Method and apparatus for manufacture of unitary lightweight concrete composite blocks

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.

INFORMATION

DETAILED DESCRIPTION OF THE INVENTION

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIG. 1, an apparatus for manufacturing lightweight concrete composite blocks 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 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 where they are broken into smaller pieces. The coarse grinder 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 and ground into smaller particles. The fine grinder 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 , the polystyrene is conveyed through a pipe to a polystyrene hopper by any suitable means, such as vacuum pressure or blowing with high-pressure air, as described herein with reference to FIG. . The grinder includes a sieve therein that prevents passage of any polystyrene particles larger than a predetermined particle. Although the preferred embodiment discloses one polystyrene hopper , those of ordinary skill in the art will recognize that any number or size of tanks, including one, may be utilized.

A mixer , 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 includes a computer , which is any commercially available microcontroller or personal computer, which controls the process of forming the lightweight concrete composite. The computer begins by starting a pump C to transfer fresh or recycled water from a water source through a pipe into a water hopper A, having a scale attached thereto. The scale is electrically connected to the computer to measure the weight or volume of water entering the water hopper A and output a representative signal to the computer . When a predetermined weight or volume of water is reached, the computer stops the first pump C and then opens a solenoid operated door of the water hopper A to convey the water from the water hopper A to the mixer 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 B, before adding to the mixer . The heated water acts as an accelerant in the mixture. The preferred method of delivering water into the water hopper 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 adds an accelerant by starting a pump E to transfer an accelerant from an accelerant source through a pipe into an accelerant hopper D, having a scale F attached thereto. The scale F is electrically connected to the computer to measure the weight or volume of accelerant entering the accelerant hopper D and output a representative signal to the computer . When a predetermined weight or volume of accelerant is reached, the computer stops the pump E and then opens a solenoid operated door of the accelerant hopper D to convey the accelerant from the accelerant hopper D to the mixer by gravity via a pipe. The preferred method of delivering accelerant into the accelerant hopper 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 adds a water conditioner by starting a pump B to transfer a water conditioner from a water conditioner source through a pipe into a water conditioner hopper A, having a scale attached thereto. The scale is electrically connected to the computer to measure the weight or volume of water conditioner entering the water conditioner hopper A and output a representative signal to the computer . When a predetermined weight or volume of water conditioner is reached, the computer stops the pump B and then opens a solenoid operated door of the water conditioner hopper A to convey the water conditioner from the water conditioner hopper A to the mixer by gravity via a pipe. The preferred method of delivering water conditioner into the water conditioner hopper 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 adds a superplasticizer by starting a pump B to transfer a superplasticizer from a superplasticizer source through a pipe into a superplasticizer hopper A, having a scale attached thereto. The scale is electrically connected to the computer to measure the weight or volume of superplasticizer entering the superplasticizer hopper A and output a representative signal to the computer . When a predetermined weight or volume of superplasticizer is reached, the computer stops the pump B and then opens a solenoid operated door of the superplasticizer hopper A to convey the superplasticizer from the superplasticizer hopper A to the mixer by gravity via a pipe. The preferred method of delivering superplasticizer into the superplasticizer hopper A is automatically, however, those of ordinary skill in the art will recognize that the superplasticizer could be added manually.

Subsequently, the computer adds cement by starting an auger B to transfer cement from cement source through the auger B into a cement hopper A, having a scale C attached thereto. The scale C is electrically connected to the computer to measure the weight or volume of cement entering the cement hopper A and output a representative signal to the computer . When a predetermined weight or volume of cement is reached, the computer stops the auger B and then opens a solenoid operated door of the cement hopper A to convey the cement from the cement hopper A to the mixer by gravity via a pipe. The preferred method of delivering cement into the cement hopper 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 until blended thoroughly into an intermediate concrete composite.

Finally, the computer outputs a signal to transfer polystyrene by any suitable means, such as vacuum pressure or blowing with high-pressure air, from the fine grinder to the polystyrene hopper , which includes a scale attached thereto. The scale is electrically connected to the computer to measure the weight or volume of polystyrene entering the polystyrene hopper and output a representative signal to the computer . When a predetermined weight or volume of polystyrene is reached, the computer shuts off a blower or vacuum pump and then opens a solenoid operated door of the polystyrene hopper to convey the polystyrene from the polystyrene hopper to the mixer by gravity via a pipe. The preferred method of delivering polystyrene into the polystyrene hopper 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 outputs a signal to transport the lightweight concrete composite by gravity to a mixer discharge hopper located below the mixer . The lightweight concrete composite is stored in the mixer discharge hopper until needed. In this preferred embodiment, the computer produces lightweight concrete composite sufficient for one form or 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 .

As illustrated in FIG. 3A, a straight form is used to cure the lightweight concrete composite into a desirable shape, which, in this preferred embodiment, is a unitary rectangular block A with two thru holes in the center and a half hole on either end. The preferred form thus includes a cap , a bottom tube assembly , and a wall assembly . Although the preferred embodiment discloses a unitary rectangular block 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 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 . The two long edges of the rectangular plate terminate in two L-shaped cap brackets that define slots between the top of the cap and each cap bracket . Two tabs on each side are attached to each ridge and extend downward from the cap , and a dowel extends perpendicularly from each tab . Two cap brackets attach to the two L-shaped cap brackets , thereby spanning the rectangular plate of the cap .

The bottom tube assembly 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 . 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 when the form is completely assembled and compressed. The entire edge of the rectangular base is recessed defining a lip. Two dowels extend outwardly from each lip. Three tabs 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 is pivotally attached to the bottom of the front tab , while rear wheels are fixed to the bottom of the rear tabs . The wheels allow the form to travel along a guide rail of a station conveyor . Although the preferred embodiment of the form 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 includes two sidewalls , two endwalls , two mating assemblies , and lifting dowels . The two mating assemblies are located on opposite corners and connect a respective sidewall and a respective endwall , thereby forming a rectangular box. The perimeter dimensions of the rectangular box match the perimeter dimensions of the cap and the bottom tube assembly .

Each corner assembly includes two fixed brackets , two sliding brackets , a fixed rod , and a sliding rod . The two fixed brackets are attached to a respective end of a long sidewall by a suitable means, such as welding. The fixed rod 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 are connected to the fixed brackets by any suitable means, such as welding. The two sliding brackets are attached to a respective endwall by any suitable means, such as welding. Each sliding bracket defines a slot that hingedly attaches to a corresponding fixed bracket by any suitable means, such as a pin. The sliding rod 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 extends outwardly from the tab. The top and bottom ends of the sliding rod are hingedly connected to the sliding brackets through each slot.

The sliding rod slides back and forth in the slot in order to assemble and disassemble the wall assembly . In the assembled position, the sliding rod is located at the end of the slot locking the studs of the sliding rod into the hooks of the fixed rod . In this position, the sidewalls and endwalls join to form a rectangular box. In the disassembled position, the sliding rod is located in the center of the slot unlocking the studs of the sliding rod from the hooks of the fixed rod . In this position, the sidewalls and endwalls separate slightly to release the contents of the form . The two lifting dowels extend outwardly parallel from each end of the long sidewalls .

A latch assembly includes a latch , a latch spring , a locking rod , and locking rod clips . A latch is pivotally attached at its mid-point to an end of each sidewall by any suitable means, such as a pin. The latch is a rectangular shaped bar with two notches located on opposite corners of the latch. A latch spring , such as a tension spring, connects from the top of the latch to a respective sidewall imparting a counter-clockwise force on the latch . A duplicate latch and latch spring are mirrored on the opposite ends of each sidewall . A locking rod extends around the end of the form and pivotally connects to the bottom of two latches using any suitable means, such as a pin. Locking rod clips attach to each end of each sidewall to limit the locking rods to one-dimensional motion. As the locking rods slide back and forth through the locking rod clips , the pivotally attached pair of latches and pivot correspondingly. Those of ordinary skill in the art will recognize that many variations in the shape and design of the straight form may be utilized.

As illustrated in FIG. 3B, a corner form 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 thus includes a cap , a bottom tube assembly , and a wall assembly . 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 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 . The edges of the plus-shaped plate terminate in L-shaped cap brackets that define slots between the top of the cap and each cap bracket . Two tabs on each side are attached to each ridge and extend downward from the cap , and a dowel extends perpendicularly from each tab . Two cap brackets attach to the top of the plus-shaped plate.

The bottom tube assembly 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 . 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 when the form is completely assembled and compressed. The corner portions of the plus-shaped base are recessed defining a lip. Two dowels extend outwardly from a front and rear portion of the plus-shaped base. A tab is attached to the bottom of the base at the front center of the base. A wheel is pivotally attached to the bottom of the front tab , while rear wheels are fixed to the bottom of the base. The wheels allow the form to travel along a guide rail of a station conveyor . Although the preferred embodiment of the corner form 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 includes inner walls , which form a plus to divide the interior of wall assembly into four corner sections; sidewalls , which are W-shaped to define a corner; two mating assemblies ; two hinges ; and lifting dowels . The two mating assemblies and the two hinges are located on opposite sides and connect adjacent sidewalls 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 and the bottom tube assembly .

Each mating assembly includes a bracket , two rods , a lever arm , levers , two rods , two brackets , and two brackets . The bracket attaches at approximately the mid-point to a respective one of sidewalls by any suitable means, such as welding, and includes a pivot rod pivotally attached thereto. The lever arm and the rods fixedly attach to the pivot rod . The brackets attach at upper and lower ends to the same sidewall as the bracket , using any suitable means, such as welding. The brackets attach in opposed relationship to a respective bracket on an adjacent sidewall , using any suitable means, such as welding. A lever pivotally connects at a midpoint to a respective bracket and at each end to a rod and a rod , respectively. A rod fixedly connects to a respective bracket .

The lever arm pivots relative to the bracket to assemble and disassemble the sidewall assembly . In the assembled position, the lever arm rotates counterclockwise to pull the levers towards the bracket via rods , thereby pulling adjacent sidewalls together about respective hinges via the rods and brackets . In the disassembled position, the lever arm rotates clockwise to push the levers away from the bracket via rods , thereby pushing apart adjacent sidewalls about respective hinges via the rods and brackets . In the disassembled position, each of the four unitary corner-shaped blocks releases from the form . The two lifting dowels on each side extend outwardly parallel from a sidewall .

A latch assembly includes a latch , a latch spring and a locking rod . A latch pivotally attaches at its mid-point to respective sidewalls adjacent each hinge using any suitable means, such as a pin. The latch is a rectangular shaped bar with two notches located on opposite corners of the latch. A latch spring , such as a tension spring, connects from the top of the latch to a respective sidewall imparting a counter-clockwise force on the latch . A duplicate latch and latch spring are mirrored on adjacent sidewalls . A locking rod extends around the end of the form and pivotally connects to the bottom of the two latches using any suitable means, such as a pin. Similarly, a locking rod extends around the end of the form and pivotally connects to the bottom of the two latches using any suitable means, such as a pin. As the locking rod and slide back and forth, the pivotally attached pair of latches and pivot correspondingly. Those of ordinary skill in the art will recognize that many variations in the shape and design of the form may be utilized.

As illustrated in FIGS. and A-D, a station conveyor routes a plurality of forms or in a continuous loop simultaneously through all the stations of the apparatus , thereby creating a time efficient process. The station conveyor includes a track assembly for straightaway sections, a turnstile for curved sections, and a guide rail along both sections. The guide rail is rigidly affixed to a foundation of the apparatus using any suitable means, such as brackets attached to the guide rail and bolts sunk into the foundation, to provide a fixed pathway for the conveyance of a form or .

The track assembly includes a conveyor rod , a plurality of roller pins , a plurality of bearings , a plurality of conveyor catches , a plurality of catch stops , a plurality of catch springs , and a conveyor cylinder , which is any suitable hydraulically or pneumatically operated cylinder. The conveyor rod extends the entire length of each straightaway section. A beginning end of the conveyor rod is attached to a piston of the conveyor cylinder . Bearings are rigidly attached to the guide rail at appropriate intervals along the conveyor rod . The bearings restrict the conveyor rod to one-dimensional motion, parallel with the conveyor cylinder . Roller pins are perpendicularly attached to the outer vertical side of the guide rail closest to the conveyor rod at appropriate intervals by any suitable means, such as a welding. The roller pins provide support while still allowing the conveyor rod to move.

The conveyor catch 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 are hingedly attached at appropriate intervals along the conveyor rod by appropriate means, such as a holding pin . 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 .

A catch stop is a rectangular block with an end face angled downward 45° and a bottom face slotted for mounting to the conveyor rod . Catch stops are attached to the conveyor rod by any suitable means, such as welding, directly preceding each conveyor catch . The angled face extends towards the direction of forward motion of the station conveyor .

A catch spring , such as a torsion spring, is connected from the holding pin to the conveyor catch . The catch spring pulls the conveyor catch clockwise until the long leg of the conveyor catch abuts the catch stop at a default position, which will be referred to as the engagement position. In this position, the long end of the conveyor catch is positioned at a 45° angle with respect to the foundation and the short leg of the conveyor catch is perpendicular to the foundation. The conveyor catch can be rotated until the long end of the conveyor catch is perpendicular to the foundation, which will be referred to as the bypass position.

The turnstile includes a turnstile post , a turnstile motor , a turnstile arm , and a turnstile catch . The turnstile post is mounted to the foundation beside the guide rail . The turnstile arm is pivotally attached perpendicular to the top of the turnstile post . The turnstile catch is a rectangular block with one face of the block extending lengthwise slightly farther than the rest of the block. The turnstile arm is pivotally attached to the extended face end of the turnstile catch so that the extended face rests against the turnstile arm and the length of the turnstile catch is parallel to the turnstile post . Gravity normally pulls the turnstile catch to a default position, parallel to the turnstile post , which will be referred to as the engagement position. The turnstile catch can be rotated until it is perpendicular to the turnstile post . This position will be referred to as the bypass position. The extended face on the turnstile catch limits the rotation of the turnstile catch to one direction. The turnstile motor is attached to the end of the turnstile arm mounted on the turnstile post by any suitable means, such as a coupling. The turnstile motor is a bi-directional motor that rotates the turnstile arm in both a clockwise and counter-clockwise direction.

In operation, the station conveyor via the track assembly and the turnstile propel a plurality of forms about the apparatus , whereby the front center wheel of a form or rolls along the guide rail following the guide rail about the entire path defined by the station conveyor . As a form or reaches the beginning of a curve, the form or engages a micro-switch positioned along the station conveyor at a turnstile . The micro-switch senses the arrival of the form or and outputs a signal that activates the turnstile motor , which rotates the turnstile arm to a start point located directly behind the form or . While the turnstile arm rotates over the form or , the turnstile catch strikes the form or and rotates to the bypass position allowing it to pass over the form or . When the turnstile arm reaches the start point, the turnstile catch returns to the engagement position. Further, the turnstile arm engages a micro-switch positioned on the turnstile post . The micro-switch senses the arrival of the turnstile arm and outputs a signal that reverses the turnstile motor , which then rotates the turnstile arm in the opposite direction. As the turnstile arm rotates, the turnstile catch strikes the form or . However, this time the extended face on the turnstile catch prevents it from rotating. Therefore, the turnstile pushes the form or along the guide rail .

As the form or enters a straightaway section of the station conveyor , the bottom of the form or strikes a conveyor catch , which rotates to the bypass position allowing the form or to slide over the conveyor catch . After the form or completely slides over the conveyor catch , the conveyor catch returns to the engagement position. When the form or has completely passed over the conveyor catch , the form or engages a micro-switch positioned along the straightaway section of the station conveyor . The micro-switch senses the arrival of the form or and outputs a signal that deactivates the turnstile motor .

The conveyor cylinder operates in continuous reciprocating manner to alternately extend and retract its piston and thus the conveyor rod . As the conveyor rod moves away from the conveyor cylinder , the conveyor catch strikes the form or pushing it along the guide rail . At full extension, the piston of the conveyor cylinder engages a micro-switch of the conveyor cylinder . The micro-switch senses the full extension of the piston and outputs a signal that reverses the conveyor cylinder , which retracts the piston and thus the conveyor rod . As the conveyor cylinder retracts its piston, a second conveyor catch slides under the form or until it reaches a point directly behind the form or . At full retraction, the piston of the conveyor cylinder engages a micro-switch of the conveyor cylinder . The micro-switch senses the full retraction of the piston and outputs a signal that reverses the conveyor cylinder , which extends the piston and thus the conveyor rod , thereby continuously propelling a form along a straightaway section of the station conveyor . The distance the form or moves after each extension of the piston of the conveyor cylinder will be referred to as one step. The station conveyor thus continuously operates as described above to move a plurality of forms or around any length loop desired. Although the preferred embodiment discloses the station conveyor , 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 includes a cap removal/replacement assembly , a screed assembly , and a compression assembly . The cap removal/replacement assembly includes a frame , two cap arms , two cap catches , two cap catch springs , a mounting block , and a cap cylinder , which is any suitable hydraulically or pneumatically operated cylinder. The frame is made of two vertical legs and a horizontal crossbar mounted to the foundation on either side of the station conveyor 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 . The cap arm 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 is attached along the entire underside of the engagement end defining a slot between the underside of the engagement end of the cap arm and the cap arm bracket . The cap catch is flat strip defining a hinged end and an engagement end. The hinged end of the cap catch is hingedly attached to the angled length of each cap arm by a pin , with the engagement end of the cap catch extending towards the engagement end of the cap arm . The cap catch spring , such as a torsion spring, is connected from the pin to the cap catch . The cap catch spring pulls the cap catch to a default position approximately parallel to the angled length of the cap arm , which will be referred to as the lifting position. The cap catch can be rotated until it is parallel to the engagement end of the cap arm . This position will be referred to as the bypass position. The ends of the two cap arms are pivotally attached to each of the vertical legs of the frame and extend towards the direction of forward motion of the station conveyor . The cap arms are connected by at least one crossbar using any suitable means, such as welding. The mounting block is attached to the crossbar of the frame by any suitable means, such as welding. The cap cylinder is hingedly connected from the mounting block to a crossbar connecting the cap arms . As illustrated in FIG. 6B, extending the piston of the cap cylinder rotates the cap arms counter-clockwise to a horizontal position. This position will be referred to the engagement position. Retracting the piston of the cap cylinder rotates the cap arms clockwise to an upward angle. The upward angle must be large enough to allow clearance for the screed assembly to pass below the cap arms . This position will be referred to as the retracted position.

The screed assembly includes a frame having supporting legs and screed tracks A attached thereto. The legs mount to the foundation on either side of the station conveyor by any suitable means, such as brackets attached to each leg and bolts sunk into the foundation. The screed assembly further includes a screed box , a leveling hopper , an auger , a screed motor , and two leveling cylinders and a screed cylinder , which are any suitable hydraulically or pneumatically operated cylinders. The screed box is a rectangular box with an open top and a slot in the bottom the same size as the top opening of the form or the form . Alternatively, the screed box could include an opening suitable for the filling of both forms and . The edges of the screed box rest within the screed tracks A, which run perpendicular to the station conveyor . The screed cylinder is connected to the frame between an end of the screed track A and a side of the screed box . When the screed cylinder extends it slides the screed box directly over the station conveyor , which will be referred to as the loading position. When the screed cylinder retracts, it slides the screed box to a position adjacent the station conveyor , which will be referred to as the retracted position.

The leveling hopper resides freely inside the screed box . Two leveling cylinders connect from the screed box to the leveling hopper using a mounting bracket . The leveling cylinders extend and retract their pistons to slide the leveling hopper one dimensionally inside the screed box . The auger is mounted inside the leveling hopper using any suitable means, such as bearings. The screed motor is coupled to the end of the auger through a lengthwise slot in the screed box . The slot allows the screed motor and auger to slide along with the leveling hopper when the leveling cylinders extend and retract.

The compression assembly includes a compression post , a compression motor , an extension arm , a mounting bar , a top compression arm , a stabilizer , a bottom compression arm , and a compression cylinder . The compression post mounts to the foundation beside the station conveyor and after the screed assembly relative to the direction of forward motion of the station conveyor using any suitable means, such as a bracket attached to the compression post and bolts sunk into the foundation. The extension arm pivotally attaches at one end perpendicular to the top of the compression post .

The mounting bar is a straight bar including a top end and a bottom end. The mid-point of the mounting bar connects in a vertical orientation to the unattached end of the extension arm using any suitable means, such as welding. The bottom compression arm is a U-shaped bar defining a hinged end and a compression end, which provides a wide stable base to support the form or during compression. Although this preferred embodiment discloses the bottom compression arm 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 attaches to the bottom end of the mounting bar in a plane parallel to the extension arm . The top compression arm is a straight bar defining a hinged end and a compression end. The hinged end of the top compression arm attaches to the top end of the mounting bar in a plane parallel to the extension arm . The stabilizer hingedly connects to the compression end of the top compression arm .

The compression cylinder hingedly connects from the top compression arm to the bottom compression arm . The compression cylinder retracts to reduce to a minimum the distance between the compression ends of the top compression arm and bottom compression arm , which will be referred to as the compression position. The compression cylinder extends to increase to a maximum the distance between the top compression arm and bottom compression arm , which will be referred to as a release position. As the compression cylinder extends and retracts, the stabilizer swivels to maintain flat contact with the form or .

The compression motor mounts to the compression post and engages the extension arm using any suitable means, such as a coupling. The compression motor rotates the extension arm counter-clockwise to a default position parallel to the station conveyor , which will be referred to as the bypass position. The compression motor further rotates the extension arm clockwise 90° to a position that permits engagement with a form or , which will be referred to as the engagement position.

In operation, the station conveyor conveys a form or to the form-loading station . The cap arms of the cap removal/replacement assembly begin in the engagement position so that, as the form or arrives at the form-loading station , the cap brackets or of the cap or strike the cap catches of the cap removal/replacement assembly , thereby rotating them to the bypass position. As generally illustrated in FIG. 6A, the cap brackets or of the cap or slide into the slots on the cap arms , and the cap catches return to the lifting position.

The station conveyor is configured relative to the form-loading station such that, at full extension, the conveyor cylinder of the station conveyor portion associated with the form-loading station delivers the form or to the cap removal/replacement assembly . Upon conveyance into the cap removal/replacement assembly , the form or engages a micro-switch that outputs a signal to the station conveyor that overrides the retraction signal of the conveyor cylinder associated with the form-loading station . Thus, the portion of the station conveyor associated with the form-loading station remains disabled during the filling of the form or . The micro-switch further outputs a signal that activates the cap cylinder , which rotates the cap arms to their retracted position, thereby lifting the cap or from the form or . As generally illustrated in FIG. 6B, the cap or slides back into the slots of the cap arms until it strikes the cap catches , which remain in the lifting position supporting the cap or .

In their retracted position, the cap arms engage a micro-switch that outputs a signal directing the screed cylinder to extend the screed box to the loading position directly over the form or . In the loading position, the leveling hopper is located directly underneath a loading conveyor , which is any suitable conveyor, such as a belt conveyor. The loading conveyor attaches underneath the mixer discharge hopper to receive the lightweight concrete composite therefrom for delivery to the leveling hopper . As the screed box reaches the loading position, it engages a micro-switch, which outputs a signal that opens a door of the mixer discharge hopper and activates the loading conveyor to deliver the lightweight concrete composite to the leveling hopper . The micro-switch further outputs a signal that activates the screed motor , thereby rotating the auger to evenly distribute the lightweight concrete composite throughout the leveling hopper . A micro-switch positioned within the leveling hopper or the mixer discharge hopper senses when either the leveling hopper is full or the mixer discharge hopper is empty. Upon sensing either condition, the micro-switch outputs a signal closing the mixer discharge hopper and deactivating the loading conveyor and the screed motor .

As generally illustrated in FIGS. 7A and 7B, the micro-switch further outputs a signal that activates the leveling cylinders , which slowly move the leveling hopper forward over the form or to a position beyond the form or . When the leveling hopper travels fully beyond the form or , it engages a micro-switch that reverses the leveling cylinders , which slowly move the leveling hopper backward over the form or to its original position in front of the form or . The movement of the leveling hopper over the form or fills and levels the form or with the lightweight concrete composite contained in the leveling hopper . As the leveling cylinders fully retract, the leveling hopper engages a micro-switch that outputs a signal resulting in the screed cylinder returning the screed box to the retracted position.

When the screed box reaches the retracted position, it engages a micro-switch, which outputs a signal that activates the cap cylinder . The cap cylinder rotates the cap arms to their engagement position, thereby returning the cap or onto the form or . The return of the cap arms to their engagement position engages a micro-switch, which outputs a signal that reactivates the conveyor cylinder of the station conveyor portion associated with the form-loading station . The conveyor cylinder retracts and then extends to move the form or forward one step into the compression assembly .

As generally illustrated in FIG. 8, upon conveyance into the compression assembly , the form or engages a micro-switch that outputs a signal to the station conveyor that again overrides the retraction signal of the conveyor cylinder associated with the form-loading station . Thus, the portion of the station conveyor associated with the form-loading station remains disabled during the compression of the form or .

The micro-switch further outputs a signal that activates the compression motor of the compression assembly , which rotates the extension arm from the bypass position to the engagement position, whereby the stabilizer of the top compression arm and the bottom compression arm engage the form or . At the engagement position, the extension arm engages a micro-switch, resulting in the output of a signal that deactivates the compression motor and activates the compression cylinder , which retracts to the compression position, thereby depressing the cap or down into the form Or . As the compression assembly presses the cap or down, the cap dowels or strike the angled top of each latch and or and , respectively. Consequently, each latch and or and pivots allowing the cap or to press further down into the form or until the cap dowels or line up with the notch in the top of each latch and or and . As a result, the latch springs and or and pulls a respective latch and or and fitting the cap dowels or into the notches and locking the cap or in place.

At full retraction, the compression cylinder engages a micro-switch, which outputs a signal reversing the compression cylinder to the release position. At full extension, the compression cylinder engages a micro-switch, resulting in the output of a signal that activates the compression motor , which rotates the extension arm from the engagement position to the bypass position. When the extension arm reaches the bypass position, it engages a micro-switch, which outputs a signal deactivating the compression motor . The micro-switch further outputs a signal that reactivates the conveyor cylinder of the station conveyor portion associated with the form-loading station . The conveyor cylinder retracts and then extends to move the form or forward toward the next station, a curing oven .

In filling a form or , the same cap removal/replacement assembly and the compression assembly may be used with either form or , and, as previously described, the screed assembly may include a screed box configured to permit the filling of both forms and . Thus, both forms and may be routed together about the apparatus to produce both unitary rectangular blocks and unitary corner-shaped blocks. Alternatively, the screed assembly could be configured with multiple screed boxes , which are positioned over a form depending upon the form type, or the apparatus could include multiple form-filling stations suitable for different form types, which ultimately feed into the curing oven .

As illustrated in FIG. 1, the dotted line designates an area of the station conveyor enclosed by the curing oven . The station conveyor moves the form or through the curing oven , which is at a temperature sufficient to accelerate curing. As the form or travels through the curing oven , the lightweight concrete composite cures. The curing oven should be of a sufficient size to allow adequate time for proper curing to occur. When the form or exits the curing oven , the lightweight concrete composite has hardened into a unitary lightweight concrete composite block A and unitary lightweight concrete composite corner-shaped blocks. The station conveyor continues to move the form or to the last station.

As illustrated in FIGS. 9-11, the last station is a block removal station . The block removal station includes a frame , a lock assembly , a bottom release assembly , a lift assembly , a sidewall release and engagement assembly , a dispatch conveyor , and a swing-arm assembly . The frame 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 . The four vertical bars are attached to a base, which mounts to the foundation beside the station conveyor using any suitable means, such as bolts sunk into the foundation. Slide rails attach vertically on either side of the frame by any suitable means, such as welding.

The lock assembly is located on both sides of the frame and includes lock cylinders attached to the base of the frame using any suitable means, such as welding. Each lock cylinder hingedly connects to the bottom of a C-shaped finger lock using any suitable means, such as a pin. When the lock cylinders retract, each finger lock is positioned away from the form or , which will be referred to as the unlocked position. When the lock cylinders extend, each finger lock is positioned with the open end of the C-shape engaged with and pressing down on the lip of the bottom tube assembly or of the form or , thereby locking the bottom tube assembly or within the station conveyor .

The bottom release assembly is located on both sides of the frame and includes bottom release cylinders each having a C-shaped bottom release clip attached thereto. Each bottom release cylinder attaches to a respective slide rail using any suitable means, such as welding. A default position of the bottom release assembly is with each bottom release cylinder retracted. An unlocking position of the bottom release assembly occurs when each bottom release cylinder extends such that their bottom release clip engages and pushes the locking rods on the form or the locking rods and on the form . Consequently, the locking rods pivot the latches and releasing the bottom dowels attached to the bottom tube assembly , or the locking rods and pivot the latches and releasing the bottom dowels attached to the bottom tube assembly .

The lift assembly is located on both sides of the frame and includes slides freely attached to a respective slide rail . Each slide includes roller bearings on each end for limiting travel of the slides one-dimensionally along the length of a respective slide rail . T-shaped engagement bars attach to a face of a respective slide using any suitable means, such as welding. Chains of fixed length connect from a top end of a respective slide to a top corner of a respective frame . Each chain rides along the top of a respective first pulley pivotally attached to a top of a respective slide rail . A pair of two connected lift cylinders vertically attach to the frame on opposing parallel portions of the base. Second pulleys pivotally attach to the end of a respective lift cylinders pair opposite to the end attached to the base, and each chain rides along the bottom of a respective second pulley .

The lift cylinders of each pair extend and retract to move a respective chain and, thus, a respective slide up and down a respective slide rail to one of three levels. When both lift cylinders of each pair are extended, the slides reside at the bottom of the slide rails , which will be referred to as the lower level. At the lower level, the engagement bars attached to a respective slide reside below the lifting dowels or of the form or . When one lift cylinder of each pair retracts while the other lift cylinder of each pair remains extended, the engagement bars engage the lifting dowels or , and the slides raise the sidewall assembly or and cap or to approximately the mid-point of a respective slide rail , which will be referred to as the intermediate level. After both lift cylinders of each pair retract, the slides raise the sidewall assembly or and cap or to the top of a respective slide rail , which will be referred to as the upper level.

A sidewall release and engagement assembly is located on both sides of the frame and includes sidewall release cylinders having a C-shaped sidewall release clip attached thereto and sidewall engagement cylinders having a V-shaped sidewall engagement clip attached thereto. The sidewall release cylinders and sidewall engagement cylinders attach to the base of the frame using any suitable means, such as a bracket bar welded to a respective sidewall release cylinder and sidewall engagement cylinder and to the base of the frame . The sidewall release cylinders and sidewall engagement cylinders are positioned within the frame such that the slides and respective engagement bars freely pass by to raise the sidewall assembly or and cap or to the intermediate and upper levels.

A default position of the sidewall release and engagement assembly is with each sidewall release cylinder retracted and with each sidewall engagement cylinder extended. To release the sidewall assembly or , the sidewall release cylinders extend so that their respective sidewall release clips engage and push a respective engaging rod or pivot a respective lever arm . As a result, the sidewall assembly or disassembles as previously described. To engage the sidewall assembly or , the sidewall engagement cylinders retract so that their respective sidewall engagement clips engage and pull a respective engaging rod or pivot a respective lever arm . As a result, the sidewall assembly or assembles as previously described.

The dispatch conveyor resides adjacent to the frame and perpendicular to the station conveyor . The dispatch conveyor includes a belt conveyor with a plurality of belts defining slots therebetween. The dispatch conveyor transfers unitary lightweight concrete composite blocks A or four unitary corner-shaped lightweight concrete composite blocks from the block removal station to a storage or shipping area. Therefore, the direction of forward motion for the belt conveyor is away from the station conveyor .

The swing-arm assembly includes a swing-arm member , a first rotary motor , a first gear , a loading arm , an unloading post , a second rotary motor , and a second gear . A post of the swing-arm member mounts to the foundation using any suitable means, such as a bracket attached to the swing-arm post and bolts sunk into the foundation. An arm of the swing-arm member pivotally attaches to the post using any suitable coupling that includes a bearing surface. The first gear pivotally attaches to the arm of the swing-arm member through a suitable coupling that includes a bearing surface. The first gear freely rotates clockwise and counter-clockwise about a center axis of the first gear extending perpendicular to the arm of the swing-arm member .

A loading arm attaches to the first gear using any suitable means, such as welding. The loading arm is a straight bar at least the length of the form or with a plurality of L-shaped loading brackets appropriately spaced along the straight bar to support a unitary lightweight concrete composite block A or the four unitary corner-shaped lightweight concrete composite blocks. The loading arm must be of sufficient strength to support the weight of a unitary lightweight concrete composite block A or the four unitary corner-shaped lightweight concrete composite blocks. Further, the loading brackets should be spaced such that they fit in between the belts of the dispatch conveyor .

The first rotary motor connects to the arm of the swing-arm member using any suitable means, such as a coupling. The first rotary motor rotates the arm of the swing-arm member around a center axis of the post of the swing-arm member from a loading position to an unloading position. In the loading position, the loading arm is extended directly over the station conveyor . Alternatively, in the unloading position, the loading arm is extended directly over the dispatch conveyor in an upright position to support a unitary lightweight concrete composite block A or the four unitary corner-shaped lightweight concrete composite blocks.

The unloading post mounts to the foundation directly adjacent to the swing-arm member using any suitable means, such as a bracket attached to the unloading post and bolts sunk into the foundation. The second rotary motor attaches perpendicularly to the unloading post and extends towards the dispatch conveyor . The second gear pivotally attaches to the second rotary motor through a suitable coupling that includes a bearing surface. When the swing-arm member resides in the unloading position, the second gear meshes with the first gear . Accordingly, the second rotary motor rotates the second gear and, consequently, the first gear and loading arm from the unloading position to a dispatch position. In the dispatch position, the loading arm is rotated 90° with respect to the axis of the first gear , thereby inserting the loading brackets between the belts of the dispatch conveyor . A unitary lightweight concrete composite block A or the four unitary corner-shaped lightweight concrete composite blocks supported by the loading arm thus engage the belts of the dispatch conveyor for transport to a storage or shipping area.

In operation, the station conveyor is configured relative to the block removal station such that, at full extension, the conveyor cylinder of the station conveyor portion associated with the block removal station delivers a form or to the block removal station . In this preferred embodiment, the forms or are spaced along the station conveyor such that a form or enters the block removal station at the same time another form or enters the form-filling station . Consequently, the form-filling station controls the stopping and restarting of the portion of the station conveyor associated with the block removal station and the form-filling station . Nevertheless, those of ordinary skill in the art will recognize that the block removal station could control that same portion of the station conveyor . Furthermore, although this preferred embodiment discloses the synchronous operation of the block removal station and the form-filling station , those of ordinary skill in the art will recognize other control schemes for regulating the movement of the forms through the block removal station and the form-filling station .

Upon conveyance into the block removal station , the form or engages a micro-switch, which outputs a signal that activates the lock cylinders of the lock assembly , thereby moving the finger locks to the locked position and, thus, locking the bottom tube assembly or within the station conveyor . The extension of the lock cylinders engages a micro-switch, which outputs a signal that deactivates the lock cylinders and activates the bottom release cylinders of the bottom release assembly to move the bottom release clips to their unlocked position. The bottom release clips contact and push the locking rods on the form or the locking rods and on the form , which pivots the latches and or and and releases the bottom dowels or attached to the bottom tube assembly or .

The extension of the bottom release cylinders engages a micro-switch, which outputs a signal that retracts the bottom release cylinders and activates a first respective lift cylinder of each lift cylinder pair of the lift assembly . The first activated lift cylinders retract to raise the sidewall assembly or , cap or , and unitary lightweight concrete composite block 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 or .

A micro-switch engaged through the extension of the first activated lift cylinders outputs a signal that deactivates the first activated lift cylinders and activates the first rotary motor of the swing-arm assembly . The first rotary motor pivots the loading arm to the loading position. As the loading arm travels to its loading position, it engages a micro-switch that deactivates the first rotary motor and activates the sidewall release cylinders , which extend to contact their sidewall release clips with a respective engaging rod or lever arm . The sidewall release clips push a respective engaging rod of the corner assemblies to disassemble the form as previously described, hence, dropping the unitary lightweight concrete composite block A onto the loading arm . Alternatively, the sidewall release clips pivot a respective lever arm of the securing assemblies to disassemble the form as previously described, hence, dropping the four unitary lightweight concrete composite blocks onto the loading arm .

The extension of the sidewall release cylinders engages a micro-switch, which outputs a signal that retracts the sidewall release cylinders and activates a second respective lift cylinder of each lift cylinder pair of the lift assembly . The second activated lift cylinders retract to raise the sidewall assembly or and the cap or from the intermediate level to the upper level, hence, separating the sidewall assembly or and the cap or from the unitary lightweight concrete composite block A or the four unitary lightweight concrete composite blocks.

A micro-switch engaged through the extension of the second activated lift cylinders outputs a signal that deactivates the second activated lift cylinders and activates the first rotary motor of the swing-arm assembly . The first rotary motor returns the loading arm to the unloading position, thereby delivering the separated unitary lightweight concrete composite block A or the four unitary lightweight concrete composite blocks over the dispatch conveyor . As the loading arm travels to its unloading position, it engages a micro-switch that deactivates the first rotary motor and activates the second rotary motor . The second rotary motor pivots the second gear and, thus, the first gear to move the loading arm from its unloading position to a dispatch position, whereby the unitary lightweight concrete composite block A or the four unitary lightweight concrete composite blocks are transported to a storage or shipping area by the belts . The travel of the loading arm to its dispatch position engages a micro-switch that reverses the second rotary motor , thereby returning the loading arm to its unloading position. Upon reaching its unloading position, the loading arm engages a micro-switch that deactivates the second rotary motor .

The micro-switch engaged due to the travel of the loading arm from its unloading position to its loading position also outputs a signal that reactivates the second respective lift cylinders of each lift cylinder pair of the lift assembly . The second reactivated lift cylinders extend to lower the sidewall assembly or and the cap or from the upper level to the intermediate level. A micro-switch engaged through the retraction of the second reactivated lift cylinders outputs a signal that deactivates the second activated lift cylinders and activates the sidewall engagement cylinders , which retract to contact their sidewall engagement clips with a respective engaging rod or lever arm . The sidewall engagement clips pull a respective engaging rod of the corner assemblies to assemble the form as previously described. Alternatively, the sidewall engagement clips pivot a respective lever arm of the securing assemblies to assemble the form as previously described.

The retraction of the sidewall engagement cylinders engages a micro-switch, which outputs a signal that extends the sidewall engagement cylinders and reactivates the first respective lift cylinder of each lift cylinder pair of the lift assembly . The first reactivated lift cylinders extend to lower the sidewall assembly or and the cap or from the intermediate level to the lower level. A micro-switch engaged through the retraction of the first reactivated lift cylinders outputs a signal that deactivates the first reactivated lift cylinders and retracts the lock cylinders of the lock assembly , thereby moving the finger locks to the unlocked position and, thus, releasing the bottom tube assembly or . After the release of the bottom tube assembly or , the now empty form or is ready to return to the form-filling station for repeat of the entire process. The bottom release assembly does not reengage the locking rod or the locking rods and as this occurs during the compression of the form or as previously described.

The preferred embodiment employs a micro-switch control scheme whereby the engaging of various micro-switches controls the station conveyor , the form filling station , and the block removal station . 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 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 .

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.

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.

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.

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.

COPYRIGHT

User acknowledges that Fairview Research and its third party providers retain all right, title and interest in and to this xml under applicable copyright laws. User acquires no ownership rights to this xml including but not limited to its format. User hereby accepts the terms and conditions of the License Agreement.