GB1585277A - Production of construction blocks - Google Patents

Production of construction blocks Download PDF

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Publication number
GB1585277A
GB1585277A GB3872476A GB3872476A GB1585277A GB 1585277 A GB1585277 A GB 1585277A GB 3872476 A GB3872476 A GB 3872476A GB 3872476 A GB3872476 A GB 3872476A GB 1585277 A GB1585277 A GB 1585277A
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GB
United Kingdom
Prior art keywords
blocks
extrudate
conveyor
formers
block
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB3872476A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Redland Technology Ltd
Original Assignee
Redland Technology Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Redland Technology Ltd filed Critical Redland Technology Ltd
Priority to GB3872476A priority Critical patent/GB1585277A/en
Publication of GB1585277A publication Critical patent/GB1585277A/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/10—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads by using presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/14—Apparatus or processes for treating or working the shaped or preshaped articles for dividing shaped articles by cutting
    • B28B11/16—Apparatus or processes for treating or working the shaped or preshaped articles for dividing shaped articles by cutting for extrusion or for materials supplied in long webs

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Description

(54) PRODUCTION OF CONSTRUCTION BLOCKS (71) We, REDLAND TECHNOLOGY LIMITED, a British Company, of Redland House, Reigate, Surrey, RH2 OSJ, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to the production of construction blocks such as landscape blocks or pressed bricks.
According to the invention, there is provided a method of producing construction blocks including the steps of extruding a length of material of predetermined cross sectional area onto a bed, moving dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, the surfaces of adjacent partitions forming, with the bed and a top plate, a mould box for the block located therebetween; and impressing desired contours onto the longitudinal surfaces of each of the blocks simultaneously by advancing pairs of formers towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block.
The material extruded may be either clay or a cement mixture or other plastics material, although clay is preferable in many circumstances, being more easily workable.
Preferably, the cross sectional area of the extrudate is chosen so that a cut and divided block has the same volume as the moulded block leaving the mould cavity for curing or firing, with minimum wastage.
The invention also includes within its scope apparatus for performing the method defined above. In one embodment of the apparatus to the invention, there is provided a die for extruding material onto a bed, means for cutting the extrudate to a length, dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, said dividing means being movable towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, a top plate for forming the bed and the surfaces of adjacent partitions a mould box for the block located therebetween and a plurality of pairs of formers movable towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block, said formers including contoured mould surfaces for impressing desired contours onto the longitudinal surfaces of the bocks.
Further features and advantages of the invention will become apparent from the following description, by way of example, of one embodiment of the present invention, the description being read with reference to the accompanying drawings, in which: Figure 1 Sllustrates diagrammatically and in perspective, apparatus for producing landscape blocks in relatively small batches; Figure 2 illustrates the cross section of the extrudate in relation to an end view of a finished block before it is cured or fired; and Figure 3 illustrates diagrammatically and in Figure 3 underneath plan view, a modification to the apparatus of Figure 1.
Referring to Figure 1, an extruder (not shown) having an adjustable die is arranged to supply an extrudate 1 of clay or a cement mixture to a conveyor 2 which moves at a preset speed, x. When a predetermined length 4 of extrudate has passed a primary cutter 3 located adjacent the conveyor 2, the conveyor 2 stops and the primary cutter 3 severs this length 4 of extrudate. The cut length 4 is transferred by suitable means (not shown) to a second conveyor 5, in this embodiment adjacent and parallel to conveyor 1, and the conveyor 5 moves at a faster rate of (x + y) to transfer the cut length 4 of extrudate towards a moulding station 6. The first conveyor 2 is then restarted to begin the feeding of a subsequent length of extrudate past the cutter 3.The conveyor 5 must be strong enough to withstand cutting and moulding pressures and may comprise linked platelets which are supported by a solid conveyor bed in the form of a platen.
As the cut length 4 is moved by conveyor 5, a second cutter which also acts as a divider as described below, descends towards the conveyor 5 while being moved along at the same speed as the conveyor 5, so as to cut the length 4 of extrudate into a plurality of blocks 8. The second cutter comprises a frame 7 formed by an elongate top plate 9 and, attached thereto, a plurality of downwardly and laterally extending parallel partitions 10 which are longitudinally spaced at regular intervals. It is the partitions 10 which penetrate the cut length 4 of extrudate to cut it into the blocks 8, which are thus divided from each other by the partitions 10. The frame may be vibrated to facilitate this cutting and dividing operation, particularly if the extrudate contains aggregate.
By the time the cutting and dividing operation is completed, the blocks 8 and frame 7 have arrived at the moulding station 6, and the conveyor 5 and frame 7 are halted. Correct location of the frame 7 and blocks 8 is ensured by pneumatic stops 11.
The frame 7 and the surface of the conveyor 5 on which the blocks 8 rest serve as a mould box for each block by defining the shape of the upper, lower and end faces of each block, but leaving its longitudinal surfaces 12 exposed for further moulding to a desired profile. A hydraulic ram 13 on each side of the conveyor 5 is then operated to move a respective block former 14 along guide tracks (not shown) towards the conveyor 5. Each block former comprises a plurality of mould surfaces 15, one for each of the blocks 8, so that when the two formers complete their movement towards the conveyor 5, each mould box is closed off by a respective pair of mould surfaces, one on each former, to form a mould cavity for the block contained therein, so that the longitudinal surfaces of all the blocks are simultaneously impressed with desired contours, in this embodiment a sinusoidal profile.The former may be vibrated while impressing contours onto the blocks. The cutter frame 7 remains in position dividing the blocks 8 during this pressing operation, and may be vibrated to assist in moulding if required. It will be realised that the edges of partitions 10 form guide surfaces between which the mould surfaces 15 slide when the rams 13 are operated.
Once the correct contours are impressed on the longitudinal surfaces of the blocks, the cutter frame 7 and formers 14 are withdrawn and the frame 7 is returned to its start position, ready for subsequent use on another cut length of extrudate. The moulded blocks 10a are transported away on a third conveyor 16 for firing or curing. It may be necessary to spray a release agent onto the formers 14 and cutter frame 7 to ease the release of the moulded blocks therefrom.
The apparatus described in this embodiment may conveniently be operated so that the first conveyor 2 supplies extrudate at a rate of 1 ft. in 5 seconds, so that for a desired length 4 of 4ft. (for six 8 inch long blocks) to pass the primary cutter 3 takes 20 seconds. If the time taken to transfer the cut length 4 to the second conveyor 5 and to transport it to the moulding station 6 whilst cutting and segmenting it into the six blocks 10 is 5 seconds, and the time taken to impress contours on the lateral surfaces of the blocks and to return the frame 7 to a position in which it is ready to cut a second length of extrudate is 10 seconds, then this leaves 5 seconds waiting time before a subsequent 4 ft. length of extrudate has passed the cutter 3.
It will be apparent that the apparatus constructed as described above takes less time to produce a given number of moulded blocks than the majority of previously proposed block making machines which do not operate on a continuous basis but require the filling of a rigid mould box with an excess of material, and scraping away the excess before a pressing operation to mould the remainder into a block. By using an extruder with an adjustable die to produce an extrudate of predetermined cross sectional area, the exact volume of material required for each block is contained in each mould box after the cutting and dividing of the length 4 of extrudate, without any wastage.
As illustrated in Figure 2, the cross sectional area 17 of the extrudate (indicated by cross hatching) is chosen so that the volume of a given length is equal to the volume of the moulded block having the same length.
In this Figure, the end face 18 of a moulded block is illustrated also.
Because the extruder also acts as a mixer, the consistency of the extrudate remains substantially constant. Consequently, subsequent shrinkage of the block due to curing or firing should be the same for one block as another.
As far as the landscape block is concerned, it does not matter how much the blocks shrink, but it is important that they all shrink by the same amount.
The invention is not limited to the preferred embodiment described above and various modifications may be made.
One such modification is illustrated in Figure 3. In this modification, the partitions 10 of the second cutter 7 are replaced by partitions 101 including a central contoured portion 18 and planar edge portions 19.
When lowered into the extrudate 1, the central portions 18 of partitions 101 form contoured ends on the blocks 12 while the planar portions 19 still serve as guide surfaces for the mould surfaces 15.
Furthermore for certain materials used in the manufacture of construction blocks, it is more convenient for the material to be extruded continuously rather than at intervals as described above.
In this case, the apparatus may be so arranged that the first and second cutters and block forming apparatus are also mounted on conveyors so that the whole moulding apparatus is continuously moving.
Alternatively or additionally, the first conveyor may feed cut lengths of material to two or more second conveyors arranged in parallel, each of the second conveyors having second cutters and block forming apparatus.
The extrudate may be materials other than clay or a cement mixture provided such materials are suitable for construction blocks and are self supporting when extruded.
WHAT WE CLAIM IS:- 1. A method of producing construction blocks including the steps of extruding a length of material of predetermined cross sectional area onto a bed, moving dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, the surfaces of adjacent partitions forming, with the bed and a top plate, a mould box for the block located therebetween; and impressing desired contours onto the longitudinal surfaces of each of the blocks simultaneously by advancing pairs of formers towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block.
2. A method as claimed in claim 1 in which the material extruded is clay.
3. A method as claimed in claim 1 in which the extruded material is a cement mixture.
4. A method as claimed in any one of the preceding claims in which the cross sectional area of the extrudate is chosen so that a cut and divided block has the same volume as the moulded block formed in the mould cavity.
5. A method as claimed in any one of the preceding claims in which the formers are vibrated while impressing contours onto the blocks.
6. A method as claimed in any one of the preceding claims in which the partitions are vibrated while cutting the extrudate.
7. A method as claimed in any one of the preceding claims further comprising the step of curing or firing the moulded blocks after removal from the mould cavities.
8. A method of producing construction blocks substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
9. Apparatus for producing construction blocks comprising a die for extruding material onto a bed, means for cutting the extrudate to a length, dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, said dividing means being movable towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, a top plate for forming with the bed and the surfaces of adjacent partitions a mould box for the block located therebetween and a plurality of pairs of formers movable towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block, said formers including contoured mould surfaces for impressing desired contours onto the longitudinal surfaces of the blocks.
10. Apparatus as claimed in claim 9 in which the top plate is part of the dividing means and the partitions depend from the top plate.
11. Apparatus as claimed in claim 9 or claim 10 in which the bed comprises a movable conveyor means which is halted before the formers are advanced.
12. Apparatus as claimed in claim 9 in which the plurality of formers on each side of the blocks are mounted on respective single supports and hydraulic rams are provided for moving the formers towards the blocks.
13. Apparatus as claimed in claim 11 in which the movable conveyor means comprises a first moving conveyor onto which the material is extruded and a second moving conveyor on which the extrudate is cut and divdied, means being provided for transferring the length of extrudate from the first conveyor to the second conveyor.
14. Apparatus as claimed in claim 13 in which the second conveyor moves faster than the first conveyor.
15. Apparatus as claimed in claim 13 in which the dividing means moves at the same speed as the second conveyor during the cutting and dividing operation and is halted with the conveyor before the formers are advanced.
16. Apparatus for producing construction blocks substantially as hereinbefore described with reference to and as shown in Figures 1 and 2, or Figures 1 and 2 as modified by Figure 3, of the accompanying drawings.
17. A construction block when produced
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (18)

**WARNING** start of CLMS field may overlap end of DESC **. central portions 18 of partitions 101 form contoured ends on the blocks 12 while the planar portions 19 still serve as guide surfaces for the mould surfaces 15. Furthermore for certain materials used in the manufacture of construction blocks, it is more convenient for the material to be extruded continuously rather than at intervals as described above. In this case, the apparatus may be so arranged that the first and second cutters and block forming apparatus are also mounted on conveyors so that the whole moulding apparatus is continuously moving. Alternatively or additionally, the first conveyor may feed cut lengths of material to two or more second conveyors arranged in parallel, each of the second conveyors having second cutters and block forming apparatus. The extrudate may be materials other than clay or a cement mixture provided such materials are suitable for construction blocks and are self supporting when extruded. WHAT WE CLAIM IS:-
1. A method of producing construction blocks including the steps of extruding a length of material of predetermined cross sectional area onto a bed, moving dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, the surfaces of adjacent partitions forming, with the bed and a top plate, a mould box for the block located therebetween; and impressing desired contours onto the longitudinal surfaces of each of the blocks simultaneously by advancing pairs of formers towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block.
2. A method as claimed in claim 1 in which the material extruded is clay.
3. A method as claimed in claim 1 in which the extruded material is a cement mixture.
4. A method as claimed in any one of the preceding claims in which the cross sectional area of the extrudate is chosen so that a cut and divided block has the same volume as the moulded block formed in the mould cavity.
5. A method as claimed in any one of the preceding claims in which the formers are vibrated while impressing contours onto the blocks.
6. A method as claimed in any one of the preceding claims in which the partitions are vibrated while cutting the extrudate.
7. A method as claimed in any one of the preceding claims further comprising the step of curing or firing the moulded blocks after removal from the mould cavities.
8. A method of producing construction blocks substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
9. Apparatus for producing construction blocks comprising a die for extruding material onto a bed, means for cutting the extrudate to a length, dividing means having a plurality of laterally extending partitions which are longitudinally spaced at intervals, said dividing means being movable towards the length of extrudate so that the partitions laterally cut and divide the length of extrudate into a linear array of blocks, a top plate for forming with the bed and the surfaces of adjacent partitions a mould box for the block located therebetween and a plurality of pairs of formers movable towards the array of blocks, one former of each pair being on each side of the array so that the formers close off the mould boxes to form a mould cavity for each block, said formers including contoured mould surfaces for impressing desired contours onto the longitudinal surfaces of the blocks.
10. Apparatus as claimed in claim 9 in which the top plate is part of the dividing means and the partitions depend from the top plate.
11. Apparatus as claimed in claim 9 or claim 10 in which the bed comprises a movable conveyor means which is halted before the formers are advanced.
12. Apparatus as claimed in claim 9 in which the plurality of formers on each side of the blocks are mounted on respective single supports and hydraulic rams are provided for moving the formers towards the blocks.
13. Apparatus as claimed in claim 11 in which the movable conveyor means comprises a first moving conveyor onto which the material is extruded and a second moving conveyor on which the extrudate is cut and divdied, means being provided for transferring the length of extrudate from the first conveyor to the second conveyor.
14. Apparatus as claimed in claim 13 in which the second conveyor moves faster than the first conveyor.
15. Apparatus as claimed in claim 13 in which the dividing means moves at the same speed as the second conveyor during the cutting and dividing operation and is halted with the conveyor before the formers are advanced.
16. Apparatus for producing construction blocks substantially as hereinbefore described with reference to and as shown in Figures 1 and 2, or Figures 1 and 2 as modified by Figure 3, of the accompanying drawings.
17. A construction block when produced
by a method as claimed in any one of claims 1 to 8.
18. A construction block when produced on apparatus as claimed in any one of claims 9 to 16.
GB3872476A 1977-09-16 1977-09-16 Production of construction blocks Expired GB1585277A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB3872476A GB1585277A (en) 1977-09-16 1977-09-16 Production of construction blocks

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB3872476A GB1585277A (en) 1977-09-16 1977-09-16 Production of construction blocks

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GB1585277A true GB1585277A (en) 1981-02-25

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0437858A2 (en) * 1990-01-16 1991-07-24 Ziegelwerk W.H. Hagemeister Kg Apparatus for making blanks with pattern on the upper surface for bricks, tiles or the same
WO2010069057A1 (en) * 2008-08-28 2010-06-24 Techo-Bloc Inc. Casted concrete stone with opposed molded textured surfaces and method of manufacture

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0437858A2 (en) * 1990-01-16 1991-07-24 Ziegelwerk W.H. Hagemeister Kg Apparatus for making blanks with pattern on the upper surface for bricks, tiles or the same
EP0437858A3 (en) * 1990-01-16 1991-11-13 Ziegelwerk W.H. Hagemeister Kg Process and apparatus for making blanks with pattern on the upper surface for bricks, tiles or the same
WO2010069057A1 (en) * 2008-08-28 2010-06-24 Techo-Bloc Inc. Casted concrete stone with opposed molded textured surfaces and method of manufacture
US7862754B2 (en) 2008-08-28 2011-01-04 Techo-Bloc Inc. Casted concrete stone with opposed molded textured surfaces and method of manufacture

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PCNP Patent ceased through non-payment of renewal fee