Patent Application
20060182839
The present invention relates to a concrete block press used to manufacture concrete blocks.
Concrete blocks have been commonly used in construction for many decades. However, since the 1980's several companies have looked for systems, which could be assembled more rapidly. A dry stack system was introduced in order to reduce skilled labour requirements, permit faster stacking and eliminate wet material. Initially dry stack systems suffered from quality control. Variations in height dimensions of 1/16 inch caused deviations from plumb after just three or four courses and required shims to adjust the height. However, while still suffering from some height variation, dry stack systems have since improved and are now competitive in many more market segments than before.
Machines to manufacture concrete blocks provide for a hopper to temporarily hold the mixed concrete until it can be poured into a mold. Many different cast moldings are known but generally the negative shape of the finished block is formed on the inside of the mold. The mold is placed on a support board and then pushed onto a vibrating table where it is filled with concrete from the hopper. As soon as the mold is filled with concrete, a pressure plate descends upon the concrete in the mold. Either concurrently with vibrating the vibrating table or after, pressure is applied to the fresh concrete in the mold by depressing the pressure plate. The pressure plate is raised vertically and then the support plate is raised with the finished pre-cast brick remaining on the support board. The support board and brick are carried away by a board carriage for onward transportation by a conveyor system. A new support board is then pushed into the mold, which rests on the vibrator plate. Generally, such manufacturing systems include a turntable with several work stations as well as the concrete block molding machine. Such systems are large, relatively expensive and difficult to move.
Accordingly, it is an object of the invention to provide a compact mold-making machine that is easily moved and which produces concrete blocks of precise accuracy.
According to the invention, there is provided a concrete block-molding machine having a concrete mix feed station, and a concrete molding and block ejection station adjacent to the feed station wherein the concrete molding and block ejection station has a vibratile plate having a plurality of holes in a pre-selected hole pattern, a mold having a mold interior positionable on the vibratile plate and having holes in the pre-selected hole pattern, and a support plate dimensioned and patterned to form a bottom face of a molded concrete block. An ejector plate having a plurality of projecting rods in the pre-selected hole pattern is positionable below the vibrating plate, with the rods of a diameter such that they pass through the holes in the vibratile plate and the mold. Means are provided for raising and lowering a pressure plate assembly so as to compress a concrete mix in the mold provided. Means are also provided for raising and lowering the ejector plate so as to contact and raise and lower the support plate out of and into the mold.
Further features and advantages will be apparent from the following detailed description, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:
The concrete block mold machine 10 as shown in
A large arm 24 passes through the top of frame 12 and is supported by the bottom thereof. Attached to the arm 24 are two spaced apart piston-cylinder units 28 and 29 having piston arms to the end of which is attached a pressure plate 26. Hydraulic hoses 34, and 36 coming from hydraulic pump 59 and return line 38 feed hydraulic fluid to the piston cylinders 28 and 29. Switches coupled to control handles 21 control the lines.
Referring to
Referring to
Various designs of molds 31 and corresponding support plates 44 are possible as seen by the support plate designs in
In operation, the desired mold 31 and support plate 44 are put in place atop vibrating plate 40 depending on the design of the block desired. A charge of pre-mixed concrete is then poured into hopper 20 and pusher and hopper block 16 is manually pushed forward causing the concrete charge to be advanced and to drop into mold opening 31 and mold interior 33. Ejector plate 48 is in its lowermost position. Any excess concrete is captured atop a blocking plate 14. Consequently, a precise amount of concrete is contained in each charge advanced to the mold 31. The hydraulic cylinders 28 and 29 are extended causing pressure plate 26 to lower and compress the concrete block 30. Simultaneously, the vibrating plate 40 is caused to vibrate by operation of a motor and cam contacting plate 40 (not shown). Projections 35 create holes 43 in a desired hole pattern in the concrete block 30. Once compressed by pressure plate 26 and the vibrating plate 40, the pressure plate 26 is raised then the ejector plate 48 is raised until it contacts the support plate 44. The block 30 and support plate 44 are raised above the top of frame 12. Block 30 and support plate 44 are removed by a small forklift (not shown) that carries the block to a drying rack (not shown). A new support plate 44 is inserted into the mold and the process is repeated for a next block.
The relatively small, self-contained concrete block mold machine 10 means it can be easily transported and put into operation. The precise amount of concrete being placed in the mold allows more efficient operation with less waste. The fact that the concrete 30 is raised out of the mold 33 and is removed immediately after pressurizing with the pressure plate 26 avoids any problems of expansion of the curing mix of concrete 30. As compared to most block fabricating plants the present block molding machine 10 does not require an expensive multi-station fabricating assembly. Operation can be set up inexpensively in relatively small quarters.
It will be obvious to those skilled in the art that one could make more than one mold opening 31 and mold 33.
Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description.
