Method and apparatus for manufacture of unitary lightweight concrete composite blocks

Information

  • Patent Grant
  • 6827570
  • Patent Number
    6,827,570
  • Date Filed
    Friday, June 22, 2001
    23 years ago
  • Date Issued
    Tuesday, December 7, 2004
    20 years ago
Abstract
A method and apparatus for manufacturing unitary concrete blocks includes a form that defines the desired shape of the unitary concrete block. A form loading station delivers a lightweight concrete composite into the form. A station conveyor conveys the form from the form loading station through a curing oven. In the curing oven, the composite-filled form is cured into a unitary concrete block. The station conveyor conveys the form to a block removal station that removes the unitary concrete block from the form. The station conveyor returns the form to the form loading station to manufacture more unitary concrete blocks. For increased production, multiple forms can be conveyed between stations simultaneously. Additionally, a metering ingredient assembly may be used to deliver appropriate amounts of desired ingredients to a mixer for producing the lightweight concrete composite.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The present invention relates to lightweight concrete and, more particularly, but not by way of limitation, to a method and apparatus for manufacturing unitary lightweight concrete composite blocks.




2. Description of the Related Art




The primary building materials utilized today are wood and concrete. Wood unfortunately has become extremely expensive due to reduced supplies caused by restrictions resulting from today's environmentally conscious society. Further, wood often does not provide the structural safety available from other building materials, such as concrete. Concrete, however, is also expensive, which restricts its use to projects requiring the structural safety advantages associated with concrete.




Thus, the building industry constantly seeks to reduce building costs while at least meeting or actually improving upon structural safety standards. One such improved product consists of lightweight concrete, which is composed of water, cement, and polystyrene. Lightweight concrete provides reduced costs in materials by replacing cement with less expensive polystyrene. Lightweight concrete further provides structural safety comparable to cement and improved over wood.




Unfortunately, the reduced materials costs of lightweight concrete are counteracted through manufacturing difficulties, which drive up costs. Currently, lightweight concrete is virtually manufactured manually in that lightweight concrete slurries are poured into molds and allowed to cure but, upon removal from molds, must be glued together and trimmed before a block sufficient for use exists. Accordingly, an apparatus and corresponding method that manufactures unitary lightweight concrete composite blocks, thereby eliminating costly and time intensive assembly would significantly improve over the foregoing related art.




SUMMARY OF THE INVENTION




In accordance with the present invention, an apparatus for manufacturing lightweight concrete composite blocks includes a form, a station conveyor, a form-loading station, a curing oven, and a block removal station.




The form can define any shape of unitary concrete block desired, including rectangular blocks and corner blocks. A station conveyor conveys the form or a multitude of forms around the apparatus in a continuous loop to produce a desired rate of production of unitary lightweight concrete blocks. First, the form-loading station fills the form with a lightweight concrete composite and compresses the form to seal the composite within the form. The station conveyor conveys the form through a curing oven to cure the lightweight concrete composite into a unitary lightweight concrete block. Next, the station conveyor conveys the form to a block removal station, where the unitary lightweight concrete block is removed from the form. Subsequently, the form is returned to the form-loading station to be reused.




It is therefore an object of this invention to provide an apparatus that manufactures unitary lightweight concrete blocks.




It is a further object of this invention to provide an apparatus that manufactures unitary lightweight concrete blocks at a high rate of production to reduce time and costs of production.




Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a plan view illustrating an apparatus for manufacturing unitary lightweight concrete composite blocks according to the preferred embodiment.





FIG. 2

is a block diagram illustrating a portion of the apparatus that forms a lightweight concrete composite mixture.





FIG. 3A

is a perspective view illustrating a preferred embodiment of a straight form.





FIG. 3B

is a perspective view illustrating a preferred embodiment of a corner form.





FIG. 4A

is a perspective view illustrating a conveyor track with a conveyor catch in an engagement position.





FIG. 4B

is a perspective view illustrating the conveyor track with the conveyor catch in a bypass position.





FIG. 4C

is a side view illustrating a turnstile catch in an engagement position and a return position.





FIG. 4D

is a perspective view illustrating a turnstile assembly and conveyor track.





FIG. 5

is a perspective view illustrating a form-filling station including a screed assembly in a loading position, a cap removal/replacement assembly with cap removed in a retracted position, and a compression assembly in a retracted position.





FIG. 6A

is a perspective view illustrating a cap removal/replacement assembly with cap removed.





FIG. 6B

is a side view illustrating a cap removal/replacement assembly with cap removed in an engagement position and a retracted position.





FIG. 7A

is a side view illustrating a screed assembly for loading and leveling a form.





FIG. 7B

is a perspective view illustrating the screed assembly for loading and leveling a form.





FIG. 8

is a perspective view illustrating a form-filling station including a screed assembly in a retracted position, a cap replacement assembly with cap replaced in an engagement position, and a compression assembly in a compression position.





FIG. 9

is a perspective view illustrating a block removal station with a form in a first lower level and a lock assembly in the locked position.





FIG. 10

is a perspective view illustrating a block removal station with a sidewall assembly and cap of a form raised to a second intermediate level, a swing-arm assembly in a receiving position, and a second conveyor.





FIG. 11

is a perspective view illustrating a block removal station with the sidewall assembly and cap of a form raised to a third upper level, a swing-arm assembly in the receiving position, and a second conveyor with a unitary lightweight concrete composite block removed from the form.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




As illustrated in

FIG. 1

, an apparatus for manufacturing lightweight concrete composite blocks


1


includes grinders, an ingredient metering assembly, a mixer, a form, a station conveyor, a form-loading station, a curing oven, and a block removal station. The apparatus


1


utilizes a method for manufacturing unitary lightweight concrete composite blocks that includes the steps of grinding and storing polystyrene, mixing polystyrene with additional ingredients to form a lightweight concrete composite, loading a form with the lightweight concrete composite, curing the lightweight concrete composite, and removing a unitary lightweight concrete composite block from the form.




Boxes or irregular pieces of virgin or recycled polystyrene are manually or mechanically loaded into a coarse grinder


2


where they are broken into smaller pieces. The coarse grinder


2


may be any grinder suitable for reducing the blocks of virgin or recycled polystyrene, such as motor driven apparatus with long chopping arms. The smaller pieces of polystyrene are then conveyed through a pipe by any suitable means, such as gravity feed, blowing with high-pressure air, and the like, to a fine grinder


3


and ground into smaller particles. The fine grinder


3


may be any grinder suitable for reducing the small pieces of polystyrene into smaller particles, such as a feed grinder commercially available from John Deere, Gehl, or Lorenz. From the fine grinder


3


, the polystyrene is conveyed through a pipe to a polystyrene hopper


4


by any suitable means, such as vacuum pressure or blowing with high-pressure air, as described herein with reference to FIG.


2


. The grinder


3


includes a sieve therein that prevents passage of any polystyrene particles larger than a predetermined particle. Although the preferred embodiment discloses one polystyrene hopper


4


, those of ordinary skill in the art will recognize that any number or size of tanks, including one, may be utilized.




A mixer


5


, which is of a type well known and understood by those of ordinary skill in the art, such as paddle mixer, is used to combine the materials that, in this preferred embodiment, form a lightweight concrete composite. In its simplest form, the lightweight concrete composite is composed of water, cement, and polystyrene. However, due to varying atmospheric conditions, in particular, temperature and humidity, it may be necessary to include other additives, such as a water conditioner, an accelerator, or a superplasticizer, to modify physical and chemical characteristics of the concrete composite. These additives may also be included in order to improve performance characteristics of the mixture before and after curing.




A water conditioner is added to increase the hydration-hardness of the resulting lightweight concrete composite. Normally, when polystyrene is added to concrete, the polystyrene absorbs some of the water used in forming the concrete, resulting in lower compressive strength of the concrete. A liquid water conditioner chemically conditions the water to prevent absorption by the polystyrene. Consequently, the cement in the mixture remains fully hydrated resulting in improved hardness and compressive strength of the resulting lightweight concrete composite. Accelerants decrease mixture curing time and are typically added when atmospheric temperatures are low or when humidity is high. Superplasticizers increase the flowability of the concrete composite making it easier to pour while, at the same time, increasing the ultimate compressive strength. They also act as a retardant, delaying the curing of the concrete composite.




As illustrated in

FIG. 2

, an ingredient metering assembly


13


includes a computer


6


, which is any commercially available microcontroller or personal computer, which controls the process of forming the lightweight concrete composite. The computer


6


begins by starting a pump


7


C to transfer fresh or recycled water from a water source through a pipe into a water hopper


7


A, having a scale


8


attached thereto. The scale


8


is electrically connected to the computer


6


to measure the weight or volume of water entering the water hopper


7


A and output a representative signal to the computer


6


. When a predetermined weight or volume of water is reached, the computer


6


stops the first pump


7


C and then opens a solenoid operated door of the water hopper


7


A to convey the water from the water hopper


7


A to the mixer


5


by gravity via a pipe. If necessary, the water may be heated to a temperature of a least 150° F. by any suitable means, such as a commercial water heater


7


B, before adding to the mixer


5


. The heated water acts as an accelerant in the mixture. The preferred method of delivering water into the water hopper


7


A is automatically, however, those of ordinary skill in the art will recognize that the water, even heated, could be added manually.




Although the preferred embodiment discloses heated water as the accelerant, those of ordinary skill in the art will recognize that any suitable additives or combinations thereof, including calcium chloride, may be utilized. The computer


6


adds an accelerant by starting a pump


7


E to transfer an accelerant from an accelerant source through a pipe into an accelerant hopper


7


D, having a scale


7


F attached thereto. The scale


7


F is electrically connected to the computer


6


to measure the weight or volume of accelerant entering the accelerant hopper


7


D and output a representative signal to the computer


6


. When a predetermined weight or volume of accelerant is reached, the computer


6


stops the pump


7


E and then opens a solenoid operated door of the accelerant hopper


7


D to convey the accelerant from the accelerant hopper


7


D to the mixer


5


by gravity via a pipe. The preferred method of delivering accelerant into the accelerant hopper


7


D is automatically, however, those of ordinary skill in the art will recognize that the accelerant could be added manually.




Next, if desired, the computer


6


adds a water conditioner by starting a pump


11


B to transfer a water conditioner from a water conditioner source through a pipe into a water conditioner hopper


11


A, having a scale


9


attached thereto. The scale


9


is electrically connected to the computer


6


to measure the weight or volume of water conditioner entering the water conditioner hopper


11


A and output a representative signal to the computer


6


. When a predetermined weight or volume of water conditioner is reached, the computer


6


stops the pump


11


B and then opens a solenoid operated door of the water conditioner hopper


11


A to convey the water conditioner from the water conditioner hopper


11


A to the mixer


5


by gravity via a pipe. The preferred method of delivering water conditioner into the water conditioner hopper


11


A is automatically, however, those of ordinary skill in the art will recognize that the water conditioner could be added manually.




Then, if necessary, the computer


6


adds a superplasticizer by starting a pump


10


B to transfer a superplasticizer from a superplasticizer source through a pipe into a superplasticizer hopper


10


A, having a scale


15


attached thereto. The scale


15


is electrically connected to the computer


6


to measure the weight or volume of superplasticizer entering the superplasticizer hopper


10


A and output a representative signal to the computer


6


. When a predetermined weight or volume of superplasticizer is reached, the computer


6


stops the pump


10


B and then opens a solenoid operated door of the superplasticizer hopper


10


A to convey the superplasticizer from the superplasticizer hopper


10


A to the mixer


5


by gravity via a pipe. The preferred method of delivering superplasticizer into the superplasticizer hopper


10


A is automatically, however, those of ordinary skill in the art will recognize that the superplasticizer could be added manually.




Subsequently, the computer


6


adds cement by starting an auger


14


B to transfer cement from cement source through the auger


14


B into a cement hopper


14


A, having a scale


14


C attached thereto. The scale


14


C is electrically connected to the computer


6


to measure the weight or volume of cement entering the cement hopper


14


A and output a representative signal to the computer


6


. When a predetermined weight or volume of cement is reached, the computer


6


stops the auger


14


B and then opens a solenoid operated door of the cement hopper


14


A to convey the cement from the cement hopper


14


A to the mixer


5


by gravity via a pipe. The preferred method of delivering cement into the cement hopper


14


A is automatically, however, those of ordinary skill in the art will recognize that the cement could be added manually. The resulting mixture of at least water and cement as well as a water conditioner, accelerant, and superplasticizer, if added, is mixed in the mixer


5


until blended thoroughly into an intermediate concrete composite.




Finally, the computer


6


outputs a signal to transfer polystyrene by any suitable means, such as vacuum pressure or blowing with high-pressure air, from the fine grinder


3


to the polystyrene hopper


4


, which includes a scale


12


attached thereto. The scale


12


is electrically connected to the computer


6


to measure the weight or volume of polystyrene entering the polystyrene hopper


4


and output a representative signal to the computer


6


. When a predetermined weight or volume of polystyrene is reached, the computer


6


shuts off a blower or vacuum pump and then opens a solenoid operated door of the polystyrene hopper


4


to convey the polystyrene from the polystyrene hopper


4


to the mixer


5


by gravity via a pipe. The preferred method of delivering polystyrene into the polystyrene hopper


4


is automatically, however, those of ordinary skill in the art will recognize that the cement could be added manually. The polystyrene is allowed to mix until it is completely coated with the intermediate concrete composite to form a lightweight concrete composite. When the mixing of lightweight concrete composite has completed, the computer


6


outputs a signal to transport the lightweight concrete composite by gravity to a mixer discharge hopper


16


located below the mixer


5


. The lightweight concrete composite is stored in the mixer discharge hopper


16


until needed. In this preferred embodiment, the computer


6


produces lightweight concrete composite sufficient for one form


17


or


170


at a time; however, those of ordinary skill in the art will readily recognize that multiple batches could be made for storage in the mixer discharge hopper


16


.




As illustrated in

FIG. 3A

, a straight form


17


is used to cure the lightweight concrete composite into a desirable shape, which, in this preferred embodiment, is a unitary rectangular block


17


A with two thru holes in the center and a half hole on either end. The preferred form


17


thus includes a cap


18


, a bottom tube assembly


20


, and a wall assembly


21


. Although the preferred embodiment discloses a unitary rectangular block


17


A, those of ordinary skill in the art will recognize that a form producing any desirable shape, such as a square, circle, or angle, may be utilized.




The cap


18


is a rectangular plate with two cylinders and two half cylinders extending perpendicular from the lower face of the plate. In this preferred embodiment, the cylinders are equally spaced along the center of the plate with a half cylinder on each end. Each one of the two half cylinders are flush with their respective ends of the plate. The base of the cylinders should slope into a cone shape to allow for easier removal of the cap


18


. The two long edges of the rectangular plate terminate in two L-shaped cap brackets


19


that define slots between the top of the cap


18


and each cap bracket


19


. Two tabs


23


on each side are attached to each ridge and extend downward from the cap


18


, and a dowel


24


extends perpendicularly from each tab


23


. Two cap brackets


22


attach to the two L-shaped cap brackets


19


, thereby spanning the rectangular plate of the cap


18


.




The bottom tube assembly


20


in this preferred embodiment is a rectangular base with two cylinders and two half cylinders extending perpendicular from the face of the base. The cylinders are equally spaced along the center of the base with a half cylinder on each end. Each one of the two half cylinders are flush with their respective ends of the base. The base of the cylinders should slope into a cone shape to allow for easier removal of the base. The spacing of the cylinders and half cylinders must equal the spacing of the cylinders and half cylinders on the cap


18


. In addition, the length of the cylinders and half cylinders should be long enough for the tops to meet flush with the cylinders and half cylinders on the cap


18


when the form


17


is completely assembled and compressed. The entire edge of the rectangular base is recessed defining a lip. Two dowels


25


extend outwardly from each lip. Three tabs


26


are attached to the bottom of the base. One is located in the front center of the base, while the other two are located in the rear corners of the base. A wheel


27


is pivotally attached to the bottom of the front tab


26


, while rear wheels


27


are fixed to the bottom of the rear tabs


26


. The wheels


27


allow the form


17


to travel along a guide rail


46


of a station conveyor


43


. Although the preferred embodiment of the form


17


discloses two cylinders and two half cylinders, those of ordinary skill in the art will recognize that any number of cylinders or shapes may be utilized.




The wall assembly


21


includes two sidewalls


28


, two endwalls


29


, two mating assemblies


30


, and lifting dowels


31


. The two mating assemblies


30


are located on opposite corners and connect a respective sidewall


28


and a respective endwall


29


, thereby forming a rectangular box. The perimeter dimensions of the rectangular box match the perimeter dimensions of the cap


18


and the bottom tube assembly


20


.




Each corner assembly


30


includes two fixed brackets


32


, two sliding brackets


33


, a fixed rod


34


, and a sliding rod


35


. The two fixed brackets


32


are attached to a respective end of a long sidewall


28


by a suitable means, such as welding. The fixed rod


34


is a straight rod with a hook extending perpendicularly from a top and a bottom end. The top and bottom ends of the fixed rod


34


are connected to the fixed brackets


32


by any suitable means, such as welding. The two sliding brackets


33


are attached to a respective endwall


29


by any suitable means, such as welding. Each sliding bracket


33


defines a slot that hingedly attaches to a corresponding fixed bracket


32


by any suitable means, such as a pin. The sliding rod


35


is a straight rod with an L-shaped stud extending perpendicular from a top and a bottom end, and a tab extending perpendicularly from the mid-point. T-shaped engaging rod


36


extends outwardly from the tab. The top and bottom ends of the sliding rod


35


are hingedly connected to the sliding brackets


33


through each slot.




The sliding rod


35


slides back and forth in the slot in order to assemble and disassemble the wall assembly


21


. In the assembled position, the sliding rod


35


is located at the end of the slot locking the studs of the sliding rod


35


into the hooks of the fixed rod


34


. In this position, the sidewalls


28


and endwalls


29


join to form a rectangular box. In the disassembled position, the sliding rod


35


is located in the center of the slot unlocking the studs of the sliding rod


35


from the hooks of the fixed rod


34


. In this position, the sidewalls


28


and endwalls


29


separate slightly to release the contents of the form


17


. The two lifting dowels


31


extend outwardly parallel from each end of the long sidewalls


28


.




A latch assembly includes a latch


37


, a latch spring


38


, a locking rod


41


, and locking rod clips


42


. A latch


37


is pivotally attached at its mid-point to an end of each sidewall


28


by any suitable means, such as a pin. The latch


37


is a rectangular shaped bar with two notches located on opposite corners of the latch. A latch spring


38


, such as a tension spring, connects from the top of the latch


37


to a respective sidewall


28


imparting a counter-clockwise force on the latch


37


. A duplicate latch


39


and latch spring


40


are mirrored on the opposite ends of each sidewall


28


. A locking rod


41


extends around the end of the form


17


and pivotally connects to the bottom of two latches


37


using any suitable means, such as a pin. Locking rod clips


42


attach to each end of each sidewall


28


to limit the locking rods


41


to one-dimensional motion. As the locking rods


41


slide back and forth through the locking rod clips


42


, the pivotally attached pair of latches


37


and


39


pivot correspondingly. Those of ordinary skill in the art will recognize that many variations in the shape and design of the straight form


17


may be utilized.




As illustrated in

FIG. 3B

, a corner form


170


is used to cure the lightweight concrete composite into a desirable shape, which, in this preferred embodiment, is four unitary corner-shaped blocks with one thru hole in the center and a half hole on either end. The preferred form


170


thus includes a cap


180


, a bottom tube assembly


200


, and a wall assembly


210


. Although the preferred embodiment discloses four unitary corner-shaped blocks, those of ordinary skill in the art will recognize that any number of corner shaped blocks may be created or a form producing any desirable shape, such as a square, circle, or angle, may be utilized.




The cap


180


is a plus-shaped plate with four cylinders and eight half cylinders extending perpendicular from the lower face of the plate. In this preferred embodiment, the cylinders are equally spaced adjacent a corner of the plate with two half cylinders on each end. Each one of the two half cylinders are flush with their respective ends of the plate. The base of the cylinders should slope into a cone shape to allow for easier removal of the cap


180


. The edges of the plus-shaped plate terminate in L-shaped cap brackets


190


that define slots between the top of the cap


180


and each cap bracket


190


. Two tabs


230


on each side are attached to each ridge and extend downward from the cap


180


, and a dowel


240


extends perpendicularly from each tab


230


. Two cap brackets


220


attach to the top of the plus-shaped plate.




The bottom tube assembly


200


in this preferred embodiment is a plus-shaped base with four cylinders and eight half cylinders extending perpendicular from the face of the base. The cylinders are equally spaced adjacent a corner of the base with two half cylinders on each end. Each one of the two half cylinders are flush with their respective ends of the base. The base of the cylinders should slope into a cone shape to allow for easier removal of the base. The spacing of the cylinders and half cylinders must equal the spacing of the cylinders and half cylinders on the cap


180


. In addition, the length of the cylinders and half cylinders should be long enough for the tops to meet flush with the cylinders and half cylinders on the cap


180


when the form


170


is completely assembled and compressed. The corner portions of the plus-shaped base are recessed defining a lip. Two dowels


250


extend outwardly from a front and rear portion of the plus-shaped base. A tab


260


is attached to the bottom of the base at the front center of the base. A wheel


27


is pivotally attached to the bottom of the front tab


260


, while rear wheels


270


are fixed to the bottom of the base. The wheels


270


allow the form


170


to travel along a guide rail


46


of a station conveyor


43


. Although the preferred embodiment of the corner form


170


discloses four cylinders and eight half cylinders, those of ordinary skill in the art will recognize that any number of cylinders or shapes may be utilized.




The wall assembly


210


includes inner walls


280


, which form a plus to divide the interior of wall assembly


210


into four corner sections; sidewalls


290


, which are W-shaped to define a corner; two mating assemblies


300


; two hinges


301


; and lifting dowels


310


. The two mating assemblies


300


and the two hinges


301


are located on opposite sides and connect adjacent sidewalls


290


together, thereby forming a plus-shaped box suitable for forming four unitary corner-shaped blocks. The perimeter dimensions of the plus-shaped box match the perimeter dimensions of the cap


180


and the bottom tube assembly


200


.




Each mating assembly


300


includes a bracket


315


, two rods


320


, a lever arm


330


, levers


325


, two rods


335


, two brackets


340


, and two brackets


345


. The bracket


315


attaches at approximately the mid-point to a respective one of sidewalls


290


by any suitable means, such as welding, and includes a pivot rod


316


pivotally attached thereto. The lever arm


330


and the rods


320


fixedly attach to the pivot rod


316


. The brackets


340


attach at upper and lower ends to the same sidewall


290


as the bracket


315


, using any suitable means, such as welding. The brackets


345


attach in opposed relationship to a respective bracket


340


on an adjacent sidewall


290


, using any suitable means, such as welding. A lever


325


pivotally connects at a midpoint to a respective bracket


340


and at each end to a rod


320


and a rod


335


, respectively. A rod


335


fixedly connects to a respective bracket


345


.




The lever arm


330


pivots relative to the bracket


315


to assemble and disassemble the sidewall assembly


210


. In the assembled position, the lever arm


330


rotates counterclockwise to pull the levers


325


towards the bracket


315


via rods


320


, thereby pulling adjacent sidewalls


290


together about respective hinges


301


via the rods


335


and brackets


345


. In the disassembled position, the lever arm


330


rotates clockwise to push the levers


325


away from the bracket


315


via rods


320


, thereby pushing apart adjacent sidewalls


290


about respective hinges


301


via the rods


335


and brackets


345


. In the disassembled position, each of the four unitary corner-shaped blocks releases from the form


170


. The two lifting dowels


310


on each side extend outwardly parallel from a sidewall


290


.




A latch assembly includes a latch


370


, a latch spring


380


and a locking rod


420


. A latch


370


pivotally attaches at its mid-point to respective sidewalls


290


adjacent each hinge


301


using any suitable means, such as a pin. The latch


370


is a rectangular shaped bar with two notches located on opposite corners of the latch. A latch spring


380


, such as a tension spring, connects from the top of the latch


370


to a respective sidewall


290


imparting a counter-clockwise force on the latch


370


. A duplicate latch


390


and latch spring


400


are mirrored on adjacent sidewalls


290


. A locking rod


410


extends around the end of the form


170


and pivotally connects to the bottom of the two latches


370


using any suitable means, such as a pin. Similarly, a locking rod


420


extends around the end of the form


170


and pivotally connects to the bottom of the two latches


390


using any suitable means, such as a pin. As the locking rod


410


and


420


slide back and forth, the pivotally attached pair of latches


370


and


390


pivot correspondingly. Those of ordinary skill in the art will recognize that many variations in the shape and design of the form


170


may be utilized.




As illustrated in FIGS.


1


and


4


A-


4


D, a station conveyor


43


routes a plurality of forms


17


or


170


in a continuous loop simultaneously through all the stations of the apparatus


1


, thereby creating a time efficient process. The station conveyor


43


includes a track assembly


44


for straightaway sections, a turnstile


45


for curved sections, and a guide rail


46


along both sections. The guide rail


46


is rigidly affixed to a foundation of the apparatus


1


using any suitable means, such as brackets attached to the guide rail


46


and bolts sunk into the foundation, to provide a fixed pathway for the conveyance of a form


17


or


170


.




The track assembly


44


includes a conveyor rod


47


, a plurality of roller pins


49


, a plurality of bearings


50


, a plurality of conveyor catches


51


, a plurality of catch stops


52


, a plurality of catch springs


53


, and a conveyor cylinder


48


, which is any suitable hydraulically or pneumatically operated cylinder. The conveyor rod


47


extends the entire length of each straightaway section. A beginning end of the conveyor rod


47


is attached to a piston of the conveyor cylinder


48


. Bearings


50


are rigidly attached to the guide rail


46


at appropriate intervals along the conveyor rod


47


. The bearings


50


restrict the conveyor rod


47


to one-dimensional motion, parallel with the conveyor cylinder


48


. Roller pins


49


are perpendicularly attached to the outer vertical side of the guide rail


46


closest to the conveyor rod


47


at appropriate intervals by any suitable means, such as a welding. The roller pins


49


provide support while still allowing the conveyor rod


47


to move.




The conveyor catch


51


is an L-shaped bracket with a short leg set 45° counter-clockwise about an axis perpendicular to an end of a long leg. Conveyor catches


51


are hingedly attached at appropriate intervals along the conveyor rod


47


by appropriate means, such as a holding pin


54


. The end of the long leg opposite the end affixed to the short leg extends towards the direction of forward motion of the station conveyor


43


.




A catch stop


52


is a rectangular block with an end face angled downward 45° and a bottom face slotted for mounting to the conveyor rod


47


. Catch stops


52


are attached to the conveyor rod


47


by any suitable means, such as welding, directly preceding each conveyor catch


51


. The angled face extends towards the direction of forward motion of the station conveyor


43


.




A catch spring


53


, such as a torsion spring, is connected from the holding pin


54


to the conveyor catch


51


. The catch spring


53


pulls the conveyor catch


51


clockwise until the long leg of the conveyor catch


51


abuts the catch stop


52


at a default position, which will be referred to as the engagement position. In this position, the long end of the conveyor catch


51


is positioned at a 45° angle with respect to the foundation and the short leg of the conveyor catch


51


is perpendicular to the foundation. The conveyor catch


51


can be rotated until the long end of the conveyor catch


51


is perpendicular to the foundation, which will be referred to as the bypass position.




The turnstile


45


includes a turnstile post


55


, a turnstile motor


56


, a turnstile arm


57


, and a turnstile catch


58


. The turnstile post


55


is mounted to the foundation beside the guide rail


46


. The turnstile arm


57


is pivotally attached perpendicular to the top of the turnstile post


55


. The turnstile catch


58


is a rectangular block with one face of the block extending lengthwise slightly farther than the rest of the block. The turnstile arm


57


is pivotally attached to the extended face end of the turnstile catch


58


so that the extended face rests against the turnstile arm


57


and the length of the turnstile catch


58


is parallel to the turnstile post


55


. Gravity normally pulls the turnstile catch


58


to a default position, parallel to the turnstile post


55


, which will be referred to as the engagement position. The turnstile catch


58


can be rotated until it is perpendicular to the turnstile post


55


. This position will be referred to as the bypass position. The extended face on the turnstile catch


58


limits the rotation of the turnstile catch


58


to one direction. The turnstile motor


56


is attached to the end of the turnstile arm


57


mounted on the turnstile post


55


by any suitable means, such as a coupling. The turnstile motor


56


is a bi-directional motor that rotates the turnstile arm


57


in both a clockwise and counter-clockwise direction.




In operation, the station conveyor


43


via the track assembly


44


and the turnstile


45


propel a plurality of forms about the apparatus


1


, whereby the front center wheel


27


of a form


17


or


170


rolls along the guide rail


46


following the guide rail


46


about the entire path defined by the station conveyor


43


. As a form


17


or


170


reaches the beginning of a curve, the form


17


or


170


engages a micro-switch positioned along the station conveyor


43


at a turnstile


45


. The micro-switch senses the arrival of the form


17


or


170


and outputs a signal that activates the turnstile motor


56


, which rotates the turnstile arm


57


to a start point located directly behind the form


17


or


170


. While the turnstile arm


57


rotates over the form


17


or


170


, the turnstile catch


58


strikes the form


17


or


170


and rotates to the bypass position allowing it to pass over the form


17


or


170


. When the turnstile arm


57


reaches the start point, the turnstile catch


58


returns to the engagement position. Further, the turnstile arm


57


engages a micro-switch positioned on the turnstile post


55


. The micro-switch senses the arrival of the turnstile arm


57


and outputs a signal that reverses the turnstile motor


56


, which then rotates the turnstile arm


57


in the opposite direction. As the turnstile arm


57


rotates, the turnstile catch


58


strikes the form


17


or


170


. However, this time the extended face on the turnstile catch


58


prevents it from rotating. Therefore, the turnstile


45


pushes the form


17


or


170


along the guide rail


46


.




As the form


17


or


170


enters a straightaway section of the station conveyor


43


, the bottom of the form


17


or


170


strikes a conveyor catch


51


, which rotates to the bypass position allowing the form


17


or


170


to slide over the conveyor catch


51


. After the form


17


or


170


completely slides over the conveyor catch


51


, the conveyor catch


51


returns to the engagement position. When the form


17


or


170


has completely passed over the conveyor catch


51


, the form


17


or


170


engages a micro-switch positioned along the straightaway section of the station conveyor


43


. The micro-switch senses the arrival of the form


17


or


170


and outputs a signal that deactivates the turnstile motor


56


.




The conveyor cylinder


48


operates in continuous reciprocating manner to alternately extend and retract its piston and thus the conveyor rod


47


. As the conveyor rod


47


moves away from the conveyor cylinder


48


, the conveyor catch


51


strikes the form


17


or


170


pushing it along the guide rail


46


. At full extension, the piston of the conveyor cylinder


48


engages a micro-switch of the conveyor cylinder


48


. The micro-switch senses the full extension of the piston and outputs a signal that reverses the conveyor cylinder


48


, which retracts the piston and thus the conveyor rod


47


. As the conveyor cylinder


48


retracts its piston, a second conveyor catch


59


slides under the form


17


or


170


until it reaches a point directly behind the form


17


or


170


. At full retraction, the piston of the conveyor cylinder


48


engages a micro-switch of the conveyor cylinder


48


. The micro-switch senses the full retraction of the piston and outputs a signal that reverses the conveyor cylinder


48


, which extends the piston and thus the conveyor rod


47


, thereby continuously propelling a form along a straightaway section of the station conveyor


43


. The distance the form


17


or


170


moves after each extension of the piston of the conveyor cylinder will be referred to as one step. The station conveyor


43


thus continuously operates as described above to move a plurality of forms


17


or


170


around any length loop desired. Although the preferred embodiment discloses the station conveyor


43


, those of ordinary skill in the art will recognize that any type of conveying apparatus may be utilized.




As illustrated in

FIGS. 5-8

, a form-loading station


60


includes a cap removal/replacement assembly


61


, a screed assembly


62


, and a compression assembly


63


. The cap removal/replacement assembly


61


includes a frame


64


, two cap arms


65


, two cap catches


66


, two cap catch springs


67


, a mounting block


68


, and a cap cylinder


69


, which is any suitable hydraulically or pneumatically operated cylinder. The frame


64


is made of two vertical legs and a horizontal crossbar mounted to the foundation on either side of the station conveyor


43


using any suitable means, such as brackets attached to each leg and bolts sunk into the foundation. The crossbar connects the ends of the legs opposite the ends mounted to the foundation by any suitable means, such as welding, thus spanning the crossbar over the station conveyor


43


. The cap arm


65


is a bar with two equal and opposite bends defining a hinged end, an angled length, and an engagement end, with the engagement end being parallel to the hinged end. An L-shaped cap arm bracket


70


is attached along the entire underside of the engagement end defining a slot between the underside of the engagement end of the cap arm


65


and the cap arm bracket


70


. The cap catch


66


is flat strip defining a hinged end and an engagement end. The hinged end of the cap catch


66


is hingedly attached to the angled length of each cap arm


65


by a pin


71


, with the engagement end of the cap catch


66


extending towards the engagement end of the cap arm


65


. The cap catch spring


67


, such as a torsion spring, is connected from the pin


71


to the cap catch


66


. The cap catch spring


67


pulls the cap catch


66


to a default position approximately parallel to the angled length of the cap arm


65


, which will be referred to as the lifting position. The cap catch


66


can be rotated until it is parallel to the engagement end of the cap arm


65


. This position will be referred to as the bypass position. The ends of the two cap arms


65


are pivotally attached to each of the vertical legs of the frame


64


and extend towards the direction of forward motion of the station conveyor


43


. The cap arms


65


are connected by at least one crossbar using any suitable means, such as welding. The mounting block


68


is attached to the crossbar of the frame


64


by any suitable means, such as welding. The cap cylinder


69


is hingedly connected from the mounting block


68


to a crossbar


72


connecting the cap arms


65


. As illustrated in

FIG. 6B

, extending the piston of the cap cylinder


69


rotates the cap arms


65


counter-clockwise to a horizontal position. This position will be referred to the engagement position. Retracting the piston of the cap cylinder


69


rotates the cap arms


65


clockwise to an upward angle. The upward angle must be large enough to allow clearance for the screed assembly


62


to pass below the cap arms


65


. This position will be referred to as the retracted position.




The screed assembly


62


includes a frame


79


having supporting legs and screed tracks


79


A attached thereto. The legs mount to the foundation on either side of the station conveyor


43


by any suitable means, such as brackets attached to each leg and bolts sunk into the foundation. The screed assembly


62


further includes a screed box


73


, a leveling hopper


74


, an auger


75


, a screed motor


76


, and two leveling cylinders


77


and a screed cylinder


78


, which are any suitable hydraulically or pneumatically operated cylinders. The screed box


73


is a rectangular box with an open top and a slot in the bottom the same size as the top opening of the form


17


or the form


170


. Alternatively, the screed box


73


could include an opening suitable for the filling of both forms


17


and


170


. The edges of the screed box


73


rest within the screed tracks


79


A, which run perpendicular to the station conveyor


43


. The screed cylinder


78


is connected to the frame


79


between an end of the screed track


79


A and a side of the screed box


73


. When the screed cylinder


78


extends it slides the screed box


73


directly over the station conveyor


43


, which will be referred to as the loading position. When the screed cylinder


78


retracts, it slides the screed box


73


to a position adjacent the station conveyor


43


, which will be referred to as the retracted position.




The leveling hopper


74


resides freely inside the screed box


73


. Two leveling cylinders


77


connect from the screed box


73


to the leveling hopper


74


using a mounting bracket


80


. The leveling cylinders


77


extend and retract their pistons to slide the leveling hopper


74


one dimensionally inside the screed box


73


. The auger


75


is mounted inside the leveling hopper


74


using any suitable means, such as bearings. The screed motor


76


is coupled to the end of the auger


75


through a lengthwise slot in the screed box


73


. The slot allows the screed motor


76


and auger


75


to slide along with the leveling hopper


74


when the leveling cylinders


77


extend and retract.




The compression assembly


63


includes a compression post


81


, a compression motor


82


, an extension arm


83


, a mounting bar


84


, a top compression arm


85


, a stabilizer


86


, a bottom compression arm


87


, and a compression cylinder


88


. The compression post


81


mounts to the foundation beside the station conveyor


43


and after the screed assembly


62


relative to the direction of forward motion of the station conveyor


43


using any suitable means, such as a bracket attached to the compression post


81


and bolts sunk into the foundation. The extension arm


83


pivotally attaches at one end perpendicular to the top of the compression post


81


.




The mounting bar


84


is a straight bar including a top end and a bottom end. The mid-point of the mounting bar


84


connects in a vertical orientation to the unattached end of the extension arm


83


using any suitable means, such as welding. The bottom compression arm


87


is a U-shaped bar defining a hinged end and a compression end, which provides a wide stable base to support the form


17


or


170


during compression. Although this preferred embodiment discloses the bottom compression arm


87


as a U-shaped bar, those of ordinary skill in the art will recognize that any suitable shape may be utilized. The hinged end of the bottom compression arm


87


attaches to the bottom end of the mounting bar


84


in a plane parallel to the extension arm


83


. The top compression arm


85


is a straight bar defining a hinged end and a compression end. The hinged end of the top compression arm


85


attaches to the top end of the mounting bar


84


in a plane parallel to the extension arm


83


. The stabilizer


86


hingedly connects to the compression end of the top compression arm


85


.




The compression cylinder


88


hingedly connects from the top compression arm


85


to the bottom compression arm


87


. The compression cylinder


88


retracts to reduce to a minimum the distance between the compression ends of the top compression arm


85


and bottom compression arm


87


, which will be referred to as the compression position. The compression cylinder


88


extends to increase to a maximum the distance between the top compression arm


85


and bottom compression arm


87


, which will be referred to as a release position. As the compression cylinder


88


extends and retracts, the stabilizer


86


swivels to maintain flat contact with the form


17


or


170


.




The compression motor


82


mounts to the compression post


81


and engages the extension arm


83


using any suitable means, such as a coupling. The compression motor


82


rotates the extension arm


83


counter-clockwise to a default position parallel to the station conveyor


43


, which will be referred to as the bypass position. The compression motor


82


further rotates the extension arm


83


clockwise 90° to a position that permits engagement with a form


17


or


170


, which will be referred to as the engagement position.




In operation, the station conveyor


43


conveys a form


17


or


170


to the form-loading station


60


. The cap arms


65


of the cap removal/replacement assembly


61


begin in the engagement position so that, as the form


17


or


170


arrives at the form-loading station


60


, the cap brackets


22


or


220


of the cap


18


or


180


strike the cap catches


66


of the cap removal/replacement assembly


61


, thereby rotating them to the bypass position. As generally illustrated in

FIG. 6A

, the cap brackets


22


or


220


of the cap


18


or


180


slide into the slots on the cap arms


65


, and the cap catches


66


return to the lifting position.




The station conveyor


43


is configured relative to the form-loading station


60


such that, at full extension, the conveyor cylinder


48


of the station conveyor portion associated with the form-loading station


60


delivers the form


17


or


170


to the cap removal/replacement assembly


61


. Upon conveyance into the cap removal/replacement assembly


61


, the form


17


or


170


engages a micro-switch that outputs a signal to the station conveyor


43


that overrides the retraction signal of the conveyor cylinder


48


associated with the form-loading station


60


. Thus, the portion of the station conveyor


43


associated with the form-loading station


60


remains disabled during the filling of the form


17


or


170


. The micro-switch further outputs a signal that activates the cap cylinder


69


, which rotates the cap arms


65


to their retracted position, thereby lifting the cap


18


or


180


from the form


17


or


170


. As generally illustrated in

FIG. 6B

, the cap


18


or


180


slides back into the slots of the cap arms


65


until it strikes the cap catches


66


, which remain in the lifting position supporting the cap


18


or


180


.




In their retracted position, the cap arms


65


engage a micro-switch that outputs a signal directing the screed cylinder


78


to extend the screed box


73


to the loading position directly over the form


17


or


170


. In the loading position, the leveling hopper


74


is located directly underneath a loading conveyor


89


, which is any suitable conveyor, such as a belt conveyor. The loading conveyor


89


attaches underneath the mixer discharge hopper


16


to receive the lightweight concrete composite therefrom for delivery to the leveling hopper


74


. As the screed box


73


reaches the loading position, it engages a micro-switch, which outputs a signal that opens a door of the mixer discharge hopper


16


and activates the loading conveyor


89


to deliver the lightweight concrete composite to the leveling hopper


74


. The micro-switch further outputs a signal that activates the screed motor


76


, thereby rotating the auger


75


to evenly distribute the lightweight concrete composite throughout the leveling hopper


74


. A micro-switch positioned within the leveling hopper


74


or the mixer discharge hopper


16


senses when either the leveling hopper


74


is full or the mixer discharge hopper


16


is empty. Upon sensing either condition, the micro-switch outputs a signal closing the mixer discharge hopper


16


and deactivating the loading conveyor


89


and the screed motor


76


.




As generally illustrated in

FIGS. 7A and 7B

, the micro-switch further outputs a signal that activates the leveling cylinders


77


, which slowly move the leveling hopper


74


forward over the form


17


or


170


to a position beyond the form


17


or


170


. When the leveling hopper


74


travels fully beyond the form


17


or


170


, it engages a micro-switch that reverses the leveling cylinders


77


, which slowly move the leveling hopper


74


backward over the form


17


or


170


to its original position in front of the form


17


or


170


. The movement of the leveling hopper


74


over the form


17


or


170


fills and levels the form


17


or


170


with the lightweight concrete composite contained in the leveling hopper


74


. As the leveling cylinders


77


fully retract, the leveling hopper


74


engages a micro-switch that outputs a signal resulting in the screed cylinder


78


returning the screed box


73


to the retracted position.




When the screed box


73


reaches the retracted position, it engages a micro-switch, which outputs a signal that activates the cap cylinder


69


. The cap cylinder


69


rotates the cap arms


65


to their engagement position, thereby returning the cap


18


or


180


onto the form


17


or


170


. The return of the cap arms


65


to their engagement position engages a micro-switch, which outputs a signal that reactivates the conveyor cylinder


48


of the station conveyor portion associated with the form-loading station


60


. The conveyor cylinder


48


retracts and then extends to move the form


17


or


170


forward one step into the compression assembly


63


.




As generally illustrated in

FIG. 8

, upon conveyance into the compression assembly


63


, the form


17


or


170


engages a micro-switch that outputs a signal to the station conveyor


43


that again overrides the retraction signal of the conveyor cylinder


48


associated with the form-loading station


60


. Thus, the portion of the station conveyor


43


associated with the form-loading station


60


remains disabled during the compression of the form


17


or


170


.




The micro-switch further outputs a signal that activates the compression motor


82


of the compression assembly


63


, which rotates the extension arm


83


from the bypass position to the engagement position, whereby the stabilizer


86


of the top compression arm


85


and the bottom compression arm


87


engage the form


17


or


170


. At the engagement position, the extension arm


83


engages a micro-switch, resulting in the output of a signal that deactivates the compression motor


82


and activates the compression cylinder


88


, which retracts to the compression position, thereby depressing the cap


18


or


180


down into the form


17


Or


170


. As the compression assembly


63


presses the cap


18


or


180


down, the cap dowels


24


or


240


strike the angled top of each latch


37


and


39


or


370


and


390


, respectively. Consequently, each latch


37


and


39


or


370


and


390


pivots allowing the cap


18


or


180


to press further down into the form


17


or


170


until the cap dowels


24


or


240


line up with the notch in the top of each latch


37


and


39


or


370


and


390


. As a result, the latch springs


38


and


40


or


380


and


400


pulls a respective latch


37


and


39


or


370


and


390


fitting the cap dowels


24


or


240


into the notches and locking the cap


18


or


180


in place.




At full retraction, the compression cylinder


88


engages a micro-switch, which outputs a signal reversing the compression cylinder to the release position. At full extension, the compression cylinder


88


engages a micro-switch, resulting in the output of a signal that activates the compression motor


82


, which rotates the extension arm


83


from the engagement position to the bypass position. When the extension arm


83


reaches the bypass position, it engages a micro-switch, which outputs a signal deactivating the compression motor


82


. The micro-switch further outputs a signal that reactivates the conveyor cylinder


48


of the station conveyor portion associated with the form-loading station


60


. The conveyor cylinder


48


retracts and then extends to move the form


17


or


170


forward toward the next station, a curing oven


90


.




In filling a form


17


or


170


, the same cap removal/replacement assembly


61


and the compression assembly


63


may be used with either form


17


or


170


, and, as previously described, the screed assembly


62


may include a screed box


73


configured to permit the filling of both forms


17


and


170


. Thus, both forms


17


and


170


may be routed together about the apparatus


1


to produce both unitary rectangular blocks and unitary corner-shaped blocks. Alternatively, the screed assembly


62


could be configured with multiple screed boxes


73


, which are positioned over a form depending upon the form type, or the apparatus


1


could include multiple form-filling stations


60


suitable for different form types, which ultimately feed into the curing oven


90


.




As illustrated in

FIG. 1

, the dotted line designates an area of the station conveyor


43


enclosed by the curing oven


90


. The station conveyor


43


moves the form


17


or


170


through the curing oven


90


, which is at a temperature sufficient to accelerate curing. As the form


17


or


170


travels through the curing oven


90


, the lightweight concrete composite cures. The curing oven


90


should be of a sufficient size to allow adequate time for proper curing to occur. When the form


17


or


170


exits the curing oven


90


, the lightweight concrete composite has hardened into a unitary lightweight concrete composite block


17


A and unitary lightweight concrete composite corner-shaped blocks. The station conveyor


43


continues to move the form


17


or


170


to the last station.




As illustrated in

FIGS. 9-11

, the last station is a block removal station


91


. The block removal station


91


includes a frame


92


, a lock assembly


93


, a bottom release assembly


94


, a lift assembly


95


, a sidewall release and engagement assembly


96


, a dispatch conveyor


97


, and a swing-arm assembly


98


. The frame


92


includes four vertical bars and four horizontal crossbars attached together by any suitable means, such as welding, to form a wire-frame box directly over the station conveyor


43


. The four vertical bars are attached to a base, which mounts to the foundation beside the station conveyor


43


using any suitable means, such as bolts sunk into the foundation. Slide rails


99


attach vertically on either side of the frame


92


by any suitable means, such as welding.




The lock assembly


93


is located on both sides of the frame


92


and includes lock cylinders


100


attached to the base of the frame


92


using any suitable means, such as welding. Each lock cylinder


100


hingedly connects to the bottom of a C-shaped finger lock


101


using any suitable means, such as a pin. When the lock cylinders


100


retract, each finger lock


101


is positioned away from the form


17


or


170


, which will be referred to as the unlocked position. When the lock cylinders


100


extend, each finger lock


101


is positioned with the open end of the C-shape engaged with and pressing down on the lip of the bottom tube assembly


20


or


200


of the form


17


or


170


, thereby locking the bottom tube assembly


20


or


200


within the station conveyor


43


.




The bottom release assembly


94


is located on both sides of the frame


92


and includes bottom release cylinders


102


each having a C-shaped bottom release clip


103


attached thereto. Each bottom release cylinder


102


attaches to a respective slide rail


99


using any suitable means, such as welding. A default position of the bottom release assembly


94


is with each bottom release cylinder


102


retracted. An unlocking position of the bottom release assembly


94


occurs when each bottom release cylinder


102


extends such that their bottom release clip


103


engages and pushes the locking rods


41


on the form


17


or the locking rods


410


and


420


on the form


170


. Consequently, the locking rods


41


pivot the latches


37


and


39


releasing the bottom dowels


25


attached to the bottom tube assembly


20


, or the locking rods


410


and


420


pivot the latches


370


and


390


releasing the bottom dowels


250


attached to the bottom tube assembly


200


.




The lift assembly


95


is located on both sides of the frame


92


and includes slides


104


freely attached to a respective slide rail


99


. Each slide


104


includes roller bearings


105


on each end for limiting travel of the slides


104


one-dimensionally along the length of a respective slide rail


99


. T-shaped engagement bars


106


attach to a face of a respective slide


104


using any suitable means, such as welding. Chains


107


of fixed length connect from a top end of a respective slide


104


to a top corner of a respective frame


92


. Each chain


107


rides along the top of a respective first pulley


108


pivotally attached to a top of a respective slide rail


99


. A pair of two connected lift cylinders


109


vertically attach to the frame


92


on opposing parallel portions of the base. Second pulleys


110


pivotally attach to the end of a respective lift cylinders pair opposite to the end attached to the base, and each chain


107


rides along the bottom of a respective second pulley


110


.




The lift cylinders


109


of each pair extend and retract to move a respective chain


107


and, thus, a respective slide


104


up and down a respective slide rail


99


to one of three levels. When both lift cylinders


109


of each pair are extended, the slides


104


reside at the bottom of the slide rails


99


, which will be referred to as the lower level. At the lower level, the engagement bars


106


attached to a respective slide


104


reside below the lifting dowels


31


or


310


of the form


17


or


170


. When one lift cylinder


109


of each pair retracts while the other lift cylinder


109


of each pair remains extended, the engagement bars


106


engage the lifting dowels


31


or


310


, and the slides


104


raise the sidewall assembly


21


or


210


and cap


18


or


180


to approximately the mid-point of a respective slide rail


99


, which will be referred to as the intermediate level. After both lift cylinders


109


of each pair retract, the slides


104


raise the sidewall assembly


21


or


210


and cap


18


or


180


to the top of a respective slide rail


99


, which will be referred to as the upper level.




A sidewall release and engagement assembly


96


is located on both sides of the frame


92


and includes sidewall release cylinders


111


having a C-shaped sidewall release clip


112


attached thereto and sidewall engagement cylinders


113


having a V-shaped sidewall engagement clip


114


attached thereto. The sidewall release cylinders


111


and sidewall engagement cylinders


113


attach to the base of the frame


92


using any suitable means, such as a bracket bar


130


welded to a respective sidewall release cylinder


111


and sidewall engagement cylinder


113


and to the base of the frame


92


. The sidewall release cylinders


111


and sidewall engagement cylinders


113


are positioned within the frame


92


such that the slides


104


and respective engagement bars


106


freely pass by to raise the sidewall assembly


21


or


210


and cap


18


or


180


to the intermediate and upper levels.




A default position of the sidewall release and engagement assembly


96


is with each sidewall release cylinder


111


retracted and with each sidewall engagement cylinder


113


extended. To release the sidewall assembly


21


or


210


, the sidewall release cylinders


111


extend so that their respective sidewall release clips


112


engage and push a respective engaging rod


36


or pivot a respective lever arm


330


. As a result, the sidewall assembly


21


or


210


disassembles as previously described. To engage the sidewall assembly


21


or


210


, the sidewall engagement cylinders


113


retract so that their respective sidewall engagement clips


114


engage and pull a respective engaging rod


36


or pivot a respective lever arm


330


. As a result, the sidewall assembly


21


or


210


assembles as previously described.




The dispatch conveyor


97


resides adjacent to the frame


92


and perpendicular to the station conveyor


43


. The dispatch conveyor


97


includes a belt conveyor


131


with a plurality of belts defining slots therebetween. The dispatch conveyor


97


transfers unitary lightweight concrete composite blocks


17


A or four unitary corner-shaped lightweight concrete composite blocks from the block removal station


91


to a storage or shipping area. Therefore, the direction of forward motion for the belt conveyor


131


is away from the station conveyor


43


.




The swing-arm assembly


98


includes a swing-arm member


115


, a first rotary motor


116


, a first gear


117


, a loading arm


118


, an unloading post


119


, a second rotary motor


120


, and a second gear


121


. A post of the swing-arm member


115


mounts to the foundation using any suitable means, such as a bracket attached to the swing-arm post


115


and bolts sunk into the foundation. An arm of the swing-arm member


115


pivotally attaches to the post using any suitable coupling that includes a bearing surface. The first gear


117


pivotally attaches to the arm of the swing-arm member


115


through a suitable coupling that includes a bearing surface. The first gear


117


freely rotates clockwise and counter-clockwise about a center axis of the first gear


117


extending perpendicular to the arm of the swing-arm member


115


.




A loading arm


118


attaches to the first gear


117


using any suitable means, such as welding. The loading arm


118


is a straight bar at least the length of the form


17


or


170


with a plurality of L-shaped loading brackets


122


appropriately spaced along the straight bar to support a unitary lightweight concrete composite block


17


A or the four unitary corner-shaped lightweight concrete composite blocks. The loading arm


118


must be of sufficient strength to support the weight of a unitary lightweight concrete composite block


17


A or the four unitary corner-shaped lightweight concrete composite blocks. Further, the loading brackets


122


should be spaced such that they fit in between the belts of the dispatch conveyor


97


.




The first rotary motor


116


connects to the arm of the swing-arm member


115


using any suitable means, such as a coupling. The first rotary motor


116


rotates the arm of the swing-arm member


115


around a center axis of the post of the swing-arm member


115


from a loading position to an unloading position. In the loading position, the loading arm


118


is extended directly over the station conveyor


43


. Alternatively, in the unloading position, the loading arm


118


is extended directly over the dispatch conveyor


97


in an upright position to support a unitary lightweight concrete composite block


17


A or the four unitary corner-shaped lightweight concrete composite blocks.




The unloading post


119


mounts to the foundation directly adjacent to the swing-arm member


115


using any suitable means, such as a bracket attached to the unloading post


119


and bolts sunk into the foundation. The second rotary motor


120


attaches perpendicularly to the unloading post


119


and extends towards the dispatch conveyor


97


. The second gear


121


pivotally attaches to the second rotary motor


120


through a suitable coupling that includes a bearing surface. When the swing-arm member


115


resides in the unloading position, the second gear


121


meshes with the first gear


117


. Accordingly, the second rotary motor


120


rotates the second gear


121


and, consequently, the first gear


117


and loading arm


118


from the unloading position to a dispatch position. In the dispatch position, the loading arm


118


is rotated 90° with respect to the axis of the first gear


117


, thereby inserting the loading brackets


122


between the belts


131


of the dispatch conveyor


97


. A unitary lightweight concrete composite block


17


A or the four unitary corner-shaped lightweight concrete composite blocks supported by the loading arm


118


thus engage the belts


131


of the dispatch conveyor


97


for transport to a storage or shipping area.




In operation, the station conveyor


43


is configured relative to the block removal station


91


such that, at full extension, the conveyor cylinder


48


of the station conveyor portion associated with the block removal station


91


delivers a form


17


or


170


to the block removal station


91


. In this preferred embodiment, the forms


17


or


170


are spaced along the station conveyor


43


such that a form


17


or


170


enters the block removal station


91


at the same time another form


17


or


170


enters the form-filling station


60


. Consequently, the form-filling station


60


controls the stopping and restarting of the portion of the station conveyor


43


associated with the block removal station


91


and the form-filling station


60


. Nevertheless, those of ordinary skill in the art will recognize that the block removal station


91


could control that same portion of the station conveyor


43


. Furthermore, although this preferred embodiment discloses the synchronous operation of the block removal station


91


and the form-filling station


60


, those of ordinary skill in the art will recognize other control schemes for regulating the movement of the forms through the block removal station


91


and the form-filling station


60


.




Upon conveyance into the block removal station


91


, the form


17


or


170


engages a micro-switch, which outputs a signal that activates the lock cylinders


100


of the lock assembly


93


, thereby moving the finger locks


101


to the locked position and, thus, locking the bottom tube assembly


20


or


200


within the station conveyor


43


. The extension of the lock cylinders


100


engages a micro-switch, which outputs a signal that deactivates the lock cylinders


100


and activates the bottom release cylinders


102


of the bottom release assembly


94


to move the bottom release clips


103


to their unlocked position. The bottom release clips


103


contact and push the locking rods


41


on the form


17


or the locking rods


410


and


420


on the form


170


, which pivots the latches


37


and


39


or


370


and


390


and releases the bottom dowels


25


or


250


attached to the bottom tube assembly


20


or


200


.




The extension of the bottom release cylinders


102


engages a micro-switch, which outputs a signal that retracts the bottom release cylinders


102


and activates a first respective lift cylinder


109


of each lift cylinder pair of the lift assembly


95


. The first activated lift cylinders


109


retract to raise the sidewall assembly


21


or


210


, cap


18


or


180


, and unitary lightweight concrete composite block


17


A or the four unitary corner-shaped lightweight concrete composite blocks from the lower level to the intermediate level, hence, separating the bottom tube assembly


20


or


200


.




A micro-switch engaged through the extension of the first activated lift cylinders


109


outputs a signal that deactivates the first activated lift cylinders and activates the first rotary motor


116


of the swing-arm assembly


98


. The first rotary motor


116


pivots the loading arm


118


to the loading position. As the loading arm


118


travels to its loading position, it engages a micro-switch that deactivates the first rotary motor


116


and activates the sidewall release cylinders


111


, which extend to contact their sidewall release clips


112


with a respective engaging rod


36


or lever arm


330


. The sidewall release clips


112


push a respective engaging rod


36


of the corner assemblies


30


to disassemble the form


17


as previously described, hence, dropping the unitary lightweight concrete composite block


17


A onto the loading arm


118


. Alternatively, the sidewall release clips


112


pivot a respective lever arm


330


of the securing assemblies


300


to disassemble the form


170


as previously described, hence, dropping the four unitary lightweight concrete composite blocks onto the loading arm


118


.




The extension of the sidewall release cylinders


111


engages a micro-switch, which outputs a signal that retracts the sidewall release cylinders


111


and activates a second respective lift cylinder


109


of each lift cylinder pair of the lift assembly


95


. The second activated lift cylinders


109


retract to raise the sidewall assembly


21


or


210


and the cap


18


or


180


from the intermediate level to the upper level, hence, separating the sidewall assembly


21


or


210


and the cap


18


or


180


from the unitary lightweight concrete composite block


17


A or the four unitary lightweight concrete composite blocks.




A micro-switch engaged through the extension of the second activated lift cylinders


109


outputs a signal that deactivates the second activated lift cylinders


109


and activates the first rotary motor


116


of the swing-arm assembly


98


. The first rotary motor


116


returns the loading arm


118


to the unloading position, thereby delivering the separated unitary lightweight concrete composite block


17


A or the four unitary lightweight concrete composite blocks over the dispatch conveyor


97


. As the loading arm


118


travels to its unloading position, it engages a micro-switch that deactivates the first rotary motor


116


and activates the second rotary motor


120


. The second rotary motor


120


pivots the second gear


121


and, thus, the first gear


117


to move the loading arm


118


from its unloading position to a dispatch position, whereby the unitary lightweight concrete composite block


17


A or the four unitary lightweight concrete composite blocks are transported to a storage or shipping area by the belts


131


. The travel of the loading arm


118


to its dispatch position engages a micro-switch that reverses the second rotary motor


120


, thereby returning the loading arm


118


to its unloading position. Upon reaching its unloading position, the loading arm


118


engages a micro-switch that deactivates the second rotary motor


120


.




The micro-switch engaged due to the travel of the loading arm


118


from its unloading position to its loading position also outputs a signal that reactivates the second respective lift cylinders


109


of each lift cylinder pair of the lift assembly


95


. The second reactivated lift cylinders


109


extend to lower the sidewall assembly


21


or


210


and the cap


18


or


180


from the upper level to the intermediate level. A micro-switch engaged through the retraction of the second reactivated lift cylinders


109


outputs a signal that deactivates the second activated lift cylinders


109


and activates the sidewall engagement cylinders


113


, which retract to contact their sidewall engagement clips


114


with a respective engaging rod


36


or lever arm


330


. The sidewall engagement clips


114


pull a respective engaging rod


36


of the corner assemblies


30


to assemble the form


17


as previously described. Alternatively, the sidewall engagement clips


114


pivot a respective lever arm


330


of the securing assemblies


300


to assemble the form


170


as previously described.




The retraction of the sidewall engagement cylinders


113


engages a micro-switch, which outputs a signal that extends the sidewall engagement cylinders


111


and reactivates the first respective lift cylinder


109


of each lift cylinder pair of the lift assembly


95


. The first reactivated lift cylinders


109


extend to lower the sidewall assembly


21


or


210


and the cap


18


or


180


from the intermediate level to the lower level. A micro-switch engaged through the retraction of the first reactivated lift cylinders


109


outputs a signal that deactivates the first reactivated lift cylinders and retracts the lock cylinders


100


of the lock assembly


93


, thereby moving the finger locks


101


to the unlocked position and, thus, releasing the bottom tube assembly


20


or


200


. After the release of the bottom tube assembly


20


or


200


, the now empty form


17


or


170


is ready to return to the form-filling station


60


for repeat of the entire process. The bottom release assembly does not reengage the locking rod


41


or the locking rods


410


and


420


as this occurs during the compression of the form


17


or


170


as previously described.




The preferred embodiment employs a micro-switch control scheme whereby the engaging of various micro-switches controls the station conveyor


43


, the form filling station


60


, and the block removal station


91


. The micro-switches employed are of a type well known to those of ordinary skill in the art, such as optical sensing switches, pressure switches, mechanically activated switches, and the like. Further, the use of such switches to control the components of the apparatus for manufacturing lightweight concrete composite blocks


1


are well known and understood by those of ordinary skill in the art. It should be understood, however, that a computer control scheme could be implemented in the apparatus for manufacturing lightweight concrete composite blocks


1


.




Although the present invention has been described in terms of the foregoing embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope accordingly, is not to be limited in any respect by the foregoing description; rather, it is defined only by the claims that follow.



Claims
  • 1. An apparatus for manufacturing unitary concrete blocks, comprising:a form defining a desired shape that holds a volume of composite, the form, comprising: a bottom assembly, a wall assembly that seats on the bottom assembly, and a cap that seats on the wall assembly; a form loading station that receives composite and delivers the composite to the form; a station conveyor, whereby the bottom assembly of the form couples with the station conveyor such that the station conveyor conveys the form about the apparatus in a continuous loop; a curing oven, wherein the station conveyor conveys the composite-filled form from the form loading station through the curing oven, thereby curing the composite into a unitary concrete block; and a block removal station that, upon delivery of the form from the curing oven via the station conveyor, removes the unitary concrete block from the form.
  • 2. The apparatus according to claim 1, wherein the wall assembly comprises:walls; and mating assemblies that couple the walls, thereby forming the desired shape that is assembled and disassemble.
  • 3. The apparatus according to claim 2, wherein the walls comprise:two sidewalls located opposite and parallel to each other; and two endwalls located opposite and parallel to each other.
  • 4. The apparatus according to claim 2, further comprising interior walls that divide the form into sections.
  • 5. The apparatus according to claim 2, further comprising hinges that couple the walls, whereby the walls assemble and disassemble.
  • 6. The apparatus according to claim 2, wherein each mating assembly comprises:fixed brackets that attach to a respective wall; sliding brackets that attach to a corresponding wall and define slots that hingedly attach to a corresponding fixed bracket; a fixed rod with a hook extending perpendicular from the fixed rod, wherein top and bottom ends of the fixed rod link the fixed brackets; a sliding rod with a stud and a tab both extending perpendicular from the sliding rod wherein top and bottom ends of the sliding rod hingedly link the sliding brackets through each slot, whereby the sliding rod slides back and forth to assemble and disassemble the wall assembly; and an engaging rod hingedly connected to the tab of the sliding rod and extending outwardly from the tab.
  • 7. The apparatus according to claim 2, wherein each mating assembly comprises:a first bracket attached to a respective wall; a second bracket attached to the same wall as the first bracket a third bracket attached to an adjacent wall; a pivot rod pivotally attached to the first bracket; a lever pivotally attached to the second bracket; a first rod fixedly attached to the third bracket and hingedly attached to the lever; a second rod fixedly attached to the pivot rod and hingedly attached to the lever; a lever arm fixedly attached to the pivot rod, whereby pivoting the lever arm assembles and disassembles the wall assembly.
  • 8. The apparatus according to claim 1, further comprising a latch assembly that couples the bottom assembly, the wall assembly, and the cap.
  • 9. The apparatus according to claim 8, wherein the latch assembly comprises:a latch that pivotally attaches to the walls, whereby the latch is adapted to rotate from an engagement position to a release position; and a latch spring connecting the latch to a respective wall imparting a rotational force on the latch, thereby rotating the latch to the engagement position.
  • 10. The apparatus according to claim 9, further comprising a locking rod that pivotally connects to the latch, whereby sliding the locking rod back and forth rotates the corresponding latch.
  • 11. The apparatus according to claim 10, further comprising a locking rod clip that attaches to the wall, whereby the locking rod clip limits the locking rod to one-dimensional motion.
  • 12. The apparatus according to claim 1, further comprising lifting dowels that allow the form to be lifted.
  • 13. The apparatus according to claim 1, wherein the cap comprises a plate with shapes extending perpendicular from the plate defining hollow areas within the unitary concrete block.
  • 14. The apparatus according to claim 13, wherein a base of the shapes slope into a cone shape to allow for easier removal of the cap.
  • 15. The apparatus according to claim 1, wherein the cap further comprises cap brackets attached to the cap, whereby the cap brackets are adapted for engagement that removes and replaces the cap.
  • 16. The apparatus according to claim 1, wherein the bottom assembly comprises a base with shapes extending perpendicular from the plate defining hollow areas within the unitary concrete block.
  • 17. The apparatus according to claim 1, wherein the bottom assembly includes wheels attached to the bottom of the base, whereby the form engages the station conveyor.
  • 18. An apparatus for manufacturing unitary concrete blocks, comprising:a form defining a desired shape that holds a volume of composite; a form loading station that receives composite and delivers the composite to the form, the form loading station, comprising: a cap removal/replacement assembly that removes and replaces the cap on the form, a screed assembly that receives composite and delivers the composite into the form, and a compression assembly that compresses the composite-filled form, thereby sealing the composite therein, a station conveyor that conveys the form about the apparatus in a continuous loops; a curing oven, wherein the station conveyor conveys the composite-filled form from the form loading station through the curing oven, thereby curing the composite into a unitary concrete block; and a block removal station that, upon delivery of the form from the curing oven via the station conveyor, removes the unitary concrete block from the form.
  • 19. The apparatus according to claim 18, wherein the cap removal/replacement assembly comprises:a cap arm; a cap cylinder attached to the cap arm, wherein the cap cylinder rotates the cap arm from an engagement position to a retracted position; and a catch assembly hingedly attached to the cap arm, whereby the catch assembly rotates between a lifting position and a bypass position.
  • 20. The apparatus according to claim 19, wherein the catch assembly comprises:a catch hingedly attached to the cap arm; and a catch spring that pulls the catch to the engagement position.
  • 21. The apparatus according to claim 19, wherein in the engagement position the cap arm engages the cap.
  • 22. The apparatus according to claim 19, wherein in the retracted position the cap arm rotates to allow the screed assembly to pass below the cap arm with the removed cap.
  • 23. The apparatus according to claim 19, wherein in the lifting position the catch supports the cap engaged by the cap arm.
  • 24. The apparatus according to claim 19, wherein in the bypass position the catch rotates until the catch allows the cap to bypass the catch assembly as the station conveyor moves the form forward.
  • 25. The apparatus according to claim 18, wherein the screed assembly comprises:a screed track extending over the station conveyer; a screed box coupled with the screed track; a screed cylinder coupled with the screed box, whereby the screed cylinder conveys the screed box along the screed track between a retracted position and a loading position; a leveling hopper disposed within the screed box that fills and levels the form with composite; and a leveling cylinder coupled with the leveling hopper, whereby the leveling cylinder slides the leveling hopper back and forth inside the screed box.
  • 26. The apparatus according to claim 25, wherein the screed assembly further comprises:an auger disposed within the leveling hopper that evenly distributes composite into the form; and a screed motor coupled with the auger, whereby the screed motor rotates the auger.
  • 27. The apparatus according to claim 25, wherein in the retracted position the screed box allows the cap removal/replacement assembly and compression assembly to engage the form.
  • 28. The apparatus according to claim 25, wherein in the loading position the screed box is directly over the form.
  • 29. The apparatus according to claim 18, wherein the compression assembly comprises:an extension arm; a compression motor that rotates the extension arm between a bypass position and an engagement position; a compression arm hingedly attached to the extension arm; and a compression cylinder that couples to the compression arm, whereby the compression cylinder rotates the compression arm between a compression position and a released position.
  • 30. The apparatus according to claim 29, wherein the compression assembly further comprises a stabilizer hingedly attached to the compression arm, whereby the stabilizer swivels to produce level contact with the form when the compression arm is rotated to the compression position.
  • 31. The apparatus according to claim 29, wherein in the engagement position the extension arm causes the compression arm to engage the form.
  • 32. The apparatus according to claim 29, wherein in the bypass position the extension arm allows the station conveyor to move the form forward bypassing the compression assembly.
  • 33. The apparatus according to claim 29, wherein in the compression position the compression arm depresses the form until the wall assembly is completely seated on the bottom tube assembly and the cap is completely seated on the wall assembly.
  • 34. The apparatus according to claim 29, wherein in the released position the compression arm disengages the form.
  • 35. An apparatus for manufacturing unitary concrete blocks, comprising:a form defining a desired shape that holds a volume of composite; a form loading station that receives composite and delivers the composite to the form; a station conveyor that conveys the form about the apparatus in a continuous loop, the station conveyor, comprising: a track assembly that conveys the form along straight sections, a turnstile that conveys the form along curved sections, and a guide rail along straight and curved sections that provides a fixed pathway for the conveyance of the form; a curing oven, wherein the station conveyor conveys the composite-filled form from the form loading station through the curing oven, thereby curing the composite into a unitary concrete block; and a block removal station that, upon delivery of the form from the curing oven via the station conveyor, removes the unitary concrete block from the form.
  • 36. The apparatus according to claim 35, wherein the track assembly comprises:a conveyor rod extending the entire length the straight section; a conveyor cylinder coupled with the conveyor rod, whereby the conveyor cylinder extends and retracts the conveyor rod; and a catch assembly attached at appropriate intervals along the conveyor rod, whereby the catch assembly rotates between an engagement position and a bypass position.
  • 37. The apparatus according to claim 36, further comprising bearings that rigidly attach to the guide rail at appropriate intervals along the conveyor rod, whereby the bearings restrict the conveyor rod to one-dimensional motion parallel with the conveyor cylinder.
  • 38. The apparatus according to claim 36, further comprising roller pins that attach to the guide rail at appropriate intervals, whereby the roller pins provide support without restricting motion to the conveyor rod.
  • 39. The apparatus according to claim 36, wherein the catch assembly comprises:a catch hingedly attached to the conveyor rod; a catch stop that rigidly attaches to the conveyor rod directly preceding each catch; and a catch spring that pulls the catch until it abuts the catch stop.
  • 40. The apparatus according to claim 36, wherein in the engagement position the catch spring pulls the conveyor catch until the conveyor catch abuts the catch stop, whereby the catch assembly engages the form as the conveyor cylinder coupled with the conveyor rod advances in the direction of forward motion of the station conveyor.
  • 41. The apparatus according to claim 35, wherein in the bypass position the conveyor catch rotates until the catch allows the form to bypass the catch assembly as the conveyor cylinder coupled with the conveyor rod moves in the direction opposite of forward motion of the station conveyor.
  • 42. The apparatus according to claim 1, wherein the station conveyor conveys multiple forms simultaneously to accommodate various production rates.
  • 43. An apparatus for manufacturing unitary concrete blocks, comprising:a form defining a desired shape that holds a volume of composite; a form loading station that receives composite and delivers the composite to the form; a station conveyor that conveys the form about the apparatus in a continuous loop; a curing oven, wherein the station conveyor conveys the composite-filled form from the form loading station through the curing oven, thereby curing the composite into a unitary concrete block; and a block removal station that, upon delivery of the form from the curing oven via the station conveyor, removes the unitary concrete block from the form, the block removal station, comprising: a lock assembly that locks the bottom assembly of the form in place, a bottom release assembly that uncouples the bottom assembly, walls, and cap, a lift assembly that raises and lowers the wall assembly and cap of the form between levels, a wall release and engagement assembly that disassembles and reassembles the walls, whereby the walls disassemble releasing the unitary concrete block from the form and the walls reassemble for reuse of the form, and a swing-arm assembly that removes the unitary concrete block from the block removal station.
  • 44. The apparatus according to claim 43, wherein the block removal station further comprises a dispatch conveyor that receives the unitary concrete block from the swing-arm assembly and conveys the unitary concrete block from the apparatus to a desired storage, shipping, or packaging area.
  • 45. The apparatus according to claim 43, wherein the lock assembly comprises:lock cylinders; and lock fingers hingedly attached to the lock cylinders, whereby the lock cylinders rotate the lock fingers between a locked position and an unlocked position.
  • 46. The apparatus according to claim 43, wherein the bottom release assembly comprises:a release cylinder; and a release clip attached to the release cylinders, whereby the cylinder extends and retracts the release clip between an engagement position and a retracted position.
  • 47. The apparatus according to claim 43, wherein lift assembly comprises:a frame; a slide coupled with the frame that travels along the frame, wherein the slide engages the wall assembly and cap; a first pulley attached to the frame; a second pulley; a chain connecting from the slide to the frame wherein the chain runs along the first and second pulleys; and a lift cylinder attached to the second pulley, whereby the cylinder extends and retracts the second pulley to convey the slide between a lower level and an upper level.
  • 48. The apparatus according to claim 43, wherein wall release and engagement assembly comprises:a release clip that engages the mating assembly coupling the walls; a release cylinder attached to the release clip, whereby the release cylinder extends and retracts to disassemble the walls; an engagement clip that engages the mating assembly coupling the walls; and an engagement cylinder attached to the engagement clip, whereby the engagement cylinder extends and retracts to assemble the walls.
  • 49. The apparatus according to claim 43, wherein the swing-arm assembly comprises:a swing-arm member; a first gear pivotally attached to the swing-arm member; a loading arm pivotally attached to the first gear, whereby the loading arm supports the unitary concrete block; and a first rotary motor coupled with the swing-arm member, whereby the first rotary motor rotates the swing-arm member between a loading position and an unloading position; an unloading post; a second gear that engages the first gear when the swing-arm member is in the unloading position; and a second rotary motor attached to the unloading post and coupled with the second gear, whereby the second rotary motor rotates the loading arm, between an upright position and a dispatch position via the second gear which is engaged with the first gear.
  • 50. The apparatus according to claim 49, wherein the loading position comprises a position, whereby the loading arm is extended directly over the station conveyor.
  • 51. The apparatus according to claim 49, wherein in the unloading position the loading arm is extended directly over the dispatch conveyor.
  • 52. The apparatus according to claim 49, wherein in the upright position the loading arm supports the unitary concrete block.
  • 53. The apparatus according to claim 49, wherein in the dispatch position the loading arm delivers the unitary concrete block.
  • 54. An apparatus for manufacturing unitary concrete blocks, comprising:an ingredient metering assembly that receives desired ingredients comprising water, cement, and polystyrene, whereby the ingredient metering assembly meters and delivers appropriate amounts of the desired ingredients to produce a composite; a grinder that reduces the size of the polystyrene; a sieve that allows only a desired size of reduced polystyrene to be delivered from the grinder to the ingredient metering assembly; a mixer that receives the desired ingredients from the ingredient metering assembly, whereby the mixer combines the desired ingredients to produce the composite; a form defining a desired shape that holds a volume of composite; a form loading station that receives composite from the mixer and delivers the composite to the form a station conveyor that conveys the form about the apparatus in a continuous loop; a curing oven, wherein the station conveyor conveys the composite-filled form from the form loading station through the curing oven, thereby curing the composite into a unitary concrete block; and a block removal station that, upon delivery of the form from the curing oven via the station conveyor, removes the unitary concrete block from the form.
  • 55. The apparatus according to claim 54, wherein the grinder comprises:a coarse grinder that reduces polystyrene into small pieces; and a fine grinder that receives small pieces of polystyrene from the coarse grinder and reduces the small pieces into even smaller particles.
  • 56. The apparatus according to claim 54, wherein the ingredient metering assembly comprises:a hopper that receives and delivers the desired ingredients; a scale attached to the hopper that measures an amount of the desired ingredients contained in the hopper; and a computer in communication with the scale and hopper that controls the type and quantity of the desired ingredients the hopper receives and delivers.
  • 57. The apparatus according to claim 56, further comprising an auger to convey the desired ingredients into the hopper.
  • 58. The apparatus according to claim 56, further comprising a pump to convey the desired ingredients into the hopper.
  • 59. The apparatus according to claim 56, further comprising a heater to heat the desired ingredients.
  • 60. The apparatus according to claim 54, wherein the ingredient metering assembly receives further desired ingredients comprising a superplasticizer that increases the flowability, delays curing time, and increase the ultimate compressive strength of the resulting composite.
  • 61. The apparatus according to claim 54, wherein the ingredient metering assembly receives further desired ingredients comprising a water conditioner that increases the hydration hardness of the resulting composite.
  • 62. The apparatus according to claim 54, wherein the ingredient metering assembly receives further desired ingredients comprising an accelerant that decreases the curing time of the resulting composite.
  • 63. The apparatus according to claim 59, wherein the heater heats the water to a temperature of at least 150° F.
  • 64. The apparatus according to claim 54, wherein the mixer further comprises a mixer discharge hopper that stores composite until needed by the form loading station.
RELATED APPLICATION

This present application claims all available benefit, under 35 U.S.C. §119(e), of U.S. provisional patent application Ser. No. 60/214,960 filed Jun. 29, 2000.

US Referenced Citations (17)
Number Name Date Kind
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Foreign Referenced Citations (5)
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Provisional Applications (1)
Number Date Country
60/214960 Jun 2000 US