US3853452A - Molding machine - Google Patents

Abstract

A molding machine and method of industrially, mass producing concrete building modular units or modules with repetitive use and accuracy is disclosed. In accordance with the invention, the molding machine produces a modular unit with draft free walls, square corners and offset corners by featuring parallel moving interior and exterior wall forming panels which are normal to a precast concrete floor and interior corner panels which move along diagonally into and out of molding positions. The interior and exterior wall forming panels and corner panels are interlocked and spaced apart to form a cavity for pouring and setting concrete therein to form vertical monolithic walls with the precast floor. The parallel movable interior, exterior wall forming panels and corner panels are suspended and movable on a frame having a superstructure which can be lifted above the formed monolithic concrete walls to release the molded concrete unit from the molding machine.

Description

[ Dec. 10, 1974 Primary Examiner-Richard B. Lazarus [57] ABSTRACT A molding machine and method of industrially, mass producing concrete building modular units or modules with repetitive use and accuracy is disclosed. In accordance with the invention, the molding machine produces a modular unit with draft free walls, square corners and offset corners by featuring parallel moving interior and exterior wall forming panels which are normal to a precast concrete floor and interior corner panels which move along diagonally into and out of molding positions. The interior and exterior wall forming panels and comer panels are interlocked and spaced apart to form a cavity for pouring and setting concrete therein to form vertical monolithic walls with the precast floor. The parallel movable interior, exte- Inventor: Ernest J. Delmonte, 46 Harwood Ln., East Rochester, N.Y. 14445 May 22, 1972 425/450 R, 249/20, 249/22 B28b 1/00 425/450, 450 C, 469, 63; 249/20, 21, 22

References Cited UNITED STATES PATENTS United States Patent Delmonte 1 MOLDING MACHINE [22] Filed:

211 Appl. 'No.: 255,386

[51] Int. [58] Field of Search..........

rior wall forming panels and corner panels are suspended and movable on a frame having a superstructure which can be lifted above the formed monolithic concrete walls to release the molded concrete unit from the molding machine.

8 Claims, 26 Drawing Figures 425/63 Canada..........................'....... 249/27 4/1947 Australia............ 11/1963 XXXXXUXX 99000W 0 66555 5 44444 04 Ill// 5/ 55555 5 22222 /2 44444 b4 mmmmmm m n" ntnuu u nm am m ma I n "m u u e n u m S n N Hg] mm smhmm m mwnNmw oao fla PPHDNMTL 0005005 2 23356777 99999999 1 l l 1 l l ll 02319 08 ll 1 PATENIEB 3.853.452

sum 01 or 10 PATENTEI] DEC 1 0 I974 0mm mmm mmm mmv PMENTEQ DUI I 01974 sum as or w FIG- 8a PATEHIEL SEC 1 01974 SHEET PATENTEL ["974 3,853,452

sum as or 10 23 FIG. I4

PAIENI'EI, BEE I 0 I974 MIX CONCRETE MOLD FLOORS MOLD WALLS WITH FLOOR MOLD CEILING ASSEMBLE CEILING TO WALLS MODULAR UNIT FURNISH MODULAR UNIT MODULAR BUILDING FIG. 23

AIR HYRAULIC CONTROL CIRCUIT s 454 FRY 44 VIBRATION CONTROL 423 425 42/, CIRCUIT 420 v 426 500 FIG. 24 3 1 MOLDING MACHINE BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to industrially, massproduced structural building modular units or modules such as stackable room modules from which motels, hotels, apartments, hospitals, stores, offices and houses may be built and more particularly to a novel MOLD- ING MACHINE and method of mass-producing such modules complete with such items as windows, doors, electrical and plumbing services.

2. Prior Art In the past, many attempts have been made to manufacture houses, apartments and components thereof in a factory so as to relieve the housing shortage and provide adequate living accommodations for the ever increasing population. Such attempts have included factory built panels, structural elements and modular building units such as precut or preformed room or rooms for houses and apartments.

While prebuilt and precast panels and structural elements advanced the art in that the panels and structural elements were larger than the well known smaller building elements such as bricks, stones and precut lumber, studs and joists, considerable work still remained at the building site in building the apartments and houses with these panels and precast structural elements.

Heretofore, the prior art modular building units were generally constructed by using conventional building techniques, trades and materials. For example, wood floor joists, studding and ceiling joists, spaced and connected according to some conventional building code were then covered by plywood sheets and siding on the outside and plasterboard on the inside by tradesmen or workers on an assembly line.

Although some time was saved by merely bringing the known technique of conventional building within the confines of an assembly line in a factory away from the building site, the building techniques were just an extension of the prior art in building modular units. v

Construction time for building such modular units were reduced to great measure in that more workers were allowed to work on an assembly line. Thus the building art was notadvanced per se by such techniques.

Generally, prior art factory built concrete modular building units were molded by using an inverted molding process, that is, hollow molding a concrete building modular unit bottom-up. In such a process, an inner core having side walls and ceiling was surrounded by outside wall forms spaced from the side walls of the inner core to define a cavity equal to the wall thickness of the modular unit. Concrete was then poured into the cavity and on top of the inner core. Once the concrete was set, the outside walls were disassembled and the concrete modular unit was pulled from the inner core and inverted so that the portion of the unit core over the top of the inner core was actually the floor of the modular unit.

Other attempts in the prior art for molding hollow concrete articles such as vaults employed complicated forms which were assembled for pouring of concrete between retaining walls. These forms were later disassembled after the formed concrete was set. While such prior art methods and apparatus were adequate for their intended purpose, they did not lend themselves for industrially, mass-produced modular units or modules, since it was difficult to reassemble the forms after each pouring and to repeat the same performance in a relatively short period of time.

Accordingly there still exists a pressing need for a truly industrially means and method for massproducing modular units or modules for motels, hotels, apartments, hospitals, stores, offices and houses, which means and method are efficient, accurate, easy to operate to produce a'sound structural and architecturally artistic modular unit or module for the above use.

SUMMARY OF THE INVENTION Briefly described, a MOLDING MACHINE for producing modular units or modules with draft free walls and square corners in accordance with a preferred embodiment includes a frame having a superstructure and locating means for locating the frame relative to a precast concrete floor having steel reinforcing therein and vertically thereon in a predetermined perimeter defining walls of the modular unit. The machine includes interlocking interior corner panels and interior wall forming panels in molding positions on one side of the vertical steel reinforcing movably suspended from the superstructure. The interlocking interior panels are movable within the modular unit in a parallel direction to the walls of the modular unit and the corner panels are movable diagonally to the walls of themodular unit. The MOLDING MACHINE further includes interlocking exterior wall forming panels in molding positions on the other side of the vertical steel. reinforcing and spaced from the interior wall forming panels and corner panels by an amount equal to the desired thickness of the modular walls thereby forming a cavity in which concrete may be poured and vibrated by vibrators on the wall forming panels to form a monolithic structure with the floor. The interlocking interior and exterior wall forming panels are movable on the superstructure in a parallel direction to the walls of the poured concrete modular unit and may also be vibrated to part from the poured and set modular unit and raised by lifting means.

DESCRIPTION OF THE DRAWINGS The invention, both as to its organization and method of operation, will best be understood by reference to the following description taken in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a molding machine in accordance with a preferred embodiment of the invention.

FIG. la is a plan top view of two different modular units or modules of the type produced by the molding machine of the present invention;

FIG. 2 is an exploded perspective view of a building utilizing the modular units of FIG. 1a;

FIG. 3 is a plan view of a factory layout for molding modular units in four different work stations by transporting the molding machine on an overhead crane in x-y directions in accordance with the invention;

FIG. 4 is a fragmentary enlarged plan view of a section of a floor mold shown in FIG. 5 formolding a concrete floor for the modular unit of FIGS. la and 2;

FIG. 5 is a top view of a floor mold for both floors and ceilings of the modular unit of FIGS. 1a and 2;

FIG. 6 is a partial fragmentary view of the floor mold of FIGS. '5 and 6 taken along line 6-6 of FIG. 4 showing steel reinforcing bars for the floor and walls of the modular units of FIGS. 1a and 2;

FIG. 7 is a partial fragmentary view of a typical wall section of the modular unit showing vertical wall reinforcing bars piping and means for lifting the modular unit;

FIGS. 8, 8a are front and sectional views respectively of the molding machine taken along line 8-8;

FIG. 9 is a rear view of the molding machine of FIG.

FIG. 10 is a right side view of the molding machine of FIG. 8;

FIG. 11 is a left side view of the molding machine of FIG. 8;

FIG. 12 is a partial fragmentary top view of the molding machine of FIG. 8 showing details of the right front and rear corners of the molding machine;

FIG. 13 is a partial fragmentary view showing a vertical cross section of the left side of the molding machine taken along line 13-13 of FIG. 14;

FIG. 14 is a partial fragmentary top view of the left rear corner of the molding machine of FIG. 8;

FIG. 15 is a partial fragmentary vertical cross section of the rear of the molding machine taken along line 15-15 of FIG. 9;

FIG. 16 is a partial fragmentary cross section view taken along line 16-16 of FIG. 9;

FIG. 17 is a fragmentary sectional view of the left rear corner of the molding machine similar to FIG. 14;

FIG. 18 is a partial fragmentary sectional view of the molding machine taken along line 18-18 of FIG. 8 showing a wall and door frame section;

FIG. 19 is a partial fragmentary sectional view of the locating means for the molding machine taken along line 19-19 of FIGS. 3 and 8;

FIG. 20 is a partial fragmentary top view of the left front section of the molding machine in an open position;

FIG. 21 is a partial fragmentary sectional view of the left front corner similar to FIG. 20 in a closed molding position showing piping for the modular unit;

FIG. 22 is a partial fragmentary vertical sectional view of the front left corner of the modular unit showing bathroom fixtures in place;

FIG. 23 illustrates a flow diagram of the method in manufacturing modular units in accordance with the invention; and

FIG. 24 is a schematic view of the hydraulic system for the molding machine.

DETAILED DESCRIPTION Referring first to FIG. 1, there is shown in pictorial form (perspective view) a molding machine 100 in accordance with the invention, which molding machine is disclosed more fully hereinafter. Only those aspects of the MOLDING MACHINE 100 necessary for those skilled in the art to understand the various features of the invention have been shown.

Referring now to FIG. 1a of the drawings, a plan view of two different modular units or modules 1 and la of the type molded in accordance with the present invention are shown. The modular units 1 and la are also shown in FIG. 2 which is an exploded perspective view of a building 20 utilizing the modular units 1, 1a. The modular units 1, 1a are similar in construction and include the same components and are mirror images of each other. Accordingly, like elements will have designations and reference numerals which are alike except that the designation for modular unit la will have a small letter a" after the designation.

Modular unit 1 comprises a floor 2, a ceiling 3, a front wall 4, rear wall 5 and side walls 6, 7. At the intersection of front wall 4 and side wall 7, the modular unit 1 includes an offset or inverse corner 8 for electrical and plumbing services such as pipes 22, 159. Modular units 1 and la are shown as representing single rooms, however, it should be understood that within the modular units 1 and la, additional walls (not shown) may be added after molding the modular units 1 and la in accordance with this invention. Such additional rooms may for example include a bathroom 10 shown in dotted lines at the inverse corner 8, which bathroom 10 will be discussed in greater detail hereinafter.

The modular building units 1 and 1a are stackable either in a side by side relationship or in a vertical relationship to form a building 20 which can be multi-story or multi-module to form motels, hotels, apartments, hospitals, stores, offices and other buildings. A particular advantage of the present invention is that modular units 1 and 1a may be industrially produced in a factory complete with doors ll, 12, window 13, air conditioning unit 14, electrical service ancl'the aforesaid bathroom 10. In addition, the modular unit 1 may be completed in the factory by painting, interior plumbing and electrical fixtures, installation of rugs and furniture and the doors 11, 12, may be locked and the complete modular unit may be shipped and assembled to form the building 20, as shown in FIG. 2. Thus, a building of this type can be built at the building side completely furnished and ready for occupancy with turnkey occupancy. This is a particular advantage since factory production control methods may be used to inventory the components that are .used in the modular units 1 and 1a. Furnishings, such items as furniture, fixtures, may be installed in the modular unit and locked therein until the building 20 is ready for occupancy. In other words, once the modular units 1 and la are completed at the factory, workers will have no need to enter the furnished modular units 1 and 1a at the building site and the modular units 1 and 1a will be ready for occupancy.

Referring now to .FIG. 23, a flow diagram of the major steps taken in the manufacture of the modular units 1 and la is shown. The MOLDING MACHINE (FIGS. 8, 9, 10 and 11) of the present invention may be best understood by viewing the method of making the modular units 1 and 1a. The modular units 1 and la are made of steel-reinforced concrete; that is, the floor 2, ceiling 3 and walls have steel-reinforcement therein of the type shown in FIGS. 4, 6 and 7. Concrete, a preferred material, is blended or mixed in the factory under very accurate controls and conditions. The cement, aggregate and water used in making the concrete are carefully weighed and measured under quality control technique which can best be done under factory conditions well known to those skilled in the art. In fact, the MOLDING MACHINE 100 can repeatedly produce walls 4, 5, 6 and 7 of close tolerance so that these walls may be made relatively thin in order of four (4) inches but of high strength and quality. Other formable materials may be molded in the MOLDING MACHINE 100 besides concrete such as plastics (rigid or foam), polyurethane and the like.

In the practice of the invention, the concrete floor 2 is precast, then the front wall 4, the rear wall 5 and side walls 6 and 7 are monolithically cast on the floor 2 within the MOLDING MACHINE 100 with concrete and reinforcing steel grid 21 therein, including door frames 15, 16, window frame 17, piping 22 and electrical box 23 and conduit 24.

After the floor 2 and the concrete walls 4, 5, 6 and 7 are formed and set, the MOLDING MACHINE 100 is lifted in the manner to be described hereinafter to release the modular unit 1. The ceiling 3 is then placed on top of the walls 4, 5, 6 and 7 to complete the modular unit 1 away from the MOLDING MACHINE 100. Accordingly, a better appreciation of the MOLDING MACHINE 100 may be had by understanding a method of precasting the floors 2 and ceiling 3 and preparing the precast floor 2, the steel reinforcement grid 21, pipe 22, electrical box 23 before molding the walls 4, 5, 6 and 7 within the MOLDING MACHINE 100.

Referring now to FIGS. 4, 5, 6 and 7, the floors 2 and ceiling 3 may be precast in the same floor mold 50 since the concrete floor 2 and ceiling 3 are of the same design and configuration except that the floor 2 has a front balcony 26 and rear. balcony 27. The ceiling 3 may be cast in the floor mold 50 by inserting a front header 52 and a rear header 53 in the floor mold 50 to eliminate the front and rear balconies 26 and 27 respectively. The floor mold 50 includes a floor panel 54 having a grid defined by transverse recesses 55, 56 and raised rectangular portions 57 to produce a waffle design in the floor 2 and ceiling 3. The floor panel 54 is surrounded by retaining walls 58, 59, 60 and 61. The retaining walls 58, 59, 60 and 61 are higher than the raised portions 57 of the floor panel 54 by an amount equal to the desired thickness of concrete shown at section 62 of FIG. 6. The recesses 55 and 56 define the beam sections 63 of the floor 2 and ceiling 3 and the waffle design which reduces the weight of the floor 2 and ceiling 3. Disposed on the retaining walls 58 and 60 are vibrators 64 which may be of the electrical or hydraulic type well known to those skilled in the art for vibrating concrete within the floor mold 50. The floor mold 50 includes a notch portion 65 for producing the inverse corner 8 of the modular unit 1. In FIG. 4, an enlarged section of floor mold 50 is shown with-steelreinforcing bars 66 disposed in the rear balcony section of the mold 50 and in the recesses 55 and 56. The steelreinforcing bars 66 are raised from the floor panel 54 by chairs 67 so that concrete may be poured beneath the steel-reinforcing bars 66. Threaded anchors 68 are disposed along a perimeter recess 68 of the floor mold 50. The threaded anchors 68 are adapted to receive vertical threaded reinforced rods 70 (FIGS. 6, 7) and are also used for lifting the concrete floor 2 and ceiling,

3. When the concrete is poured into the floor mold 50, it is vibrated within the recesses 55, 56 and 69 and leveled with the retaining walls 58,59, 60 and 61 and allowed to set within the floor mold 50. The precast floor 2 is then removed from the floor mold 50 and is ready for placement within the MOLDING MACHINE 100. Preferably, the precast floor 2 is removed from the floor mold 50 while it is still in the green state or not fully cured so that the floor mold may be utilized more fully in the factory. Generally; the floor 2 and ceiling 3 may be removed from the floor mold 50' after a few hours of curing. Loss of water from the concrete may be retarded by applying a polyethylene sheet over the precast floor 2 and ceiling 3 to retain moisture therein.

Referring now to FIG. 7, a typical section of the steelreinforcement or steel grid 21 for the modular unit 1 is shown together with pipe 22, electrical box 23 and conduit 24, all of which will be cast within the concrete walls 4, 5, 6, 7. The vertical steel reinforcement or grid 21 is connected to the threaded rods 70 and four steel lifting hooks 71 for raising or lowering and transporting the modular unit 1. The steel reinforcement or grid 21 includes connecting rods 72 which are used to connect the walls 6 and 7 to the ceiling 3 as by welding to steel pipes 73 in the ceiling 3. The pipe 22 may include a conventional flange 74 for connecting a wall mounted bathroom fixture thereon and additional'plumbing and electrical services may bemolded within the floor 2, ceiling 3 and walls 4, 5, 6, 7 without departing fromthe invention. As was previously mentioned, the steel reinforcement or grid 21 is embedded in the walls 4, 5, 6, 7 of the modular unit 1 and is placed on the floor 2 and connected to the steel rods 70 before concrete is poured into the MOLDING MACHINE .in a manner to be discussed in the following paragraphs.

Referring now to FIGS. 1, 8, 8a, 9, 10, 11, a MOLD- ING MACHINE 100 in accordance with a preferred embodiment of the invention is shown. The MOLDING MACHINE 100 includes a truck 101 for transporting the precast floor 2 to and from the MOLDING MA- CHINE 100. The truck 101 includes a flat bed 102 and four wheels 103 rotatably supported on axles 105. The truck 101 also includes locating means 107 for locating the floor 2 on the flatbed 102. The rail tracks 104 include locating notches 106 (FIGS. 3, 10,11) for locating the truck 101 within the MOLDING MACHINE 100. The locating notches 106 in the rail tracks 104 are preferably V-shaped so that the truck 101 drops into the V-shaped notches 106 and is accurately located within the MOLDING MACHINE 100. The truck 101 is a preferred means for transporting the floor 2 and steel reinforcement 21 within the MOLDING MA- CHINE 100; however, it should be understood that the precast floor 2 may be located within the MOLDING MACHINE 100 by other means without departing from the invention and may, for example, be carried into the MOLDING MACHINE 100 by an overhead crane systern 300 as shown in FIG. 3 which will be described hereinafter. The-MOLDING MACHINE 100 includes a frame 110 having a superstructure 1 11 supported on at least four (4) columns 112, 113, 114 and 115. If desired, intermediate columns 116 and 117 may be used to support the superstructure 111 to eliminate bending of the superstructure 111.

Referring now to FIG. 8, a front view of the MOLD- ING MACHINE 100 is shown. The frame 110 and-superstructure 111 are located with respect to the floor 2 of the modular unit 1 and the truck 101 by locating means 118 (FIG. 19) whichincludes a locating pin 119 at the base of each column 112, 113, 114, 115, namely at 121, 122, 123, 124 respectively. The column base 122 (FIG. 19) rests on a flat plate 127 and is positioned thereon by a mating pilot hole 126 in the plate 127 coacting with pin 110. In a similar manner, each of the columns bases 121, 123, 124 rest on corresponding plates 125, 128, 129. Since the MOLDING MACHINE 100 can produce a relatively large modular unit 1 in the order of fifty feet (50) long by twelve'( l2feet wide and eight feet (8) high, the plates 125, 127, 128, 129 may be fastened and fixed to a concrete floor slab 130 in order to maintain the appropriate relative position between the frame 110 and the floor 2. However, it should be understood that the invention is not limited to the above modular unit size but may be larger or smaller and the locating plates 125, 127, 128, 129 may be fixed to a movable floor frame (not shown) which may be affixed to the factory floor or slab 130.

In accordance with the invention, the MOLDING MACHINE 100 includes interior corner forming means 137 for forming the interior corners 28, 29, 30 and inverse corner 8 of the modular unit 1. While the interior corners 28, 29, 30 of the modular unit 1 arre shown as square corners, it should be understood that in the practice of the present invention, other shaped corners such as round corners may be formed without departing from the invention, and may be seen in particular by viewing inverse corner 8 of the modular unit 1. The interior corners 28, 29, 30 (right front corner 28, right rear corner 29 and left rear corner 30) of the modular unit I are similar in construction and accordingly the structure elements of the MOLDING MACHINE 100 for producing these corners 28, 29, 30 are substantially similar and may be seen in FIGS. 12, 14 and 17. Referring first to FIG. 14 which shows the left rear portion of the MOLDING MACHINE 100 in a top fragmentary view, the interior corner forming means 137 includes a left rear corner forming panel 139 which is normal to the floor 2 of the modular unit 1 and is suspended from the structure 111 on a rail l40."The left rear corner forming panel 139 is novably supported on the guide rail 140 on casters 141. The guide rail 140 is on an imaginary line (not shown) diagonally disposed to the side 7 and the rear wall of the modular unit 1. The imaginary diagonal line may also be the bisector of the interior angle formed by the walls 5 and 7, viz., the interior corner 30. The corner panel 139 includes plate members 142 and 143 normal or perpendicular to each other and to the precast floor 2 within the MOLDING MACHINE 100. The plates 142 and 143 are supported by a structural reinforcing member 144.

The structural member 144 stiffens the left rear corner forming panel 139 and provides proper rigidity for connection to a left rear corner hydraulic cylinder 145 (FIG. 17) which is used for moving the left rear corner forming panel 139 into the molding position as shown in FIG. 14 or into the open stowed position as shown in FIG. 17. The left rear corner forming panel 139 is normal and contiguous to the floor 2 and establishes the interior left rear interior corner 30 of the modular unit 1.

The other interior corners, namely interior corners 28 and on the right side of the modular unit 1 are formed in the same manner as interior corner by right front corner forming panel 146 and right rear corner forming panel 147 (FIG. 12). The right front corner forming panel 146 includes plate 148 and 149 which are perpendicular to each other and to the floor 2 to establish the interior corner 28 of the modular unit 1 when in the molding position. The corner forming panel 146 is slideably supported on a guide rail 150 fixed to the superstructure 111. The corner forming panel 146 rolls on overhead castors 151 which coact with the guide rail 150. The right front corner forming panel 146 includes structure members 152 for stiffness and rigidity. An hydraulic cylinder 153 is connected to the right front forming panel 146 for moving the panel 146 from the molding position as shown in FIG. 12 to the open stow position similar to that shown in FIG. 17.

The right rear corner forming panel 147 is similar to the right front corner forming panel 146 and includes plate 154 and plate 155 at right angles to each other and perpendicular to the floor 2 within the MOLDING MACHINE 100. The right rear corner forming panel 147 is suspended from the superstructure 111 on castors 157 supported on a guide rail 156. The guide rail 156 bisects the angle formed by the plates 154 and 155, so that the panel 147 moves diagonally to the walls 5 and 6. The right rear corner forming panel 147 is connected to an hydraulic cylinder 158 for moving the right rear corner forming panel 147 into the molding position as shown in FIG. 12 and into an open stow position similar to the position shown in FIG. 17 for the left rear corner forming panel 139.

In accordance with the invention, the interior corner forming means 137 may be used to form complex interior corners such as the inverse corner 8 of the modular unit 1. The inverse corner 8 is draft free and is a particular advantage since plumbing service such as pipes 22 and 159 within wall 7 may be directed to the inverse corner 8 of the modular unit 1 (FIG. 21) for bathroom fixtures (FIG. 22) in the bathroom 10 of the modular unit 1. v

The inverse corner forming panel 160 includes a plate 161 at right angle to another plate 162 which is at right angle to another plate 163 which in turn is at right angle to yet another plate 164. All the plates 161, 162, 163 and 164 are normal to the floor 2 and are reinforced by a structural member 165 and movable on a pair of overhead castors 166, 167, which ride on guide rails 168, 169 respectively fixed to the superstructure 111. The inverse corner forming panel 160 as seen in FIG. 20 provides an offset corner for the modular unit 1 and is used to produce wall sections 170 and 171 of the modular unit 1. The wall section 170 is recessed so that the pipes 172, 173, 174 and 175 may supply water to the bathtub 176 and provide an access to the tub and pipe 22. The guard rails 168 and 169 are set diagonally or transverse to the plates 161, 162, 163 and 164 such that the inverse corner forming panel 160 moves into and out of the corner in a manner similar to the corner forming panels 139, 146, 147. In FIG. 20 the inverse corner forming panel 160 is shown in the open stowed position and the walls 4 and 7 of the modular unit 1 are shown in dash line. The inverse corner forming panels are moved into and out of the molding position by hydraulic cylinders 176 and 177.

The interiorcorner forming means 137 including the corner forming panels 139, 146, 147 and 160 just described, establish the interior corners 30, 28, 29, 8 respectively of the modular unit 1 and the boundaries or walls 4, 5, 6 and 7 of the modular unit 1 when disposed in the molding position. All of the interior corner forming panels 139, 146, 147 and 160 may be moved to the stowed position within the boundaries or within the modular unit and will be described more fully in conjunction With FIG. 24.

Referring now to FIG. 24, the MOLDING MA- CHINE 100 includes interior right side wall forming panel 180 and an opposed exterior right side wall forming panel 181; interior left side wall forming panel 182 and an opposed exterior left side wall forming panel 183; an interior front wall forming panel 184 and opposed exterior wall forming panel 185; an interior rear wallforming panel 186 and an opposed exterior wall forming panel 187; all of which are movable and vertically suspended from the superstructure 111 of the frame 1 10. The panels 180-187 and corner panels 139, 146, 147, 160 are movable on the superstructure 111 between a first position or the molding position for molding walls 4, 5, 6, 7 as shown in FIG. 24, and a second position or an open stowed position for releasing the modular unit 1 from the MOLDING MACHINE 100 in a manner to be described hereinafter. The panels 180-187 are rectangular in'shape and correspond in size with the mating wall of the modular unit 1. For a better understanding of the panels 180 and 181, reference is made to FIGS. and 12. The panels 180 and 181 are perpendicular to the floor 2 (FIG. 8a) and are suspended on the superstructure 111 on fixed castors 193' and 194 respectively which ride on guide rails 190-192. The exterior right wall forming panel 181 (FIGS. 10, 12) is movable on castors 194 between the molding positions as shown in FIG. 12 and an open position and is driven in these positions by two rows of hydraulic cylinders 200-209 ,whichkeep the panel 181 parallel to the wall 6 and panel 180. FIG. 24 shows only hydraulic cylinders 200-204 for exterior panel 181 to illustrate the operation of the cylinders 200-209 and the wall forming panels 181.

The hydraulic cylinders 200-209 not only move the panel 181 between the aforesaid positions but in accordance with the invention, also function to eliminate distortion in the relatively long panel 181. Distortion is eliminated or corrected in the panel 181 by hydraulic cylinders 200-209. Each of the cylinders 200-209 are in effect stiff rods which when under high pressure and fully extended may be made to push or pull on the panel 181. This is accomplished by fixing one end 197 of the hydraulic cylinder 200 to the panel 181 and the other end 199 by bolts 211 to a cylinder mounting bracket 299 fixed to strut 210 of the frame 110. The cylinder 200 is fastened to a cylinder mounting bracket by four (4) bolts 211. The cylinder 200 may be moved away from the vertical strut 210 by a center bolt 212 which is threaded in the bracket 299. A typical section showing bracket 299, bolts 211, 212 is illustrated at FIGS. 20, 14. Thus the bolts 211 hold the cylinder 200 to the frame 110 while the bolt 212 pushes the cylinder 200 away from the strut 210 of the frame 110. Thus the bolt 212 may counteract againstthe bolts 211 to move the cylinder 200 away from the frame 110 andtherefore between the two counteracting bolts 211 and 212, adjustments may be made to either push or pull the panel 181 to remove distortion.

In a similar manner, hydraulic cylinders 201-209 are made adjustable or tuneable as just described for cylinder 200, that is to say cylinder 205 is connected to strut 210 by bolts 211 and 212; cylinders 201 and 206 are connected to strut 213 by bolts 211, 21 2; cylinders 202 and 207 are connected to intermediate columns by bolts 211, 212; cylinders 203 and 208 are connected to strut 214 by bolts 211, 212, and cylinders 204 and 209 by bolts 211, 212 on strut 215.

The panel 181 butts against the floor 2 (FIG. 8) an coacts with wall forming panel 180 for defining the wall cavity 'for the wall 6 of the modular unit 1'. Concrete mix of the right consistency well known to those skilled in the art may be poured at the top 9 of the panels 180 and 181 to form the wall 6 of the modular unit 1 or it may be injected under pressure through the tube 216.

(FIG. 8).

In accordance with the invention, the interior right side wall forming panel overlaps the corner panels 146 and 147 and locks the corner panels 146, 147 in the molding position. Vibrators 188 are fastened to the panel 181 for vibrating the concrete when poured in the MOLDING MACHINE 100. Y

The internal right side wall forming panel 180 is structurally similar to the panel 181 in that it is suspended by the castors 193 on the superstructure 111. The castors 193 are similar to castors 260 shown in FIG. 8. The internal wall forming panel 180 is also moved into and out of the molding position by hydraulic cylinders 220-224 (FIGS. 12 and 24). A typical section of the wall forming panels 180 and 181 is shown in FIG. 8a. The wall forming panels 180, 181 are held together by tapered bolts 225 and wing nut 226 and a spacer bar 227 having a hole 228 for receiving .the bar 72 and two locating pins 229 and 230 which fit into the holes at the top of the panels 180, 181 at 231 and 232 respectively. In effect, the spacer bars 227 and the bolts 225 offer a fail safe mechanism just in case the .hydraulic cylinders 200-209 and 220-224 fail or lose pressure. In fact, this arrangement of bolts is used in all the wall forming panels of the MOLDING MACHINE 100 to be described in detail now. FIG. 13 shows the bolts 225.

Referring now to FIGS. 11, 14 and 20, the left side view of the MOLDING MACHINE 100 is shown. The left side of the MOLDING MACHINE 100 is similar to the right side of the MOLDING MACHINE 100 except that the left side of the MOLDING MACHINE 100 includes the structure for molding the inverse corner 8. The interior wall forming panels 182, 183 are constructed similar to the wall forming panels 180, 181; that is, the interior and exterior left wall forming panels 182, 183 are movable and vertically supported perpendicular to the floor 2 from the superstructure 111 on casters 233, 234 respectively. The casters 233 and 234 are also like casters 260 (FIG.- 8). Internal left wall forming panel 182 is moved into and out of the molding position by hydraulic cylinders 235-239. External left wall forming panel 183 is likewise moved into and out of the molding position by hydraulic cylinders 240-248 (FIG. 24). As was previously described, the hydraulic cylinders 240-248 are likewise used for eliminating distortion and warping of the panel 183. The panels 182 and 183 are also spaced apart by spacer 227'and bolts 225 to form a cavity for molding modular unit wall 7. (FIG. 13)

The corner forming means 137 includes a hinge mounted inverse exterior panel 251 mounted to the exterior front wall forming panel 185. The hinge mounted inverse exterior panel 251 is supported on a guide rail 252 by a roller 253 so that when the frontexterior panel 185 moves, it carries with it the panel 251. The

inverse exterior panel 251 is hinged to the exterior panel 185 at 258 so that it may be easily moved into the molding position or in the stowed position. Thus the hinge-mounted panel 251 may be placed in an open stowed position as shown in FIG. 20 or in a molding position as shown in FIG. 21. In the molding position, a

plate 254 connects the left exterior side panel 183 to' the inverse panel 251 by bolts 255. Plate 251 includes one or more holes 256 for locating and supporting pipes 22 as shown in FIG. It should be understood that the MOLDING MACHINE 100 may produce square corner instead of an inverse corner 8 by employing a corner panel like one of the corner panels 139, 146 and 147 without departing from the invention.

Referring again to FIG. 8, the front wall forming panel 185 is movably supported on the superstructure 111 on overhead casters 260 on guide rails 261 fixed to the superstructure 111. The overhead casters 260 include rollers 262, a yoke 263 and a bolt 264 fixed to the panel 185 and yoke 263 for leveling the panel 185. It should be understood that the overhead casters 260 for moving the wall forming panels 180-187 are of similar construction and operate the same. The external front panel 185 is moved into and out of the molding position by hydraulic cylinders 265-270 connected between the panel 185 and the frame 110 at struts 271-273. These hydraulic cylinders 265-270 operate and function in the same manner as cylinders 200-209 as previously described. The front wall forming panel 185 overlaps the floor 2 and panel 251 of the inverse corner 8 and the exterior side panel 181 so that when it is disposed in the molding position it interlocks with panel 181 and is located by a pin 275 (FIG. 8) and bolted thereto by bolts 276. The front panel 185 is also bolted to the interior front panel 184 by bolts 225 and wing nuts 226 (FIG. 13). The front panel 185 also includes a door means 280 which is a means for holding or clamping a metal door frame 15 between the panels 184 and 185 so that concrete mix may be poured therebetween while the door frame 15 is accurately held and made an integral part of the wall 4 by panels 184 and 185. The door means 280 includes two door panels 283, 284 clamped to the door frame 15 by bolts 286 at door stop 287. The two door panels 283 and 284 accurately hold the door frame 15 so that a precut door 11 may be hinged on the door frame 15 directly without further cutting or fitting after molding. This is a particular advantage when the doors 11 are metal instead of wood. Locating members 289 are fixed to the panels 185, 184 so as to maintain the proper relationship with respect to the frame 110. It should be understood that the door means 280 is also applicable to window frames and other framing requirements of the modular unitl l and 1a.

Referring to FIGS. 12 and 20, the interior panel 184 is movably supported on overhead castors 260 coacting with guide rails 302, 303 which are fixed to the superstructure 11 1. The interior panel 184 is moved into and out of the molding position by cylinders 304, 305 and 306 and is kept in a parallel relationship with the front panel 185 in a manner similar to all of the panels 180-187. The interior wall forming panel 184 overlaps the corner panel 146 and the inverse corner forming panel 160 at plates 149 and 164 respectively to lock the corner panels 149 and 160 in the molding position. The interior front panel 184 is similar to the front interior panel 185 and when both panels 184 and 185 are in the molding position they are opposed and parallel in spaced relationship to form a cavity for receiving concrete mix therein for forming the front wall 4.

Referring now to FIG. 9, a rear view of the MOLD- ING MACHINE 100 is shown. The MOLDING MA- CHINE 100 includes an interior wall forming panel 186 and an exterior wall forming panel 187 which operate in substantially the same manner as the exterior front wall forming panel 185 and the interior front wall forming panel 184. That is, the exterior rear wall forming panel 187 is movably supported on castors 260 which roll on guide rails 310-312 fixed to the superstructure 111. The panel 187 overlaps exterior panel 181 and exterior panel 183 and is bolted thereto by bolts 31 1. The exterior rear panel 187 is movable into and out of the molding position by hydraulic cylinders 315-320 which are similar to the other hydraulic cylinders for moving the wall forming panels into and out of the molding position just described. The hydraulic cylinders 315-320 also include bolts 211, 212 for tuning or adjusting to remove distortion or warping of the exterior rear panel 187 as previously described. The interior rear wall forming panel 186 (FIGS. 12, 14) is supported on castors 260 which coact with guide rails 321 and 322 which are fixed to the superstructure 111. The interior rear wall forming panel 186 overlaps the corner panels 139 and 147 for locking the comer panels 139, 147 in the molding position. The interior rear wall forming panel 186 and the exterior rear wall forming panel 187 are locked together by bolts 225 in the manner hereinbefore described. The interior rear wall forming panel 186 is moved into and out of the molding position by hydraulic cylinders 350-352. The rear panel 187 includes means 330 for molding openings 331 in the wall 5 as shown in FIGS. 9 and 15, for air conditioner 14. The means 330 includes an horizontal plate 332 fixed to the wall 187 and supported by an angle member 335 and side plate 336, 337. The horizontal plate 332 is welded or fixed to the panel 187 and rests on angle supporting member 329 fixed to the interior panel 186. In effect, the horizontal plate 332 is a lintel to support the concrete between the panels 186 and 187. The opening 17 for the window 13 is made in substantially the same manner as the air conditioner opening by means 330. The window opening means includes movable lintel 337- supported on . angles 338 and 339 and fixed to angle 338 which is fixed to exterior wall forming panel 187. Side plates 341 and 342 are fixed to the exterior wall panel 187 to frame the window opening 17 and mold the wall 5 with the opening 17.

The MOLDING MACHINE includes a liftingmeans 400 for lifting the frame 1 10, superstructure 1 1 1 together with the wall forming panels 180, 181, 182, 183, 184, 185, 186 and 187 and corner forming panels 139, 146, 147 and 160 above the walls 4, 5, 6 and 7 of the molded concrete modular unit 1 after each pouring and setting of the concrete. In the preferred embodiment, the lifting means 400 includes four hydraulic cylinders 401, 402, 403, 404 connected to the frame 1 10. Hydraulic cylinders 401-404 are fixed to the slab and to the frame 110 at 405-408 respectively so that the frame may be lifted evenly above the poured and set concrete walls 4, 5, 6 and 7 to remove the unit 1 from the MOLDING MACHINE 100. Other means may be used for lifting the frame 110, superstructure 111 and the wall forming panels 180, 181, 182, 183, 184, 185, 186, 187, 139, 146, 147 and above the poured and set concrete walls 4, 5, 6, 7 to remove the unit 1 from the MOLDING MACHINE 100 without departing from. the invention. For example, the entire MOLDING MACHINE 100. may be lifted by the crane system 300 at a balancing point 410 within the MOLD- ING MACHINE 100. A bar 411 disposed at 410 is fixed to two steel beams 412, 413 which are fixed to the superstructure 1 1 1. The point 410 is the center of gravity of the MOLDING MACHINE 100 so that the MOLDING MACHINE 100 may be raised at that point v 410 without appreciable tilt. When the entire MOLD- ING MACHINE 100 is lifted by the crane system 300, the hydraulic cylinders 401, 402, 403 and 404 are of course disconnected from the frame 110 at 405, 406, 407, 408. The lifting of the entire MOLDING MA- CHINE 100 may have many advantages, for example, where it is desired to cure the walls 4, 5, 6, 7 with the floor 2 for a longer period of time without movement, the MOLDING MACHINE 100 may be moved to different work stations as defined by the bearing plates set in the concrete slab 130 of the factory floor. For example, the plates 125 may be common to all the work stations and each station may be defined by the plates as follows: (Station No. 1) plates 125, 125, 125a, 125b; (Station No. 2) plates 125, 125, 125b, 1251:; (Station No. 3) 125, 125, 125d, 125e; (Station No. 4) 125, 125, 1252, l25f. The lifting of the entire MOLDING MA- CHINE 100 has additional advantages in that not only can the MOLDING MACHINE 100 itself be transported more easily, but also the MOLDING MA- CHINE 100 may be transported to a city or town for building modular units 1, hand buildings 20 during a high demand for modular units 1, 1a and after this demand is met, the MOLDING MACHINE 100 may be transported by train, truck or other vehicle to another city or location to help relieve a housing or building shortage. The floor mold 50 of course may also be transported and used in a similar manner.

Referring now to FIG. 24, an hydraulic system 500 for the MOLDING MACHINE 100 is shown. The hydraulic system 500 includes two hydraulic circuits, one of which controls the raising and lowering of the frame 110 by hydraulic cylinders 401, 402, 403, 404 by valve 415, and the other is for operating the hydraulic cylinders for the panels 180-187, 139, 146, 147, 160. A valve 415 is connected between a source of fluid pressure (air hydraulic control circuit) 416 and feed line 417 which is connected to the hydraulic cylinders 401, 402, 403, 404, 405. Electric vibration control circuit 418 includes vibrators 188 connected to the exterior wall forming panels 181, 183, 185, 187, 251 and control switches 420, 421, 422, 423. Each of the panels 181, 183, 185, 187, 251 is separately and individually vibrated by the vibrator 188 in sequence to effect the pouring and molding of the corresponding walls 6, 7, 4 and 5 respectively. Accordingly, switch 420 is connected between vibrator control circuit 418 and vibrator 188 on panel 181 by line 424. Switch 421 is connected between the vibrator control circuit 418 and vibrators 188 on panel 183 by line 425; switch 422 is connected between the vibrator control circuit 418 and the vibrators 188 on panel 185 by line 426; switch 423 is connected between the control circuit 418 and vibrators 188 on panel 187 by line 426. While electrical vibrators 188 are shown, it should be understood that hydraulic vibrators may be used instead of vibrators 188 without departing from the invention. The air hydraulic circuit 416 controls themovement of the panels 180, 181, 182, 183, 184, 185, 186, 187 and the corner panels 139, 146, 147 and 160. The hydraulic circuit 416 includes interlocks so that only one panel may be moved in sequence in a given order. Accordingly, the hydraulic control circuit 416 includes interlocks and means for movingthe corner forming panels 139, 146, 147, 160 and wall forming panels'l80, 181, 182, 183, 184, 186 and 187 and will be described in that sequence starting from an open stowed position to the molding position, which position is shown in FIG. 24 for all panels. Starting with the interior corner panels, valve 431 isconnected between hydraulic cylinders 176, 177 and the air hydraulic control circuit 416 by line 432; valve 433 is connected between the circuit 416 and cylinder by line 433; valve 435 is connected between the circuit 416 and cylinder 158 by line 436; valve 437 is connected between the circuit 416 and cylinder 153 by line 438. By the operation of valves 431, 433, 435, 437 in the above sequence, the corner panels 139, 147, 146 and are thus sequentially moved into the corner molding position. The interior panels 180, 182, 184 and 186 are next moved into the molding position to lock the corner panels 139, 147', 146, 160 in the molding position in the following sequence. Valve 440 is connected between the circuit 416 and cylinders 235, 236, 237, 238, 239 by line 441. Valve 442 is connected between circuit 416 and cylinders 350, 351, 352 by line 443; valve 444 is connected between circuit 416 and cylinders 220, 221, 222, 223, 224 by line 445; valve 446 is connected between circuit 416 and cylinders 304, 305, 306 by line 447.

The exterior wall forming panels 181, 183, 185, 187 are sequentially moved to interlock the side panels 181 and 183 by end panels 185 and 187 and are described in that order. Valve 450 is connected between cylinders 200-204 and hydraulic control circuit 416 by line 451. (Note: valve 450 is connected to all the cylinders 200-209 on wall forming panel 181, FIG. 10). Valve 452 is connected between circuit 416 and cylinders 240, 241, 242, 243, 244 by line 453. (Also note that valve 452 is also connected to all the valves 240-248, (FIG. 11). Valve 454 is connected between circuit 416 and cylinders 265, 272, 269 (also 266, 268, 270) by a line 455. Valve 456 is connected between cylinders 315, 317, 319 (also 316, 318, 320) and circuit 416 by line 457.

In the operation of the preferred embodiment of the invention, the MOLDING MACHINE 100 is first raised by the hydraulic cylinders 401-404 under fluid pressure from the circuit 416 through control valve 415. The wall forming panels -187 and corner panels 139, 146, 147 and 160 at this time are disposed in the open stowed position as shown in FIGS. 17 and 20.

Also, prior preparations may be made to the MOLD- ING MACHINE 100, for example, the panels 181-187 and corner panels 139, 146, 147 and 160 may be coated with a mold release agent well known to those skilled in the art so that concrete will not stick or adhere to the panels 181-187 and corner panels 139, 146, 147 and 160 after the concrete is poured into the MOLDING MACHINE 100. The precast floor 2 and steel reinforcing grid 21 are also prepared for molding within the MOLDING MACHINE 100. The grid 21 is placed on the boundaries defined by the modular unit 1 and the precast floor 2 and grid 21 are placed on the flatbed 102 of the truck 101 in a predetermined position and moved into the MOLDING MACHINE 100 andloca'ted therein by the V notches 106 on the rail track 104. Once the truck 101 precast floor 2 and grid 21 are located as just described or other suitable locating-means, the MOLDING MACHINE 100 is lowered by reducing the pressure in the cylinders 401-404 through control valve 415. The locating pins 110 on the base plates 121-124 align the frame 110 with floor plates 125, 127, 128 and 129 when the MOLDING MACHINE 100 comes to rest on the slab 130.

From the above rest position, the corner panels 160, 139, 147 and 146 are moved into the molding position by sequentially actuating valves 431, 433, 435 and 437 respectively. Next, the interior panels 180, 182, 184 and 186 are moved into the molding position by sequentially actuating control valves 440, 442, 444, 446 respectively. When the interior panels 180, 182, 184 and 186 are in the molding position, workmen may walk between the following pairs of opposed panels, namely, panels 180., 181, panels 182, 183, panels 184, 185 and panels 186, 187 to' affix accessories to the interior wall forming panels 180, 182, 184, 186 for accurate alignment. The accessories may for example, include the flange 74, the piping 172, 173, 174 and 175 for tub 470, the pipes 22, 159 and door frame 15. As was previously mentioned, the panels 180, 182, 184 and 186 lock the corner panels 139, 146, 147 and 160 in the molding position by overlaping the corner panels- 160, 137, 146, 147 and applying a constant pressure thereto so as to confine the wet concrete mix. The bottom of all the panels 180, 182, 184, 186, 139, 146, 147 and 160 include a resilient tube 471 which may be for a seal or be filled with a fluid under pressure to provide a pressure seal at the floor 2 (FIG. 13) after the accessories are put in place as just described. The exterior side wall forming panels 181 and 183 are moved into the molding position by sequentially actuating valves 450 and 452 which in turn place cylinders 200-209 and cylinders 240-248 under pressure. Once the exterior side panels 181, 183 are in the molding position, the valves 454 and 456 are sequentially operated to drive the exterior front wall panel 185 and exterior rear wall panel 187 into the molding position. The floor 2 is now locked within the MOLDING MACHINE 100. The inverse corner'panel 251 is then pivoted on hinge 258 and connected to plate 254 which is also bolted to the exterior side panel 183. After the panels 180-187 and corner panels 139, 146, 147 and 160 are in the molding position (FIGS. 14, 21, 24) under pressure from the air hydraulic control circuit 416, the aforesaid fail safe means may be applied, namely the bolts 225 with wing nuts and spacer bar 227 may be assembled to the opposed pair of panels 180, 181; opposed panels 182, 183; opposed panels 184, 185 and opposed pair of panels 186, 187 (FIG. 13) as previously described. The MOLDING MACHINE 100 is now ready for pouring concrete mix into the cavities formed by the opposed wall panels 180-187 to form walls 4, 5, 6 and 7. The pouring of the concrete mix is facilitated by chutes 475 which may be moved to desired locations on top of the 7 panels 180-187.

It has been found that pouring a given charge or volume of concrete mix between side panels 180 and 181 and 182 and 183 and vibrating the panels 181 and 183 with vibrators 188 will fill the spaces therebetween then pouring another charge or quantity of concrete mix between panels 184 and 185 and vibrating panel 185 with vibrators 188 will complete walls 4, 6, 7. The rear wall 5 is completed by pouring concrete mix between panels 186, 187 and vibrating panel 187 with vibrators 188. The chutes 475 are then removed and any void left by the chutes 475 are filled and leveled. Since the concrete mix is carefully controlled, weighed and measured in the factory and the MOLDING MA- CHINE 100 can consistantly and repeatedly perform to give the same wall thickness for walls 4, 5, 6 and 7 of modular unit 1 and 1a, the quality of concrete mix for each pouring is actually predetermined.

After the concrete walls 4, 5, 6, 7 have been allowed to set or cure within the MOLDING MACHINE for a few hours, the fail safe means including'bolts 225 and spacers 227 are removed and the interior panels 180, 182, 184 and 185 are sequentially pulled into the stowed position by hydraulic cylinders in response to the actuation of the control valves 446, 444, 442,

440. The vibrators 188 may be used to vibrate the panels 180, 182, 184, 185 away from the walls 4, 5, 6, 7 of the modular unit 1. Next, the corner panels 160, 139, 146, 147 are pulled into the stowed position by the sequential actuation of valves 431, 433, 435 and 437. The exterior panels may now be freed or released from the walls 4, 5, 6, 7 by first unclamping plate 254 and pivoting panel 251 away from the inverse corner 8. The front and rear panels 185 and 187 respectively are then pulled into the open stowed position by actuating control valves 454 and 456 respectively. The side panels 181 and 183 may then be pulled into the open stowed position and their release may also be assisted by actuating vibrators 188 on panels 185 and 186 for a short period of time. After all the panels 180-187 and corner panels 139, 146, 147, are in the open stowed position, the frame 110, superstructure 111 and panels -187 may be raised by the cylinders 401-404 by actuating control valve 415 to release the molded unit 1. The MOLDING MACHINE 100 is now ready to receive another precast floor 2 and to repeat another molding cycle as just described.

After the modular unit 1 is removed from the MOLDING MACHINE 100, the precast ceiling 3 is then placed on top of the walls 4, 5, 6, 7 and allowed to cure before being painted and completed with furnishings. The MOLDING MACHINE 100 is used for modular unit 1 and a similar molding machine may be used for making modular unit 10 except that it will be a mirror image of MOLDING MACHINE 100. Additional ornamental design such as brick, stone or old barn lumber or wood may be formed on the face of the modular units 1, 1a by placing a rubber or plastic mold 476 on the panels to produce a simulated brick fac-' ing 502 on wall 4 and a rubber or plastic mold 477 on panel 187 to produce a simulated old barn wood facing 503 on wall 5. It should be understood that the present invention can also produce pilasters (not shown) 'in the walls 4, 5, 6, 7 or corners 28, 29, 30 similar to offset corner 8 except for a thicker wall section. The exterior v and interior wall forming panels 180-187 and corner panels 139, 146, 147 and 160 are thus responsive to signals viz. actuation of the hydraulic control means 500 to selectively position wall forming panels 180-187 and corner forming panels 139, 146, 147 and 160 in first and second positions such as the molding position and the open stowed position respectively.

In summary, it can now be seen that the present invention repeatedly produces by mass production techniques modular units 1, 1a which are not only structurally sound but also architecturally sound and of good fireproof construction for the aforesaid buildings.

- While specific embodiments of the invention have been described and shown, these may be considered illustrative. Still further modifications will undoubtedly occur to those skilled in the art. Therefore,the foregoing description is to be considered as illustrative and not in any limiting sense.

lclaim:

1. A molding machine for molding a formable material on a precast floor into a room module having monolithic vertical intersecting walls joined perpendicularly to said floor and having corners at the intersection of said walls, said machine comprising:

a. a hoistable frame having a superstructure including panel supporting rail means,

b. interior wall forming panels movably suspended from said rail means of said superstructure,

i. said interior wall forming panels being movable normal to said fioor into a wall molding position within said room module,

0. corner forming means including comer forming panels movably suspended from said rail means of said superstructure within said room module for movement normal to said floor into the intersections of said interior wall panels to define the interior corners of said room module when disposed in a molding position,

d. exterior wall forming panels movably suspended from said rail means of said superstructure,

'. said exterior panels being movable normal to said floor and disposed in spaced cooperative relationship to said interior wall forming panels and said corner panels when disposed in a molding position to derive a wall cavity of a predetermined width for receiving said formable material therebetween to mold said monolithic walls,

e. signal responsive interlocking means connected to said frame for sequentially controlling said movement of said corner forming panels, said interior wall forming panels and said exterior forming panels, in a predetermined order into and out of said molding position,

i. said signal responsive interlocking means includes interlocking means connected to said frame for interlocking said corner panels, said interior panels and said exterior panels in said molding position independently of said rail means, and

f. hoisting means for raising and lowering said frame relative to said floor only when said interior panels, exterior panels and corner panels are disposed out of said molding position.

2. The invention defined in claim 1 wherein said signal responsive interlocking means includes hydraulic cylinders for moving all of said panels into and out of said molding position.

- 3. The invention defined in claim 2 further including tuning means connected between each of said hydraulic cylinders and said panels for eliminating distortion in said panels when disposed in said hydraulic molding position.

4. The invention defined in claim 1 wherein said hoisting means includes an overhead crane system for transporting said frame into a plurality of molding stations.

5. The invention defined in claim 1 further including vibrating means for vibrating said wall forming panels.

6. A molding apparatus comprising: a. a frame having a superstructure including panel supporting rail means,

b. locating means for positioning said frame in a predetermined position relative to a precast floor,

c. corner means including corner forming panels movably suspended in a vertical position on said panel supporting rail means of said superstructure contiguous to said precast floor,

i. said corner panels being disposed normal to said precast floor at predetermined corner molding positions to define boundaries of an enclosure on said floor,

ii. each of said corner panels being retractable within said boundaries of said enclosure in a stowed position,

d. corner moving means connected to said frame for moving each of said corner forming panels on said rail means between said corner molding positions and said stowed position,

'e. interior wall forming means positioned in cooperative relationship with said fioor and said corner means in said molding position to define a continuous wall around said boundaries of said enclosure,

i. said interior forming means includes interior forming panels movably suspended from said rail means of said superstructure and contiguous to said floor,

ii. said interior wall forming panels being movable within said boundaries between said stowed position and said molding position,

f. interior wall moving means connected to said frame for moving said interior wall forming panels between said molding position and said stowed position,

g. exterior wall forming means including movable exterior wall forming panels spaced from said corner means and said interior wall forming means to form a cavity the thickness of said contiguous wall to be molded on said boundaries when said exterior wall forming means are disposed in a molding position,

and said exterior panels in said molding positionindependently of said rail means, and

j. lifting means connected to said frame for lifting said frame above said molded continuous wall.

7. The invention defined in claim 6 wherein said wall forming means further includes a wall facingmeans on any one of said interior and exterior wall forming panels contiguous to said monolithic walls for forming simulated designs on said monolithic walls.

8. In a molding machine for molding an offset corner in a modular unit having at. least two walls made of a formable material on a floor, the combination comprising:

a. a frame having a superstructure,

b. a first exterior wall forming panel mounted on said superstructure,

I movably

Claims (8)

1. A molding machine for molding a formable material on a precast floor into a room module having monolithic vertical intersecting walls joined perpendicularly to said floor and having corners at the intersection of said walls, said machine comprising: a. a hoistable frame having a superstructure including panel supporting rail means, b. interior wall forming panels movably suspended from said rail means of said superstructure, i. said interior wall forming panels being movable normal to said floor into a wall molding position within said room module, c. corner forming means including corner forming panels movably suspended from said rail means of said superstructure within said room module for movement normal to said floor into the intersections of said interior wall panels to define the interior corners of said room module when disposed in a molding position, d. exterior wall forming panels movably suspended from said rail means of said superstructure, i. said exterior panels being movable normal to said floor and disposed in spaced cooperative relationship to said interior wall forming panels and said corner panels when disposed in a molding position to derive a wall cavity of a predetermined width for receiving said formable material therebetween to mold said monolithic walls, e. signal responsive interlocking means connected to said frame for sequentially controlling said movement of said corner forming panels, said interior wall forming panels and said exterior forming panels, in a predetermined order into and out of said molding position, i. said signal responsive interlocking means includes interlocking means connected to said frame for interlocking said corner panels, said interior panels and said exterior panels in said molding position independently of said rail means, and f. hoisting means for raising and lowering said frame relative to said floor only when said interior panels, exterior panels and corner panels are disposed out of said molding position.

2. The invention defined in claim 1 wherein said signal responsive interlocking means includes hydraulic cylinders for moving all of said panels into and out of said molding position.

3. The invention defined in claim 2 further including tuning means connected between each of said hydraulic cylinders and said panels for eliminating distortion in said panels when disposed in said hydraulic molding position.

4. The invention defined in claim 1 wherein said hoisting means includes an overhead crane system for transporting said frame into a plurality of molding stations.

5. The inventioN defined in claim 1 further including vibrating means for vibrating said wall forming panels.

6. A molding apparatus comprising: a. a frame having a superstructure including panel supporting rail means, b. locating means for positioning said frame in a predetermined position relative to a precast floor, c. corner means including corner forming panels movably suspended in a vertical position on said panel supporting rail means of said superstructure contiguous to said precast floor, i. said corner panels being disposed normal to said precast floor at predetermined corner molding positions to define boundaries of an enclosure on said floor, ii. each of said corner panels being retractable within said boundaries of said enclosure in a stowed position, d. corner moving means connected to said frame for moving each of said corner forming panels on said rail means between said corner molding positions and said stowed position, e. interior wall forming means positioned in cooperative relationship with said floor and said corner means in said molding position to define a continuous wall around said boundaries of said enclosure, i. said interior forming means includes interior forming panels movably suspended from said rail means of said superstructure and contiguous to said floor, ii. said interior wall forming panels being movable within said boundaries between said stowed position and said molding position, f. interior wall moving means connected to said frame for moving said interior wall forming panels between said molding position and said stowed position, g. exterior wall forming means including movable exterior wall forming panels spaced from said corner means and said interior wall forming means to form a cavity the thickness of said contiguous wall to be molded on said boundaries when said exterior wall forming means are disposed in a molding position, i. said exterior panels being movably suspended from said rail means, h. exterior wall moving means connected to said frame for moving said exterior wall forming means outwardly from said interior wall forming means a predetermined distance, i. interlocking means positioned in cooperative relationship with said corner moving means, interior moving means and exterior moving means for interlocking said corner panels, said interior panels and said exterior panels in said molding position independently of said rail means, and j. lifting means connected to said frame for lifting said frame above said molded continuous wall.

7. The invention defined in claim 6 wherein said wall forming means further includes a wall facing means on any one of said interior and exterior wall forming panels contiguous to said monolithic walls for forming simulated designs on said monolithic walls.

8. In a molding machine for molding an offset corner in a modular unit having at least two walls made of a formable material on a floor, the combination comprising: a. a frame having a superstructure, b. a first exterior wall forming panel movably mounted on said superstructure, c. an exterior corner forming panel having a contour corresponding to said offset corner pivotally mounted on said first exterior wall forming panel, d. a second exterior wall forming panel movably mounted on said superstructure and coacting with said exterior corner forming panel to define a continuous exterior wall panel, e. an interior corner forming panel means having a corner panel movably suspended from said superstructure, i. said corner panel being movable into and out of said offset corner on a rail connected to said superstructure, and f. lifting means for lifting said frame above said modular unit to release said modular unit from said machine.

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