The present invention relates to a tumbler for artificially ageing the appearance of pre-cast blocks. More particularly but not exclusively, the present invention relates to a block tumbler with a block-immobilizing device for maintaining blocks in place within the tumbler.
Artificially ageing the appearance of cementitious blocks is required since cementitious blocks such as concrete building blocks prepared by conventional manufacturing operations produce blocks that have a geometrically rectangular configuration with substantially planar surfaces and sharp edges.
Typically, in order to give these blocks a natural or stone-cut allure, they are introduced into a large tumbling drum. This tumbling drum or tumbler is rotated in order to cause tumbling of the blocks contained therein thus causing multiple random collisions between the blocks, thereby damaging the surfaces, edges and corners giving the blocks a worn, aged or natural stone cut appearance. Since these blocks are loose within the tumbler, once tumbled they are then dumped in a pile.
A drawback or piling the tumbled blocks is the amount of time and/or manual labor required to separate, sort and organize tumbled blocks. Another drawback of tumbling blocks as explained above is the amount of block material that is lost in order to produce the desired blocks.
An object of the invention is to provide a tumbler for artificially ageing blocks.
Another object of the invention is to provide a tumbler for artificially ageing blocks with a block-immobilizing device for maintaining the blocks in place during tumbling.
A further object of the invention is to provide a tumbler for artificially ageing blocks with a vacuum device for maintaining the blocks in place during tumbling.
Yet another object of the invention is to provide a tumbler for artificially ageing blocks with a clamping device for maintaining the blocks in place during tumbling.
In accordance with an aspect of the present invention, there is provided an apparatus for modifying the appearance of a surface-texture of cementitious blocks, the apparatus comprising: a container comprising block-receiving areas for receiving blocks; a movement imparting device for imparting a movement to the container; and at least one block-immobilizing device for immobilizing blocks on a given block-receiving area during movement of the container; wherein when introducing an impacting material in the container and imparting a movement to the container the impacting material is caused to so impact the cementitious blocks as to modify the appearance of the surface texture thereof.
In accordance with another aspect of the present invention, there is provided an apparatus for modifying the appearance of a surface-texture of cementitious blocks, the apparatus comprising: a container comprising block-receiving areas for receiving blocks; a movement imparting device for imparting a movement to the container; and at least one vacuum device for immobilizing blocks on a given block-receiving area during movement of the container; wherein when introducing an impacting material in the container and imparting a movement to the container the impacting material is caused to so impact the cementitious blocks as to modify the appearance of the surface texture thereof.
In accordance with a further aspect of the present invention, there is provided an apparatus for modifying the appearance of a surface-texture of cementitious blocks, the apparatus comprising: a container comprising block-receiving areas for receiving blocks; a movement imparting device for imparting a movement to the container; and at least one clamping device for immobilizing blocks on a given block-receiving area during movement of the container; wherein when introducing an impacting material in the container and imparting a movement to the container the impacting material is caused to so impact the cementitious blocks as to modify the appearance of the surface texture thereof.
In accordance with yet another aspect of the present invention, there is provided a method for modifying the appearance of a surface-texture of cementitious blocks, the method comprising: immobilizing blocks within a moveable container; introducing an impacting material in the container; and imparting a movement to the container so as to cause the impacting material to so impact the cementitious blocks as to modify the appearance of the surface texture thereof
The expression “modifying the appearance of a surface-texture” includes without limitation artificially ageing, scathing, abrading, scratching, breaking, the planar surface, the edges, and the corners of blocks and the like.
The term “cementitious blocks” includes without limitation concrete blocks, pre-cast blocks, pavers, bricks, and the like.
The term “impacting material” includes without limitation any material than when impacting with sufficient force the surfaces, edges, or corners of cementitious blocks will artificially modify or age the foregoing
The term “block-immobilizing device” includes without limitation any device, mechanism, machine, tool, assembly, means, apparatus, system, element, and the like of any kind within the context of the invention for immobilizing blocks on a block-receiving area of container that is to be so moved as to cause the impacting material therein to impact the blocks so as to modify the appearance of a surface-texture thereof
Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.
In the appended drawings, where like reference numerals indicate like elements throughout and where:
Generally stated, the invention is concerned with a block tumbler apparatus that includes a rotating drum having internal surfaces, defining block-receiving areas, on which blocks are immobilized via a block-immobilizing device. In two non-limiting examples illustrated herein, the block-immobilizing device comprises a vacuum device or a clamping device. In this way, instead of tumbling the blocks together in a random fashion, an impacting material is inserted into the rotating drum and as the drum rotates, the impacting material impacts the blocks which are immobilized thereby modifying their surface-textures.
A first Illustrative embodiment of the present invention will be discussed in further details hereinbelow and with reference to FIGS. 1 to 4.
The pre-cast blocks 12 may be any type of molded cementitious blocks such as concrete blocks, bricks, pavers to give but a few non-limiting examples. Blocks 12 may have different sizes and configurations and may be destined to be used as paving stones, bricks, steps, retaining walls and other like structures known in the art. Blocks 12 may be prepared by a variety of conventional processes such as casting, cutting, drying and the like. After a curing process these blocks have a generally rectangular geometric shape with substantially planar surfaces and substantially sharp corners.
The blocks 12 are placed on a platform, generally denoted 14 that is adapted to move the blocks 12. Platform 14 may comprise a conveyor, a moveable board, a robotic apparatus, a supporting platform with a push member to push the blocks 12 or any other device suitable in the art so as to infeed blocks 12 into the tumbler 10 and so as to out-feed blocks 12 from the tumbler 10. Of course, such platforms are well known in the art and need not be discussed further. The blocks 12 are typically arranged in a certain layout on the platform 14 which results from the prior processing operation. In the illustrated example of
The tumbler 10 comprises a container 16 in the form of a drum that is rotatable in either a clockwise or counterclockwise direction as shown by arrows R in
As shown in
The drum 16 also defines a working space 22, shown in
With respect of
With reference to
The drum 16 can be moved so as to rotate by a variety of movement imparting devices. In this respect and with reference to
Rotatable drums for blocks are well known in the art and the skilled artisan may contemplate a multitude of alternative ways of rotating a drum 16 within the context of the present invention. The present example illustrates one of the many available ways of performing such an operation. In this way, a variety of actuators such as hydraulic, pneumatic or electric motors as well as driving mechanisms and the like can be used.
The block-immobilizing devices 60 of
As shown in 1-4, the drum frame 32 includes block-immobilizing devices 60 in the form of vacuum devices. Referring now to
In operation, an in-feed platform 14A moves blocks inside the tumbler 10 beneath yet sufficiently close to the surface of a superimposed block-receiving area 20. The vacuum device 60 is activated and sucks up the blocks 12 thereunder. The in-feed platform 14A is then removed from the tumbler empty. In this example, platform 14B is the same as 14A except that it is empty since the blocks thereon were sucked. Hence, platforms 14 move in the direction shown by arrows I in
An impacting material (not shown) is inserted inside the drum 16. This impacting material may include concrete scrap or any other suitable material that the skilled artisan can contemplate for impacting the surface-texture of blocks 12 in order to artificially age them in appearance. The doors 28 and 30 seal the drum 16 and the actuator 54 acts on drum 16 to cause it to rotate while the vacuum devices 60 hold the blocks 12 in the block-receiving areas 20. In this way, the impacting material is tumbled within the working area 22 defined by the drum 16; this causes the tumbling impacting material to collide with the immovable blocks 12. These multiple collisions damage and modify the surface textures including corners and edges of the blocks 12 thereby imparting to the blocks an aged or worn appearance.
After the tumbling process, rotation of the drum 16 is stopped and doors 28 and 30 are opened An out-feed platform 14B enters the drum 16 and is positioned beneath blocks 12 at position T. The vacuum system 60 acting on the blocks 12 at position T is shut off and the blocks 12 fall on the platform 14B. The platform 14B is sufficiently close to the immobilized blocks 12 so that when they fall after suction ceases, they substantially retain their positioning on the platform 14B. The platform 14B with the modified blocks 12 thereon is removed from the drum 16 and a the drum 16 is rotated so that the subsequent block-receiving area 20 holding blocks 12, via vacuum is brought to position T until the drum 16 has been emptied. Of course, when a block-receiving area 20 is emptied of blocks 12 as explained above, a new batch of blocks 12 may be brought to this area 20 to be sucked by vacuum before rotating to the subsequent area 20 with immobilized blocks 12. In this way, blocks 12 are emptied from an area 20 and new blocks 12 fill this same area 20. Of course, the skilled artisan will use an approach block emptying and filling approach that is suitable to specifics needs and goals within the context of the present invention.
Referring now to FIGS. 5 to 10, a second illustrative embodiment of the present invention will be discussed.
FIGS. 5 to 10 show a tumbler 100 that is similar to tumbler 10. In fact, the principle operation of tumbler 100 is substantially the same to that of tumbler 10; what differs is the block-immobilizing device used by tumbler 100. Whereas tumbler 10 provided a vacuum device 60 as the block-immobilizing device, tumbler 100 provides a clamping device (which will be described herein). Hence, the description below will focus mostly, but not exclusively, on the differences between tumbler 100 and tumbler 10 for concision purposes only.
Therefore, keeping the foregoing in mind,
The blocks 12 are uploaded to (see
A vacuum handle tool 302 is mounted to the wrist 304 of the robotic arm 300. The vacuum handle tool 302 acts as a platform for the blocks 12. The vacuum handle tool 302 includes a vacuum reservoir 306, a block receiving face 308 having openings 310 for the blocks 12. The openings 310 include gaskets (not shown) about their internal perimeters so as not to damage the blocks 12. Hence, the vacuum handle tool 302 via vacuum uploads, via suction, a group of cementitious blocks 12 following processing thereof.
As shown in
As shown in
As shown in
Turning now to
The clamping device 160 includes a pair of clamping members 162A and 162B at each lateral end 164A and 164B, respectively, of a block-receiving area 120. Clamping member 162A is operated by an actuator 166 in the form of pneumatic cylinders (to give but one example) so as to be moveable from an unclamping position U, shown in
When the blocks 12 are on the block-receiving area 120, the clamp member 162A is are activated by the pneumatic cylinders 166 to be moved towards the blocks 12. Clamp member 162A engages the row of blocks 12 at the lateral end 164A of the block-receiving area 120 and pushes the full group of blocks towards clamp member 162B. Clamp member 164B is engaged by the row of blocks 12 at the lateral end 164B of the block-receiving area 120 which are being forced thereon by the pressure of the moveable clamp 162A. The pressure applied to the foregoing lateral rows of blocks 12 acts on all the rows of blocks 12 therebetween, as well as the separators 121, to clamp the whole group of blocks 12 in place, via the fictional tension force provided by the pneumatic cylinders 164 between clamps 162A and 162B, thereby immobilizing the blocks 12 so that they be frictionally maintained in place as the drum 116 rotates.
Hence, as previously explained impacting material is inserted into the drum 116, the drum 116 is closed at each lateral side 124 and 126 and rotated, thereby causing the impacting material to tumble within the working space 122 (see
Once the tumbling process is complete, the vacuum handle tool 302 enters the opened drum 116 and its block receiving face 308 is brought near to a given block-receiving area 120. The blocks 12 of the particular block-receiving area 120 are unclamped via the clamp members 162A and 162B moving to the unclamping position U (shown in
Of course whether for block tumbler 100 or block tumbler 10, the blocks 12 can be re-loaded within these tumblers for further impacting. Since only one side of the blocks 12 is mostly expose to impacting material, the user may wish to have the opposite side impacted for surface modification thereof as well.
Also shown in FIGS. 5 to 8 is a ladder device 200 that provides access to tumbler 100.
The clamp members 162A and 164 may be provided in a variety of suitable sizes and configurations and may be powered by various actuators known in the art.
The block-immobilizing devices of the invention are not limited to clamping devices and vacuum devices, a variety of like mechanisms can be contemplated within the context of the present invention using various grasping instruments that can hold the blocks when actuated by an actuator. In another non-illustrated embodiment, a series of longitudinal elements which engage opposite lateral sides of the blocks 12 and then tighten to frictionally hold these blocks 12 during the tumbling operation can be used.
In another non-illustrated embodiment, the working areas 22 or 122 include an internal member for impacting the blocks 12 thereby enhancing the artificial ageing of the blocks 12. Therefore, in another embodiment, the impacting material may comprises this internal block-impacting member.
The various features of tumblers 10 and 100 illustrated and/or discussed herein can be combined in a variety of ways to provide other non-limiting embodiments within the scope of the present invention.
It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present invention has been described hereinabove by way of embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject invention as defined in the appended claims.
The present application relates to U.S. Provisional Application No. 60/774,636 filed on Feb. 21, 2006, on which priority is requested and which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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60774636 | Feb 2006 | US |