NZ203766A - Brick moulding apparatus: die between two movable platens - Google Patents

Description

NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION AFTER PROVISIONAL NO; 203766 DATED: 31 March 1983 IMPROVEMENTS IN AND RELATING TO THE FORMATION OF SETTABLE M ATERIAL I, JOHN HASTINGS D'OYLY SNOW, of 1623 Great North Road, Auckland, New Zealand, a British subject and New Zealand citizen, do hereby declare the invention for which I pary that a patent may be granted to me and the method by which it is performed to be particularly described in an by the following statement: 203766 This invention relates to improvements in relation to formation of articles in settable material and more particularly to an apparatus and method of operation for forming articles in settable material, for example, concrete blocks such as spacer blocks.

In the past, concrete spacer blocks have been formed according to an essentially frianual method of operation by merely pouring mixed concrete into mould boxes, hammering the box or vibrating the concrete and allowing the material to set. In most other production techniques apparatus has been provided to mechanise production however, there have been significant problems in handling settable material when forming concrete blocks, such as spacer blocks.

Machinery for achieving the mechanisation has been hitherto substantially complicated in construction and therefore expensive to produce and maintain and further more, the machinery has been relatively slow and inefficient in operation and has not provided blocks of a high degree of strength and compressive accuracy without skilled operators and skilled supervision.

It is an object of this invention to come some way in overcoming the abovementioned problems or at least to come some way in overcoming the abovementioned problems or at least provide the public with a useful choice.

Other objects of this invention become apparent from the following description. 203766 According to one aspect of this invention there is provided a forming means for forming settable material including a first platen opposed to a second platen, said platens movable in a common plane relative to each other and to a die defining an open ended die cavity, said die cavity positioned between said first and second platen, filling means provided to at least partially fill said die cavity with the settable material, a portion of said second platen movable to adjacent said die cavity to close a second open end thereof, a portion of said first platen movable toward and into said die cavity through an opposite first open end thereof to at least partially compress said settable material; said first and second platens movable relative to said die cavity at substantially constant pitch whilst said portion of said first platen passes into said die cavity to move the settable material in said die cavity outwardly thereof in contact with the portion of the second platen.

According to a further aspect of this invention there is provided a method of moulding settable material in a die cavity defined by a die positioned between opposing first and second platens, including the steps of moving said second platen toward said die to position a portion thereof adjacent a second open end of said die cavity, to positioning said 20376 « settable material in said die cavity so that it assumes a shape corresponding to said die cavity, to discharging said moulded settable material to form said cavity by moving said first and second platens in unison at a predetermined and substantially constant pitch, portions of said first platen moving through at least a part of said mould cavity from an opposite first open end thereof to extrude said moulded settable material from said second open end thereof.

Other aspects of this invention which should be considered in all its novel aspects will become "N apparent from the following description. Modifications are envisaged and may be incorporated without departing from the scope of the invention as defined in the appended claims.

One form of the invention will now be described with reference to the accompanying drawings which show three general phases of operation of the apparatus of this invention according to the method described hereinafter.

The apparatus is in this form of the invention preferably fabricated from substantially robust material such as steel or other metals and in this preferred form of the invention is electro-pneumatically controlled however, it is to be understood that the actual means of control is non-essential to the 203766 I invention and that the operation and control of the device could be provided by alternative means such as by hydraulic, mechanical or electric/electronic means.

The form of the invention described is intended for multiple manufacture of concrete spacer blocks in a multiple die cavity, the drawings depict a die having a pair of die cavities however it is to be appreciated that the number and shape of the die cavities is again inessential to the invention.

The apparatus of this invention is preferably supplied with mixed concrete material when forming spacer blocks from a hopper or shute. The invention is particularly suited to batch operation, using batches of settable material, however, the invention is not limited to this configuration and ±1 alternative forms it is also to be appreciated that a continuous feeding process of settable material can be provided.

Whilst the invention is described with reference to the use of concrete as a settable material, it is to be appreciated that all forms of settable material could be utilized by the method and apparatus of this invention described hereinafter.

The drawings are identified hereinafter: Figure 1; is a substantially diagrammatic side view of the apparatus of this invention showing the initial filling 20376 • phase of a die and showing a transfer means in a filling position.

Figure 2; is a further substantially diagrammatic side view of the apparatus in a subsequent phase of operation showing the transfer means in a retracted position and compression of the settable material in the die cavities Figure 3: shows a subsequent phase of operation including extrusion of moulded articles from the die cavities It is to be appreciated that whilst the invention in this form of the invention is described with reference to a substantially upright plane of operation, it is to be appreciated that in alternative forms of the invention the plane of operation could be other than upright, for example horizontal or inclined.

With reference to the drawings, the apparatus as generally indicated by arrow 1 is preferably electro-pneumatically operated, controlled by a series of sequences switching means (not shown) so that upon completion of one sequence of events, the next sequence is set into operation so that the apparatus can be continuously for semi-continuously operated with a minimum of supervision.

The apparatus 1 includes a frame 2 which is preferably formed in substantially robust material, 10370 I for example rolled.hollow section mild steel and the like, however, alternative material can be utilized. The frame 2 in this preferred arrangement is arranged in a generally upright plane and mounts a pair of preferably (although not essentially) co-axially aligned rams 3 arranged to oppose one another. The first ram 3a is provided to extend and retract an upper platen 4 and lower ram 3b is provided to extend and retract a lower platen 5. Each ram 3 is operable to move the platens 4 and 5 toward and away from a die 6 positioned between said rams 3a and 3b in a path of said platens 4 and 5.

In fais preferred form of the invention, the die 6 is resiliently mounted to portions 2 of said frame via resilient (rubber) mounting blocks 7 and further, the die 6 is vibratable via vibrating means 8 which in this form of the invention are provided in the form of a fluid motor connected to said die 6, said motor supporting an eccentric weight 9 thereon such that upon operation of said prime mover, the eccentric 9 causes vibration of said die 6 on its resilient mountings 7.

The die 6 is provided with a plurality of die cavities 10 shown by broken lines. The die cavities 10 are of course shaped to suit the required cross section of the block to be produced and are each open ended providing an upper or first open end 10a and a lower or second open end 10b. Correspondingly 203766 4 formed platen portions 4a are provided on the first platen 4, so shaped as to fit within the mould cavities 10 in a relatively close fit however leaving a working tolerance. Preferably bores or grooves 11 are provided in a front operative face 4b of the portions 4a extending through the portions 4a and terminating remotely from the front face (in this case a rear face) in this form, preferably a number such as four holes are provided in the platen 4 however in alternative arrangements, a groove or series of grooves are provided in the front face 4b extending to side edges of the portion 4a.

Preferably the portions 4a of the first platen 4 are arranged on elongate shafts 12 mounted from a base portion 4c of the platen 4, the shafts 12 being of sufficient length that the portion 4a can extend right through the die cavity 10 and extend outwardly of a lower or second open end 10b of the die cavity 10, in the position as shown in figure 3.

In this form of the invention, preferably the die 6 is provided in suitably durable robust material such as steel with the mould cavities defined by fabricated or cast cavities and further, preferably, the portions 4a or indeed, the whole platen 4 is removable and the die 6 is correspondingly interchangeable so tiat articles of differing shapes can be moulded in the apparatus of this invention. 203766 * Transverse hole forming means 15 are preferably provided to one side of the die 6 and operate through bores 16 provided in a side wall of the die 6 aligned with the die cavities 10 and extending through the die substantially transversely of a longitudinal line of the die cavity 10.

The transverse hole forming means 15 are associated with a transverse bore forming ram 17 which is connected with at least one and preferably a plurality of rods 18 (commensurate with the number of cavities 10 and bores 16 provided in the die) which are mounted to the die 6 via bushes 19. An extension of the transverse bore forming ram 17 causes the rod/s 18 to extend through the apertures 16 and across the die cavities 10 at the predetermined position as is shown by figure 2.

In the preferred form of the invention, as the die 6 is inter-changeable, it is to be appreciated that in normal conditions, said die 6 and transverse bore forming assembly 15; at least as far as the rods 18 and bushes 19 are concerned, is provided in a single assembly.couplable to the transverse bore forming ram 17.

Transfer means as generally indicated by arrow 20 are provided to move settable material from a storage hopper 21 positioned in the frame and fed from a shute 22 to the die cavities 10. 203766 In this form of the invention, the transfer means 20 is provided in the form of a transversely movable box member having a substantially open bottom and open top and movable on a plate 23 aligned with the upper open ends 10a of the die cavities 10 and upon rails aligned therewith (not shown). An upper portion of the transfer means 20 has a shut-off plate 24 extending to one side thereof which shuts off the lower end of the hopper 21 when the transfer means 20 is in the extended position as is shown in figure 1 positioned over the die 6. When in the retracted position the transfer means 20 refills from the hopper 21.

Further, preferably the cross-sectional dimensions of the box transfer means; when viewed in plan, and also, in this form, the hopper 21 are so provided as to be slightly less than the dimensions of the next lower adjacent unit; the transfer box 20 in relation to the hopper 21 and the die cavities 10 in relation to the transfer box 20, so that it will be appreciated material partially consolidated within the hopper 21 or the transfer means 20 can readily slip therefrom when required.

The rest portion for the transfer box is retracted, away from the die 6 substantially as is shown by figures 2 and 3.

The lower or second platen 5 is provided with a locking means as generally indicated by arrow 30, the locking means 30 is 20376 in this form of the invention provided by a pair of downwardly depending rods 31 extending a predetermined distance from said lower or second platen 5, actuable cam locking means 32 being provided, actuable by cam rams 33 to move locking dogs 34 beneath lower end portions 35 of the rods 31 when the lower or second platen 5 is in an extended or raised position, that is, when the platen 5 closes off the lower or second open ends 10b of the cavity 10. The rod 31 length is adjustable.

It will be appreciated that with the locking means 30 in locking position, compression placed upon the lower or second platen 5 is taken by the frame 2 rather than the hydraulic or pneumatic system of the lower ram 3b.

The lower or second platen 5 is in this preferred form of the invention provided with the portion 5a thereof provided to lie adjacent and to substantially close off the lower open end 10b of the cavities 10 when in an extended position.

In this form of the invention, the portion 5a is provided in the form of a panel or board hereinafter referred to as a mould board 5a. Preferably, the mould board 5a is of a size substantially commensurate with the die 6 and slightly larger than the die cavities 10 so that the mould board 5a can readily provide the closure for the lower or second open end 10b and further, support moulded articles thereon. 203766 t In the preferred form of the. invention, a magazine apparatus 40 is provided for holding a plurality of mould boards 5a in a stacked relationship and a discharge means 41 in the form of a discharge ram coupled with suitable sequential circuitry to the remainder of the apparatus is provided to discharge a lower most board 5a in the magazine 40 outwardly along a support rail 42 for passing on to the remaining portions of the platen 5 when it is in a retracted position as shown by figure 3.

It will be appreciated that action of the discharge means 41 causes both loading and discharging of mould boards 5a from the lower or second platens when it is in the retracted position.

In this form of the invention, the rods 31 are provided of such a length that end portions 35 contact frame portion 2 adjacent the base of the frame 2 to thus cause the lower or second platen 5 to position in register with support rails 42 when in a retracted position such as shown in figure 3. Adjustment means is provided to enable fine adjustment of the positioning of the platen 5 when in the retracted position.

Operation of the invention as hereinbefore described will now be outlined with reference to figures 1, 2 and 3.

The apparatus of this invention is provided with premixed settable material through the shute 22 into 20376 th e hopper 21 wh'en the transfer means 20 is in the retracted position beneath the hopper 21 and thus the transfer means 20.

The cycle commences with the second or .lower ram 3 moving, to position the platen 5 with a mould board 5b positioned thereon to position an upper surface of the mould board 5b adjacent an underside of the die 6 to close off the second open ends 10b of the die cavities 10.

The locking means 30 then actuate and the lower or second platen 5a is thus held in the extended position.

Thereafter, transfer box 20 moves over the die 6 and the settable material tends to fall into the die cavities 10 and is supported by the platen 5 (in particular the mould board 5a) subsequent actuation of the vibrating means 8 causes the die cavities 10 to fill with settable material, the transverse bore forming means 15 operate to exctend rods 18 transversely of the die cavities 10, if transverse apertures are required. After vibration of the die 6 the transfer means 20 retracts to the rest position and leaving the cavities 10 filled; a trailing lower edge of the transfer means box slices off the excess settable material in the cavities 10 adjacent the upper open end 10a. A brush, or cleaning means 50 can be optionally provided on an upper trailing edge of the transfer means 20 to brush or.otherwise clean faces 4b of the platen portions 4a and maintain them clean however this is not 203 7 6 essential to the'invention.

Thereafter, the upper ram 3a operates to bring the upper or first platen 4 downwardly and for portions 4a to impinge upon the upper surface of the material in the die cavities 10. Once in position, the die 6 is again vibrated. During the vibration, some compression of the settable material between the upper platen 4 and lower platen 5 takes place so that a degree of consolidation of the material is achieved. The cycle at this stage-is as is shown in figure 2.

A momentary release of the compression by the first or upper platen 4 enables retraction of the transverse bore forming rods 18 and the locking means 31. Thereafter, a simultaneous movement in unison of the upper or first platen 4 and lower or second platen 5 takes place such as is shown by the embodiment of figure 3 whereby the upper or first platen 4 extends and lower or second platen 5 retracts at a constant pitch or distance relative to one another (commensurate with the distance between the platens 4 and 5 after termination of vibration of the material in the die cavities) and thus it will be appreciated that the settable material is extruded in the moulded form outwardly of the lower or second open 10b of the die 6, supported by the mould board 5b until such time as the upper or first platens 4 reach the lower or second open ends 10b. The upper 203766 or first platen 4 then returns to its retracted position.

In its retracted position, the lower or second platen 5 aligns with the rails 42 and the discharge means 41 actuates to load a further mould board 5a onto the platens 5 and in the process discharges the mould board 5a with the mould article thereon on to the rail 42 on the opposite discharge side of the platen 5. The cycle then recommences.

An alternative embodiment of the invention (not shown) provides for the die 6 to be reciprocably movable in the frame 2 relative to the supply of settable material and the line of operation of the rams 3. In this arrangement, the die 6 is movable 1 on a suitable plate or the mould board 5a thereunder shutting off the lower or second open ends 10b.

The transverse bore forming rod assembly 15 is also provided to be correspondingly movable or alternatively, is positioned to an opposite side of the die 6 so that the die 6 can move away from the transverse bore forming assembly 15 to beneath the filling assembly and thereafter returns to between the platens 4 and 5 completion of the formation.

Thus by this invention there is provided a method and apparatus for moulding articles in settable material in a substantially continuous or semi-continuous prcoess.

Claims (31)

203766 16 WHAT JffE CLAIM IS:

1. A forming means for forming settable material including a first platen opposed to a second platen, said platens movable along a common axis relative to each other and to a die defining an open ended die cavity, said die cavity positioned between said first and second platen, filling means provided to at least partially fill said die cavity with the settable material, a portion of said second platen movable to adjacent said die cavity to close a second open end thereof, a portion of said first platen movable toward and into said die cavity through an opposite first open end thereof to at least partially compress said settable material; said first and second platens movable relative to said die cavity at a substantially constant pitch whilst said portion of said first platen passes into said die cavity to move the settable material in said die cavity outwardly thereof-

2. Apparatus as claimed in Claim 1 wherein the first platen is movable relative to the second platen whilst it closes the second open end of the die cavity.

3. Apparatus as claimed in Cliaim 1 or Claim 2 wherein the portion of the first platen is shaped to correspond with the die cavity. 203766 17

4. Apparatus as claimed in any one of the preceding claims wherein the common axis of said first and second platens is substantially upright, said settable material movable from said die cavity in a downward direction supported by said second platen.

5. Apparatus as claimed in any one of the preceding claims wherein said filling means includes a vibrating means for vibrating said die to assist in filling said die cavity with the settable material.

6. Apparatus as claimed in any one of the preceding claims wherein the filling means includes a transfer means positionable above the die for transferring the settable material to adjacent the die cavity.

7. Apparatus as claimed in Claim 6 wherein the transfer means is provided of small internal cross-sectional area than the die cavity.

8. Apparatus as claimed in Claim 6 or Claim 7 wherein the transfer means has tapered internal faced reducing internal dimension away from a discharge opening therein.

9. Apparatus as claimed in any one of the preceding claims 6, 7 8 wherein the transfer means includes an open ended box fillable with thesettable material and movable over the die.

10. Apparatus as claimed in any one of the preceding Claims 6 to 8 wherein the die is movable under the transfer means for the filling of the die cavity. 203766 18

11. Apparatus as claimed in any one of the preceding claims wherein the portion of the first platen is provided with at least one hole or groove extending from an operative face thereof to a portion remote thereof.

12. Apparatus as claimed in any one of the preceding claims wherein the die and/or at least the portions of the first platen are removable from remaining portions of the apparatus.

13. Apparatus as claimed in any one of the preceding claims wherein a locking means is provided to lock the second platen in an extended position at least during the at least partial compression phase of said settable material by said first platen.

14. Apparatus as claimed in any one of the preceding claims wherein the abovementioned portion of the second platen is removable from remaining portions of said second platen.

15. Apparatus as claimed in Claim 14 wherein said removable portion is a mould panel or board mountable on the remaining portions of said second platen, a magazine being provided to hold a plurality of mould panels or boards, transfer means provided to feed said mould panels or boards from said magazine to said second platen.

16. Apparatus as claimed in any one of the preceding claims wherein at least the die is resiliently mounted to remaining portions of the apparatus.

17.Apparatus as claimed in any one of the preceding ___ 203766 19 claims wherein hole forming means are provided to coact in a bore through a wall of said die into said die cavity, said hole forming means including at least one rod member extensible through said bore to form a hole in the settable material.

18. A method of moulding settable material in a die cavity defined by a die positioned between opposing first and second platens, including the steps of moving said second platen toward said die to position a portion thereof adjacent to a second open end of said die cavity, positioning said settable material in said die cavity so that it assumes a shape corresponding to said die cavity, discharging said mould settable material from said cavity, moving said first and second platens at a predetermined and substantially constant pitch, portions of said first platen moving through at least a part of said die cavity from an opposite first open end thereof to extrude said moulded settable material from said second open end thereof.

19. A method as claimed in Claim IS including the step of vibrating said settable material in said die cavity.

20. A method as claimed in Claim 19 including compressing said settable material in said die cavity between the opposing portions of said first and second platens prior to extruding said settable material from said second open end. 203766 20

21. A method as claimed in any one of Claims 18, 19 or 20 wherein the step of positioning said settable material in said die cavity includes the step of positioning a transfer means holding said settable material over said die cavity.

22. A method as claimed in Claim 21 including the step of moving said transfer means over said die cavity with said second open end of said die cavity closed.

23. A method as claimed in Claim 21 including moving said die cavity beneath the transfer means with said second open end of said die cavity closed.

24. A method as claimed in any one of the preceding Claims 18 to 23 including forming a transverse aperture in said settable material whilst positioned in said die cavity by passing a rod through said settable material.

25. A method as claimed in any one of the preceding Claims 18 to 24 including the step of providing as the abovementioned portion of said second platen a removable panel or board mountable on the remaining portions of said second platen and supporting said moulded settable material on said panel or board after extrusion from said die cavity.

26. A method as Claimed in Claim 25 including tbestep of providing a plurality of panels in a magazine and providing a transfer means to transfer each said panel from said magazine to said remaining portions of said second platen. 203766 21

27. A method as claimed in any one of the preceding Claims 18 to 26 including the step of supporting said moulded settable material extruded from said second open end by said second platen at least during a partial retraction of said first platen.

28. A method as claimed in Claim 20 or any one of the preceding Claims 21 to 27 when dependant on Claim 20 including locking said second platen in an extended position at least during compression of said settable material in said die cavity.

29. A method as claimed in Claim 28 including releasing the compression by said first platen temporarily during retraction of said lockiig means.

30. Apparatus as hereinbefore described with reference to the accompanying drawings.

31. A method as hereinbefore described with reference to the accompanying drawings. JOHN HASTINGS D'OYLY SNOW, BY HIS ATTORNEYS, BALDWIN, SON & CAREY.