KR100527266B1 - Method and apparatus for forming a concrete block - Google Patents

Abstract

The present invention relates to methods and apparatus for producing concrete blocks, in particular composite blocks with, but not entirely, reflective surface layers. The block is subjected to a dry forming technique in which the subsequent block is subjected to compressive molding forces in accordance with BS 6717, published in 1993, Part 1, and has a water / cement ratio of 0.35 or less in water / cement ratio of the mixture for forming the block. Are manufactured.

Description

Method and apparatus for manufacturing concrete block {METHOD AND APPARATUS FOR FORMING A CONCRETE BLOCK}

FIELD OF THE INVENTION The present invention relates to a method and apparatus for producing concrete blocks, particularly composite blocks having, but not exclusively, base and reflective surface layers.

The term "block" is used throughout the specification and claims to include curbs, driveway separators, or road pavers, all or part of which are constructed by concrete or similar materials.

One type of composite block is disclosed in British Patent Publication No. 2159556A. The block includes a base portion and a reflective surface layer, and is formed by putting the base mixture and the surface mixture into a form and pressing the base mixture and the surface mixture to remove excess water.

Another concrete block in the form of curb is disclosed in British Patent No. 2200936. This curbstone comprising the reflective material is formed by arbitrarily mixing the reflective material with the fluid concrete, or by pressing the reflective material into the concrete when the curb is partially cured.

All of the known types of concrete blocks described above are manufactured by wet forming techniques, which may take a significant amount of time, such as three days, to cure the blocks.

1 is a perspective view of a mixing assembly,

2 is a perspective view of the formwork assembly,

3A is an isometric view of a composite block,

3B is a side view of the block of FIG. 3A,

3C is a plan view of the blocks of FIGS. 3A and 3B;

4 is a perspective view showing a part of an apparatus used for batch processing a block manufactured according to the present invention.

It is an object of the present invention to provide a block manufacturing method and apparatus using dry forming technology. To the best of our knowledge, dry forming has not been used to produce curbs until now because of the reduced strength and durability of the blocks, the British Standards Institution of London This is because it is generally believed that the wet molding method was specified to meet the requirements for curbstone, as set forth in British Standard BS 7263, Part 1, published in 1990. However, the present invention uses a dry forming method with a compacting step so that the resulting block can meet the conditions of the 1993 edition, BS 6717, first part.

According to the present invention, there is provided a method for producing a concrete block comprising preparing a base mixture having a water / cement ratio of 0.35 or less, pouring the base mixture into a formwork, and applying a compression molding force to pressurize the mixture.

It is preferable to pour the surface mixture into the formwork before applying the compression molding force, so that both the base mixture and the surface mixture are pressurized.

It is preferred to join the base mixture prior to applying the compressive molding force to create a recess by the base mixture and the formwork and to pour the surface mixture into the recess.

Preferably, the surface mixture comprises a reflective material. Optionally, the surface layer mixture is provided with a reflective material on its surface prior to compression molding.

Preferably, a binder is provided between the base mixture and the surface mixture prior to compression molding.

In order to improve the filling of the formwork and subsequent compression molding, it is preferable to vibrate the base mixture before applying the compression molding force.

The preparation of the base mixture preferably includes mixing granite debris up to 9 mm in diameter and sand particles up to 5 mm in diameter with cement to enhance the bonding properties of the block.

In another aspect, there is provided an apparatus for carrying out the method described above, the apparatus comprising: mixing means for mixing a base mixture and a surface mixture; A formwork assembly comprising a formwork, a feeder for receiving the base mixture and the surface mixture and transporting the formwork to the formwork; And a ram device for applying compression molding force to the mixture held in the formwork.

The formwork assembly preferably includes a vibrating device that vibrates the formwork to improve the filling of the form and subsequent compression molding.

The ram device is preferably adapted to apply the vibration compression molding force.

The feeder preferably has two portions, each holding a base mixture and a surface mixture, the feeders being arranged such that the two portions are alternately displaced over the formwork for dispensing the base mixture and surface mixture separately in the formwork.

In another aspect, a concrete block molded according to the method described above is provided.

The present invention is described in more detail with reference to the accompanying drawings as a non-limiting example only.

The mixing assembly 1 is shown in FIG. 1 with a supply assembly 2 arranged to supply the component material to the mixing assembly 1.

The feed assembly 2 has a plurality of hoppers 3, 4, 5, 6, 7 arranged to distribute the component material on the main conveyor 8, which main material 8 carries the component material. Carry to the bucket (9). The bucket 9 itself is arranged to move along the track 10 in which the bucket is turned over at the upper end 11 to feed the component material into the feed hopper 12 of the mixing assembly 1. The material in the hopper is conveyed into the first mixing device 13 for the base mixture or the second mixing device 14 for the surface mixture.

In one form of production, the hoppers 2, 3 and 5 receive granite debris, coarse sand and fine sand respectively. The hopper 6 may receive silica sand and the hopper 7 may receive glass beads. The ingredient material for the base mixture is then dispensed with a predetermined amount of granite debris and sand from the hoppers 3 to 5 and mixing the debris and sand for the base mixture via the conveyor 8 and the bucket 9. By transporting into the device 13. The component material for the surface mixture can be similarly obtained by dispensing a predetermined amount of material from the hoppers 5 to 7 and conveying the material into the mixing device 14 for the surface mixture.

It is preferable that a base layer mixture contains the following components.

Name of raw material amount

20% of ordinary Portland cement sand and mix weight

0.1-3mm fine sand 8%

60% of sand from 0.4 to 0.5mm

5-9mm granite shavings 32%

2-3% by weight of additive cement

Water / Cement Ratio 30 kgs (0.28 to 0.35)

The surface layer mixture preferably includes the following components, including the reflective element used to create a layer of at least 8 mm on the block.

Name of raw material amount

50% silica sand

0.1 to 3mm fine sand 10%

10% white flakes

White cement 30%

5-7% of white pigment (titanium dioxide) cement weight

7-9% of yellow pigment cement weight

5-7% of red pigment cement weight

20-35% of 250-800 μm glass beads total mixture

5% of additive or binder cement weight

Water / Cement Ratio 30 kgs (0.28 to 0.35)

Cement, water and other ingredient materials not provided by the hoppers 3, 4, 5, 6, 7 can be added directly to the mixing assembly either automatically or manually.

The feed assembly and the mixing assembly are preferably operated to alternate between the base mixture and the surface mixture. When the mixing of the base mixture or the surface mixture is completed, the resulting mixture is unloaded into the bucket conveyor 15, which discharges the formwork assembly 20 and the mixing device shown in FIG. It is to move between parts (not shown). A belt conveyor may be used instead of the bucket conveyor, or the mixing assembly may be arranged to discharge the mixture directly into the formwork assembly.

The formwork assembly 20 has a feeding mechanism 21, a ram device 22 and a formwork 23. The feeding mechanism 21 has two feeding hoppers 24, 25 which are arranged on either side of the hydraulically actuated ram head 26 of the ram device 22 and which alternately rest on the formwork 23. The feeding mechanism also includes tray portions 27 and 28 disposed under each hopper 24 and 25. The tray portion is interconnected to the frame 29 of the formwork assembly 20 by articulated arms 30, 31, wherein the articulated arms 30, 31 are unloaded on the formwork by the tray portions 27, 28. It is possible to slide from the position to the laterally displaced position under each hopper 24, 25.

In operation, the bucket conveyor 15 is moved from the mixing assembly 1 to the formwork assembly 20 and placed on either of the feeding hoppers 24, 25 according to the mixture carried by the bucket conveyor. The shutter mechanism 26 is operated at the bottom of the bucket conveyor to unload the mixture into each hopper. Thereafter, the mixture is distributed to the associated tray portions 27 and 28, after which the tray portions 27 and 28 slide over the formwork to unload the mixture into the formwork.

In addition, the formwork assembly is equipped with a vibrating device (not shown), so that the vibrating device is operated to impart vibrational motion to the formwork to facilitate filling of the formwork and to improve compression molding. The ram head is then lowered into the formwork to further compression mold the base mixture such that a cavity of approximately 15 mm is left between the top of the formwork and the base mixture. The filling process, vibration and initial compression molding process takes about 10 seconds to complete. Thereafter, the ram head is raised and the surface mixture previously unloaded to the tray portion 28 is disposed on top of the substrate mixture with the reflective material. If necessary, additives and additional binders may be provided to the cavity prior to addition of the surface mixture. The ram head is lowered again and vibratory compression molding forces are applied to compress the base mixture and the surface mixture. The hydraulic pressure of the ram head is preferably operable to provide a simple harmonic vibration of less than 3,600 rpm with the maximum compressive force exerted on the block mixture on the order of 120 bar (122.kgf / cm ² ). It takes approximately four seconds to fill the formwork with the surface mixture, and subsequent compression molding lasts approximately four to six seconds. Therefore, the formwork assembly can execute approximately five working cycles per minute.

The resulting block is separated from the formwork in the form shown in FIG. 3, where the thickness T of the compression molded substrate element 32 is, for example, about 80 mm, and the thickness t of the surface layer element 33 is, for example, 10 mm or more. . The specific structure and block size can vary as desired, but the length of the block (L) is about 200 mm and the width (W) is about 100 mm.

The blocks can be separated directly from the formwork over pellets 37 as shown in FIG. 4, which are conveyed to racks via conveyors, which are separated by a forklift and placed in the curing chamber. Curing may take 8 to 12 hours, after which the block will solidify sufficiently for handling and packaging. Pellet can be facilitated by passing pellets down the fastening device 38 that clamps the blocks together from four opposite sides, which blocks are densely positioned to bind and pack as at the point shown by reference numeral 39 .

As can be appreciated, the aforementioned method of operation has been described in connection with an automated process. However, any of the manufacturing processes can be performed manually instead. In addition, the formwork and the ram may be configured to form one block or a plurality of blocks as a single work cycle. The shape and structure of the blocks can be defined by the user so that the apparatus of the present invention can produce blocks for various different purposes. For example, reflective blocks made in accordance with the present invention may be used as directional arrows, dividing lines, double yellow lines or white lines, road humps, numbering or wording, curb or road pavement materials in a driveway. It can be produced in the required color, such as white, yellow or red. If desired, the block can also be manufactured without reflective material.

However, the most important advantage is that the blocks are manufactured using dry forming techniques combined with compression molding, which makes the curing time much shorter than that associated with wet forming, while published in 1993. This is because it meets the compressive strength requirements listed in BS 6717, Part 1, to improve production rates and production efficiency.

Finally, the concept of the invention may be inherent in many other structures in any aspect, and thus the general idea of the foregoing description is not limited to the specific idea of the accompanying drawings. Various changes, modifications, or additions may be incorporated into various structures and devices without departing from the spirit or scope of the invention.

Claims (10)

As a method of manufacturing a concrete block, Preparing a base mixture having a water / cement ratio of 0.35 or less; Pouring the base mixture into a formwork; Pressurizing the mixture by applying vibrational compression molding force; Including but not limited to: Prior to applying the compressive molding force, pressurizing the base mixture to create a recess formed by the base mixture and the formwork in which the surface mixture is poured; A method for producing a concrete block in which the surface mixture is injected into the formwork and pressurized both the substrate mixture and the surface mixture before applying the compression molding force. The method of claim 1 wherein a binder is provided between the base mixture and the surface mixture prior to compression molding. 3. The method of claim 1 or 2, wherein the surface mixture comprises a reflective material. A method according to claim 1 or 2, wherein the surface mixture is provided with reflective material on its surface prior to compression molding. The method of claim 1 or 2, wherein the base mixture is vibrated before applying compression molding to improve the filling of formwork and subsequent compression molding. The concrete according to claim 1 or 2, wherein the preparing of the base mixture comprises mixing cement with granite crumbs up to 9 mm in diameter and sand particles up to 5 mm in diameter to improve the bondability of the blocks. Block manufacturing method. An apparatus for executing the method according to claim 1, A mixing device for forming the base mixture and the surface mixture; A formwork assembly comprising a formwork and a feeder for receiving the base mixture and the surface mixture and transferring the base mixture and the surface mixture to the formwork; A ram device applying compression molding force to the mixture held in the formwork; Concrete block manufacturing apparatus comprising a. 8. The apparatus of claim 7, wherein the formwork assembly comprises a vibrating device for vibrating the formwork to improve the filling of the formwork and subsequent compression molding. 10. The apparatus of claim 7 or 8, wherein the ram device is adapted to apply vibrational compression molding force. 9. The feeder according to claim 7 or 8, wherein the feeder has two portions for holding the base mixture and the surface mixture, respectively, wherein the feeder separately distributes the base mixture and the surface mixture in two portions disposed on opposite sides of the formwork. The concrete block manufacturing apparatus which is arrange | positioned so that it may be alternately displaced on a formwork.