consisting of the forming part 2 and the forming mat 3, as shown in Figure 13 As shown schematically, a precast concrete part 10 is cast, the positive contour of which results from a contour 8 of the surface of the forming part 2.

The forming part 2 has several individual cardboard forming elements 21. In the Figure 1 In the embodiment shown, the cardboard preforms 21 are plate- or strip-shaped, i.e., two-dimensional. In the embodiment shown, the cardboard preforms 21 stand on their lower edges and are aligned vertically. In the embodiment shown, the cardboard preforms 21 each have slots or gaps, using which they are assembled to form the three-dimensional forming part 2.

In the embodiment shown, the cardboard form elements 21 have a hydrophobic coating. However, this coating can also be omitted.

The width of the slots or gaps is either exactly the same as or slightly, such as 0.1 mm, 0.2 mm or 0.3 mm, larger than the thickness of the cardboard preforms 21. It influences the handling of the plug-in connection.

There are therefore gaps or cavities between the cardboard forming elements 21. The forming part 2 is thus a cardboard compartment. As a result, the forming part 2 is lightweight despite its high stability. In the embodiment shown, the cavities have a square cross-section and are vertically aligned, forming through openings 23.

In the embodiment shown, the cardboard preform elements 21 have at least partially different heights and/or differently shaped upper edges or upper sides 22. As a result, the shaping part 2 formed from the cardboard preform elements 21 has on its upper side a contour 8 resulting from the size and shape of the upper edges or upper sides 22 and their imaginary connection, from which a negative contour of a surface of a component to be formed with the shaping system 1 is formed when the shaping mat 3 rests thereon.

As in the Figures 1 and 2 As can be seen, contour 8, for example, has a specific curvature that can vary along different axes. Contour 8 can, for example, be computer-aided modeled before forming the cardboard shaped elements 21.

The molding part 2 stands on a support 4. In the embodiment shown, the support 4 is designed as a support grid. This means that the support 4 has a horizontal support surface for the molding part 2, which in the embodiment shown is grid-shaped. Between the grid elements of which the support grid is composed, square through-openings 43 are formed in an inner region of the support surface.

The carrier 4 rests on a lifting system 5. In the embodiment shown, the lifting system 5 has four lifting columns 51. The lifting columns 51 are each arranged under corner areas of the carrier 4. The lifting columns 51 can be telescopically extended and retracted by means of motors 52. By means of the lifting columns 51, the carrier 4 with the forming part 2 standing thereon can be lifted from the Figure 1 shown upper position into at least one example in Figure 2 or in Figure 9 shown position below.

A fixed base 6 is arranged under the support 4. As shown in the Figures 1 and 5 As can be seen, the base 6 has a plate 61 with a plurality of square elevations 63 arranged thereon in rows and columns. Retaining grooves 62 are formed between these elevations 63. In the illustrated embodiment, the retaining grooves 62 are milled into the plate 61, simultaneously forming the elevations 63.

In Figure 6 The base 6, mounted on a fixed base frame 60, for example by means of screws, is shown in a perspective view from below. In the embodiment shown, the base frame 60 is constructed from aluminum profiles.

In the embodiment shown, the lifting columns 51 are bolted to the support 4 and the base frame 60. Horizontal compensation plates can be provided between the lifting columns 51 and the support 4 to prevent the generation of moments in the lifting columns 51 and thus damage to their drives.

As in Figure 2 As shown, a plurality of cardboard cuboids 7 arranged in rows and columns are placed on the base 6. In the embodiment shown, the cardboard cuboids 7 are upright, hollow, open-bottomed, elongated structures which are placed with their lower opening onto the square elevations 63 of the base 6, with the undersides of the cardboard cuboids 7 being held in the holding grooves 62. The cardboard cuboids 7 each have a closed, flat surface. The sum of these surfaces forms a plane onto which the mold mat 3 and, for example, a frame 9 (explained in more detail below) can be easily applied.

In Figure 8 an embodiment of one of the cardboard cubes 7 is shown schematically.

As it is in Figure 7 As can be seen, the cardboard cuboid 7 can be formed from a cardboard cuboid blank 71. The cardboard cuboid blank 71 is formed from a single cardboard layer and can be converted into the cardboard cuboid 7 by simply folding and inserting the tabs 72 formed on the cardboard cuboid blank 71 into the slots 73 formed in the cardboard cuboid blank 71.

If the carrier 4 with the forming part 2 is moved downwards, the cardboard cuboids are first guided through the through openings 43 in the carrier grid and then move through the through openings 23 which are formed by the cavities formed between the cardboard forming elements 21 in the forming part 2.

As in Figure 9 shown, the cardboard blocks 7 are moved upwards until they protrude from the through openings 23 in the shaping part 2 at the top and thus together form a suitable, flat storage surface for the shaping mat 3 to be applied to the shaping part 2.

An example of such a form mat 3 is shown in Figure 3 shown. The forming mat 3 shown schematically here is a fabric structure made up of bands 31, 32 in a linen weave. In the embodiment shown, the bands 31, 32 are unidirectional bands made of carbon-reinforced polyamide, but they can also be made of a different material. The linen weave allows the individual bands 31, 32 to be easily moved relative to one another, which can prevent unwanted bulging when bent due to deformation through the compartments. The flexural rigidity of the individual bands 31, 32 reduces the possibility of concrete being forced through into the spaces between the compartments of the forming part 2, so that a dimensionally accurate and dent-free concrete element can be produced.

In other embodiments of the present invention, the at least one mold mat 3 can be formed, for example, from two polyurethane mats and a silicone mat located between them. Preferably, the polyurethane mats have a thickness of 5 to 10 mm, for example, 7.5 mm, and the silicone mat has a thickness in the range of 3 to 15 mm, for example, 10 mm. By combining multiple mold mats, the imprinting of the cavities of the molding part 2 on the precast concrete element to be formed can be reduced.

Furthermore, numerous other embodiments of the at least one molded mat 3 are possible with regard to the number of mats, the mat material, and the respective mat thickness. Furthermore, the at least one molded mat 3 can have a structured surface on at least one side. Furthermore, the material of the molded mat 3 can have local reinforcements, for example, made of carbon or glass fibers. The molded mat 3 is preferably rectangular, for example, square, as shown in the Figure 11 shown embodiment.

As it is in Figure 11 As shown schematically in FIG. 1, in a preferred embodiment of the invention, a frame 9 is applied to the form mat 3. The frame 9 serves to laterally hold an initially viscous building material applied to the form mat 3, thus forming a formwork edge. The frame 9 is preferably, as shown schematically in FIG. Figure 10 shown, firmly attached to the mold mat 3, for example by means of silicone or double-sided adhesive tape 90. In addition, a transition of the frame 9 to the mold mat 3 can be sealed by an acrylic joint.

The frame 9 can be pre-curved according to the curvature of the precast concrete element to be formed.

The frame 9 can, for example, be formed from several strips 91, as shown schematically in Figure 12 are shown. Preferably, the strips 91 are positively connected to one another to form the frame 9. For this purpose, in the embodiment shown, each of the strips 91 has a flat section 92 adjacent to this strip 91 and a bow-shaped or C-shaped receptacle 93 formed at one end of the strip 91, which is placed over the flat section 92 of the adjacent strip 91. Instead of the bow-shaped receptacle 93, an annular receptacle 93 with a preferably rectangular inner cross-section can also be used. The strips 91 can thus be moved relative to one another and the size of the frame 9 can be changed accordingly.

The strips 91 can be made of polyurethane, for example.

The height of the frame 9 is at least the height or thickness of the precast concrete element to be manufactured.

Claims (14)

1. Shaping system (1) with at least one shape component, wherein the shape component comprises a shaping component (2) which comprises a plurality of individual cardboard form elements (21), wherein upper edges and/or upper sides (22) of the cardboard form elements (21) together form a contour (8), the cardboard form elements (21) are inserted into one another, and through openings (23) are formed between the cardboard form elements (21), and at least one shaping mat (3) resting against the contour (8) is arranged on the shaping component (2), characterized in that the shaping component (2) stands on a carrier (4) which is coupled with a lifting system (5).
2. Shaping system according to claim 1, characterized in that the cardboard form elements (21) have a hydrophobic coating.
3. Shaping system according to claim 1 or 2, characterized in that the cardboard form elements (21) are plate-shaped.
4. Shaping system according to claim 3, characterized in that the cardboard form elements (21) comprise slots or gaps.
5. Shaping system according to one of the preceding claims, characterized in that the lifting system (5) comprises four lifting columns (51), each of which is arranged in corner regions of the carrier (4).
6. Shaping system according to one of the preceding claims, characterized in that the carrier (4) is designed as a carrier grid, a positionally fixed base (6) is arranged under the carrier (4), and cardboard blocks (7) passed through through openings (23, 43) of the shaping component (2) and the carrier grid are placed on the base 6).
7. Shaping system according to claim 6, characterized in that the base (6) is formed from a plate (61) with holding grooves (62) arranged in a grid shape adapted to the carrier grid.
8. Shaping system according to claim 6 or 7, characterized in that the cardboard blocks (7) are each folded from a single cardboard layer.
9. Shaping system according to one of the preceding claims, characterized in that a frame (9) is arranged on the shaping mat (3).
10. Shaping system according to claim 9, characterized in that the frame (9) is formed from four strips (91), wherein at least two of the strips (91) each have a receptacle (93) on at least one side, in which a respective adjacent strip (91) of the four strips (91) is held.
11. Shaping system according to claim 9 or 10, characterized in that the frame (9) is firmly attached to the at least one shaping mat (3).
12. Shaping system according to one of the preceding claims, characterized in that at least one of the at least one shaping mat (3) is formed from bands (31, 32) connected in a plain weave.
13. Shaping system according to one of the preceding claims, characterized in that the at least one shaping mat (3) is formed from two polyurethane mats and a silicone mat lying between them.
14. Shaping system according to one of the preceding claims, characterized in that the at least one shaping mat (3) has a structured surface on at least one side.

Images