Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
A METHOD AND APPARATUS FOR ARTIFICIALLY AGING PRE-CAST
BLOCKS
FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for modifying
the
texture of a block. More specifically, the present invention is concerned with
a method and
apparatus for modifying the texture of a block before curing. The present
invention also relates
to a block spacer for spacing a plurality of blocks and a block stabilizer for
stabilizing blocks
during surface-texture modification operations.
BACKGROUND OF THE INVENTION
[0002] Devices for artificially ageing blocks are well known in the art. Some
of the
prior art included block tumblers; these devices though were inadequate
because of the loss of
much block material, which raised production costs. Improvements were on-line
devices where
blocks were conveyed under or through impacting devices for surface
modification,,
deformation, chipping etc. thereof.
[0003] Conventional block-conveying systems include a support table for moving
the blocks thereon as they are acted on during texture surface modification.
The following are
examples of block-texture modifying apparatuses.
[0004] Canadian Patent Application No. 2,343,338 teaches an apparatus for
roughing the surfaces of concrete casted blocks. A roller having chains
attached thereon and
spaced apart from one another is provided above blocks that are being
supported on a
moveable table. The support table has a flat upper surface. The support table
inciudes holes
through which pins are projected in order to tilt the bottom surface of the
blocks hence tilting the
whole blocks at predetermined locations in order for the chain to impact the
blocks on their
upper surface at different locati.ons.
[0005] Canadian Patent Application No. 2,350,979 teaches a system for
modifying
the texture of blocks. The system includes texturing elements that are on
support cables which
spin and which are brought closer to the block in order to bring the texturing
elements in
contact with the block for impacting the surface. The texturing elements can
be moved at
different angles in order to impact the block's surfaces in different areas
during the translational
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movement of the block.
[0006] Canadian Patent Application No. 2,392,934 teaches a concrete texture
machine for modifying the surface texture of stone blocks. The machine conveys
concrete
blocks at a pitching station having opposed pitching blades. Each of the
blades have a forward
projecting cutting edge that are displaced towards and away from one another
at
predetermined distances.
[0007] European Patent Application No. 1211036 teaches a device for
artificially
ageing stones. This device includes top and bottom rollers with mangling
elements that
engage the edges stones passed therebetween in order to break and mangles
these edges.
[0008] A limitation of these prior art apparatuses is that they do not provide
for the
blocks to be spaced apart at a constant distance when acting on them.
Furthermore, these
prior art apparatuses are inconvenient for acting on the edges of the blocks.
[0009] Japanese Patent Application No. 04194202 teaches a spacer which
functions to create a gap between mutual blocks in order to make it look wide
in external
appearance. The spacer is used for the construction of the blocks. All the
documents referred
above are included herewith by reference.
[0010] The spacers and positioning mechanisms of the prior art are not
constructed for modifying pre-cast blocks.
[0011] Hence, the prior art teaches chains on a spinning longitudinal member
to
impact the surface of concrete blocks; rollers for engaging the edges of
blocks as well as
spacers for building and laying concrete blocks are also known.
[0012] A general limitation of the prior art is that is does not provide an
apparatus
and method for maintaining the block that provides easy access to the block
edges so as to act
thereon as well as various block-texture modifying actions that modify these
edges accordingly.
[0013] A drawback of such devices is that high pressure must be applied on
these
blocks.
[0014] There thus remains a need for an improved apparatus and method for
modifying the surface texture of blocks.
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SUMMARY OF THE INVENTION
[0015] More specifically, in accordance with the present invention there is
provided
a method for modifying the surface texture of pre-cast building blocks, said
method comprising:
(a) pressing cementitious material within a mould into pre-cast blocks; (b)
applying pressure on
the surface of pre-cast blocks obtained in step (a) so as to modify the
texture thereof; and (c)
providing for curing of pre-cast blocks obtained in step (b).
[0016] In an embodiment, the method further comprises after (c): (d) applying
pressure on the surface of pre-cast blocks after curing so as to further
modify the texture
thereof. In an embodiment, step (b) comprises applying pressure on the top
edges of pre-cast
blocks. In an embodiment, said pressure in (b) is applied via a pressure-
applying member. In
an embodiment, said pressure applying member comprises a longitudinal rod
member. In an
embodiment, said longitudinal rod member comprises ridges on its outer
surface. In an
embodiment, said pressure in step (b) is applied via air-pressure. In an
embodiment, said
pressure is step (d) is applied by a block-texture modifying device. In an
embodiment, said step
(b) creates weak areas on the surface of blocks. In an embodiment, pressure in
step (d) is
applied on said weak areas.
[0017] In accordance with another aspect of the invention there is provided an
apparatus for modifying the surface texture of pre-cast building blocks, said
apparatus
comprising a support for supporting blocks thereon, a pressure-applying device
so positioned
as to selectively engage blocks on said support, wherein said pressure-
applying device is so
adapted as to apply a pressure on the surface of blocks so as to modify the
texture thereof
before curing of said blocks.
[0018] In an embodiment, the apparatus further comprises a translational
movement-imparting device from imparting a translation movement between blocks
on said
support and said pressure-applying device. In an embodiment, the translational
movement
imparting device comprises a push member, said push member comprising a block-
engaging
member and being connected to an actuator for translational movement thereof.
In an
embodiment, said translational movement imparting device comprises a conveyor
for
translationally conveying said support with blocks thereon. In an embodiment,
said pressure-
applying device is moveable between a block engaging position and a block
disengaging
position. In an embodiment, said pressure-applying device is adjacent to a
press and mould
apparatus for pressing cementitious material into pre-cast blocks, said
pressure-applying
device being so positioned as to engage the surface of blocks after said
pressing. In an
embodiment, said pressure applying device comprises a longitudinal rod member.
In an
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embodiment, said longitudinal rod member comprises ridges on its outer
surface. In an
embodiment, said pressure applying device comprises a lateral rod member. In
an
embodiment, said longitudinal rod member comprises ridges on its outer
surface. In an
embodiment, said pressure-applying device comprises longitudinal members and
lateral
members crossing said longitudinal members so as to form individual generally
rectangular
members for engaging the edged perimeter of blocks. In an embodiment, said
longitudinal and
lateral members comprise respective rod members having ridges on their
respective outer
surfaces. In an embodiment, said pressure-applying device comprises an air
blower for
applying air pressure on blocks. In an embodiment, the apparatus further
comprises a block-
texture modifying device for further modifying the surface texture of blocks
after both initial
modification of blocks by said pressure-applying device and curing thereof
[0019] In accordance with a further aspect of the invention, there is provided
a
spacer for spacing adjacent blocks apart at a pre-determined distance when
modifying the
surface texture of these blocks, said spacer comprising spacing elements for
placing between
adjacent blocks.
[0020] In an embodiment, said spacing elements comprises crossed members
defining individual areas for receiving a given block therethrough. In an
embodiment, said
spacing elements are so configured as to expose the top and bottom edges of
blocks. In an
embodiment, said spacing elements are of a substantially equal thickness, said
receiving areas
being of substantially equal sizes. In an embodiment, said spacer comprises
peripheral
enclosing members for enclosing a plurality of blocks therein. In an
embodiment, said
enclosing elements are so configured as to expose the top and bottom edges of
blocks. In an
embodiment, said spacer comprises four peripheral enclosing members defining a
generally
rectangular shape, longitudinal spacing members extending between opposite
said peripheral
enclosing member, said spacing members extending between one pair of opposite
enclosing
members crossing said spacing members extending between another pair of
opposite
enclosing members thereby defining individual receiving areas, each said
receiving areas are
configured to receiving a block therein.
[0021] In accordance with yet another aspect of the present invention, there
is
provided block-stabilizing device for stabilizing blocks during surface-
texture modification
operations, said device comprising a plurality of stabilizing members for
respectively engaging
a portion of block surfaces thereby exposing another portion of block
surfaces, wherein each
said stabilizing member exerts sufficient pressure on a block so as to
substantially avoid
movement thereof during surface-texture modification operation on said exposed
block surface
portion.
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[0022] In an embodiment, each of said stabilizing members comprises a plaque.
In
an embodiment, said plaques are mounted to supports. In an embodiment, said
supports are
mounted to actuators so at to move said plaques between block engaging and
disengaging
positions. In an embodiment, said exposed block surface portion comprises the
edged
5 perimeter of blocks.
[0023] In another embodiment, a block-stabilizing device for stabilizing
blocks
during surface-texture modification operations is provided, said device
comprising a plurality of
stabilizing members for respectively engaging a portion of block surfaces
thereby exposing
another portion of block surfaces, wherein each said stabilizing member exerts
sufficient
pressure on a block so as to substantially avoid movement thereof during
surface-texture
modification operation on said exposed block surface portion.
[0024] Another embodiment provides an apparatus for modifying the surface
texture of pre-cast building blocks the apparatus comprising a primary frame
defining a
longitudinal axis between a forward portion and a rearward portion, a tool
holder, defining a tool
holder axis, moveably connected to the frame, a first motor supported by the
frame for
displacing the tool holder along the longitudinal axis, and a second motor
supported by the
frame for rotating a wearing tool about a wearing tool axis, the wearing tool
supported by the
tool holder and adapted to rotate about the tool holder axis.
[0025] An advantage of the present invention is that it provides a method and
apparatus for modifying the surface texture of blocks using less pressure than
prior art devices
and methods.
[0026] Other objects, advantages and features of the present invention will
become more apparent upon reading of the following non-restrictive description
of
embodiments thereof, given by way of example only with reference to the
accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] In the appended drawings:
[0028] Figure 1 is front elevational view of the apparatus for modifying the
surface
texture of pre-cast building blocks in accordance with an embodiment of the
present invention;
[0029] Figures 2 to 5 are perspective views of the operation of the pressure-
applying device in accordance with an embodiment of the present invention as
well as the
support of the apparatus of Figure 1.
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[0030] Figure 6 is an enlarged perspective partial view of the pressure-
applying
device of Figure 1
[0031] Figure 7 is an enlarged perspective view of the blocks of Figure 5
after
having been treated by the apparatus of Figure 1;
[0032] Figure 8 is a schematic front view of the apparatus for modifying the
surface
texture of pre-cast building blocks in accordance with another embodiment of
the present
invention;
[0033] Figure 9 is a top plan view of a block surface-texture modifying device
in
accordance with an embodiment of the invention;
[0034] Figure 10 is a top plan view of a block surface-texture modifying
device in
accordance with another embodiment of the invention;
[0035] Figure 11 is top plan view of a block stabilizing device in accordance
with an
embodiment of the invention;
[0036] Figure 12 is a side elevation view of a block modification device of
Figure
10;
[0037] Figure 13 is a front elevation view of a portion of the block
modification
device of Figure 12;
[0038] Figure 14 is a front elevation view of a portion of the block
modification
device of Figure 12;
[0039] Figure 15 is a front elevation view of a portion of the block
modification
device of Figure 12;
[0040] Figure 16 is a section view of a series of blocks spaced apart by a
spacer;
[0041] Figure 17 is a combined side and front elevational views of another
embodiment of the invention;
[0042] Figure 18 includes a side elevational view and a top plan view of a
portion
in addition of various parts of the embodiment depicted on Figure 17;
[0043] Figure 19 includes side elevational views and a top plan view of a
portion of
the embodiment depicted on Figure 17;
[0044] Figure 20 is a combined side and front elevational views and top plan
view
of the embodiment depicted on Figure 17
[0045] Figure 21 is a combined side and front elevational views of a portion
of the
embodiment depicted on Figure 17
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[0046] Figure 22 is a combined side elevational view and top pian view of a
portion
of the embodiment depicted on Figure 17
[0047] Figure 23 is a combined side and front elevational views of a portion
of the
embodiment depicted on Figure 17 and
[0048] Figure 24 is a combine side and front elevational views and top plan
view of
a portion of the embodiment depicted on Figure 17
DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0049] With reference to the appended drawings an embodiment of the invention
will be herein described so as to exemplify the invention and not limit its
scope.
[0050] Figure 1 shows an apparatus 10 for modifying the surface texture of pre-
cast building blocks 12 which are mounted on a support 14.
[0051] Apparatus 10 includes a pressure-applying device 16 positioned above
support 14. The pressure-applying device 16 is movable between a block
disengaging position
as shown in Figures 1 and 2 and a block engaging position as shown in Figures
3 and 4.
Returning to Figure 1, the pressure-applying device 16 is mounted to actuators
18 and 20,
which can be hydraulic motors, for movement between the block engaging and
disengaging
positions.
[0052] As shown in Figure 2 to Figure 6, the pressure applying device 16
includes
lateral and longitudinal pressure applying members 22 and 24 respectively
which are rod
elements having ridges 26 thereon. A block stabilizing device 82 is also
disclosed and is used
in conjunction with the pressure applying device 16 to maintain the blocks 12
in place. The
block-stabilizing device 82 is sized and designed to mate with the pressure
applying device 16.
Each contact pad 86 are disposed on the block-stabilizing device 82 to be
aligned with a
corresponding opening on the pressure-applying device 16 when the block-
stabilizing device 82
is disposed above the pressure-applying device 16. A leg 84 connects the
contact pad 86 to
the block-stabilizing device 82 and provides sufficient space to move the
pressure-applying
device 16 between the blocks 12 and the block-stabilizing device 82 still
contacting the blocks
12.
[0053] Illustratively, in operation, the block-stabilizing device 82, while
the pressure
applying device 16 is disposed between the block-stabilizing device 82 and the
blocks 12, is
moved in contact with the series of blocks 12. Each block 12 is thus
maintained in place by the
pressure from the pads 86. Then, the pressure applying device 16 is moved
toward the series
CA 02609557 2008-04-04
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of blocks 12 in contact with the blocks 12 while the block-stabilizing device
82 still ensures the
series of blocks do not move. The pressure applying device 16 imprints the
blocks and is
moved away from the blocks 12. Once the pressure applying device 16 is moved
away from
the series of blocks 12, the block-stabilizing device 82 is then moved away
from the series of
blocks 12.
[0054] As shown in Figure 2 to Figure 7, right after the blocks 12 are formed
by
pressing cementitious material in moulds as in known in the art, the blocks 12
being still humid
will be pressed by the pressure applying device 16. The lateral member 22 will
press two
edges of two adjacent blocks and the longitudinal member 24 will press two
edges of two
adjacent blocks as well.
[0055] More specifically, element 24 engages top adjacent lateral edges 28 and
30
of two adjacent blocks 12A and 12B while element 22 engages the respective top
back edge
and top front edge 32 and 34 of two adjacent blocks 12B and 12C. As shown in
Figure 1, the
device 16 engages blocks 12 on support 14 via the actuators 18 and 20, which
move the
pressure-applying device 16 in a up and down movement in a vertical direction
as shown by
arrows U and D respectively.
[0056] Once blocks are molded from cementitious material, they can be moved
under a pressure applying device 16 via translational movement imparting
device such as a
support 14. Of course other ways of moving blocks along a support such as
shown in Figures
9 and 10 can be contemplated within the scope of the present invention. For
examples, in
Figures 9 and Figure 10, there is shown a push member 36 having a block
engaging member
38 and being powered by an actuator (not shown).
[0057] In another embodiment, that can be deducted from Figures 2 to 5, the
pressure applying device 16 can be moved manually by workers in order to press
on the
surface texture of still humid blocks 12 after blocks 12 have been formed.
[0058] In another embodiment, shown in Figure 8, the pressure-applying device
40
comprises air blowers 42. The air blowers 42 are actuated so as to engage and
disengage
blocks 12. Hence when the air blowers 42 are actuated to engage blocks 12 they
engage
these blocks via air pressure denoted by numerical reference 44. Specifically,
the air blowers
42 blow air 44 onto the top surface 13 of blocks 12. As shown in Figure 8, the
air blowers 42
can be so positioned as to blow at the top edges 28 and 30, a blower 42A can
be so positioned
as to apply air pressure 44 onto the adjacent edges 28 and 30 of two adjacent
blocks 12D and
12E.
[0059] With particular reference to Figure 7, the contoured edge 46 of freshly
CA 02609557 2008-04-04
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pressed blocks 12 has had its surface texture modified or made weak. The
foregoing
modification or imparted weakness, allows the blocks after complete curing to
have those same
contoured edges 46, or any other like treated surface texture, be easily
broken and modified by
surface texture modification apparatuses in order to artificially age these
blocks.
[0060] With reference to Figures 9 and 10, there is shown block surface
texture
modification apparatuses 48 (see Figure 9) and 50 (see Figure 10). The
apparatuses 48 and
50 are described in Canadian application No. 2,509,064 filed on June 2, 2005
and in United
States application No. 7,281,537 filed on June 3, 2005. Generally the blocks
are spaced by a
spacer 52. It should be noted that the spacer 52 can also be used as a
pressure-applying
device as well. For example, when placing the spacer 52 onto the blocks 12 in
order to space
them apart, the spacer 52 will engage the top edges of still humid blocks 12,
or any other
surface thereof, similar to the way the pressure applying device 16 does, as
shown in Figures 2
to 4.
[0061] The blocks 12 are moved along the support 53 by push members 36 in
order to be engaged by block modification devices 54A, 54B
[0062] This way, the block modification apparatuses described above can engage
the modified or weakened contoured edge 46, or any other like treated surface
after the blocks
12 have gone through curing and these pre-modified surfaces can be easily
modified with less
pressure or impact by surface-texture modifying devices since the pre-modified
surfaces have
been broken or deformed right after the blocks were molded by the pressure
applying devices
and methods disclosed above.
[0063] With reference to Figure 11, there is shown a block-stabilizing device
60.
This block-stabilizing device 60 comprises a plurality of optional plaques 62
of varying sizes
and shapes that are connected to each other by connecting member 64.
Connecting members
64 are connected to supports 66A and 66B at each of their longitudinal ends.
These supports
66A and 66B are mounted to actuators 68A and 68B respectively for vertical
movement thereof
between block disengaging and block engaging positions.
[0064] Plaques 62 are used to engage blocks 12 and apply pressure thereon. The
plaques 62 cover most of the top surface of 13 of a block 12 yet expose its
outer perimeter or
contoured edge 46 thereby providing for a variety of block modification
devices to engage this
exposed contoured edge such that the various block modification devices can
modify the
texture surface of the exposed perimeter or contoured edge 46.
[0065] Still referring to Figure 11, the block-stabilizing device 60 could be
used
without the plurality of plaques 62. The contact with the blocks 12 is
directly made with the
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connecting members 64. The exposed surface of the block 12 is greater when no
plaque 62 is
used. The block modification devices 54 have access to the top surface to
alter the texture.
[0066] The direction of the connecting members 64 is orthogonally disposed in
respect with the axis of rotation of the block modification devices 54. The
block modification
5 devices 54 can perform the action on the series of blocks 12 using rotative
tools without
crossing the connecting members 64. Once the series of blocks 12 has been
modified in a first
direction the connecting member is removed and turned at a 90 angle. The
block modification
devices 54 can perform the action in the second direction, orthogonal to the
first direction, to
complete modifying the texture on each side of the blocks 12.
10 [0067] Figures 9, 10 and 12 show a multi-station block texture modifying
apparatus
54. This apparatus 54 includes a support 53 for supporting a plurality of
blocks 12 thereon. In
this embodiment, there are two multi-station block texture modifiers 54A and
54B. In other
embodiments, apparatus 54 may include one or more multi-station block texture
modifier. In
this embodiment, each multi-station block texture modifier 54 respectively
includes a pressure-
applying station 56, an impacting station 57, and a polishing station 58. In
this embodiment,
stations 56, 57 and 58 are in an upstream arrangement.
[0068] In accordance with this embodiment, the multi-station block texture
modifier
54 may include only a pressure-applying station 56 and an impacting station
57. Furthermore,
in another embodiment, the impacting station 57 can be upstream of the
pressure-applying
station 56.
[0069] The multi-station block texture modifying apparatus 54 also includes a
translational displacer (push member 36) for imparting translational
displacement between
blocks 12 on the support 53 and the multi-station block texture modifier 54.
[0070] In this embodiment, the support 53 is a table that provides for the
plurality of
blocks 12 to be moved thereon through the multi-station block texture modifier
54. As shown in
Figures 13, 14 and 15 support 53 includes longitudinal separate panels that
are so spaced
apart as to expose the bottom edges of blocks 12 as will be further explained
below.
[0071] The translational displacer 36 is a push member. The push member 36 has
one end (not shown) mounted to an actuator (not shown) for translational
movement thereof,
and a free block engaging end for pushing the engaging blocks 12 or a
plurality of blocks 12 on
the support and through the multi-station block texture modifier 54.
[0072] In another embodiment, the translational displacer can comprise a
conveyor
as is understood by the skilled artisan to displace blocks 12 relative to the
modifier 54. Still in a
further embodiment, the translational displacer can comprise a wide variety of
actuation
=' = ' CA 02609557 2007-11-24- 20110
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assemblies for displacing the modifier 54 relative to immobile blocks 12. In
this embodiment,
the modifier 54 can be displaced as a unit or its stations 56, 57 and 58 can
be displaced
separately. Furthermore, combinations of push members 36, conveyors and
actuators to
displace modifier 54 and/or its stations 56, 57 and 58 can also be
contemplated within the
scope of the present invention.
[0073] As shown in Figures 12 through 16, the blocks 12 are spaced apart by a
spacer 52. As more clearly shown in Figure 9, this spacer 52 is a rectangular-
shaped grid and
comprising spacing members in the form horizontal cross lateral members and
longitudinal
members thereby creating receiving areas for receiving blocks 12 therethrough.
Longitudinal
spacer members extend between opposite enclosure members, whereas longitudinal
spacer
members extend between opposite enclosure members for a plurality of blocks 12
to be =moved
together on the support 53. Furthermore, the grid spacer 52 provides for the
blocks 12 to be
spaced from each other at a predetermined constant distance. As better shown
in Figure 16,
and as will be explained later, the top edges and bottom edges 73 of two
adjacent blocks 12
are kept apart at a predetermined constant distance allowing for the multi-
station block texture
modifier 54 to modify edges 73, as will be explained herein.
[0074] As better shown in Figure 12, and as aforementioned, the multi-station
block texture modifier 54 includes a pressure-applying station 56, an
impacting station 57, and
a polishing station 58.
[0075] Tuming to Figure 13, there is shown the pressure-applying station 56,
which
serves to apply a sustained pressure to blocks 12 that are engaged thereby.
The pressure-
applying station 56 includes pressure-applying elements 72, which engage the
blocks 12 in
order to apply a sustained pressure to the texture surface of the blocks 12 so
that this texture
surface is modified.
[0076] In the embodiment shown here, the pressure-applying elements 72 are top
rollers mounted along a top rotating longitudinal member 74, the pressure-
applying elements
72 are also present as bottom rollers mounted along a bottom rotating
longitudinal member 74,
and so positioned as to respectively engage the top and bottom opposite edges
73 of blocks
12. As shown, a single given roller 72 of the top member 74 engages two
opposite edges 73 of
two adjacent blocks 12 and a single given roller 72 of the bottom member 74
engages two
opposite edges 73 of two adjacent blocks 12. In this illustrative example the
top and bottom
rollers are collinear. The top and bottom longitudinal members 74 are actuated
by motors 70 to
change their relative distance.
[00771 As aforementioned, the support surface 53 also includes separate
vertical
members 53, which are so spaced apart as to expose the bottom edges 73 of
block 12, so they
AMENDED SHEET
CA 02609557 2008-04-04
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can be engaged by the multi-station block texture modifier 54.
[0078] The top moveable member 74 or bottom member 74 can be moveable in an
upward or downward fashion, as shown by arrow Y in order to modulate the
pressure applied
by a roller 72 mounted thereon. In another embodiment, the rollers 72 may be
expandable,
again in order to modulate the sustained pressure applied to the texture
surface of the blocks
12. The foregoing features are described in PCT publication WO/2004078441.
[0079] In an embodiment, the pressure-applying station 56 may comprise only
top
pressure applying elements 72. In another embodiment, the pressure-applying
station 56 may
comprise only bottom pressure applying elements 56.
[0080] Turning now to Figure 14, there is shown an impacting station 57, which
includes top and bottom impacting elements 76. In this example, these
impacting elements 76
are chains extending from a rotating member in the form of a rod 76 that is
mounted to an
actuator in order to rotate about its longitudinal length, hence, actuating
the chains 77 so that
they spin in the clockwise direction shown by arrow R, of course the chains 77
can also be
spun in a counter-clockwise direction, in order to impact the texture surface
of blocks 12. In
this example, it is the top and bottom edges 73 of the blocks 12 which are
respectively
impacted by the chains 77. A shown, a given top impacting element 77 is so
position as to
simultaneously impact the adjacent top edges 73 of two adjacent blocks 12 and
a given bottom
impacting element 77 is so position as to simultaneously impact the adjacent
bottom edges 73
of two adjacent blocks 12. In this example the top and bottom-impacting
element 76 are
collinear. In an embodiment, the impacting station 57 may comprise only top
impacting
elements 76, in another embodiment the impacting station 57 may comprise only
bottom
impacting elements 76. Of course impacting elements 76 can comprise any type
of protrusion
member for impacting the surface texture of blocks 12 as will be understood by
the skilled
artisan. A variety of such impacting elements are described in PCT publication
WO/2004078441.
[0081] With respect to Figure 15, there is shown the polishing station 58,
which
includes top and bottom polishing members 80. These top and bottom polishing
members 80
are respectively mounted along a top and bottom rotating members 74. Rotating
longitudinal
members 74 are operatively mounted to motors 70 so as to be actuated to rotate
about their
respective longitudinal axes. In this way, the top polishing member 80 will
rotate along the axis
formed by member 74 and the bottom polishing member 80 will rotate along the
axis formed by
member 74. In this example, the polishing members 80 are in the form of
brushes; brushes 80
are so spaced along their respective top or bottom members 74 so as to
respectively engage
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the top edges 73 and bottom edges 73 of blocks 12. As shown, a single given
top brush 80
engages two edges 73 of two adjacent blocks 12 and a single given bottom brush
80 engages
two edges 73 of two adjacent blocks 12. In an embodiment, the polishing
station 58 may
comprise only top polishing elements 80 or only bottom polishing elements. Of
course a variety
of polishing or brushing elements as is understood by a skilled artisan can be
used.
[0082] With respect to Figure 16, it should be noted that the spacer 52
provided for
spacing the blocks 12 at a predetermined and constant distances, the blocks 12
are laterally
displaced relative to each other and this distance is provided by the width or
thickness of
members 52. In this way the block modification devices 54 have easier access
to the edges 73.
[0083] ' Referring now to Figure 17 depicting an additional embodiment. The
apparatus for modifying the texture of pre-casted blocks 110 includes a
primaryframe 114 and
other elements supported by the primary frame 114. Steel members are used to
build the
primary frame 114 and are adapted for supporting a secondary frame 118
moveable along a
longitudinal axis 116. The top portion of the primary frame 118 is designed
such that the rail
members 120 offer proper support for the wheels 134 of the secondary frame
118. The
secondary frame 118 supports a tool holder 138 that is adapted for receiving a
tool frame 154
on its lower portion. Longitudinal movements of the secondary frame 118 move
the tool holder
138 and the tool frame 154 connected hereto. The tool holder 138 defines a
tool holder axis
128 and is adapted retract or extend to change the position of the tool frame
154. Additionally,
rotational (360 and more) or pivotal (less than 360 ) movements of the tool
holder 138 about
the tool holder axis 128 changes the angle of the tool frame 154. A pivot,
preferably disposed
between the tool holder 138 and the tool frame 154, could allow pivotal or
rotational
movements of the tool frame 154 about the tool holder axis 128 thus avoiding
the tool holder
138 to rotate or pivot about the tool holder axis 128. All rotation or pivotal
movements of the
tool frame 154 and the tool axis 158 about the tool holder axis 128 or the
longitudinal axis 116
are considered within the realm of the present application.
[0084] The movements of the apparatus of Figures 17-24 are illustratively
assisted
by electric motors. A first motor 130, affixed to the secondary frame 118,
moves longitudinally
on the secondary frame 118. A second motor 126, also affixed to the secondary
frame 118,
provides a rotational or a pivotal movement to the tool holder 138. A third
motor 122,
connected on top of the tool holder 138, changes the length of the tool holder
138. Each motor
130, 126, 122 has variable speed and is operatively coupled to its respective
associated
elements using either a gearbox, a chain and sprocket mechanism, a lever or a
pulley and belt
connection. Other means for moving portions of the apparatus that are known in
the art of
designing industrial and manufacturing machines, such as hydraulic cylinders
or linear
:AMENDED SHEET
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WO 2006/136009 PCT/CA2006/000911
14
positioning servo motors, are within the scope of the present application.
[0085] Each motors 130, 126, 122 are electronically managed by a computer or
other programmable means for obtaining the desired wearing effect on the
blocks 12. The
combined movements of the apparatus' moveable members are coordinated by the
computer
to get a weathered, or aged, look on the pre-casted blocks 12. The linear
movements, the
height, the angle and the rotational speed of the wearing tool 166 are
combined and vary
according to an algorithm. The algorithm is interpreted by the computer and
may be modified
to change the desired aged-look of the pre-casted blocks. Slight continuous
modifications to
the tool axis 158 angle about the tool holder axis 128 while moving the
secondary frame 118
along the longitudinal axis 116 with a spinning wearing tool 166 contacting
the blocks 12
procure a random aged-look to the blocks 12.
[0086] The lower portion of the tool holder 138 discussed above is adapted for
receiving a tool frame 154. The connection between the tool holder 138 and the
tool frame 154
uses an arrangement of pivots 142 and damper 146. This arrangement of pivots
142 and
damper 146 reduces the amount of vibrations generated by the wearing tool 166,
supported by
the tool frame, that is connected to the tool holder 138. The lower portion of
the tool holder 138
is designed for easily changing the tool 166 in favor of various other tools
(not shown)
including, but not limited to, chipper, blades, brushes, rollers and hammers.
Chipper and
hammer tools can be used to completely cut a block 12 in smaller blocks.
[0087] An illustrative tool 166 is shown on Figures 17 and 23. The tool 166
mounted on the tool frame 154 comprises a central portion 156 defining a tool
axis 158. The
illustrative tool 166 is rotatably connected on each side to tool frame 154
with bearings or
bushings 160. A pair of additional electric motors 150 is affixed to the tool
frame, on each side
of the tool frame 154, and operatively connected to the central portion 156
via sprockets 152.
A series of wearing means, illustratively chains 166, are fastened 168 to the
central portion
156. The central portion's 156 rotation induces movement to the chains 166
used to
repetitively hit the blocks thus changing the texture of the blocks. The
distance between the
chains 166 is adjustable by moving the fastening means 168 along the central
portion 156. A
key 172 ensures the fastening means 168 do not rotate with the central portion
156. Other
means for positioning the fastening means appearing obvious to the skilled
reader are
encompassed by the present application.
[0088] The blocks are disposed on a block support 162 under the primary frame
114. The block support 162 is of sufficient size to accommodate a series of
blocks. The height
of the block support 162 can be adjusted with the actuator 164. Each block is
maintained on
the block support 162 by a block-stabilizing device for stabilizing blocks
during surface-texture
CA 02609557 2007-11-23
WO 2006/136009 PCT/CA2006/000911
modification operations. The block-stabilizing device comprises a plurality of
linear stabilizing
members. Each linear stabilizing member illustratively contacts the center of
the top portion of
a row of blocks leaving uncovered each lateral side portion of the blocks. The
pressure
exercised by the linear stabilizing member is sufficient to prevent any
movement of the blocks
5 during the surface-texture modification operations.
[0089] The linear stabilizing members disposed in the longitudinal direction
116,
when the tool axis 158 is perpendicular to the longitudinal axis 116, allow
the rotatable tool 166
to hit the blocks without hitting the stabilizing members. When the third
electric motor 122 is
activated to change the angle of the tool holder of illustratively about 900,
tool axis 158 is
10 moved parallel to the orientation of the linear stabilizing members. A lift
system changes the
orientation of the linear stabilizing members (of about 90 angle in the
present situation) to
position the tool axis 158 normal to the orientation of the linear stabilizing
members and avoid
any contact between the wearing tool 166 and the linear stabilizing members.
[0090] Referring to Figure 18, the second motor 126 connected to the secondary
15 frame 118 uses a gear reduction mechanism 124 to connect the tool holder
138. A link 127
having a ball joint on each side connects the gear reduction mechanism 124 to
a lever 140
disposed on the tool holder 138.
[0091] Now referring to Figure 19, it can be appreciated that the tool holder
138
includes two members sliding one on the other to provide a telescopic
mechanism. The third
motor 122 influences the length of the tool holder 138 by rotating a screw
132. The movement
of the screw 132 moves the internal wall 136 affixed inside the internal
member of tool holder
138. The electric motor 122 is connected to the outside member of the tool
holder 138 as
opposed to the internal wall 136 that is welded into the internal member of
the tool holder 138.
[0092] It is to be understood that the invention is not limited in its
application to the
details of construction and parts illustrated in the accompanying drawings and
described
hereinabove. The invention is capable of other embodiments and of being
practised in various
ways. It is also to be understood that the phraseology or terminology used
herein is for the
purpose of description and not limitation. Hence, although the present
invention has been
described hereinabove by way of embodiments thereof, it can be modified,
without departing
from the spirit, scope and nature of the subject invention as defined in the
appended claims.
