Concrete blocks, also referred to as concrete masonry units (CMU's), are typically manufactured by forming them into various shapes as part of an automated process employing an automated concrete block machine, such as those machines manufactured by Besser Company (Alpena, Mich.) and Columbia Machine, Inc. (Vancouver, Wash.), for example. Such machines typically employ a mold frame assembled so as to form a mold box, within which a mold cavity having a negative of a desired block shape is formed. To form a block, a pallet is moved by a conveyor system onto a pallet table, which is then moved upward until the pallet contacts and forms a bottom of the mold cavity.
A hopper is used to fill a feedbox assembly with a dry-cast concrete mixture. The feedbox assembly is then moved from a refracted or withdrawn position to an extended position over the mold frame and fills the mold cavity with concrete via the open top. A head shoe assembly is then moved into (descends) the top of the mold cavity and compresses the concrete (typically via hydraulic or mechanical means) to a desired psi rating (pounds-per-square-inch) while simultaneously vibrating the mold cavity along with the vibrating table.
As a result of the compression and vibration, the concrete reaches a level of “hardness” which enables the resulting finished block to be immediately removed from the mold cavity. To remove the finished block, the mold frame and mold cavity remain stationary while the shoe assembly, pallet, and pallet table move downward and force the finished block from the mold cavity. The conveyor system then moves the pallet bearing the finished block away and a clean pallet takes its place. This process is repeated for each block.
Feedbox assemblies typically employ agitator grids to assist in mixing and dispersing the dry cast concrete material in the feedbox so that it is evenly distributed into the mold cavity. Conventional agitator grids typically comprise a set of parallel bars that are joined by one or more cross-members, with prongs or fingers extending vertically downward form the parallel bars and into the concrete material in the feedbox. The agitator grid is then moved or vibrated so that the prongs or fingers agitate the dry cast concrete so as to better disperse the dry cast concrete material over and into the mold cavity.
In order to prevent dry cast concrete from being ejected from the feedbox and onto other parts of the concrete block machine and mold assembly while agitated, deflector or containment plates are sometimes attached to the top of the feedbox drawer. However, due to gaps between the plates, such plates blocking or deflector plates are not always effective at preventing concrete from being ejected from the feedbox during agitation.
In the following Detailed Description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
Concrete block machine 30 includes a headshoe assembly 32, a table or pallet table 34, a hopper 36, in which a supply of a dry-cast concrete mixture is maintained, and a feedbox 38 (sometimes referred to as a drawer or feedbox drawer) having a bottom 39 and including an agitator grid 40, in accordance the present disclosure, which will be described in greater detail below. A mold assembly 50 defining one or more mold cavities 52, in which dry-cast concrete blocks are formed, is mounted to concrete block machine 30. In one embodiment, a top plate 54 is mounted to an upper side of mold assembly 50 which assists in confining dry-cast concrete mixtures to areas of mold assembly 50 and from spreading to other areas of the concrete block machine 30. Pallet table 34 moves vertically up/down, as indicated by directional arrows 56, to position a pallet 57 below an open bottom of mold assembly 50, and head shoe assembly 32 moves vertically up/down, as indicated by directional arrows 58, to compress a dry-cast concrete mixture within mold cavity 52. Feedbox 38 moves between a refracted position below hopper 36 and an extended position above mold assembly 50, as indicted by the dashed lines 38a, and by directional arrows
During a block formation process, a pallet, such as pallet 57, is moved by a conveyor system (not shown) onto pallet table 34 which, in-turn, is moved upward until pallet 57 contacts and forms a bottom to mold cavity 52 (or mold cavities) formed by mold assembly 50. Feedbox 38 is positioned below hopper 36, which fills feedbox 38 with a desired amount of dry-cast concrete mixture. After being filled with a dry-cast concrete mixture, feedbox 38 is moved to extended position 38a (dashed lines in
After the dry-cast concrete mixture has been emptied from feedbox 38 into mold cavity 52, feedbox 38 is returned to the retracted position below hopper 36. Concrete block machine 30 then moves head shoe assembly 32 down into the mold cavities 52 and compresses the dry-cast concrete mixture while simultaneously vibrating head shoe assembly 32, mold assembly 30, and pallet table 34 with pallet 57.
As a result of the compression and vibration, the dry-cast concrete within mold cavities 52 reaches a level of “hardness” which enables the resulting molded concrete blocks to be removed from therefrom. To remove the mold concrete blocks from the mold cavities 52, head shoe 32 and table 34, along with pallet 57, are moved downward until a top surface of molded concrete block is lower than the bottom of mold assembly 50, at which point the conveyor system moves the pallet 57 bearing the molded blocks to a curing oven. Simultaneously, the conveyor system positions a new pallet 57 on table 34, which raises the new pallet 57 to close the open bottom of mold assembly 50 and the above described process is repeated.
As described above, an agitator grid 40 is used to mix and loosen the dry-cast concrete mixture within feedbox 38 to assist in dispersing the dry-cast concrete mixture into the one or more mold cavities 52 of mold assembly 50. Conventional agitator grids typically comprise a set of parallel bars or rods which are joined by one or more cross-members to form an agitator framework, with a plurality of fingers or prongs extending downward from the parallel bars into the feedbox. The agitator grid is moved so as to agitate the dry-cast concrete mixture within feedbox 38 and assist in dispersing the mixture into mold cavities 52 as feedbox 38 moves over mold assembly 50.
While such conventional agitator grids effectively assist in dispersing the dry-cast concrete mixture from feedbox 38, the dry-cast mixture is not always evenly distributed within the mold cavities 52. For example,
As feedbox 38 passes over mold assembly 50 from a rear side 51a toward a front side 51b and empties the dry-cast concrete mixture into mold cavities 52a, 52b, and 52c, often, excess concrete is often deposited in central portions of the mold cavities 52a, 52b, and 52c while the front side 51b and corners of the mold cavity, particularly the corners along the front side 51b thereof, receive less concrete than is desired. Such uneven distribution of dry-cast concrete mixture within the mold cavities 52a-52c can lead to over and/or under compaction of the concrete mixture which, in-turn, can lead to defects in the molded concrete blocks, such as cracks or even portions of the blocks crumbling and falling away.
Such uneven distribution of concrete within mold cavity 52 can be particularly troublesome when a texture is formed on a surface of the block(s) formed in mold cavity 52, especially when the textures surfaces are formed along the front and rear sides 51a, 51b of mold cavity 52. Many types of CMUs (e.g. pavers, patio blocks, light-weight blocks, cinder blocks, etc.), retaining wall blocks and architectural units in particular, it is desirable for at least one surface of the block to have a desired texture, such as a stone-like texture, for instance. When arranged to form a structure with the textured surface visible, the structure will have the appearance of being constructed from natural stone, for example.
In operation, moveable liner plates 76a, 76b are moved from a retracted position to a desired extended position by drive assemblies 79a, 79b and mold cavities 52a, 52b are filled with dry-cast concrete via feedbox 38. Head shoe assembly 32 then compresses the concrete within mold cavities 52a, 52b while mold assembly 50 is vibrated to form pre-cured concrete block therein. The moveable liner plates 76a, 76b are then moved to a retracted position and the pre-cured concrete blocks, having textured surfaces formed by textured faces 78a, 78b, are removed form mold cavities 52a, 52b through action of head shoe assembly 32 and table 34 and pallet 57 and sent to a curing oven, as described above.
While such techniques are effective at forming textured surfaces on the faces of the resulting pre-cast concrete blocks, air pockets trapped between the textured faces 78a, 78b of the moveable liner plates 76a, 76b and the dry-cast concrete mixture within mold cavities 52a, 52b are forced out during the compression/vibration process. As the air pockets are forced out, the dry-cast concrete mixture settles proximate to the textured faces 78a, 78b and causes the finally finished concrete block to a height along the textured surface (e.g. front face of block) which is shorter than that along an opposite surface (e.g. rear face of block). The settling and resulting differences in height between the opposing surfaces of the block is exacerbated by the uneven distribution of dry-cast concrete mixture deposited within mold cavities 52a, 52b by feedbox 38, especially when the moveable liner plates 76a, 76b and corresponding textured faces 78a, 78b are positioned on the front and rear sides 51a, 51b of mold assembly 50, as illustrated by
As a result, as illustrated by
In attempts eliminate problems associated with the uneven distribution of concrete within mold cavity 52, deflector elements are sometimes affixed (such as by welding) to various locations on the upper surfaces of the framework of agitator grid 40, opposite the prongs extending downward into the feedbox 38. The deflector elements are intended to lessen the amount of dry-cast concrete mixture deposited in areas of mold cavity 52 that tend to receive too much concrete and to direct more dry-cast concrete to areas of mold cavity 52 that tend to receive too little concrete, and thereby even out the level of dry-cast concrete throughout mold cavity 50. However, because of their height relative to feedbox 38, such metal elements tend to be ineffective at evenly distributing dry-cast concrete within mold cavity 52 and often result in concrete being ejected from feedbox 38 during agitation of agitator grid 40. Such metal elements are also very difficult, if not impossible, to adjust.
According to the embodiment of
As more clearly illustrated in
According to one embodiment, the position of restrictor plates 110 and collars 112 is vertically adjustable along a length of prongs 106 by sliding collars 112 and plates 110 thereon. According to one embodiment, restrictor plates 110 are held at a desired position along prongs 106 by a retaining mechanism, such as a set-screw in collar 112. It is noted that any suitable retaining mechanism other than a collar and set-screw arrangement can also be employed to adjustably secure diverter plates 110 to prongs 106. According to one embodiment, as illustrated by
According to one embodiment, as illustrated by
In contrast to conventional techniques of fixedly attaching diverter elements to the upper surface of feedbox 40, agitator grid 40 according to the present disclosure employs restrictor plates 110 that can be individually and readily adjusted along the length of prongs 106 via set-screw collars 112 (or any suitable adjusting mechanism) so as easily control, fine-tune, and provide desired amounts of concrete to different parts of the mold cavity or cavities 52 within mold assembly 50. By distributing volumes of dry-cast concrete to desired locations with mold cavity or mold cavities 50, more even compression of the dry-cast concrete within mold cavities 50 by head shoe assembly 32 is obtained, thereby reducing or eliminating problems associated with over and under compression (e.g. cracking, crumbling of the dry cast concrete blocks). Also, by directing more concrete to areas of the mold cavities where textures are imparted to the block faces (see
Additionally, restrictor plates 110, according to the present disclosure, are fully adjustable and customizable to meet different mold cavity shapes and can be readily employed on existing concrete block machines without requiring any additional or custom components. Instead, restrictor plates 110 can be adapted to be readily installed on the agitator grids of conventional concrete block machines without the need for additional components. Additionally, the restrictor plates 110 of agitator gird 40 can be used in conjunction with or as a replacement for controllable cutoff bars, which are also employed to adjust/vary the volume of concrete deposited in mold cavities, but which can require more complicated installation and operation (e.g. more moving parts) than restrictor plates 110 of agitator grid 40 of the present disclosure.
Although defined above as having a set of four parallel bars 102a-102d and eight restrictor plates 110a-110h, and being employed with a mold assembly 50 having four mold cavities 52a-52d, it is noted that agitator grid 40 according to the present disclosure can employ any number of bars 102, prongs 106, and restrictor plates 110, and be used with molds having any number of mold cavities.
Additionally, although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
This Non-Provisional patent application claims benefit of U.S. Provisional Application No. 61/908,490, filed Nov. 25, 2013, entitled: AGITATOR GRID WITH ADJUSTABLE RESTRICTOR PLATES FOR CONCRETE BLOCK MACHINE, incorporated herein.
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Number | Date | Country | |
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20150147428 A1 | May 2015 | US |
Number | Date | Country | |
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61908490 | Nov 2013 | US |