Note: Descriptions are shown in the official language in which they were submitted.
~l3n72a
-- 1 --
METHOD AND APPAP~ATUS FOR
PRODUCING PATTERNED SHAPED ARTICLE
BACKGROUND OF THE INVENTION
Field of the Invention:
This invention relates to a method for producing
patterned shaped articles using an air flow controller,
more particularly to such a method for producing patterned
concrete shaped articles, patterned artificial stone
shaped articles, patterned raw products for sintering into
ceramic shaped articles, patterned ceramic shaped
articles, patterned metal shaped articles, patterned
impasto shaped articles, patterned plastic shaped
articles, patterned shaped foodstuffs and the like, and to
an apparatus for producing patterned shaped articles.
Description of the Prior Art:
Up to now the only way available for providing a
part of a surface, such as of paving blocks, with a
pattern indicating a crosswalk, a stop sign or other such
traffic control mark or for providing the entire surface
of the blocks with a pattern has been to paint the surface
with a coating material such as paint or to inlay the
desired pattern.
Since the patterns painted on a part or all of
the surface of paving blocks are exposed to abrasion from,
for example, the shoes of pedestrians walking on the
blocks and the tires of vehicles driving over them, they
quickly wear off and have to be redone at frequent
intervals. The amount of labor involved in this work is
considerable. Where the pattern is formed by inlaying,
the work itself is troublesome and very costly.
An object of this invention is to provide a
method and an apparatus for producing various types of
patterned shaped articles with surface patterns formed by
pattern courses of prescribed thickness, by use of an air
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flow controller and computer control.
SUMMARY OF THE INVENTION
For attaining this object, the invention
provides a method of producing a pattern shaped article
comprising the steps of forming a course of dry particles
on a base surface; using an air flow controller having
either a suction port or a blow port or both a suction
port and a blow port to cause an air flow to form a cavity
in the dry particle course by removing a part of the
particles thereof under the control of at least one
parameter among air pressure, air flow rate, air flow
speed, air flow direction, air flow pulsation, air flow
intermittence, suction port size, blow port size, suction
port position and blow port position; charging the cavity
with a different type of dry particles; and allowing the
particles to set into an integral mass.
The invention further provides an apparatus for
producing a patterned shaped article, comprising: cavity
forming means having an air flow controller disposed above
a course of dry particles formed on a base surface,
provided with at least one of a suction port and a blow
port, and causing an air flow to form a cavity in the dry
particle course by removing a part of the particles
thereof under the control of at least one parameter among
air pressure, air flow rate, air flow speed, air flow
direction, air flow pulsation, air flow intermittence,
suction port size, blow port size, suction port position
and blow port position; and means for supplying a
different type of particles into the formed cavity.
Thus the method of producing a patterned shaped
article according to the invention uses an air flow
controller e~uipped with a suction port and/or blow port
and computer controls at least one paramete among the
pressure, flow rate, flow speed, flow direction, flow
pulsation and flow intermittence of air supplied to the
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suction port or blow port, the suction port size, the blow
port size, the suction port position and the blow port
position, whereby it becomes possible to mass produce
patterned shaped articles with high precision.
The above and other objects, characteristic
features and advantages of the invention will become
apparent to those skilled in the art from the description
of the invention given hereinbelow with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. l(a) is a perspective view showing a first
example of a shaped article produced by the invention.
FIG. l(b) is a perspective view of one type of
suction port used in this invention.
FIG. 2(a) is a sectional view showing the
suction port of FIG. l(b) being used to form a cavity in a
particle course.
FIG. 2(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 2(c) is a sectional view showing the cavity
charged with a different type of particles.
FIG. 3(a) is a sectional view showing a cavity
being formed by inserting a suction port into a particle
course.
FIG. 3(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 3(c) iS a sectional view showing the cavity
charged with a different type of particles.
FIG. 4(a) is a sectional view showing a cavity
being formed in a particle course using a suction port
equipped with a skirt.
FIG. 4(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 4~c) is a sectional view showing the cavity
charged with a different type of particles.
~- 2130725
FIG. 5(a) is a sectional view showing a cavity
being formed in a particle course using a suction port
equipped with a skirt and a breather tube.
FIG. 5(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 5(c) is a sectional view showing the cavity
charged with a different type of particles.
FIG. 6(a) is a perspective view showing a second
example of a shaped article produced by the invention.
FIG. 6(b) is a perspective view of one type of
blow port equipped with a skirt and used in this
invention.
FIG. 7(a) is a sectional view showing a cavity
being formed in a particle course by the blow port of FIG.
6(b) deeply inserted into the particle course.
FIG. 7(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 7(c) is a sectional view showing the cavity
charged with a different type of particles.
FIG. 8(a) is a sectional view showing a cavity
being formed in a particle course by a blow port
positioned above the particle course.
- FIG. 8(b) is a sectional view showing the cavity
formed in the particle course.
FIG. 8(c) is a sectional view showing the cavity
charged with a different type of particles.
FIG. 9(a) is a sectional view showing a cavity
being formed in a particle course by a blow port inserted
to a shallow depth in the particle course.
FIG. 9(b) is a sectional view showing the cavity
formed in the partic~e course.
FIG. 9(c) is a sectional view showing the cavity
charged with a different type of particles.
FIG. lO(a) is a sectional view showing a cavity
being formed in a particle course by a blow port with
`~ 2130725
skirt inserted in the particle course.
FIG. lO(b) is a sectional view showing further
formation of the cavity with movement of the skirt of the
blow port.
FIG. lO(c) is a sectional view showing the
cavity formed in the particle course.
FIG. lO(d) is a sectional view showing the
cavity charged with a different type of particles.
FIG. ll(a) is a perspective view showing a third
example of a shaped article produced by the invention.
FIG. ll(b) is a perspective view showing a
suction port and a blow port used in the invention.
FIG. 12(a) is a sectional view showing a cavity
being formed in a particle course by a suction port and a
blow port positioned in parallel.
FIG. 12(b) is a sectional view showing the
cavity formed in the particle course.
FIG. 12(c) is a sectional view showlng the
cavity charged with a different type of particles.
FIG. 13(a) is a sectional view showing a cavity
being formed in a particle course by a suction port and a
blow port inclined with respect to the blow port.
FIG. 13(b) is a sectional view showing the
cavity formed in the particle course.
FIG. l~(c) is a sectional view showing the
cavity charged with a different type of particles.
FIG. 14(a) is a sectional view showing a cavity
being formed in a particle course by a suction port and a
blow port positioned inside the suction port. -~
FIG. 14(b) is a sectional view showing the
cavity formed in the particle course.
FIG. 14(c) is a sectional view showing the
cavity charged with a different type of particles.
FIG. 15(a) is a sectional view showing a cavity
being formed in a particle course by a blow port and a
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suction port positioned inside the blow port.
FIG. 15(b) is a sectional view showing the
cavity formed in the particle course.
FIG. 15(c) is a sectional view showing the
cavity charged with a different type of particles.
FIG. 16(a) is a perspective view showing a first
example of an end stop.
FIG. 16(b) is a perspective view showing a
second example of an end stop.
FIG. 16(c) is a perspective view showing a third
example of an end stop.
FIG. 16(d~ is a perspective view showing a
fourth example of an end stop.
FIG. 16(e) is a perspective view showing a fifth
example of an end stop.
FIG. 17 is a perspective view showing a first
exar;lple of a molding apparatus that utilizes blowing.
FIG. 18 is a schematic view for explaining the
operation of an air flow controller of the molding
apparatus of FIG. 17.
FIG. 19 is a perspective view showing a second
example of a molding apparatus that utilizes blowing.
FIG. 20(a) is a schematic vie~ for explaining
how the air flow controller of the molding apparatus of
FIG. 19 operates when a gate of a particle supply tank is
closed.
FIG. 20(b) is a schematic view for explaining
how the air flow controller of the molding apparatus of
FIG. 19 operates when the gate of the particle supply tank
is open. ~ --
FIG. 21 is a schematic view for explaining the
operation of another example of the air flow controller.
FIG. 22 is a perspective view showing a first
example of a molding apparatus that utilizes suction.
FIG. 23 is a schematic view for explaining the
-'~` 213~72.j
operation of a first example of the air flow controller
of the molding apparatus utilizing suction.
FIG. 24(a) is a schematic view for explaining
how a second example of the air flow controller of the
molding apparatus utilizing suction operates when a gate
of a particle supply tank is closed and the supply of air
commenced.
FIG. 24(b) is a schematic view for explaining
how the air flow controller of FIG. 24(a) operates when
the gate is open.
FIG. 24(c) is a schematic view for explaining
how the air flow controller of FIG. 24(a) operates when
both the gate and an extension pipe of an air supply pipe
are closed.
FIG. 24(d) is a schematic view for explaining
how the air flow controller of FIG. 24(a) operates when
both the gate and the extension pipe is closed and the
supply of air cut off.
FIG. 25 is a schematic view for explaining the
operation of a third example of the air flow controller of
the molding apparatus utilizing suction.
FIG. 26 is a schematic view for explaining the
operation of a first example of the air flow controller
of the molding apparatus utilizing suction and blowing.
FIG. 27 is a schematic view for explaining the
operation of a second example of the air flow controller
of the molding apparatus utilizing suction and blowing. ~
FIG. 28 is a schematic view for explaining the :
operation of a third example of the air flow controller of
the molding apparatus utilizing suction and blowing.
FIG. 29(a) is a schematic view showing a first
example of the arrangement of a suction port, a blow port
and a particle supply port.
FIG. 29(b) is a schematic view showing a second
example of the arrangement of a suction port, a blow port
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and a particle supply port.
FIG. 29(c) is a schematic view showing a third
example of the arrangement of a suction port, a blow port
and a particle supply port.
FIG. 30(a) is a schematic view showing a first
example of a suction port, a blow port and a particle
supply port arranged in a triple pipe structure.
FIG. 30(b) is a schematic view showing a second
example of a suction port, a blow port and a particle
supply port arranqed in a triple pipe structure.
FIG. 30(c) is a schematic view showing a third
example of a suction port, a blow port and a particle
supply port arranged in a triple pipe structure.
FIG. 30(d) is a schematic view showing a fourth
example of a suction port, a blow port and a particle
supply port arranged in a triple pipe structure.
FIG. 30(e) is a schematic view showing a fifth
example of a suction port, a blow port and a particle
supply port arranged in a triple pipe structure.
FIG. 30(f) is a schematic view showing a sixth
example of a suction port, a blow port and a particle
supply port arranged in a triple pipe structure.
FIG. 31(a) is a schematic view showing a first
example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed inside the inner pipe.
FIG. 31(b) is a schematic view showing a second
example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed inside the inner pipe.
FIG. 31(c) is a schematic view showing a first
example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed inside the outer pipe.
FIG. 31(d) is a schematic view showing a second
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example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed inside the outer pipe.
FIG. 31(e) is a schematic view showing a first
example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed outside the outer pipe.
FIG. 31(f) is a schematic view showing a second
example of a suction port and a particle supply port
arranged in a double pipe structure and a blow pipe
disposed outside the outer pipe.
FIG. 32(a) is a perspective view showing another
type of suction port equipped with a diaphragm.
FIG. 32(b) is a perspective view showing still
another type of suction port equipped with a skirt formed
into a U-shaped frame with its channel directed downward.
FIG. 32(c) is a perspective view showing yet
another type of suction port equipped with a skirt
rotatably disposed thereabouts.
FIG. 33(a) is a perspective view showing a first
example of a suction port and a blow port.
FIG. 33(b) is a perspective view showing a
second example of a suction port and a blow port.
FIG. 33(c) is a perspective view showing a third
example of a suction port and a blow port.
FIG. 34(a) is a perspective view showing a first
example of a plurality of suction ports and blow ports in
a block assembly.
FIG. 34(b) is a perspective view showing a
second example of a plurality of suction ports and blow
ports in a block assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The inventors previously applied for patent on
an invention entitled "Method for producing patterned
shaped article" (Canadian Patent Application No.
213~72~
-- 10
2,090,36~ corresponding to Japanese Patent Application No.
4-73221).
The present invention improves on the earlier
invention by providing it with an air flow controller for
particle supply and removal which, by enabling connection
with a computer, considerably facilitates the production
of variously patterned shaped articles. More
specifically, the method of producing patterned shaped
articles using an air flow controller according to this
invention enables the production of shaped articles with a
wide variety of patterns by employing any of variously
configured air flow controllers equipped with a suction
port and/or a blow port and by controlling at least one
parameter among air pressure, air flow rate, air flow
speed, air flow direction, air flow pulsation, air flow
intermittence, suction port size, blow port size, suction
port position and blow port position. Nhile in the
interest of brevity the following description will be
limited to the patterns shown in FIGS. 1-15, the invention
is also capable of producing a great variety of other
forms. FIG. l(a) shows and example of a shaped article
patterned with the letter B expressed in dots, FIGS. 2-5
show examples of cavity formation using an air flow
controller having a suction port, FIG. 6 shows an example
of a shaped article patterned with a mountain scene
produced from a photograph, FIGS. 7-10 show examples of
cavity formation using an air flow controller having a
blow port, FIG. 11 shows an example of a shaped article
patterned with alphabet letters expressed in continuous
lines, and ~IGS. 12-15 show examples of cavity formation
using an air flow controller having both a suction port
and a blow port.
The "air flow controller" used throughout herein
is defined by an apparatus equipped with a suction port
and/or a blow port for forming cavities in a particle
.
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course by the action of suction and/or blowing.
Although the particles for producing a particle
course on a base surface and the particles to be charged
in the cavity/cavities formed in the particle course are
dry, they may have absorbed one or more of water, oil,
lubricant-bonding agent, solvent, setting agent or
plasticizer if they are not kneaded with water, oil,
lubricant-bonding agent, solvent, setting agent or
plasticizer and are in a state readily broken up for
supply.
The dots making up the letter B pattern of the
shaped article shown in FIG. l(a) are all of the same
size. This shaped article can be formed in accordance
with the invention using any air flow controller having
one or both of a suction port and a blow port. In the
interest of brevity, however, the explanation will be
limited to the case where the cavities are formed using an
air flow controller equipped with the suction port 11
shown in FIG. l(b). FIG. 2 shows an example in which the
suction port 11 is positioned above a dry particIe course
1 for sucking up particles from a selected portion
thereof. Air flows through a hemispherical region
centered on the suction port (FIG. (2a)), thereby forming
a hemispherical cavity 4 in the particle course (FIG.
(2b)). The cavity 4 is then charged with a different type
of particles 2 (FIG. 2(c)), whereafter the same steps are
repeated for producing additional cavities in the pattern
of the letter B. In this case, the cavity does not reach
the bottom of the particle course but stops midway
thereof. Although the cavity can be formed to pass
completely through the particle course by increasing the
suction force while maintaining the size of the suction
port constant, the resulting cavity will become much
larger than the diameter of the suction port owing to the
increased dispersion of the air flow caused by the
2130~2~j
- 12
increase in suction force. FIG. 3 shows an example in
which the suction of particles is conducted with the
suction port ll inserted to near the base surface at the
bottom of the dry particle course l. As shown in FIGS.
3(a) and 3(b), in this case the air flow forms a tapered
cavity 4 in the shape of a conical frustum starting as a
circle on the base surface and expanding upward to the
sùrface of the particle course. In this case, the size
and shape of the cavity formed can be controlled by using
an adjustable suction port with a variable diameter, by
increasing only the suction force or by varying the
position of the suction port between the upper and lower
regions of the particle course. FIG. 4 shows an example
in which the tip of the suction port ll is fitted with a
disk-shaped skirt 13. A number of breather holes 14 of
diameters smaller than that of the suction port 11 are
formed in the portion of the skirt 13 next to the suction
port 11 so that the skirt 13 is able to control the flow
of air around the suction port 11 by blocking most of the
air flow but allowing a small amount of air to flow
through the breather holes 14. In the illustrated
example, the suction port 11 with the skirt 13 is
positioned above the particle course 1 for sucking up
particles therefrom. Since the air flowing through the
breather holes 14 first passes downward before rising into
the suction port 11, the frustum-shaped cavity can be
formed with a smaller taper angle than in the case of FIG.
3. ~hen the arrangement of FIG. 4 is used, it is
preferable to conduct the suction in discrete pulses so
that the air will flow down through the breather holes and
then up into the suction port in a sharply defined
pattern. This makes it possible to produce a cavity that
ex~ends from the upper to the lower surface of the
particle course. FIG. 5 shows an example in which the
suction port 11 is provided with a disk-shaped skirt 13
213072'J
- 13
and a breath~r tube 15 of a diameter smaller than that of
the suction port 11 is disposed on the skirt in contact
with the suction port. In the illustrated case, the
suction port 11 with the skirt 13 and breather tube 15 is
positioned above the particle course 1 for sucking up
particles therefrom. With this arrangement, since the air
flow is focused by the breather tube 15 it becomes even
more sharply defined than in the case of FIG. 4, whereby
the wall of the cavity 4 can be formed to be almost
vertical. As in the case of FIG. 4, it is again
preferable to conduct the suction in discrete pulses in
order to ensure a sharply defined flow which minimizes the
amount of stress imparted to the remaining particle course
and thus ensures formation of a neat cavity 4. Since the
sharply defined air flow through the breather tube and the
pulsating suction prevent the pressure on the wall of the
cavity from becoming excessively negative, the wall of the
cavity can be formed to be almost vertical.
Any one of the arrangements of FIGS. 2-5 can be
used to produce the letter B by repeatedly conducting the
steps of forming cavities 4 using the method described in
the foregoing and of charging the formed cavities with a
different type of particles 2 (as shown in FIGS. 2(c),
3(c), 4(c) and 5(c)). After the shaped article
constituted as a patterned dry particle course is
completed it is set into an integral mass, either as it is
or after being smoothed or after being overlaid with a
backing course. Although the cavities 4 are best charged
with the different type of particles 2 immediately after
they are formed, it is also possible to charge them some
time later if the cavities are formed with surfaces
inclined at an angle equal to the angle of repose of the
particles or if the risk of cave-in has otherwise been
eliminated. The charging of particles can be conducted by
any of various prior art methods, including hand charging.
- 213~72~ -
- 14
It is also possible to conduct the charging using a
particle feeder integrated with the air flow controller.
In particular, the particle supply port can be disposed
near or integrally with the suction port or the blow port
and be supplied with particles through a pipe connected
with a source tank or be supplied with particles from a
supply tank positioned directly above the supply port.
FIG. 6(a) shows a shaped article patterned with
a mountain scene produced from a photograph and
constituted of dots of various sizes. This shaped article
can be formed in accordance with the invention by using
any air flow controller having one or both of a suction
port and a blow port. In the interest of brevity,
however, the explanation will be limited to the case where
the cavities are formed using an air flow controller
equipped with a slender blow port 12 (FIG. 6(b)) whose
length is longer than the thickness of the dry particle
course formed on the base surface. FIG. 7 shows an
example in which air is blown from the blow port 12 after
it has been inserted to near the base surface- at the
bottom of a dry particle course l produced in a form 3.
The air blown from the blow port 12 rises along the pipe
of the blow port 12 (FIG. 7(a)) and forms a cylindrical
cavity 4 in the particle course whose diameter is only
slightly larger than that of the blow port 12 (FIG. 7(b~).
As the air flow is constricted by the wall of the particle
course l, it follows a clean upward course and produces a
slender cylindrical cavity. Since the air exerts an
appropriate positive pressure on the wall of the cavity,
the slender cylindrical cavity 4 formed has a vertical
wall that does not cave in (though the extent to which
this is true depends on the nature of the particles). The
diameter of the cylindrical cavity formed can be varied by
varying the size of the blow port 12 or by varying the
flow speed of the blown air while maintaining the size of
: , : - .
:; ~ ,.. : .-, - .
... - . ... .... ~ . -. . . . ~
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- 15
the blow port constant. FIG. 8 shows an example in which
the blowing of particles is conducted with the blow port
12 positioned above the upper surface of the particle
course 1. As can be seen from a comparison of FIG. 7(a)
and FIG. 8(a), for the same air flow speed and blow port,
the air flow produced in this case forms a cylindrical
eavity 4 of a larger diameter than that formed by the
method of FIG. 7. In the case of FIG. 8(a), the air flow
freed from the constriction of the slender pipe and having
spread until reaching a balance progressively digs into
the particle course 1 by blowing the particles thereof.
At the beginning of this process, since the flow is not
constricted by a wall of the particle course, the diameter
of the cavity 4 formed is much greater than that in the
case of FIG. 7. The size and shape of the cavity can be
controlled by using a blow port that can be varied in size
or by eontrolling the flow rate ete. of the blown air.
FIG. 9(a) shows an example in which air is blown at the
same flow speed from the same blow port inserted to the
center region of the particle course 1. This method falls
midway between those illustrated in FIGS. 7 and 8 and
produces a cylindrical cavity 4 of a size about midway
between those of the same figures. While the air flow is
eonstrieted by the wall of the partiele eourse, it also
has some degree of freedom, whieh aeeounts for the
produetion of a eavity 4 of intermediate size. From this
it will be understood that it is possible to control the
size, shape etc. of the cavity produced merely by varying
the position of the blow port between the upper and lower
regions of the particle course, without varying either the
size of the blow port or the flow rate of the blown air.
FIG. lO(a) shows an embodiment in which the blow port 12
of FIG. 7 is fitted with a disk-shaped skirt 13 which can
be moved vertically along the blow port 12 and serves to
deflect the air flow. In the illustrated method, a
~130~2 ~
- 16
slender cylindrical cavity 4 is first formed using the
method of FIG. 7(a) (FIG. lO(a)). Next, the air flow
deflecting skirt 13 is lowered gently as shown in FIG.
lO(b) so as to form an upwardly flared tapered region
above the slender cylindrical cavity. It thus becomes
possible to form an angle of repose above the cylindrical
cavity. Controlling the air flow at the top of the
vertical wall of the cavity in this manner makes it
possible to form a surface 5 having the angle of repose,
which is advantageous because the resulting stabilization
of the cavity against cave-in provides a greater range of
freedom in selecting the method and time of particle
charging.
Any one of the arrangements of FIGS. 7-10 can be
used to produce the mountain scene by repeatedly
conducting the steps of forming cavities 4 using the
method described in the foregoing and of charging the
cavities formed with a different type of particles 2 (as
shown in FIGS. 7(c), 8(c), 9(c) and lO(d)). After the
shaped article constituted as a patterned dry particle
course is completed, it is set into an integral mass,
either as it is or after being smoothed or after being
overlaid with a backing course. Although the cavities 4
are best charged with the different type of particles 2
immediately after they are formed, it is also possible to
charge them some time later if the cavities are formed
with surfaces 5 inclined at an angle equal to the angle of
repose of the particles or if the risk of cave-in of the
cavities forming the pattern has otherwise been
eliminated. The charging of particles can be conducted by
any of various prior art methods, including hand charging.
It is also possible to conduct the charging using a
particle feeder integrated with the air flow controller.
In particular, the particle supply port can be disposed
near or integrally with the suction port or the blow port
213~2~
- 17
and be supplied with particles through a pipe connected
with a source tank or be supplied with particles from a
supply tank positioned directly above the supply port.
FIG. ll(a) shows a shaped article patterned with
alphabet letters expressed in continuous lines. This
shaped article can be formed in accordance with the
invention by using any air flow controller having one or
both of a suction port and a blow port. In the interest
of brevity, however, the explanation will be limited to
the case where the cavities are formed using an air flow
controller equipped with both a suction port 11 and a blow
port 12 as shown in FIG. ll(b). FIG. 12 shows an example
in which an air flow controller having a suction port 11
and an adjacent blow port 12 of smaller diameter than the
suction port is position at the upper surface of a dry
particle course 1 and blowing and suction of air are
conducted simultaneously. Air is blown from the blow port
12 into the interior of the particle course 1 and, after
making a U-turn, is sucked into the suction port 11.
Most of the air flowing into the suction port 11 is air
blown from the blow port 12 and little air flows into the
suction port 11 from its immediate surroundings. Thus by
controlling the suction force and the amount, speed,
direction etc. of the blown air it is possible to produce
a sharply defined U-shaped flow. As the removed particles
are being entrained by this flow, the suction port 11 and
the blow port 12 are moved over the surface of the
particle course 1 in the pattern of the letters to be
formed so as to produce a vertically-walled groove as
shown in FIG. 12(a). A balance should preferably be
established for making the air pressure against the walls
of the groove appropriately positive, and for ensuring
formation of a continuous groove with vertical walls the
pressure should be kept from becoming any more negative
than necessary (though the extent to which the walls can
213~2:~
be maintained vertical also depends on the nature of the
particles). The width, shape and the like of the groove-
like cavity produced can be varied by varying the size of
the blow port and/or the suction port, the flow speed of
the blown air while maintaining the sizes of the blow port
and the suction port constant, varying the suction force,
or by varying other such parameters. In addition,
surfaces having the angle of repose can be produced at the
upper portion of the groove-like cavity by carrying out
control for expanding the air flow in the vicinity of the
suction port. Controlling the air flow at the top of the
vertical wall of the groove-like cavity so as to form
surfaces having the angle of repose has the advantageous
effect of stabilizing the particle course and, as such,
provides a greater range of freedom in selecting the
method and time of particle charging. FIG. 13 shows an
exa.mple in which an air flow controller similar to that of
FIG. 12 but with the blow port 12 slightly separated from
the suction port and adapted to blow air at an angle is
positioned with its suction port 11 and blow port 12 at
the same height as in the case of FIG. 12, namely with the
suction port and blow port positioned at the upper surface
of the dry particle course 1. When blowing and suction
are conducted with this arrangement, the air flow passes
along a wedge-like path angling down from the blow port 12
and then up into the suction port 11 (FIG. 13(a)). As
shown in FIG. 13(b), the cavity formed has a trapezoidal
configuration with a sloped wall on the side of the blow
port 12 and a vertical wall on the side of the suction
port opposite from the blow port. Where a line pattern
such as that of FIG. ll(a) is to be formed by this method
it is advantageous to position the suction port 11 in
front and the blow port 12 in back. This is because in
the course of forming the cavity the particles removed
from the wall in the direction of advance by the air blown
213~25
-- 19
from the blow port at the rear are simultaneously sucked
up by the suction port at the front, whereby the formed
cavity is under positive pressure and not unnecessarily
subjected to negative pressure. As a result, a neat
cavity can be formed with high efficiency. FIG. 14 shows
an example in which the air flow controller is equipped
with a slender blow port 12 that projects downward from
the center of a suction port 11 by a considerable length
and air is blown from the blow port 12 after the blow port
12 has been inserted into the lower portion of the
particle course 1. With this arrangement it is possible
to reduce the air to a fine flow. The groove-like cavity
4 produced in this case is thus narrower than when the
method of FIG. 12 or 13 is used. Because of the central
location of the blow port 12, the arrangement is
conveniently able to advance in any direction. By
further incorporating the vertically movable disk-like
skirt 13 shown in FIG. 10, moreover, it becomes possible
to vary the shape of the groove by using the skirt to
deflect the air flow. FIG. 15 shows an example employing
a double pipe structure in which the blow port 12 is a
doughnut-shaped member enclosing the suction port 11. The
air blown from the blow port 12 forms a doughnut-shaped
curtain which converges toward the center as it progresses
toward the bottom portion of the particle course 1 where
it makes a U-turn and is then sucked into the suction port
11. The convergence of this flow can be intensified by
increasing the suction force relative to the strength of
the blown air. This produces a corresponding convergence
in the groove.
Any one of the arrangements of FIGS. 12-15 can
be used to produce letters of the alphabet by forming
groove-like cavities 4 in prescribed shapes using the
method described in the foregoing and then charging the
cavities formed in various sizes and shapes with a
213~2~
- 20
different type of particles 2 (as shown in FIGS. 12(c),
13(c), 14(c) and 15(c)). After the shaped article
constituted as a patterned dry particle course is
completed it is set into an integral mass, either as it is
or after being smoothed or after being overlaid with a
backing course. Although the cavities are best charged
with the different type of particles immediately after
they are formed, it is also possible to charge them some
time later if the cavities are formed with surfaces having
the angle of repose or if the risk of cave-in of the
cavities forming the pattern has otherwise been
eliminated. The charging of particles can be conducted by
any of various prior art methods, including hand charging.
It is also possible to conduct the charging using a
particle feeder integrated with the air flow controller.
In particular, the particle supply port can be disposed
near or integrally with the suction port or the blow port
and be supplied with particles through a pipe connected
with a source tank or be supplied with particles from a
supply tank positioned directly above the supply port.
In any of the arrangements it is possible to use
any of variously configured air flow controllers and to
produce various patterns by varying at least one parameter
among the air pressure, air flow rate, air flow speed, air
flow direction, air flow pulsation, air flow
intermittence, suction port size, blow port size, suction
port position and blow port position. Any type of pattern
can be freely produced by whatever method desired.
The diameter of the individual suction ports
and/or blow ports should preferably be not greater than
twice the thickness of the particle course. Fine blow and
suction ports are preferable for the production of fine
pattern features. A particularly sharply defined flow can
be obtained by making the diameter of the blow port equal
to or smaller than the thickness of the particle course.
2~3~72:J
- 21
For obtaining well straightened air flows and ensuring
formation of sharply defined cavities, it is further
preferable for the blow port pipe and breather tube to
have lengths which are not less than three times their
diameters so that the supplied air can be formed into a
laminar flow. In view of the purpose of the skirt, it is
preferably provided with a breather tube or breather tubes
for the formation of a laminar flow.
The suction related parameters adjusted for
controlling the air flow include the size of the suction
port, the vertical position of the suction port, the
suction intensity (flow rate, flow speed and pressure),
the intermittence or pulsation of the suction, the
direction of the suction, the amount of swirling flow
imparted by the suction, the positioning etc. of a skirt
etc., and the size, length and shape of the breather
tube(s) etc. Blowing related parameters adjusted for
controlling the air flow include the size of the blow
port, the vertical position of the blow port, the blowing
intensity (flow rate, flow speed and pressure), the
intermittence or pulsation of the blowing, the direction
of the blowing, the amount of swirling flow imparted by
the blowing, and the positioning etc. of a skirt etc. The
pipe connecting the suction port with an aspirator and the
pipe connecting the blow port with a compressor can be
equipped with regulators and/or other types of control
valves which can be controlled for controlling the flow of
air outside the suction port and the blow port. Otherwise
the control signals for the regulators and other control
valves, the control signals for the aspirator, compressor
and the like and the control signals for the positioning
devices and the like can be integrally processed and
managed in a computer or a distributed control system.
This is preferable in that it enables cavities with neat
(regular) sections, cavities with irregular sections, or
213~2~i
- 22
any other type of cavity to be formed as desired.
A balance should preferably be established for
making the air pressure against the wall of the cavity
appropriately positive, and for ensuring formation of a
hole or continuous groove with vertical walls the pressure
should be kept from becoming any more negative than
necessary (though the extent to which the walls can be
maintained vertical also depends on the nature of the
particles). In the case where blowing is conducted with
the blow port positioned at the surface of the particle
course, for producing a fine and sharply defined cavity it
is preferable not to conduct the blowing at a fixed
pressure from the beginning but to begin it at a low
pressure and then increase the pressure when the cavity
being formed has been completed to a size and shape
enabling its wall to resist pressure and when a U-turn
course has been established by the air flow. The same
overall process control should preferably also be
implemented in the case where blowing and suction are
conducted in combination since this ensures the formation
of sharply formed cavities. When suction is used to impart
a negative pressure, it is preferable in the case of
forming dot-like cavities to conduct the processing in
short, pulse-like periods because this prevents cave-in
owing to inflow of surrounding air, and preferable in the
case of linework to increase the speed of line formation
because this minimizes the negative pressure applied at
any one point.
In the case of linework, it is advantageous to
position the suction port in front and the blow port in
back. This is because the wall in the direction of
advance is broken down by the air blown from the blow port
at the rear so that the formed cavity is under positive
pressure and not unnecessarily subjected to negative
pressure. As a result, a clean cavity can be formed with
213~725
high efficiency. Similarly, in the case of using only
suction it is preferable to form the line with the
breather port, breather tube or other breather member
positioned at the rear and the suction port positioned at
the front so as not to expose the cavity to unnecessary
negative pressure after it is formed.
The angle of repose is formed by controlling the
air flow. More specifically, the required configuration
is formed at the time of raising the suction port from an
inserted position or by enlarging the size of a variable
suction port, or the angle of repose is adjusted by
selecting the size of a skirt. Forming a surface having
the angle of repose has the advantageous effect of
stabilizing the particle course and, as such, provides a
greater range of freedom in selecting the method and time
of particle charging.
A skirt can be preferably used for a wide
variety of purposes such as for adjusting the size of the
cavity formed, preventing inflow of surrounding air and
thus enabling full utilization of the stress pro-duced by
the air flowing through the breather ports, and producing
an air flow for the formation of an angle of repose. The
skirt need not have the disk-like shape described in the
foregoing but may be elliptical or triangular or have a
drooping configuration with a sectional shape like an
inverted letter U. Moreover, it does not have to be in
the form of a flange but may instead be a solid body and
may be either soft or hard. In addition, it may be
attached directly to the suction port or the blow port or
be attached so that the length of the suction pipe or the
blow pipe can be adjusted by moving the skirt vertically.
At the time of charging a different type of
particles into a cavity formed in the particle course 1, a
well finished pattern can be ensured by inserting end
stops 6 at the start, end and branch points of the
,~ , , . : : - ........... ~ ........... . . - :
A, . .; . . .
2 1 3 0 7 2 ~
- 24
pattern, as shown in FIG. 16(a), and removing them after
the pattern has been completed.
While the end stops 6 are shown to be H-shaped
in FIG. 16(a), they are not limited to this shape and can
be of various other configurations as shown in FIGS.
16(b)-16(e).
As the base surface it is possible to use the
bottom plate of a form or, alternatively, a sheet, belt,
board or the like, the bottom plate of a double action or
other type press, the bottom plate of a form placed on a
conveyor, or a belt conveyor or other such endless
surface. The particle course can be placed on a board,
sheet or other such base surface either as it is or as
turned upside down. Although any type of material can be
used for the base surface, it is preferable to use unwoven
fabric, woven fabric, paper or the like. This is because
the particles are able to fit into the irregularities of
such materials and this has the effect of stabilizing the
bottom surface of the particle course.
In all cases, the various types of an air flow
controllers can be disposed at the desired position on the
particle course either by hand operation or by use of a
robot or other such machine. If necessary, moreover, a
skirt or other such auxiliary member can be attached to
the suction port or the blow port, vibrators and other
such auxiliary devices can be installed, and the supply
port of a particle feeder can be provided together with
the suction and blow ports.
The air flow controller used for forming
patterned shaped articles according to this invention can
be designed as desired. While it is possible to combine
various methods with various arrangements for designing a
wide range of different air flow controllers, the
explanation will, in the interest of brevity, be limited
to those shown in FIGS. 17-31.
213~72S
The air flow controller shown in FIG. 17 has a
blow port 12 connected via a hose with a controllable
regulator 21 which is in turn connected by a hose with an
air compressor 22 serving as the air source. The blow
port 12 is supported by a robot 23 and can be positionally
controlled within an xYz coordinate system and also be
directionally controlled (by tilting). The regulator,
compressor and robot are integrally controlled by control
signals from a computer 24. This air flow controller can
be used in the production of shaped articles by the
methods of FIGS. 7, 8, 9, etc. but the supply of the
different type of particles to the formed cavities has to
be conducted separately by hand or some other device. In
the case of producing a shaped article by the method of
FIG. 10, a vertically movable disk-like skirt 13 is
attached to the blow port 12, as shown in FIG. 18.
The air flow controller shown in FIG. 19 has a
gated particle supply tank 25 positioned immediately above
a blow port 12. The blow port 12 is connected by a hose
via a motor operated valve 38 with a controllable
regulator 21 which is in turn connected with an air
compressor 22 serving as the air source. The blow port 12
is mounted on a bridge-like frame 26 which is movable in
the X and Y directions and is movable vertically with
respect to the frame 26. The regulator, compressor and
robot are integrally controlled by control signals from a
computer 24. The particle supply tank 25 mounted on the
frame 26 can be supplied with particles from a source tank
27 when positioned at one end of the frame 26. Since in
this air flow controller the supply pipe from the particle
supply tank 25 operates to deflect the air flow, the air
flow controller can be used not only in the methods of
FIGS. 7, 8 and 9 but also in the method of FIG. 10. In
addition, as shown in FIG. 20ta), a part of the air which
would otherwise be supplied to the blow port 12 is
.. . - . .. ,~ -- .. . . , . . , , . - . . . . . . . .
213~72
- 26
diverted through a branch and blown directly onto the
bottom of a gate 25' of the particle supply tank 25. When
the gate of the supply tank is open as shown in FIG.
20(b), the particles in the supply tank are fluidized by
the air flow, making it easier for them to fall. Owing to
this arrangement, the particles 2 can be supplied to
cavities 4 by momentarily opening and closing the gate
25'. Since this method makes it possible to form a cavity
4 and then charge it with the particles 2 without moving
any positioning device, it enables continuous operation
and greatly improves operating efficiency. In addition,
when this method is used in cavity formation that does not
involve insertion of the blow port or the suction port in
the particle course 1, it becomes possible to produce
patterns without touching the particle course, which is
ideal in the production of patterned shaped articles.
FIG. 21 shows an example in which air is branched off
directly into the region of the particle supply tank 25
above the gate 25' via a control valve 28 and the blow
port is positioned at the side of the supply port. The
control valve 28 is opened when the gate is opened for the
charging of particles.
In the air flow controller shown in FIG. 22, a
local controller 29 equipped with a microcomputer is
provided immediately above a suction port 11. The suction
port 11 is connected by a hose with an aspirator 30 which
can be freely controlled by use of the local controller
29. The suction port 11 including the local controller 29
is held in the hand during formation of cavities. The
supply of the different type of particles to the formed
cavities has to be conducted separately by hand or some
other device. This air flow controller is distinguished
from those of FIG. 17 and 19 mainly by its simple
configuration.
FIG. 23 shows another example of an air flow
2~3~725
- 27
controller equipped with a suction port 11. Suction is
produced by an ejector section 32 located immediately
above the suction port and constituted by means of an air
supply pipe 31. A gated particle supply tank 25 is
connected with the suction pipe at a point above the
ejector section 32 and a flange-like skirt 13 is provided
around the suction port 11 for limiting air flow. The
skirt is equipped with a breather tube 15. The system is
integrally controlled by a computer or the like that
processes the control signals of an air compressor 22 for
supplying air to the ejector section 32, a controllable
regulator 21 and a motor operated valve 38 positioned
between the ejector section 32 and the air compressor 22,
a gate 25' and a positioning device (not shown).
FIG. 24 shows an example of an air flow
controller having a suction port 11 and, immediately above
the suction port 11, an ejector section 32 which uses
particles in place of a valve. An air supply pipe 31 is
provided for supplying air to the ejector section 32 and a
particle supply tank 25 for supplying a different type of
particles to the particle course is connected with an
intermediate portion of the air supply pipe 31 via a gate
25'. A motor operated valve 38, a controllable regulator
21 and an air compressor 22 are provided upstream of the
particle supply tank 25 and are connected by a hose in the
order mentioned. As shown in FIG. 24(a), the gate 25' of
the particle supply tank 25 is closed and the supply of
air commenced. When the gate 25' is opened, as shown in
FIGS. 24(b), the air carries off the particles 2 falling
from the particle supply tank 25. Once the particles have
been carried away, if the gate is closed but the supply of
air is continued, the particles 2 that were carried off
will enter an extension pipe 31' equipped with a filter,
as shown in FIG. 24(b). Since the particles are stopped
by the filter, they accumulate in and obstruct the
213~72S
- 28
extension pipe 31'. When the extension pipe 31' becomes
obstructed, the ejector section 32 begins to function and,
as shown in FIG. 24(c), particles of the particle course
immediately under the suction pipe are sucked up and
removed toform a cavity 4 in the particle course 1. When
the supply of air is cut off following the formation of
the cavity 4, the particles 2 obstructing the extension
pipe 31' (which are of a different type from those of the
particle course 1) are no longer pushed into the extension
pipe 31' and fall down through the suction pipe to fill
the cavity 4 immediately under the suction port 11 as
shown in FIG. 24(d~. A pattern is formed by repeating
these steps. Alternatively, the inlet of the extension
pipe 31' can be provided with a valve or a gate for
opening and closing it. This makes it possible to
forcibly change the air flow, delay the particle charging,
or cope with the situation where, as may happen with
certain kinds of particles, the extension pipe 31' cannot
be completely obstructed so that air continues to leak
from the filter. The system is integrally controlled by a
computer or the like that processes the control signals
for the air compressor for the ejector, the intermediately
positioned controllable regulator, the gate of the supply
tank and a positioning device (not shown).
FIG. 25 shows another example of an air flow
controller having a suction port 11. A particle supply
tank 25 is provided immediately above the suction port 11
and connected therewith via a gate 25'. An air nozzle 34
projects into the suction port 11 immediately under the
gate 25' for blowing air upward. When the gate 25' is
opened, air blown into the particle supply tank 25 from
this nozzle increases the fluidity of the particles 2 in
the particle supply tank 25, making it easier for them to
fall. A suction pipe 35 connected with an aspirator is
formed to branch from the suctionport 11 at an angle that
213~25
- 29
does not hinder the flow of air. In the illustrated
embodiment, a skirt 13 equipped with a breather hole 14 is
provided on the lower tip of the suction port. As
explained earlier, however, the provision of this skirt is
optional. The system is integrally controlled by a
computer or the like that processes the control signals
for the aspirator, the gate, a regulator (not shown), and
a positioning device (not shown).
FIG. 26 shows an example of an air flow
controller having both a blow port 12 and a suction port
11. A particle supply tank 25 is provided immediately
above the suction port 11 and connected therewith via a
gate 25'. Similarly to the arrangement in FIG. 25, an air
nozzle 34 projects into the suction port 11 immediately
under the gate 25' for blowing air upward to fluidize the
particles 2 and make it easier for them to fall. A
suction pipe 35 connected with an aspirator is formed to
branch from the suction port 11 at an angle that does not
hinder the flow of air. A blow port 12 is provided at the
side of the suctionport 11 for blowing air downward at an
angle. The blow port 12 is connected with the same air
source as the air nozzle 34. The system is integrally
controlled by a computer or the like that processes the
control signals for the gate, an aspirator (not shown), a
regulator (not shown), and a positioning device (not
shown).
FIG. 27 shows another example of an air flow
controller having both a blow port 12 and a suction port
11. While the configuration is generally the same as that
shown in FIG. 26, the arrangement differs in that the blow
port 12 is not disposed at the side of the suction port
but at its center in a double pipe structure. Air is
blown downward from the center of the double pipe
structure and sucked in through its peripheral region.
The system is integrally controlled by a computer or the
~ :.. .,. .~,. . ;: . .... :.:.:. . . .
.; ... ;;,.: - . ... . - . : : " , , -- ~
.... ,. . - - .. .... . .. . . . .. . . . . . . . .~.. .. ~ .
-
21~0725
- 30
like that processes the control signals for the gate, a
regulator (not shown), an aspirator (not shown), and a
positioning device (not shown).
FIG. 28 shows another example of an air flow
controller having both a blow port 12 and a suction port
11. The blow port 12 fully encloses the suction port 11
in a double pipe structure. Air supplied from an air
compressor through a controllable regulator is blown
downward from the peripheral region of the double pipe
structure and sucked in at the center. An air supply pipe
31 is connected with the pipe of the suction port 11 to
constitute an ejector section 32. The upstream end of the
air supply pipe 31 is connected through a controllable
regulator to an air compressor and the ejector is
connected with a particle supply tank 25 having a gate 25'
and with an exhaust pipe 36. The ejector and the blow
port are each equipped with a controllable regulator and
the system is integrally controlled by controlling these
regulators and the gate 25'.
FIG. 29 shows another example of an air flow
controller having both a blow port 12 and a suction port
11. The arrangement is made suitable for linework by
positioning a particle supply port 37 at the rear with
respect to the direction of advance. In the interest of
simplicity, the explanation is limited to the order in
which the blow port 12, the suction port 11 and the
particle supply port 37 are arranged. Other matters, such
as the angle of the blow port, whether and how it is
controlled by a regulator whether the suction port is
connected with an ejector or with a separate aspirator,
and whether the other type of particles are supplied
directly from a supply tank or are conveyed by air, can be
determined as desired to obtain numerous combinations of
arrangement and method, each of which can be further
modified by selection of the height etc. of the blow port,
- 213072~
- 31
suction port and supply port. Only three typical
arrangements of the blow port, suction port and supply
port are illustrated. In FIG. 29(a), the suction port 11
is in the lead relative to the direction of advance and
the blow port12 and the particle supply port 37 are lined
up behind it. In FIG. 29(b), the blow port 12 is in the
lead relative to the direction of advance and the suction
port 11 and the particle supply port 37 are lined up
behind it. In FIG. 29(c), a first blow port 12 is in the
lead and suction port 11, second blow port 12 and the
particle supply port 37 are lined up behind it. Control
is conducted in accordance with the controllable
parameters of the respective arrangements and since the
cavity can be continuously charged with the different type
of particles immediately after formation, linework can be
conducted with high efficiency.
FIG. 30 shows embodiments in which the blow port
12, the suction port 11 and the particle supply port 37
are constituted in a triple pipe structure with one
inside, one in the middle and one on the outside. More
specifically, FIG. 30(a) shows an embodiment in which the
particle supply port 37 is inside, the blow port 12 in the
middle and the suction port 11 on the outside; FIG. 30(b)
an embodiment in which the particle supply port 37 is
inside, the suction port 11 in the middle and the blow
port 12 on the outside; FIG. 30(c) an embodiment in which
the suction port 11 is inside, the blow port 12 in the
middle and the particle supply port 37 on the outside;
FIG. 30(d) an embodiment in which the suction port 11 is
inside, the particle supply port 37 in the middle and the
blow port 12 on the outside; FIG. 30(e) an embodiment in
which the blow port 12 is inside, the particle supply port
37 in the middle and the suction port 11 on the outside;
and FIG. 37(f) shows an embodiment in which the blow port
12 is inside, the suction port 11 in the middle and the
.. . ........ . , ., .. . . . . . - ., .,,. ". . .. ,. - .. ...
2130725
particle supply port 37 on the outside.
FIG. 31 shows embodiments in which the suction
port 11 and the particle supply port 37 are constituted in
a double pipe structure that is provided with the blow
port 12. FIG. 31(a) shows an embodiment in which the
particle supply port 37 is inside, the suction port 11 is
on the outside and the blow port 12 is provided inside the
particle supply port 37; FIG. 31~b) an embodiment in which
the suction port 11 is inside, the particle supply port 37
is on the outside and the blow port 12 is provided inside
the suction port 11; FIG. 31(c) an embodiment in which the
particle supply port 37 is inside, the suction port 11 is
on the outside and the blow port 12 is provided inside the
suction port 11; FIG. 31(d) an embodiment in which the
suction port 11 is inside, the particle supply port 37 is
on the outside and the blow port 12 is provided inside the
particle supply port 37; FIG. 31(e) an embodiment in which
the particle supply port 37 is inside, the suction port 11
is on the outside and the blow port 12 is provided outside
the suction port 11; and FIG. 31(f) an embodiment in which
the suction port 11 is inside, the particle supply port 37
is on the outside and the blow port 12 is provided outside
the particle supply port 37.
Since the foregoing embodiments enable cavity
formation and particle supply to be conducted
continuously, they make it possible to replace the
particles with another type o~ particles with high
efficiency. In addition, they are well adapted for
producing dot patterns and can also be used for linework.
In the interest of simplicity, the explanation was limited
to the arrangement of the blow port 12, the suction port
11 and the particle supply port 37. However, other
matters, such as the angle of the blow port, whether and
how it is controlled by a regulator, whether the suction
port is connected with an ejector or with a separate
21~72~
-
- 33
aspirator, and whether the other type of particles are
supplied directly from a supply tank or are conveyed by
air, can be determined as desired to obtain numerous
combinations of arrangement and method, each of which can
be further modified by selection of the height etc. of the
blow port, suction port and supply port. Control is
conducted in accordance with the controllable parameters
of the respective embodiments and since the cavities can
be continuously charged with the different type of
particles immediately after formation, pattern formation
can be conducted with high efficiency.
Any of the embodiments can be used with
variously configured suction ports, blow ports, breather
tubes, skirts and other auxiliary members and, in
addition, can be combined with the supply port of a
particle feeder and other auxiliary devices and the like.
Thus the air flow controller can be designed in any manner
desired. It is by no means limited to the illustrated
examples but can be constituted in various ways by
combination with different methods.
As the material for the suction port, blow port,
breather tube, skirt and the like there can be used, for
example, metal, ceramic, plastic, rubber, paper, wood,
unwoven fabric, woven fabric or the like. The shapes of
the suction port, blow port, breather tube, skirt and the
like can be freely selected. For example, the suction
port and blow port can be configured for forming the
individual dots as stars, hearts or any of various other
shapes. Moreover, the suction port, blow port, breather
tube, skirt and the like are preferably of the variable
type. For example, arrangements that allow diameter,
width, shape or the like to be varied can be used, as will
be understood from the suction port fitted with a
diaphragm 16 shown in FIG. 32(a). Another example is
shown in FIG. 32(b) in which a skirt is formed into a V-
- 21~ ~ 7 ~
shaped ~rame with its channel directed downward.
Otherwise, a skirt 13 may be rotatably disposed around the
suction port 11 or the blow port 12 as shown in FIG.
32(c). In this case, the skirt 13 can intercept air
flowing from behind or toward behind the direction in
which the suction port 11 or the blow port advances to
enhance the sucking or blowing efficiency of the suction
port or the blow port 12. The skirt 13 shown in FIG. 32
freely follows in the direction in which the suction port
or blow port advances and can be advantageously used to
focus the air flow in the vicinity of the cavity being
formed and ensure formation of a neat cavity. It can also
be applied to the embodiments having both the suction port
and the blow port as shown in FIGS. 11, 14, 15, etc.
Further, the suction port, blow port and supply
port do not have to be circular in section but, as shown
in FIG. 33, can instead have sections that are crucifix or
polygonal. The diameter of the individual suction ports
and/or blow ports should preferably be not greater than
twice the thickness of the particle course 1. Fine blow
and suction ports are preferable for the production of
fine pattern features. A particularly sharply defined
flow can be obtained by making the diameter of the blow
port equal to or smaller than the thickness of the
particle course. For obtaining well straightened air
flows and ensuring formation of sharply defined cavities,
it is further preferable for the blow port pipe and
breather tube to have lengths which are not less than
three times their diameters so that the supplied air can
be formed into a laminar flow. In view of the purpose of
the skirt, it is preferably provided with a breather tube
or breather tubes for the formation of a laminar flow.
While a single suction port or blow port
suffices, it is also possible to provide multiple ports
arrayed linearly or in a matrix, as shown in FIG. 34. By
2~72 .
- 35
making the arrayed ports controllable by a computer for
direct pattern production, it is possible to achieve high
productivity while enabling free pattern modification and
the production of various complex and highly sophisticated
patterns.
The suction related parameters adjusted for
controlling the air flow include the size of the suction
port, the vertical position of the suction port, the
suction intensity (flow rate, flow speed and pressure),
the intermittence or pulsation of the suction, the
direction of the suction, the amount of swirling flow
imparted by the suction, the positioning etc. of a skirt
etc., and the size, length and shape of the breather
tube(s) etc., while blowing related parameters adjusted
for controlling the air flow include the size of the blow
port, the vertical position of the blow port, the blowing
intensity (flow rate, flow speed and pressure), the
intermittence or pulsation of the blowing, the direction
of the blowing, the amount of swirling flow imparted by
the blowing, and the positioning etc. of a skirt etc. The
pipe connecting the suction port with an aspirator and the
pipe connecting the blow port with a compressor can be
equipped with regulators and/or other types of control
valves which can be directly operated for controlling the
flow of air outside the suction port and the blow port.
Otherwise the control signals for the regulators and other
control valves, the control signals for the aspirator,
compressor and the like and the control signals for the
positioning devices and the like can be integrally
processed and managed in a computer or a distributed
control system. This is preferable in that it enables
cavities with neat (regular) sections, cavities with
irregular sections, or any other type of cavity to be
formed as desired. The invention can be combined with
various freely selectable control methods. It is possible
,-~
- 213~72~
- 36
to control only one type of controllable parameter or to
control several types simultaneously. Various
arrangements are possible in addition to those described
in the foregoing. In the case of a multiple pipe system
such as in the port arrays, multiple pipe structures and
multiple port arrangements shown in FIGS. 29, 30 etc., the
control signal for the supply port can be processed
simultaneously, which makes it possible to replace the
removed particles with a different type of particles by
charging them almost simultaneously with the removal.
Charging efficiency can also be improved by applying
pressure on the supply side for forcibly replacing the
particles.
As the base surface it is possible to use the
bottom plate of a form or, alternatively, a sheet, belt,
board or the like, the bottom plate of a double action or
other type press, the bottom plate of a form placed on a
conveyor, or a belt conveyor or other such endless
surface. The particle course can be placed on a board,
sheet or other such base surface either as it is or as
turned upside down. It suffices to select the combination
easiest to use for fabricating the apparatus.
The base surface is preferably formed of unwoven
cloth, woven cloth, paper or some other material
exhibiting air permeability, liquid permeability and/or
liquid absorbing property. The advantage of such
materials is that since they promote the escape of
entrained air and the removal of excess liquid they help
to ensure the strength and uniformity of the shaped
article.
In any of the configurations, the apparatus can
be combined with particle course formation means such as a
squeegee type course forming apparatus or with a sliding
supply tank that supplies particles while sliding over the
form, a supply tank with a slitted nozzle, a rotary
213~ ~2~
- 37
feeder, a device employing an endless honeycomb belt or
the like or an endless projection-bristling belt or the
like.
In any of the configurations, the positioning of
the suction port, blow port, etc. in the X, Y and z
directions and the tilting of the suction port, blow port,
etc. can be controlled either manually or by use of any of
various positioning mechanisms such as the robot shown in
FIG. 17, the bridge-like frame shown in FIG. 19, or an xY
table a parallel linkage system, a cartesian coordinate
system, a cartesian coordinate robot, an articulated
coordinate robot, a cylindrical coordinate robot, a polar
coordinate robot or the like. If required, moreover, the
suction port, blow port, etc. can be equipped with
vibrators and various auxiliary devices, auxiliary members
and the like.
In any of the configurations, the free end of a
particle course forming apparatus located at the boundary
between a chute and a conveyor or the transfer section of
a conveyance device can be used as the base surface, and
the suction port and/or blow port can be located at this
position for forming the cavities simultaneously with the
course formation or the transfer operation. This method
enables the production of endless patterns.
Use of the various end stops shown in FIG. 16 at
the start, end and branch points of the pattern ensures a
neat finish to the shape at these points. The shapes of
the end stops are not limited to those shown and may
varied as desired for obtaining various neatly finished
start, end and branch point configurations. Preferably,
the end pieces are built into the apparatus to be
vertically movable in the vicinity of the suction port or
blow port, so that they can be lowered for use when
needed.
The method used for charging the formed cavities
213~72~j
- 38
with particles is not particularly limited. The charging
can be conducted by hand or, as shown in FIGS. 29, 30, 31,
etc., the particles can be charged through a particle
supply port 37 provided integrally with the suction port
11 and the blow port 12, or, as shown in FIGS. 20, 23,
etc., can be charged through a suction port 11 or a blow
port 12 which doubles as a particle supply port 37. The
particles can either be fed to the supply port through a
pipe connected with a source tank or be directly supplied
to the supply port through a gate from a particle tank
located immediately above the supply port. The apparatus
can further be combined with a continuous color blender
for enabling the individual cavities to be charged with
different color particles.
Any of the configurations can be used in
combination with various types of presses. For example,
it is possible to use the press plate below a double
action press as the base surface and, after a patterned
shaped article has been formed on the press plate, to
press it into a solid mass with the press. Moreover,
since there is no need for contact with the particle
course, it is also possible to use the roll surface of a
roll press as the base surface. In addition, it is
possible first to cause a plurality of patterned shaped
articles to set as one large one and later cut them into
individual articles.
In the method of the present invention, dry
particle material is used for forming a course on the base
surface. Although the material is dry, it may have
absorbed one or more of water, oil, lubricant-bonding
agent, solvent, setting agent and plasticizer, if it is
not kneaded with water, oil, lubricant-bonding agent,
solvent, setting agent or plasticizer and is in a dry
state readily amenable to pulverization for supply to the
base surface. On the other hand, the material of which
213~725
- 39
the backing layer is formed may be either dry or wet wlth
one or more of water, oil, lubricant-bonding agent,
solvent, setting agent and plasticizer. Otherwise, a
plate of metal, wood, cement, glass or ceramic or a sheet
of paper, unwoven fabric, woven fabric, knit fabric,
plastic, etc. may be used as the backing layer. In this
case, the plate or sheet serves as the base surface. In
addition, any other existing shaped article may be used as
a base surface to be formed with a course that is set
together therewith.
The materials to be supplied may differ from one
another depending on the shaped article to be produced.
Otherwise, in the finished state they are required to
aiffer from one another in color, luster, texture and the
like.
In producing a concrete shaped article, the
cou;-se material is dry and consists mainly of cement
powder, resin or a mixture thereof and may additionally
include at least one of a pigment and fine aggregates.
The material for a backing layer consists mainly o-f cement
powder, resin or a mixture of cement powder and resin, the
mixture further containing a fine aggregate and, if
necessary, additionally containing a pigment and at least
one of coarse aggregates and various kinds of fibers. The
backing material may either be dry like the course
material or in the form of a concrete slurry obtained by
kneading with water etc.
Both the materials for the course and the
material for the backing layer may additionally include
wood chips as aggregates or fine aggregates and may
further include as blended therewith crushed or pulverized
granite, crushed or pulverized marble, slag, light-
reflecting particles, inorganic hollow bodies such as
Shirasu balloons, particles of ceramics, new ceramics,
metal, ore or other substances. They may also contain as
213072~
- 40
additives a congealing and curing promoter, a
waterproofing agent, an inflating agent and the like. The
aforementioned various kinds of usable fibers include
metal fibers, carbon fibers, synthetic fibers, glass
fibers and the like.
All the materials are supplied to a form etc.
and are allowed to set into an integral mass. Otherwise
after the material has been supplied, a prescribed amount
of water is supplied to all portions of the interior of
the form etc., thereby setting the materials into an
integral mass within the form etc. If a wet material is
used for the backing layer, the amount of water supplied
is reduced in view of the water contained in the wet
material. When a plate of metal, wood, cement, glass or
ceramic or a sheet of paper, unwoven fabric, woven fabric
or knit fabric is used as the backing layer, for example,
it can be allowed to set integrally with the course. An
asphaltic concrete shaped article can be produced using a
thermal fusion material such as asphalt.
In producing an artificial stone shaped article,
the dry materials for the course may, for example, be
constituted of at least one of rock particles, ceramic
particles, new ceramic particles, glass particles, plastic
particles, wood chips and metal particles and may, as
found necessary, further have mixed therewith a pigment
etc. Also, the material for the backing layer may, for
example, be constituted of at least one of rock particles,
ceramic particles, new ceramic particles, glass particles,
plastic particles, wood chips and metal particles and may,
as found necessary, further have mixed therewith a pigment
etc. The material for the backing layer may be either dry
or wet. The wet material for the backing layer contains a
setting agent. The setting agent contained in the wet
material for the backing layer or a setting agent for
setting the dry materials for the course and/or the dry
213~72~
- 41
material for the backing layer is composed mainly of a
mixture of cement powder and water, a mixture of cement
powder, resin and water, a mixture of resin and water, a
mixture of resin and solvent, or a mixture of resin, water
and solvent and may further contain particles of at least
one of rock, ceramic, new ceramic, glass and plastic and
may, as found necessary, be kneaded with a pigment or
colorant and have mixed therewith various kinds of
particles, varinus kinds of fibers, various kinds of
mixing agents and various kinds of additives. The various
kinds of particles include particles of slag, fly ash and
fine light-reflecting substances. The various kinds of
fibers include metal fibers, carbon fibers, synthetic
fibers and glass fibers. The various kinds of mixing
agents and additives include shrink proofing agents,
congealing and setting promoters, delaying agents,
waterproofing agents, inflating agents, water reducing
agents, fluidizing agents and the like.
For enhancing the adherence of the setting agent
with the aforementioned dry materials, the dry materials
can be sprayed with or immersed in water, solvent or
surface treatment agent, but are not kneaded with water,
solvent or surface treatment agent and are in a state
readily amenable to pulverization.
All the materials can be set into an integral
mass within a form etc. by vacuum-suction treatment,
centrifugal treatment or other such treatment for
spreading the setting agent between adjacent particles or
by using a mixture of an aggregate and a setting agent as
the material for the backing layer. When a plate of
metal, wood, cement, glass or ceramic or a sheet of paper,
unwoven fabric, knit fabric, woven fabric or plastic is
used as the backing layer, the course can be allowed to
set integrally therewith.
For producing a ceramic shaped article or the
213~72~
- 42
raw product for a ceramic shaped article, the dry
materials for the course are mainly particles of one or
more of clay, rock, glass, new ceramic, fine ceramic and
glaze with or without a pigment or colorant added thereto.
Although the materials are dry, they may be ones which
have absorbed some water or been added with a lubricant-
bonding agent if they are not kneaded with the lubricant-
bonding agent or water and are in a state readily
amenable to pulverization. The material for the backing
layer is constituted mainly of particles of one or more of
clay, rock, glass, new ceramic and fine ceramic and may
additionally contain a pigment and a colorant. In the
finished state, the backing layer is required to differ
from the course in color, luster, texture and the like and
may be either dry, similarly to the course, or made wet by
kneading with water or a lubricant-bonding agent. In
addition, either the materials for the course or the
material for the backing layer may have further mixed
therewith inorganic hollow bodies such as Shirasu
balloons, and particles of ceramic, metal or ore and may
have added thereto various kinds of foaming agents,
fluidization-preventing agents, supernatant agents,
lubricating agents, bonding agents and adherence promoters
as additives.
The materials supplied into a form etc. are
allowed or caused to set into an integral mass without
adding or by adding a predetermined amount of water or
lubricant-bonding agent to plasticize them and applying
pressure to the resultant mixture. The set integral mass
is removed from the form etc. and used as a raw product.
The raw product is sintered to obtain a ceramic shaped
article. Otherwise, the materials supplied into a
refractory setter or similar form are melted or fused by
heating to obtain an integral mass, and the integral mass
is removed from the setter. In the case of a shaped
213~72~
- 43
article of enamel, stained glass or crystalline glass the
material for the course is laid on a plate of metal, glass
or ceramic, partially removed to form a cavity, supplied
at the recessed portion with another dry material, and
melted or fused by heating to be made integral with the
plate.
In producing a raw product to be sintered into a
metal shaped article, the dry materials for the course are
mainly particles of one or more of metals and alloys and
may, as found necessary, further have mixed therewith a
lubricant. Although the materials are dry, they may be
ones which have absorbed the lubricant if they are not
kneaded with the lubricant and are in a state readily
amenable to pulverization. The materials for the backing
layer are constituted mainly of particles of one or more
of metals and alloys and may be either dry or made wet by
kneading with a lubricant.
Examples of the lubricant used herein include
zinc stearate and other lubricants. The dry materials for
the course or the materials for the backing layer may
further contain a bonding agent and other additives.
All the materials are supplied into a main form
etc., pressed therein and removed therefrom to obtain the
raw product for a metal shaped article. The raw material
is sintered into a metal shaped article. A metal shaped
article may be produced by supplying all the materials
onto a sheet of metal, glass, ceramic, etc., applying
pressure to the resultant composite to obtain an integral
mass of raw product, and sintering the integral mass.
The dry materials for the course used in
producing a shaped article having an impasto layer are
various kinds of powdered paint, and the material for the
backing layer is a plate, sheet or the like of metal,
wood, cement or ceramic. The various kinds of powdered
paint include acrylic resin, polyester resin, acrylic-
. ,
~-`` 213~72~
polyester hybrid resin, fluorine resin and similar resins
having a pigment or colorant added thereto. The materials
for the course are laid on the plate, sheet, etc. as a
backing layer, supplied at a cavity with another dry
material, melted and fused by heating and baked to unite
all the layers together. In uniting all the layers
together, pressure may be applied to the layers. As a
result, it is possible to obtain a plate, sheet, etc.
having an impasto layer thereon.
In producing a plastic shaped article, the dry
materials for the course are constituted mainly of
particles of various kinds of plastics and may
additionally contain a pigment or a colorant. The
materials may also contain a plasticizer or solvent, but
are not kneaded with a plasticizer or solvent and are in a
state readily amenable to pulverization. The material for
the backing layer may be either dry or made wet by
kneading with a plasticizer or solvent. The various kinds
of plastics include polyethylene, nylon, polypropylene,
polycarbonate, acetal, polystyrene, epoxy, vinyl chloride,
natural rubber, synthetic rubber, acrylonitrile-butadiene-
styrene, polypropylene oxide, ethylene-vinyl acetate
copolymer, fluorine resin and other thermoplastics and
thermosetting resins. Both the materials for the course
and the material for the backing layer may, as found
necessary, contain a foaming agent, oxidization preventing
agent, thermal stabilizer, bridging agent, other additives
and particles of inorganic materials and the like. All
the materials are melted or fused into an integral mass by
heating, while applying pressure thereto, if necessary.
With this method, it is possible to produce a patterned
shaped article of foamed styrol, a patterned shaped
bathtub or floor tiles of plastic, etc. In this case, the
layers may be united with a plate of metal, wood, cement,
ceramic or a sheet of paper, unwoven fabric, knit fabric,
,, ,. , ,.. ; ~ ; i .
2~3072~
- 45
woven fabric or plastic.
In producing confectionery or other shaped
foodstuffs, the dry materials for the course are
constituted mainly of particles of one or more of wheat,
rice, potato, bean, corn and sugar and may additionally
contain seasonings and spices. The materials may also
contain oil, water, etc., but are not kneaded with oil,
water, etc. and are in a state readily amenable to
pulverization. The material for the backing layer may be
either dry, similarly to the materials for the course, or
made wet by kneading with oil, water, etc. Both the
materials for the course and the material for the backing
layer may, as found necessary, further contain an
inflating agent and other additives. All the materials
are supplied into a form etc. and are allowed to set or
caused to set without adding or by adding water, oil, etc.
to plasticize them into an integral mass. The integral
mass is pressed and then removed from the form, etc. to
obtain a raw product. The raw product is then baked.
Otherwise, all the materials are baked within the form
etc. With this method, it is possible to produce various
patterned baked confectioneries etc. It is also possible
to produce a patterned shaped article melted by heating,
such as a patterned chocolate shaped article etc., by
using particles of the material melted by heating, such as
chocolate etc., and melting and fusing the particles by
heating.
The materials that can be used in the present
invention are not limited to those set out as examples
herein and various other materials can also be used
depending on the shaped article to be produced. Moreover,
the range of patterned shaped articles that can be
produced can be increased by combining various materials
that, in the finished state, differ in property, color,
luster, texture and the like. When the methods described
213~723
- 46
above have the steps in common with each other, different
kinds of materials can be combined with each other. For
example, since both the method for producing a metal
shaped article and the method for producing a ceramic
shaped article require a common sintering step, metal
particles and ceramic particles are used together to form
a pattern, whereby cloisonne ware can be produced. The
materials used in the method for producing a concrete
shaped article and those used in the method for producing
an artificial stone shaped article can also be used
together.
In the method for producing any oE the patterned
shaped articles, it is desirable to apply vibration when
the materials are supplied onto the base surface so as to
ensure smooth movement of the materials. Further, by
rubbing with a brush or comb or applying a jet of air or
water to the boundary portion between the different kinds
of materials for the course, the pattern can be blurred.
In addition, by providing on the base surface or
material course a mat of unwoven fabric, paper or other
water or oil absorbing material, any excess amount of
water, oil, lubricant-bonding agent, plasticizer or
solvent can be supplied to any portion deficient in them
to uniformly disperse them in the shaped article. As a
result, the ratio of the water (auxiliary agents) in the
surface to the cement (resins) becomes small and this
means that the strength of the shaped article as a whole
is enhanced. When an air permeable mat is used in the
formation of an article under pressure, degassing is
enhanced to obtain a dense article. By vibrating or
pressing one or both of the material course and the
backing layer when the two layers are being allowed to set
into an integral article, the integral article obtained
becomes dense and is improved in strength. The article
may be reinforced with long fibers, short fibers, wire
213~72~j
- 47
nets or reinforcing rods by inserting these in or between
the two layers. The method of using an article obtained
by the sheet making method or extrusion molding method or
any of various plates or sheets as the backing layer is
applicable to the production of various articles including
architectural panels and boards, wall sheets and tiles.
The surface of an existing concrete article can be used as
the base surface. In this case, the materials for the
material course are discharged onto the concrete surface
and set to be integral with the existing concrete article.
In the method of producing a shaped article
according to this invention, it is possible to produce a
shaped article with a curved finished surface by using a
deformable mat as the base surface or using a partially or
generally deformable form.
The invention makes it possible to express a
photographed image in the form of dots or lines without
using an auxiliary form, cell body, bristling body or any
other such divider or partition member. Moreover, since
dots and lines of differing size and shape can be freely
produced without inserting a suction port or blow port
into the particle course, it is possible to use high-speed
scanning in pattern production. In addition, since the
portion of the pattern corresponding to the background is
formed on the base surface in advance so that individual
pattern portions thereof do not have to be charged
individually, the amount of charging work etc. required is
greatly reduced and the productivity is enhanced. Very
high productivity is further ensured by the fact that the
formed cavities can be charged at high speed and
efficiency by means of an air flow. Since the invention
does not require the use of auxiliary frames, cell bodies,
bristling bodies or the like as dividers or partition
members, the peculiarities of such members (such as the
hexagonal patterning produced by a honeycomb partition
213~2
- 48
member) do not show up in the product so that the patterns
can be naturally expressed. The invention is thus able to
produce patterns resembling handwriting and when used to
make sidewalk or pavement tiles patterned with maps,
directions or the like is able to produce a product that
is resistant to abrasion and pleasing to the eye.
As another of its effects, the invention enables
formation of cavity patterns in randomly blended particle
courses and, as such, makes it possible to produce
patterns within a variegated background. Further, in the
case of centrifuged concrete, since the particle course
can be formed first and the cavities can be formed and
charged to produce the pattern thereafter and, moreover,
the formation and charging of the cavities can be
conducted from the surface of the course, the pattern can
be easily produced even during high-speed rotation. In
addition, since, by dint of its operating principle, the
invention permits patterning of a particle course
irrespective of its size, it can be worked in conjunction
with an endless conveyor or the like for simple production
of continuous patterned shaped articles.
Use of computer control makes it possible to
produce patterns directly, achieve high production
efficiency and modify the patterns at will. By
controlling at least one parameter among the air pressure,
air flow rate, air flow speed, air flow direction, air
flow pulsation, air flow intermittence, suction port size,
blow port size, suction port position and blow port
position, it is possible to produce the subtle differences
in the air flow needed for forming finely configured
cavities and thus to produce patterned shaped articles
with various complex and sophisticated patterns.
By these production methods, it is possible to
easily produce concrete shaped articles, artificial stone
shaped articles, raw products for sintering into ceramic
213~2~
~,9
shaped articles, ceramic shaped articles, metal shaped
articles, impasto shaped articles, plastic shaped articles
and shaped foodstuffs including confectionery each having
a pattern of a prescribed thickness formed on part or all
of the surface thereof. Therefore, the patterned shaped
articles can maintain their patterns in excellent
condition even when exposed to surface abrasion. Since
the pattern layer is formed by a combination of various
kinds of dry materials, the materials can, owing to their
cave-in action, be densely charged without any gaps and
the boundaries between adjacent materials can be minutely
expressed. The pattern formed is thus very clear-cut.
