Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
APPARATUS AND METHOD FOR MAKING COBBLE-LIKE BLOCKS
FIELD OF THE INVENTION
[0001] The present invention relates to the fabrication of cobble-like blocks
and
more specifically to an automated apparatus and method for making molded
cobble-
like blocks.
BACKGROUND OF THE INVENTION
[0002] Molded cobble-like blocks or stones are commonly used in the
fabrication
of walls, paths and landscaping structures. These blocks are generally
fabricated by
molding cement or other such materials in various shapes and configurations
and,
once settled and dried, assembled by a mason or other such stoneworker in
various
structures.
[0003] However, apparatus and methods for making these blocks generally
require significant manpower to ensure a proper molding of the blocks, that
is, to
provide various smoothing and finishing touches to the wet and/or drying
cement
blocks to minimize unwanted defects and reduce a number of misshaped products.
SUMMARY OF THE INVENTION
[0004] In order to address the above and other drawbacks of known techniques,
it
is an aim of the present invention to provide an automated method for making
cobble-like blocks.
[0005] It is also an aim of the present invention to provide an automated
system
for making same.
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[0006] More specifically, in accordance with the present invention, there is
provided a method of filling a mold with a moldable material in a process for
making
molded structures, the method providing a substantially smooth finish to the
material
at an open surface of the mold, the method comprising the steps of:
a) providing a material feeder comprising a feeder opening, the feeder
opening comprising at least one door, the door being displaceable in a plane
substantially parallel to the opening;
b) positioning the open surface of the mold against and substantially parallel
to the door;
c) opening the door to release the material into the mold;
d) closing the door once the mold is filled; and
e) implementing a relative displacement between the open surface of the
mold and the door in the plane, thereby smoothing the material at the open
surface of the mold.
[0007] Also in accordance with the present invention, there is provided an
apparatus for making at least one molded structure using a mold and a moldable
material, the apparatus comprising a feeder having a feeder opening and a mold
support for supporting the mold at the opening, the opening comprising an
inner door
and an outer door displaceable in a plane substantially parallel to the
opening, a
combined activation of the doors controlling a flow of the material from the
feeder to
the mold. When the mold has been filled and both the inner door and the outer
door
are closed, the outer door may be reopened to smooth the material at an open
surface of the mold.
[0008] Further in accordance with the present invention, there is provided a
molding tray for making at least one molded structure using a moldable
material, the
molding tray comprising a solid outer tray and a resilient inner mold fitted
therein, the
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outer tray comprising at least one hole in a bottom face thereof providing
access to a
resilient bottom face of the inner mold such that an upward pressure may be
applied
to the bottom face of the inner mold through the hole.
[0009] Still further in accordance with the present invention, there is
provided a
system for making molded structures, the system comprising a molding station
for
filling successive molds with a moldable mixture, an input conveying system
for
conveying empty molds to the molding station and an output conveying system
for
conveying filled molds away from the molding station, the molding station
comprising
a mold feeder having a feeder opening and a mold support for positioning and
supporting the molds at the opening during filling, the opening comprising an
inner
door and an outer door displaceable in a plane substantially parallel to the
opening,
a combined activation of the doors controlling a flow of the mixture from the
feeder to
the molds. When the molds have been filled and both the inner door and the
outer
door are closed, the outer door may be reopened to smooth an open surface of
the
mixture in the mold.
[0010] Other aims, objects, advantages and features of the present invention
will
become more apparent upon reading of the following non-restrictive description
of
specific embodiments thereof, given by way of example only with reference to
the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the appended drawings:
[0012] Figure 1 is a side elevation view of an apparatus for making coble-like
blocks in accordance with a first illustrative embodiment of the present
invention;
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j0013] Figure 2 is a cross-sectional view of the apparatus of Figure 1 taken
along
line 2-2 thereof illustrating in dashed lines a travel of a molding tray for
making the
coble-like blocks during a process for making same;
[0014] Figure 3 is a perspective view of the molding tray of Figure 2
illustrating,
via a fragmentary view, a partial section of an inner mold thereof;
[0015] Figures 4A to 4E are side elevation views of an upper section of the
apparatus of Figure 1, modified to include a double tub door system,
illustrating in
five successive steps a process for making the coble-like blocks in accordance
with
a second illustrative embodiment of the present invention;
[0016] Figures 5A to 5C are side elevation views of an upper section of the
apparatus of Figure 1, modified to include a double tub door system,
illustrating in
three successive steps a process for making the cobble-like blocks, in
accordance
with a third illustrative embodiment of the present invention; and
[0017] Figures 6A to 6C are side elevation views of an upper section of the
apparatus of Figure 1, modified to include a laterally displaceable molding
platform,
illustrating in three successive steps a process for making the cobble-like
blocks in
accordance with a fourth illustrative embodiment of the present invention.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0018] Referring now to Figures 1 and 2, in accordance with a first
illustrative
embodiment of the present invention, an apparatus for making coble-like
blocks,
generally referred to using the numeral 10, will now be described. The
apparatus 10
is generally comprised of a conveying system 12 operatively conveying a series
of
molding trays, as in 14, to and from a molding station 16 where the trays 14
are
successively filled with a wet moldable material, such as cement mixture 17,
for
subsequent drying to produce the molded cobble-like blocks.
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[0019] With particular reference to Figure 2, the conveying system 12 is
comprised of an input conveyer 18 (see Figure 2) for conveying empty trays 14
to
the molding station 16 and, an output conveyer 22, disposed above the input
conveyer 18, for conveying filled trays 14 from the molding station 16 to a
drying/curing station (not shown).
[0020] Referring back to Figures 1 and 2, the molding station 16 is generally
comprised of a feeding tub 26, a funneled vat 28 for filling the tub 26 with
the wet
cement mixture 17, a vibrating platform 30 vertically displaceable by
hydraulics 32
between tray loading, feeding and unloading positions, and a series of
hydraulically
actuated means 34, 36 and 38 for loading and unloading the trays 14 between
the
vibrating platform 30, the input conveyer 18 and the output conveyer 22.
[0021] Referring now to Figure 3, a molding tray 14 for use with apparatus 10
is
generally comprised of an outer tray 40 and an inner mold 42 fitted therein to
provide
an illustratively flush upward surface at a outer tray - inner mold juncture.
In
particular, the outer tray 40 is manufactured of a solid material such as
metal or steel
and is perforated to present an number of holes 44 at a bottom thereof. The
inner
mold 42 is generally manufactured of plastic or rubber and is fitted in the
outer tray
40. The inner mold 42 is generally comprised of a number of compartments 46
configured to provide corresponding cobble-like blocks or stones, herein of
various
sizes and shapes. A bottom surface of the compartments 46 may be textured or
profiled to provide an additional ornamental or aesthetic value to the
resulting blocks.
[0022] The holes 44 of outer tray 40 are generally provided to facilitate both
an
alignment of the tray in the apparatus 10 (discussed further hereinbelow) and
a
dislodging and removal of the formed blocks from the inner mold 42. In
particular, an
extraction platform 45 comprising a number of digits or elongated
protuberances 47
configured to correspond to the holes 44 (i.e. aligned therewith), may be used
to
dislodge and initiate an extraction of the formed blocks from the outer tray
40. For
instance, a downward pressure may be applied to a periphery of the outer tray
40
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while the tray 14 rests on the extraction platform 45. As such, the digits 47
extend
through the holes 44 and apply a dislodging pressure therethrough to the
bottom
face of the inner mold 42, pushing and ultimately dislodging the formed blocks
therefrom. A suction and/or transport system may then take the formed blocks
out of
the mold 42 for storage and/or further processing.
[0023] In an optional embodiment, the entire system of outer tray 40 and inner
mold 42 and extraction platform 45 all shown in Figure 3, can be inverted
upside
down so that the extraction platform is placed above the system of outer tray
and
inner mold 42. This way, the digits 47 point downward and extend through holes
44
and apply a downward pressure to the bottom face of the mold 42. This
arrangement is more efficient since gravity helps to dislodge the formed
blocks from
the mold 42. In addition, the dislodged blocks fall to a support platform (not
shown)
on their flattened side and are ready for curing.
[0024] Thus, in general operation, an empty tray 14 is brought to the molding
station 16 by input conveyer 18. At this point, the vibrating platform 30 is
at a vertical
position below that of the input conveyer 18 such that the tray 14 may be
positioned
over the vibrating platform by the hydraulically actuated means 34. For
example, a
pair of hydraulic cylinders 48, initially extended to await the arrival of the
incoming
tray 14, may be operatively coupled to a pair of corresponding hooks 50
positioned
along and within guide rails 52 of the input conveyer 18. As the tray is
brought to the
molding station 16 by the input conveyer 18, it is thereby pushed over these
hooks
50 such that a subsequent actuation of the hydraulic cylinders 48 pulls the
tray 14
along the rails 52 over the lowered vibrating platform 30.
[0025] Once the tray 14 is positioned above the platform 30, the platform 30
is
raised by the hydraulic cylinders 32 coupled thereto thereby engaging the
empty tray
14 and raising same to the mouth of the feeding tub 26. A set of protuberances
(see
reference 116 in Figure 4A) may be provided on a top face of the platform 30
to
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engage the holes 44 at the bottom of outer tray 40, thereby increasing an
alignment
of the empty tray 14 at the mouth of the feeding tub 26.
[0026] Note that the coupling of the cylinders 32 and platform 30 is
specifically
adapted to allow a vertical displacement thereof without being obstructed by
the rails
52. For instance, the cylinders 32 may be coupled to the platform 30 via a U-
shaped
structure (not shown) adapted to accept the rails 52 therein as the platform
30 is
raised beyond a level thereof. Other such configurations should be readily
apparent
to a person of skill in the art.
[0027] In a subsequent step, a set of hydraulic cylinders 56 are actuated to
open
a set of doors 58 at the mouth of the tub 26 such that the cement mixture 17
is
released into the inner mold 42 of the tray 14. To promote a uniform
distribution of
cement within the mold 42, the vibration platform 30 is activated thereby
vibrating the
tray 14 as it fills with the cement mixture 17. An upward pressure may be
applied by
the platform 30 to the tray 14 during filling to avoid spillage and loss of
materials.
[0028] Once the mold is full, the hydraulic cylinders 56 are used to close the
doors 58, thereby sealing the tub 26. The filled tray 14 may then be lowered
by the
platform 30 to the level of the output conveyer 22 and released thereon using
the
hydraulically actuated means 36 and 38. In particular, a first set of
hydraulic
cylinders 60, operatively coupled to respective removable rail segments 62,
are
actuated to position the rail segments 62 below the filled tray 14 and
operatively
engage the segments 62 to corresponding output conveyer rail 64. As such, the
tray
14 may be lowered by the platform 30 and rested on the rail segments 62. A
hydraulically actuated arm 66 (Figure 2) then slides the tray 14 onto the
output
conveyer 22 over the connected rails 62, 64 to be removed thereby and brought
to a
subsequent station for further processing, curing and/or drying. The platform
30 may
then proceed to pick-up a new tray 14 from the input conveyer 18. As the rail
segments 62 recede, the process may be repeated with the new tray 14.
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[0029] One such post-processing step may include providing finishing touches
to
the molded mixture. For instance, as the tray 14 is lowered from the tub 26,
some of
the mixture may adhere to the closed doors 58 and thus provide an uneven block
surface at the open face of the mold 42. As such, various manual smoothing
steps
may be applied to the blocks including manually smoothing the block surface
using a
trowel or the like.
[0030] Referring now to Figures 4A to 4E, an alternative apparatus 100, in
accordance with a second illustrative embodiment of the present invention,
provides
a solution to this particular situation. In Figure 4A, the modified molding
station 100 is
again illustratively comprised of a feeding tub 102 containing a cement
mixture 104
therein and, a vibration platform 106 hydraulically actuated to move a molding
tray
108 to and from a mouth of the tub 102. The molding tray 108 is again
comprised of
an outer tray 110 and an inner mold 112, the outer tray 110 again comprising a
series of holes 114 in a bottom wall thereof to accept therein a number of
corresponding protuberances 116 located on a top face of the vibration
platform 106
and to facilitate a removal of the formed blocks using an extraction platform,
as
described hereinabove.
[0031] The molding station is further comprised of a double tub door system
117
comprised of an upper set of doors 118 hydraulically actuated by a first set
of
hydraulics 120 and, a lower set of doors 122 hydraulically actuated by a
second set
of hydraulics 124. When the empty tray is brought up to the tub 102, both sets
of
doors 118, 122 are shut (Figure 4A). The tray 108 is received at the tub 102
within a
feeding bay comprised of peripheral walls 126 encasing the outer tray 110. The
sliding doors 118, 122 are adapted to slide through a slit in the peripheral
wall 126,
possibly on a track and/or guiding support system (not seen), such that a
bottom
face of the bottom doors 122 comes in close contact with the open face of the
mold
112.
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[0032] In Figure 4B, both sets of doors 118, 122 are opened to release the
cement mixture 104 into the mold 112. The vibration platform 106 again
agitates the
molding tray 108 thereby promoting a uniform distribution of cement throughout
the
mold 112.
[0033] Once the mold 112 is full, both sets of doors 118, 122 are shut (Figure
4C)
thereby sealing the tub 102.
[0034] The lower set of doors 122 are then reopened (Figure 4D) illustratively
wiping cement adhered thereto on the open face of the mold 112 thereby leaving
behind a substantially smooth cement surface at this open face. Note that the
upper
doors 118 are still shut, thereby inhibiting a further flow of cement from the
tub 102 to
the tray 108. The reopening of the lower set of doors 122 creates a space or
gap
between the cement and the closed upper set of doors 118, which allows the
molding tray 108 to subsequently lower without suction with respect to the tub
102,
thereby minimizing, if not eliminating, any deformation of the facing surface
of the
cement.
[0035) In Figure 4E, the tray 108 is lowered and brought back to an associated
conveying system (not shown) for further processing, curing and/or drying.
Using this
technique, the need for subsequent smoothing or finishing touches to the
drying
blocks is reduced (if not eliminated), the upper surface of which being
generally
smoothed by the sliding movement of the lower doors 122 in the step
illustrated in
Figure 4D.
[0036] Referring now to Figures 5A to 5C, an alternatively modified molding
station 200 is presented in accordance with a third illustrative embodiment of
the
present invention. In Figure 5A, the molding station 200 is again
illustratively
comprised of a feeding tub 202 containing a cement mixture 204 therein and, a
vibration platform 206 hydraulically actuated to move a molding tray 208 to
and from
a mouth of the tub 202. The molding tray 208 is again comprised of an outer
tray 210
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and an inner mold 212, the outer tray 210 again comprising a series of holes
214 in a
bottom wall thereof to accept therein a number of corresponding protuberances
216
located on a top face of the vibration platform 206 and to facilitate a
removal of the
formed blocks using an extraction platform, as described hereinabove.
[0037] The molding station is further comprised of a double tub door system
217,
in this embodiment comprised of an upper door 218 hydraulically actuated by a
first
hydraulic cylinder 220 and, a lower door 222 hydraulically actuated by a
second
hydraulic cylinder 224. When the empty tray is brought up to the tub 202, both
doors
218, 222 are shut. The tray 208 is again received at the tub 202 within a
feeding bay
comprised of peripheral walls 226 encasing the outer tray 210. The sliding
doors
218, 222 are adapted to slide through a slit in the peripheral wall 226,
possibly on a
track and/or guiding support system (not seen), such that a bottom face of
bottom
door 222 comes in close contact with the open face of the mold 212.
[0038] In Figure 5A, both doors 218, 222 are open to allow the cement mixture
204 to fill the mold 212. The vibration platform 206 is again activated to
agitate the
molding tray 208 thereby promoting a uniform distribution of cement throughout
the
mold 212.
[0039] Once the mold 212 is full, both sets of doors 218, 222 are shut (Figure
5B)
thereby sealing the tub 202.
[0040] The lower door 222 is then reopened (Figure 5C) illustratively wiping
cement adhered thereto on the open face of the mold 212 thereby leaving behind
a
substantially smooth cement surface at this open face. Again note that the
upper
door 218 is still shut, thereby inhibiting a further flow of cement from the
tub 202 to
the tray 208.
[0041] The tray 208 may then be lowered and brought back to an associated
conveying system (not shown) for further processing or drying. As above, this
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technique also reduces the need for subsequent smoothing or finishing touches
to
the drying blocks, this time thanks to the sliding motion of the single lower
door 222,
as illustrated in Figure 5C.
[0042] Referring now to Figures 6A to 6C, a further alternatively modified
molding
station 300 is presented in accordance with a fourth illustrative embodiment
of the
present invention. In Figure 6A, the molding station 300 is again
illustratively
comprised of a feeding tub 302 containing a cement mixture 304 therein and, a
vibration platform 306 hydraulically actuated to move a molding tray 308 to
and from
a mouth of the tub 302. The molding tray 308 is again comprised of an outer
tray 310
and an inner mold 312, the outer tray 310 again comprising a series of holes
314 in a
bottom wall thereof to accept therein a number of corresponding protuberances
316
located on a top face of the vibration platform 306 and to facilitate a
removal of the
formed blocks using an extraction platform, as described hereinabove.
[0043] In this embodiment however, the molding station may only be comprised
of a single tub door system 317, illustrated here as a set of sliding doors
318
hydraulically actuated by a set of hydraulics 320. The vibration platform 306
is
however also adapted to be hydraulically displaced laterally by a hydraulic
cylinder
322.
[0044] When the empty tray is brought up to the tub 302, the doors 318 are
shut.
The tray 308 is received at the tub 302 below the sliding doors 318. These
doors 318
are adapted to slide, possibly on a track and/or guiding support system (not
seen),
such that a bottom face of the doors 318 comes in close contact with the open
face
of the mold 312.
[0045] In Figure 6A, the doors 318 are open to allow the cement mixture 304 to
fill
the mold 312. The vibration platform 306 is again activated to agitate the
molding
tray 308 thereby promoting a uniform distribution of cement throughout the
mold 312.
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[0046] Once the mold 312 is full, the doors 318 are shut (Figure 6B) thereby
sealing the tub 302.
[0047] In Figure 6C, the hydraulic cylinder 322 is actuated to slide the
platform
306 sideways, illustratively smoothly wiping the open face of the filled mold
312
against the doors 318 thereby providing a smooth cement surface at this open
face.
[0048] The platform 306 and tray 308 may then be lowered and brought back to
an associated conveying system (not shown) for further processing or drying.
As
above, this technique also reduces the need for subsequent smoothing or
finishing
touches to the drying blocks, this time thanks to the sliding motion of the
platform
306, as illustrated in Figure 6C.
[0049] As can be seen from the above illustrative embodiments, significant
improvements are provided by apparatus 10, 100, 200 and 300 in the filling and
ultimate fabrication of molded cobble-like blocks. A person of skill in the
art will
understand that although the above discussion is focused on the manufacture of
cement blocks, other types of moldable materials, to be formed in various
sizes and
shapes, may also be considered without extending the general scope and nature
of
the present disclosure.
[0050] Furthermore, various modifications to the disclosed apparatus may be
considered to provide a similar effect. Namely, other types of doors and/or
platforms
may be considered. In one example, sliding tub doors may be replaced by one or
plural rotating doors generally parallel to an opening of a feeding tub and
rotating in
a plane substantially parallel thereto. Alternatively, various other
configurations of
sliding and/or gliding doors may be considered and should be apparent to the
person
of skill in the art.
[0051] In addition, various mold configurations may be utilized in the present
context to provide a variety of molded structures. Single or plural
compartment molds
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may be manufactured in various shapes and sizes and adapted to be used with a
correspondingly configured feeding tub.
[0052] Also, a person of skill in the art will readily understand that a
number of
conveying and feeding mechanisms and apparatus may be configured to automate
the above process with minimal user intervention. For example, a number of
conveyer configurations may be considered in the present context and should be
apparent to the person of skill in the art.
[0053] Although the invention has been described with reference to certain
specific embodiments, various modifications thereof will be apparent to those
skilled
in the art without departing from the spirit and scope of the invention as
outlined in
the claims appended hereto.
