WO2021062531A1

WO2021062531A1 - System and method for the formation of irregular veining on concrete blocks

Info

Publication number: WO2021062531A1
Application number: PCT/CA2020/051299
Authority: WO
Inventors: Jonathan Wayne PIGNATELLI
Original assignee: Best Way Stone Limited
Priority date: 2019-09-30
Filing date: 2020-09-29
Publication date: 2021-04-08

Abstract

A roller for use with a concrete filler box, for use in the manufacture of concrete blocks, wherein the roller has a discrete surface profile, wherein when the roller makes contact with a surface of the concrete block during production thereof, the roller provides for an irregular veining on the surface of the concrete block; the roller having a first end, a second end and a cylindrical body spanning between the first and second end; the cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof.

Description

TITLE

SYSTEM AND METHOD FOR THE FORMATION OF IRREGULAR VEINING ON

CONCRETE BLOCKS

FIELD OF THE DISCLOSURE

This relates to a method and system for the formation of irregular coloured veining on concrete blocks wherein the irregular coloured veining replicates the look of veining in natural stone, marble, granite and the like.

BACKGROUND

The production of concrete blocks is known in the art. Concrete block production with simple veining (substantially straight line veins) running along the length of the concrete block is known.

A typical process involves the addition of powdered colouring agents introduced to the surface of a concrete block near the end of the production phase and blending the powdered colouring agents onto the surface of the concrete block. The process results in a concrete block with a coloured surface resembling simple veining.

Another process involves the use of wet colouring agents introduced in the concrete mix and a smooth roller is applied along the surface of the concrete block spreading the wet colouring agents along the length of the concrete block resembling simple substantially straight line veining.

It would be advantageous to have a system and method to introduce irregular coloured veining on concrete blocks that replicate the look of naturally occurring irregular (more complex) veining as found in natural stone, marble, granite and the like.

SUMMARY

According to one aspect, there is provided a textured roller for use with a concrete fdler box, in one alternative a face-mix concrete fdler box, in another alternative a through-mix concrete fdler box, for use in the manufacture of concrete blocks with an irregular veining pattern resembling naturally occurring veining found in natural stone, marble, granite, and the like, wherein said roller comprises a discrete surface profde, wherein when said roller makes contact with a surface of said concrete block during production thereof, said roller, while rotating on its own axis and simultaneously moving along the length of said concrete block delivers and distributes said concrete mix with at least one colouring agent into said concrete block mold in a longitudinal and lateral manner (i.e. diagonal manner) due to the surface profile of said roller, providing for an irregular veining effect of said concrete block, in one alternative an irregular veining effect on said surface of said concrete block. In one alternative, said textured roller comprises a first end, a second end and a cylindrical body spanning between the first and second end. Said cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof. In another alternative, said surface profile is concave to said cylindrical body surface. In another alternative, said surface profile is convex to said cylindrical body. In yet another alternative, said surface profile comprises concave and convex regions. In yet another alternative, said surface profile has a pitch that may be selected to replicate a desired veining of a natural stone or the like.

In yet another aspect, there is provided a process to create irregular veining of a concrete block, in one alternative on a surface of a concrete block, during the manufacture thereof by a concrete filler unit, in one alternative a face-mix concrete filler box, in another alternative a through-mix concrete filler box, said process comprising: i) Adding concrete mix with at least one colouring agent to a concrete form, preferably a static concrete form, via a hopper on a filler box situated above said concrete form, preferably a movable filler box, movable along the top of said static concrete form, forming a wet concrete block with a surface; ii) Applying vibration to said concrete form; iii) Adding at least one irregular vein to said surface of said concrete form via a roller on said filler box and situated proximate said surface; said roller comprising a first end, a second end and a cylindrical body spanning between the first and second end. Said cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof, wherein said filler box along with said roller transverses the surface of said concrete block in said static concrete form, and travels along the surface while said roller is rotating wherein said rotation of said roller on said surface distributes said concrete mix with colouring agents along said surface resulting in an irregular veining on said surface; said irregular veining will vary depending on the speed and direction of rotation of said roller in relation to the speed of travel of said filler box along said surface of said concrete block mold. In yet another alternative, there is provided an irregular veining unit for retrofitting onto an existing concrete block forming system. Said irregular veining unit comprising a textured roller for use with a concrete filler box, in one alternative a face-mix concrete filler box, in another alternative a through-mix concrete filler box, for use in the manufacture of concrete blocks with an irregular veining pattern resembling naturally occurring veining found in natural stone, marble, granite, and the like, wherein said roller comprises a discrete surface profile, wherein when said roller makes contact with a surface of said concrete block during production thereof, said roller, while rotating on its own axis and simultaneously moving along the length of said concrete block delivers and distributes said concrete mix with at least one colouring agent into said concrete block mold in a longitudinal and lateral manner (i.e. diagonal manner) due to the surface profile of said roller, providing for an irregular veining effect of said concrete block, in one alternative an irregular veining effect on said surface of said concrete block. In one alternative, said textured roller comprises a first end, a second end and a cylindrical body spanning between the first and second end. Said cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof. In another alternative, said surface profile is concave to said cylindrical body surface. In another alternative, said surface profile is convex to said cylindrical body. In yet another alternative, said surface profile comprises concave and convex regions. In yet another alternative, said surface profile has a pitch that may be selected to replicate a desired veining of a natural stone or the like.

In another alternative, there is provided an irregular veining system for retrofitting an existing block making system with an irregular veining block making system. Said system comprising a hopper extension comprising a top, bottom, two side walls, a front wall and a back wall, wherein the top and bottom are open; wherein the front wall, back wall and two side walls matingly engage the end of a hopper proximate a concrete block mold;

A colouring agent placement roller having two ends, each one of said two ends being rotatably attached to each one of said two side walls;

A rotator for rotating said roller;

Said rotator being programmable to regulate the speed and rotational direction of said roller;

Said roller having a profiled surface comprising at least one peak and at least one valley along the length thereof; in one alternative, said roller comprising at least one helical profile running along a length thereof; in another alternative, said roller comprising at least a double helical profile running along a length thereof; in yet another alternative, said roller comprising a parallel double helical profile; in yet another alternative, said roller comprises a transversing double helical profile.

In one alternative, said programmable rotator allows for the activation/deactivation of rotation of said roller during the travel along the length of said concrete block mold.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a cross sectional view of a system with a PRIOR ART roller

Figure 2 is a side view of a roller according to one alternative

Figure 3 is a side view of a roller according to another alternative

Figure 4 is a side view of a roller according to another alternative

Figure 5 is a side view of the profile of the roller according to several alternatives

Figure 6 is a cross sectional view of a system with two rollers according to another alternative

Figure 7 is a perspective view of the hopper extension, in one alternative

Figure 8 is a top view of the hopper extension, according to one alternative

Figure 9 shows the hopper extension matingly engaged into the filler box.

DETAILED DESCRIPTION

Referring now to FIG. 1 there is shown a cross section of a concrete block forming system 10 with a funnel shaped silo 20 for holding concrete material to be released over static concrete form 30 when forming concrete blocks. When the silo 20 and carriage 40 is moved over the concrete form (or mold) 30, the concrete material in the silo 20 is released into the carriage 40 and released into the voids 31 of the form 30 to fill same. The system 10 may allow for vibration (not shown) of the filled form 30 (or filled mold) to allow for any gas bubbles in the concrete to rise to the surface and be released. Any vibration means or system known to persons of ordinary skill may be incorporated herein. Carriage 40 when returning to the start position allows for PRIOR ART smooth surface cylindrical roller 50, situated at one edge of the carriage 40, to roll over the surface of the concrete fdled forms. PRIOR ART smooth surface cylindrical roller 50 is situated at one edge 42 of the carriage 40 and has an axis of rotation transverse the direction of travel of the carriage 40 (indicated by the bidirectional arrows). PRIOR ART smooth surface cylindrical roller 50 is also situated such that the surface of PRIOR ART smooth surface cylindrical roller 50 makes contact with the concrete surface of the concrete fdled forms. The smooth surfaced PRIOR ART smooth surface cylindrical roller 50 is able to rotate in any desired direction and speed. The smooth surfaced PRIOR ART smooth surface cylindrical roller 50 upon rolling over the surface of the concrete fdled forms, results in a coloured concrete block with simple linear veins on the surface thereof running parallel to the direction of travel of the carriage 40.

Carriage 40 has an open bottom such that when positioned over the mold 30, it allows the release of concrete into the mold 30. When not over the mold 30, carriage 40 sits on platform 60.

The mold 30 comprises, in one alternative, at least one partition 32 for the preparation of at least two concrete blocks per mold. The process is such that the concrete from silo 20 fdls the interior space of carriage 40. Carriage 40 is then moved over mold 30. Through the open bottom of the carriage 40 concrete falls from the concrete holding area 43 of carriage 40 into the mold 30.

Upon releasing the concrete into the mold 30, the emptied carriage 40 is then moved back to its position under the outlet of the silo 20.

Smooth surface cylindrical PRIOR ART roller 50 is then rolled over the surface of the concrete fdled mold. The roll axis of the PRIOR ART smooth surface cylindrical roller 50 lies transverse to the travel of the carriage 40. PRIOR ART smooth surface roller 50 may be replaced with surface profded roller 50’, having at least one peak and valley on the surface thereof to result in concrete blocks with irregular veining which mimic natural veining.

Referring now to FIG. 2 there is seen a side view of a roller 50’ of the present disclosure.

Roller 50’ seen herein has a surface 52 that is helical in profde with the helix 500 starting at a first end 54 of the roller and ending at the second end 55 of the roller. This helical surfaced roller when rolled over the mold results in a veining that is irregular non-linear and random simulating naturally occurring stone.

FIG. 3 depicts a roller 50’ with a surface with a parallel double helix 510 profde.

FIG. 4 depicts a roller 50’ with a surface with a transversing double helix 520 profde. FIG. 5 depicts a section of the roller 50’ wherein the surface profile extends outward 530 from the surface FIG. 5(a) and in another alternative extends inward 540 into the surface FIG. 5(b). The non-smooth discrete profiled surface results in a veining of the concrete surface that is more close to the veining encountered in naturally occurring stone, marble granite and the like.

The non-smooth profiled roller may be located at the end of the unit (as depicted in FIG. 1) or the roller may be situated anywhere along the carriage 40 bottom.

In one alternative, the systemlO may comprise a smooth roller 50 and anon-smoothed profiled roller 50’. In another alternative, the smooth roller 50 is situated proximate the end of the carriage 40 (as per FIG. 1) and the non-smooth profiled roller 50’ is situated within the carriage 40 proximate the outlet of the silo (see FIG. 6).

The roller 50’ may be adjustable in height to accommodate different surface veining as desired. Further, the positioning of the roller 50’ is selected such that it rolls over the entire width of the mold 30 in order to obtain a veinous surface over the entire surface of the concrete in the concrete mold 30. Roller 50 may be manually adjustable to allow for a desired amount of coloured concrete on the mold surface. Roller 50’ may be adjustable to allow for a variance in veining effect (such as but not limited to a more define veining effect or softer muted veining effect). This may be more prominent when roller 50’ is inside the filler box carriage 40 followed by the smooth planning roller 50.

The roller 50’ may be designed as a pressure-resistant roller as known to a person skilled in the art. The roller 50’ rolls over the surface of the concrete with a certain pressing force. The roller 50’ in one alternative, may have a hard surface. In another alternative, it may have a soft surface. In yet another embodiment, the surface may be a combination of a hard and soft surface. The surface of the roller 50’ may be made of metal, plastic and combinations thereof. The roller 50’ may rotate independent of the carriage 40. Roller 50’ may rotate contrary to the path of travel of the carriage 40. Roller 50’ may also be moved along the surface of the concrete with no rotation of the roller 50’. The user determines the configuration to be implemented dependent on the desired veining on the surface of the concrete.

The roller 50’ may be driven alternatively with a selectable rotation speed. The surface of roller 50’ may be treated to avoid adhesion of concrete to the surface thereof.

The direction of rotation of roller 50’ also provides for reducing the possible build-up of concrete material at one end thereof (i.e. reversing the direction of rotation compensates for the unused (undelivered) material at one end thereof.

In one alternative, roller 50’ may be flush with the surface of the mold. In another alternative, roller 50’ may be a distance from the surface of the mold. In one alternative, the distance from the outermost point of the roller 50’ to the surface of the mold may be between 0 to about 40 mm.

In one alternative, the outermost distance of the roller 50’ to the inside of the front and back plate may be from 0 to about 85 mm.

FIG. 6 depicts the system of FIG. 1 with the added non-smooth profded roller 50’ situated below the exit of silo 20 and before smooth roller 50. The system 10 functions as per the system depicted in FIG. 1 except the addition of non-smooth profded roller 50’ allows for the irregular veining on the concrete block surface. Although FIG. 6 depicts the combination of a smooth roller 50 and non-smooth roller 50’, the system may contain the non-smooth roller 50’ on its own.

In another alternative, powdered colour or liquid colour is not added to the concrete block surface, but rather the concrete mix is coloured or pre-coloured throughout the mix. In this instance with the roller 50’ inside the fdler box carriage 40 as per FIG. 6, veining may be achieved not only on the concrete block surface but under the surface, preferably throughout a depth of the mold, resulting in veining that may be seen on the side of the concrete block when de-molded.

Referring now to FIG. 7, the hopper extension is shown with the side walls trapeziodal in shape and the back wall following the shape of the trapezoidal side walls.

Referring to FIG. 8, the hopper extension is shown with the roller of the present invention inside the hopper extension.

FIG. 9 depicts the retrofd hopper inserted into the fdler box.

As many changes can be made to the preferred embodiment of the invention without departing from the scope thereof; it is intended that all matter contained herein be considered illustrative of the invention and not in a limiting sense.

Claims

1. A roller for use with a concrete filler box, for use in the manufacture of concrete blocks, wherein said roller comprises a discrete surface profile, wherein when said roller makes contact with a surface of said concrete block during production thereof, said roller provides for an irregular veining on said surface of said concrete block; said roller comprising a first end, a second end and a cylindrical body spanning between the first and second end; said cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof.

2. The roller of claim 1 wherein said concrete filler box is selected from the group consisting of face-mix, through-mix and combinations thereof.

3. The roller of claim 1 or 2 wherein said roller surface profile is selected from the group consisting of concave to said cylindrical body surface, convex to said cylindrical body and combinations thereof.

4. The roller of claim 1 or 2 wherein said roller surface profile comprises concave and convex regions.

5. A process to create irregular veining on a surface of a concrete block during the manufacture thereof by a concrete filler unit, said process comprising: a. adding concrete mix with colouring agents to a concrete form, preferably a static concrete form, via a hopper on a filler box situated above said concrete form, preferably a movable filler box, movable along the top of said static concrete form, forming a wet concrete block with a surface; b. applying vibration to said concrete form; c. adding at least one irregular vein to said surface of said concrete form via a roller on said filler box and situated proximate said surface; said roller comprising a first end, a second end and a cylindrical body spanning between the first and second end. Said cylindrical body having a surface and a surface profile selected from the group consisting of helical, double helical, transversing helix, a single continuous helix, a discrete helix, a non-continuous helix, an ellipse and combinations thereof, wherein said filler box along with said roller transverses the surface of said concrete block in said static concrete form, and travels along the surface while said roller is rotating wherein said rotation of said roller on said surface distributes said concrete mix with colouring agents along said surface resulting in an irregular veining on said surface; said irregular veining will vary depending on the speed and direction of rotation of said roller in relation to the speed of travel of said fdler box.

6. A hopper extension for a concrete block making system for irregular veining of a concrete block, said hopper extension comprising: a top, bottom, two side walls, a front wall and a back wall, wherein the top and bottom are open; wherein the front wall, back wall and two side walls matingly engage the end of a hopper proximate a concrete block mold; a colouring agent placement roller having two ends, each one of said two ends being rotatably attached to each one of said two side walls; a rotator for rotating said roller; said rotator being programmable to regulate the speed and rotational direction of said roller; said roller having a profded surface.

7. The hopper extension of claim 6 wherein said roller further comprises at least one peak and at least one valley along the length thereof.

8. The hopper extension of claim 6 wherein said roller comprises at least one helical profile running along a length thereof.

9. The hopper extension of claim 6 wherein said roller comprises at least a double helical profile running along a length thereof.

10. The hopper extension of claim 6 wherein said roller comprises a parallel double helical profile.

11. The hopper extension of claim 6 wherein said roller comprises a transversing double helical profile.

12. The hopper extension of claim 6 wherein said rotator being programmable allows for the activation/deactivation of rotation of said roller during the travel along the length of said concrete block mold.