BACKGROUND

The present invention relates to a mould. More specifically, the present invention relates to a mould used incrementally to cast an integral wall or building unit. Even more specifically, the present invention relates to a mould that automatically displaces side walls relative to each other on placement and lifting of the mould.

Moulds for either casting bricks or incrementally casting an integral wall are known. For instance:

US385,552“Brick mould’ describes a mould with a base and rectangular frame for casting bricks therein, wherein a lever presses the major sides of the frame towards each other to compress the settable material within the mould.

WO2019/003140 “An apparatus for and method of pressing wall sections” describes: a frame that is supported on the ground; and opposed planar presses for compressing a concrete wall section there between.

ZA2009/05503“Building unit” describes a rectangular mould that is open at the top, the bottom and along a minor side, which moulds can be inter-locked to provide permanent formwork within which to cast a wall.

ZA2002/1028“Construction element production device” describes a rectangular mould that: is open at the top, the bottom and along a minor side; and includes a lever for pressing the major sides towards each other to compress settable material within the mould. The open bottom and minor side enables the mould to be used incrementally to cast an integral wall.

It is an object of the present invention to provide a mould with major side walls that can be displaced relative to each other, but where such displacement:

• is used to: locate the side walls in position; and to peel / space the side walls from the moulded material, instead of to compress material within the mould; and is actuated by placement and lifting of the mould.

SUMMARY OF THE INVENTION

According to a preferred embodiment of the invention, there is provided a mould that includes: an end wall; a frame; a first pair of opposed side walls that: are spaced from each other; extend between the end wall and the frame; and are connected to the end wall and to the frame; a first handle defined by the end wall; and a second handle defined by the frame, for, in use, placing and lifting the mould; a limiter associated with each side wall, which limiters can protrude from each side wall towards the other side wall, in use, to limit the degree to which a wall section on which the mould is placed, is received between the side walls from the operative bottom of the side walls; and means for translating: operative vertical relative movement of the end wall and frame on the one hand and the side walls on the other hand; into operative horizontal displacement of the side walls towards or away from each other, such that, in use: placement of the mould on a wall section causes: the operative bottom of the side walls to overlap a portion of the wall section until the wall section contacts the limiters, restricting further movement of the side walls relative to the wall section; and further movement of the end wall and frame operatively downwards towards the wall section, and consequent operative downward movement of the end wall and frame relative to the side walls causes the side walls to move towards each other; with the mould placed on the wall section, the mould may be charged with material to be moulded; and lifting of the mould from a wall section via the handies causes: the end wall and frame to move operatively upwards relative to the side walls, and for the side walls consequently to move away from each other, thereby spacing the side walls from material moulded within the mould.

Typically, the translating means comprises: at least one inclined track defined by one of: the end wall and frame on the one hand; and the side walls on the other hand; and at least one runner located on the other of: the end wall and frame on the one hand; and the side walls on the other hand, which at least one runner is located within the at least one track.

Generally, in respect of each side wall, the limiter comprises at least one tab movably secured to the side wall, and movable between: an extended condition, in which the tab protrudes from the side wall to which it is secured towards the opposing side wall; and a retracted condition, in which the tab does not protrude from the side wall to which it is secured towards the opposing side wall, in use, to: limit the degree to which a wall section on which the mould is placed, is received betv/een the side walls from the operative bottom of the side walls; and support the side walls on the wall section on which the mould is placed, when the tabs are in the extended condition.

Preferably, the tabs are spaced from the operative bottom of the side walls, such that, in use, the portions of side walls operatively below the tabs overlap a portion of a wall section on which the mould is placed.

Typically, the tabs are hingedly connected to the side walls, and protrude between the side walls via slots defined by the side walls.

Generally, the operative bottom of the side walls extend operatively below the operative bottom of the end wall.

Preferably, the handles are disposed operatively above the operative top of the side walls.

Typically, a foot extends substantially orthogonally from the operative bottom of the end wall in a direction away from the frame, which foot, in use supports the end wall on a wall section on which the mould is placed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in more detail, by way of examples only, with reference to the accompanying drawings in which:

Figure 1 is a first perspective view of a mould according to a preferred embodiment of the invention;

Figure 2 is a second perspective view of the mould in Figure 1 ;

Figure 3 is a perspective view of the mould in Figure 1 priorto placement of the mould on a partially constructed wall; Figure 4 is a perspective view of the mould in Figure 1 upon placement of the mould on a partially constructed wall; Figure 5 is an end view of the mould in Figure 4 upon placement of the mould on a partially constructed wall;

Figure 6 is a perspective view of the mould in Figure 1 upon lifting of the mould from the partially constructed wall;

Figure 7 is an end view of the mould in Figure 6 upon lifting of the mould from the partially constructed wall; and

Figure 8 is a perspective view of a mould according to an alternative embodiment of the invention.

DESCRIPTION OF THE INVENTION With reference to Figures 1 to 7 of the drawings, a mould 10 according to a preferred embodiment of the invention includes side walls 12, an end wall 14 and a frame 16.

The mould 10 provides a cuboid inner cavity, but without a closed operative bottom wall, operative top wall and end wall. In use, the mould 10 is placed incrementally along the top of a partially constructed wall 18, incrementally to increase the length of an additional wall layer.

The frame 16 is generally U-shaped, with a pair or arms 16a spaced by a spine 16b. The arms 16a are spaced slightly further apart than the width of a wall 18 to be constructed using the mould 10. Each arm 16a defines a pair of tracks 20 in the form of an inclined slot. The drawings show the corresponding slots on each arm 16a converging towards each other as they extend towards the spine 16b

The end wall 14 comprises a planar panel, which is spaced from, and opposed to the frame 16. A foot 17 extends substantially orthogonally from the operative bottom of the end wall

14 in a direction away from the frame 16, which foot 17, in use supports the end wall 14 on a wall 18 section on which the mould 10 is placed. Each operative side of the end wall 14 defines a pair of tracks 20 in the form of an inclined slot. The drawings show the corresponding slots on each operative side of the end wall 14 converging towards each other as they extend towards the operative top of the end wall 14.

The opposed side walls 12 comprise rectangular planar panels that: are spaced from each other; extend between the end wall 14 and the frame 16; and are connected to the end wall 14 and to the frame 16. The operative bottom of the side walls 12 extend operatively below the operative bottom of the end wall 14.

It will be appreciated that: the length of the frame 16 spine 16b; the spacing the frame 16 arms 16a; and the width of the end wall 14, will vary depending on the thickness of the wall 18 to be moulded by the mould 10.

Each side wall 12 includes a pair of spigots 22 that protrude from each minor side of the side wall 12. These spigots 22 preferably define a neck terminating in an enlarged head. The spigots 22 are sized and shaped to be received and captured within the tracks 20 defined by the frame 16 and end wall 14. So, captured, the spigots 22 comprise runners 22 that are movable along the tracks 20. Not only does capture of the spigots 22 within the tracks 20 connect the side walls 12 to the end wall 14 and frame 16, but the spigots 22 (acting as runners) within the tracks 20 also comprise means for translating: operative vertical relative movement of the end wall 14 and frame 16 on the one hand and the side walls 12 on the other hand; into operative horizontal displacement of the side walls 12 towards or away from each other.

Although the translating means (20, 22) has been described as comprising: tracks 20 defined by the end wall 14 and frame 16; and spigots / runners 22 protruding from the minor sides of the side walls 12 it will be appreciated that various other forms of translating means are envisaged in addition, the translating means could comprise: tracks defined by the minor sides of the side walls 12; and spigots / runners protruding from the end wall 14 and frame 16. A pair of limiters 24 are associated with each side wall 12. Each limiter 24 comprises a tab that is hingediy connected to the side wall 12, and movable between: an extended condition, in which the tab 24 protrudes from the side wall 12 to which it is secured towards the opposing side wall 12; and a retracted condition, in which the tab 24 does not protrude from the side wall 12 to which it is secured towards the opposing side wall 12.

Each tab 24 protrudes from the side wall 12 to which it is secured via a slot defined by such side wall 12. Importantly, the tabs 24 and corresponding slots are spaced from the operative bottom of the side walls 12, such that, in use, the portions of side walls 12 operatively below the tabs 24 overlap a portion of a wall 18 section on which the mould 10 is placed. A lever associated with each tab 24 can be operated by a user from outside the mould 10 to move the tabs 24 between the extended and retracted conditions.

It will be appreciated that, when the tabs 24 are in the extended condition, the tabs 24:

. limit the degree to which a wall 18 section on which the mould 10 is piaced, is received between the side walls 12 from the operative bottom of the side walls 12; and

. support the side walls 12 on the wall 18 section on which the mould 10 is placed.

It will be appreciated that, although the side walls 12 have been shown as moulded side walls (preferably, made of a plastic material), the side walls 12 could alternatively be made of sheet metal, e.g. of steel plate. Figure 8 shows an alternative embodiment of the mould 210 with side walls 12 made of sheet metal.

Turning back to the embodiment of the mould shown in Figures 1 to 7: a first handle 26 is disposed on the end wall 14, operatively above the operative top of the side walls 12, and a second handle 26 is disposed on the frame 16, operatively above the operative top of the side walls 12. The Figures show the handles 26 in the form of apertures defined by the end wall 14 and frame 16 and sized to receive a user’s fingers there through. The handles 26 facilitate: placing of the mould 10 on a wall 18 section; and lifting of the mould 10 from the wall 18 section. in use: . With reference to Figure 3, a user takes hold of the mould 10 via the handles 28 and places the mould 10 over a section of a partially constructed wall 18, with: (i) the frame 16 receiving an axial end of a partially constructed wall 18 layer therein; and (ii) the side walls 12 receiving a wall 18 section there between from the operative bottom of the side walls 12.

. The mould 10 is lowered on top of the partially constructed wall 18, with the operative bottom of the side walls 12 overlapping a portion of the wall 18 section until the wall 18 section received between the side walls 12 contacts the tabs 24, restricting further movement of the side walls 12 relative to the wall 18 section.

. Turning to Figures 4 and 5, the user (via the handles 26) further moves the end wail 14 and frame 16 operatively downwards until the frame spine 18b contacts the operative top of the wall 18 layer received therein; and the operative bottom of the end wall 14 (and foot 17) contacts the operative top of the wall 18 section. During this further movement, since the side walls 12 are restricted by the tabs 24 from movement relative to the wall 18 section, the end wall 14 and frame 16 move operatively vertically downwards relative to the side walls 12. The translating means (20, 22) converts such relative movement between the end wall 14 and frame 16 on the one hand and the side walls 12 on the other hand into movement of the side walls 12 towards each other

. It will be appreciated that, so arranged, the mould 10 provides a cavity within which a dry-mix settable material (e.g. cement and sand mixture with a low water content; a concrete mix; a geopolymer; rammed earth; or adobe & polymer sand) can be poured/charged and compacted from above.

. Turning to Figures 8 and 7, when the dry mix within the mould 10 is sufficiently rigid, the tabs 24 are moved towards the retracted condition, and the user pulls the handies 26 upwards to lift the mould 10 from the wall 18 section. In doing so, the end wall 14 and frame 16 move operatively upwards relative to the side walls 12, and the translating means (20, 22) consequently causes the side walls 12 to move away from each other, thereby spacing the side walls 12 from material moulded within the mould 10.

Although the mould 10 has been described, in use, to cast a wall section 18, the mould 10 could, alternatively be used to cast columns.

It will be appreciated that the translating means (20, 22) does not cause compaction of settable material within the mould 10. Instead, the translating means (20, 22) facilitates: • placement of the mould 10 on a wall section by automatically moving the sidewalls 12 towards the side faces of the wall 18 section, as the mould 10 is lowered on to the wall 18 section via the handles 26.

• lifting of the mould 10 by automatically separating / peeling the side walls 12 from the material moulded within the mould 10, as the mould 10 is lifted from the wall 18 section by the handles 26.