Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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BACKGROUND OF THE INVENTION
This invention relates to a method and
apparatus for forming insulated concrete blocks and,
more particularly, relates a method and apparatus for
concurrently forming one or more concrete blocks
having at least one insulating cavity coextensive
with the height and length of the blocks.
Conventional concrete blocks have air
cavities extending the height and a portion of the
length of the blocks to reduce weight and to provide
dead air cells. However, concrete itself is a poor
heat insulator and the air cavities in the blocks,
normally interconnected in a wall structure, permit
sufficient air movPment to negate much of the heat
insulating properties of the blocksO
Canadian Patent No. i,l49,189 issued July 5,
1983 describes an insulated concrete block having one
or more mould cavities extending the full length of
the block filled with insulation material
foamed~in-place.
SUMMARY OF THE INVENTION
It is a principal object of the present
invention to provide a method and apparatus for
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forming monolithic concrete blocks having a sandwich
construction with opposite exterior concrete faces,
one or both of which can be made asthetically
pleasing, and an intermediate foamed-in-place, heat
insulating layer for adhesively bonding the block
components together of the type described in
aforesaid Canadian Patent No. 1,149,189~
It is another object of the invention to
provide a method and apparatus for reproducably
forming monolithic concrete blocks having a shape
adapted to self position and to interlock adjacent
blocks to facilitate erection in a wall structure.
Another object of the present invention is
the provision of a method and apparatus for the
concurrent production of a pair of monolithic
concrete blocks forming a mirror image of each other
and having a common centre component with a pair of
foam insulation layers formed in situ under pressure
adjacent exterior concrete components.
The apparatus of the invention for forming
insulated concrete blocks comprise`s in its broad
aspect, a frame having an inlet end and an outlet
end; a pair o opposed, continuous, upper and lower
conveyors indexed for synchronous travel within said
frame, said upper conveyor being shorter than the
lower conveyor; each of said conveyors having a
plurality of transverse, articulated segments adapted
to provide a planar surface in i.ts operative position
when the conveyors are opposed to each other; the
lower of said conveyors having a plurality of
equispaced end frames secured thereto perpendicular
to the direction of travel of the conveyor, each of
said end frames having a resilient former secured to
the front and rear faces thereof; forming plates
secured to the transverse segments of the upper and
lower conveyors for sequentially receiving a
plurality of laterally-spaced concrete blocks
therebetween defining at least one cavity between
said blocks; a foam delivery system for formlng heat
insulating foam in situ into said cavity; means for
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feeding a continuous strip of impermeable plastic
film to said conveyors for enclosing the cavities and
interposing an impermeable barrier between the foam
and the conveyors; and lateral contain~ent wheels
mounted on each side of the frame for providing
lateral support to the blocks as they are formed.
The said apparatus includes means for
feeding at least one continuous lower strip of
impermeable film to the lower conveyox to envelope
the end frame for closing the opposite ends and
bottom of the said cavity and means for feeding at
least one uppex continuous strip of impermeable
plastic film downstream of said foam delivery system
for enclosing the top of said cavity whereby heat
insulating foam formed in situ in said cavity is
substantially completely contained within said
cavity. The lower and upper continuous impermeable
strips each preferably comprises a double-walled
strip formed of flattened tubular stock of polyfilm
such as polyethylene or polypropylene.
The frame of the apparatus has a vertically
reciprocal guillotine mounted at the inlet end
thereof, a double acting piston-cylinder operatively
connected to said guillotine for raising and lowering
said guillotine~ and a diagonal plate forming a lower
part of said guillotine extending transversely
thereof whereby said diagonal p:Late engages the rear
ends of said laterally-spaced concrete blocks as they
are fed to the inmate end of the apparatus for
advancing said blocks to the adjacent end frame and
for positioning the lower continuous strip of
polyfilm against the rear ends of said blocks for
engagement by the next succeeding end frameO
Adjusting means are provided for raising and
lowering the upper conveyor relative to the lower
conveyor whereby the height of the cavity between
said blocks can be adjusted and a reciprocal table
mounted at the inlet end of the apparatus frame
laterally aligns and feeds a plurality of concrete
blocks to the inlet end of the apparatusO
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The spaced concrete blocks preferably
comprise a centre block and a pair of laterally-
spaced back-up blocks, said centre blocks and
laterally-spaced back-up blocks defining a pair of
cavities therebetween. The foam delivery system for
forming heat insulating foam in situ into said cavity
or cavities is located above said lower conveyor
ahead of the upper conveyor whereby said insulating
foam can be injected after said lower continuous
strip of polyfilm has been applied to the ends and
bottoms of the cavity prior to covering of said
cavity with the upper impermeable polyfilm.
BRIEF DÆSC~IPTION OF THE DRAWINGS
The foregoing and other objects of the
invention and the manner in which they can be
attained will become apparent from the following
detailed description of the drawings, in which:
Figure l is a perspective view of the
apparatu~ of the invention showing
block components entering the
apparatus;
Figure 2 is a side elevation of the
apparatus shown in Figure l;
Figure 3 is a plan view of thè said
apparatus of the invention;
Figure 4 is a transverse section, partly an
elevation, taken through line 4-4
of Figure 3;
Figure 5 is a plan view taken along line
5-5 of Figure 4 showing end frames
between adjacent blocks
immediately prior to foam
injectiOnt
Figure 6 is a transverse section, partly an
elevation, taken along the line
6 6 of Figure 3 illustrating foam
injected in situ.
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DETAILED DESCRIPTION OF THE PREFERRED E~MBoDIMENTs
Referring to Figures 1-3, the apparatus of
the invention comprises a frame 10 of tubular or
channel steel having longitudinal members 12, posts
14 and transverse rnembers 16 interconnect~d with
bolts or the like connectors and reinforced ~ith
gussets 18 and diagonal members 20 to provide
rigidity. A plurality of leveling feet 22 threaded
into blocks 24 welded to lowermost longitudinal
member 12 on each side of the apparatus permits
desired leveling and longitudinal alignment.
A pair of opposed, continuous plate
conveyors 26, 28 mounted longitudinally in apparatus
10 are intermittently driven in a synchronized manner
by the drive depicted by numeral 30, well known in
the art. Lower conveyor 26 is formed of a plurality
of articulated transverse plate segments 32 hinged at
adjacent ends 33 to form a substantially continuous
planar surface in its operative block-forming
position. A roller 34 at each end of segments 32
journalled at the segment hinge connection rolls on a
longitudinal guide member 36 which extends
substantially the length of apparatus 10 and is
seated on transverse members 16, as shown most
clearly in Figure 4I to maintain the lower conveyor
in the said planar upper position. Conveyor 26 is
supported during its return travel on lower
longitudinal guide members 37 supported on gussets 39
secured to the insides of posts 14.
Upper conveyor 28 comprises a plurality of
transverse articulated plate segmen~s 40 adapted to
provide a substantially planar surface in its
operative position when opposed to lower conveyor
26. Segments 40 have a roller 42 journaled at the
hinge connection 44 between adjacent segments and
also at a midpoint between hinge connections 44, as
shown most clearly in Figure 2. Upper conveyor 28 is
shorter than lower conveyor 26 and is centred
thereover such that foam in3ection delivery system 48
can be positioned over lower conveyor 26 at the
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receiving end of the apparatus and completed concrete
blocks are exposed for removal from the opposite
discharge end of the apparatus. Rollers 42 travel in
a guide frame 43 which is vertically adjustable
relative to lower fixed conveyor 26 by means of
adjusting screws 45 threaded into bracketG 47 at the
top of posts 14.
Each of the second segments 32 of lower
conveyor 26 has an end frame 50 transversely
positioned thereon centrally thereof, as shown more
clearly in Figure 5. Each end frame 50 has a former
52 secured or bolted to each transverse face
extending substantially the length of the end frame,
each former 52 having a pair of spaced recesses 54
formed therein for reasons which will become apparent
as the description proceeds. As shown most clearly
in Figure 4, it will be noted that formers 52 extend
beyond the end 56 of each end frame 50 such that
extensions 58 will abut and interlock the adjacent
face of top forming plate 60 secured such as by
bolting to upper segments 40. Lower segments 32 also
have forming plates 62 secured thereto to define with
upper forming plates 60 the sidewalls of centre block
66 and with the opposed surfaces of backup blocks 68,
70 cavities 72 having, as typified in Figure 4, an
extension of cavities 72 above the height of blocks
66, 68 and 70 but terminating above the bottom edges
of said blocks. The height of cavaties 72 is readily
controlled by raising or lowering upper conveyor 28
by means of adjustment screws 45.
Formers 52 attached to end frame 50 an~
upper and lower formers 60, 62 attached to upper and
lower segments 40, 32 respectively, can be formed of
a resiliant material such as rubber or urethane, or a
rigid material such as plastic, steel, aluminum or
the like. A compressible rubber or foam strip 74
preferably is adhesively secured to the exposed faces
of forming plates 52, 60 and 62 so that a liquid and
foam~tight, impermeable fit will be achieved between
the forming plates 52, 60 and 62 and the imperfect
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concrete surfaces of the blocks 66, 68 and 70.
Lower segments 32 and upper segments 40 thus
are positioned a predetermined distance apart by
means of conveyor rollers 34, 42 in lower and upper
conveyors 26, 28 respectively. Rollers 3~ are
journaled on shafts 82 extending between brackets 80
secured to the back side of segments 32, and rollers
42 are journaled on shafts 86 extending between
brackets 84 secured to the back side of segments 40.
A plurality of vertically aligned gangs 88 of free
rolling hard rubber contalnment wheels 90 mounted on
each side of frame 10 by means of adjustable supports
92 provide continuous lateral support and containment
of the blocks as they are formed under pressure due
to the foamed in place foam insulation. Adjustable
suppor~s 92, shown most clearly in Figures 1 and 4,
each comprises bracket sleeve 150 rigidly secured to
post 12 having arm 152 slidably mounted therein. A
locking pin 154 is adapted to pass through a hole in
bracket 150 into one of a plurality of equally-spaced
mating holes 156 in arm 152 to lock arm 152 in
bracket lS0 such that wheels 90 can be approximately
located in their desired lateral position relative to
blocks 68 or 70~ Wheels 90 are journaled on an axle
carried by bracket assembly 157 which contains
vertical shaft 158 slidably mounted in a vertical,
longitudinal recess in arm 152 such that assembly 157
can be adjusted longitudinally relative to the inner
end of arm 152. Flange 160 formed at the outer end
of arm 152 has a rod 162 threaded therein for
longitudinal axial movement by rotation of knob 164
forming part thereofO The inner end of rod 162 is
threaded into a nut or block 166 secured between
plates 168 to prevent rotational movement whereby
rotation of rod 16~ extends or retracts block 166 and
link 168 connected to assembly 157 towards or away
from blocks 68, 70 to provide fine adjustment of
wheels 90 against said blocks. When the vertically
aligned gauge 88 are precisely in place~ lock nut 170
is forced against flange 160 by means of the threaded
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rod 162 to lock this position thus eliminating any
movement~
With reference now to E~igures 1 and 2, a
pair of laterally-spaced rolls 94, 96 of polyfilm
su~h as polyethylene film are mounted above upper
conveyor 28 for feeding two strips 100, 102 as
continuous impermeable strips to upper conveyor 28
after urethane delivery system 48. Strips 100, 102
can be a single width strip or can preferably
comprise a pair of strips as illustrated fed
side-by-side, each of sufficient width to at least
cover the width of a cavity 72. A pair of back-up
rolls 104, 105 are mounted in proximity to rolls 94,
96 to permit continuity during production. A pair of
]ower rolls 108, one of which is shown in Figure 2,
is journaled at a level below the upper portion o~
lower conveyor 25 for providing a pair of polyfilm
strips 112, 114 to lower conveyor 26. A pair of
back-up rolls 110 are mounted in proximity to rolls
108 to permit continuity of film feed during
production.
A single film thickness of polyfilm such as
polyethylene, polypropylene or the like plastics film
may be used but a double-walled thickness provided by
tubular stock is preferred to provide a second layer
which essentially precludes the possibility of
overlapping pinholes which might allow high-pressure
liquid chemicals to escape and to provide the second
layer which is continuously attached to the first
layèr and thus cannot be lost during transportation
of the blocks. Dark film is preferred to prevent
ultra-violet light to deteriorate the urethane foamO
Tin foil, waxed paper or a similar membrane can be an
alternative to dark polyfilm or like plastics film in
that it is opaque and prevents ultra-violet damage
and is an effective membrane.
Backup blocks 68, 70 and centre block 66~
separated laterally a predetermined distance apart by
guides 120, are shown fed by means of a reciprocating
table 122 horizontally to the entrance of apparatus
10 to ~he position depicted by ghost lines 124 in
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Figure 2 for abutment against an end frame 50 on a
lower conveyor segment 32. Double walled strips 112,
114 are engaged by the leading edge of the
reciprocating table 122 supporting the laterally-
spaced feed b].ocks to advance said strips 112, 114
from the feed rolls 108 forcing said strips 112, 114
down the face of end frame 50 holding end for~er 52
and between the bottom of the surface plate of the
recipro~ating table 122 and the top surface of plate
segments 32 of lower conveyor 26O
In sequence, the vertically reciprocal
guillotine 125 moves downwardly causing the inclined
bevel plate 127 to come in contact with the top rear
edge of backup blocks 68, 70 and centre block 6~
simultaneously, forcing the blocks forwardly into
position against the polyfilm that in turn is against
the end former 52. Again in sequence, while the
guillotine is holding blocks 66, 68 and 70 against
end former 52, the reciprocating table 122 is pulled
out from under the positioned blocks back into
position to receive a new set of laterally-spaced
feed blocks. The guillotine is then moved up into
the original at-rest position by double-acting
piston-cylinder assembly 129 leaving a clearing
height required for new feed blocks, and the blocks
in position settle on the polyfilm 112, 114 along the
bottom of the blocks ~6, 68 and 70. In sequence, as
lower conveyor ~6 moves ahead one position placing
blocks 66, 68 and 70 into the spray location, the end
frame 50 holding end former 52 immediately following
the newly positioned blocks 66, 68 and 70 rotates up
into position behind blocks 66, 68 and 70 to fold in
polyfilm 112, 114 between the end former 52 and the
end surfaces of the blocks, thus applying a
continuous sealed polyfilm membrane to the ends and
bottom surfaces of`the insulation cavities 72. The
film being continuous carries over the top of each
end former 52 and end frame 50. The bottom and end
portions of each of the pair of cavities 72 ~ormed
between the blocks is thus closed by the polyfilm
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which is squeezed tightly against the block surfaces
by the compressible rubber or foam strips 74 secured
to all the formers.
The end frame 50 on the second following
segment 26 advances the three laterally spaced blocks
under foam delivery system 48 at which time a foaming
mixture oE chemicals such as urethane is injecked as
typified in Figure 6. It is desirable that the
blocks are dry and are at a uniform temperature to
attain effective adhesion of the foam with the
adjacent block walls. It is also desirable to ensure
the delivery of a predetermined quantity of foam to
avoid excessive pressures and to ensure adequatP foam
is provided to completely fill each void.
lS The set of blocks with foam in situ is
advanced to engage upper conveyor 28 which carries
film strips 100, 102 which close off the upper
portions of cavities 720 With reference now to
Figure 4, the blocks with foam are continually
transported through the apparatus while the foam
expands and sets under pressure, the escape of the
foam from the cavities 72 bein~ prevented by the
abutment of the vertical and horizontal formin~
plates with polyfilm interposed between khe foam and
the said forming plates which not only prevent the
escape of foam but also avoid sticking of the foam to
the forming plates.
A hot wire or the like severing device
depicted by reference numberal 14~, not shown in
detail, at the exit end of machine severs the
continuous strips of polyfilm 100, 102 and 112l 114
between the blocks while the blocks to be removed are
clear of the upper conveyor 28 supported by lower
conveyor 26 to free the blocks from the forward end
frame 50 and facilitate removal.
The fabricated insulating blocks are
discharged in pairs 130 and a prior art in-line block
splitter is used for splitting of the centre block 60
along the longitudinal centre line of weakness 130
thereof creaked by control vees 134. The blocks are
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cubed and permitted to cure for 2~ hours in plant
prior to storing outside to eliminate thermal shock
to the foam insulation.
The present invention provides a number of
important advantages. Structurally sound insulating
monolithic blocks having aesthetic exterior or
interior faces can be manufactured on a continuous
basis. The block components can be varied to produce
a multiplicity of combinations of shapes, colours and
textures on one or both sides of the finished
blocks. For example, a completely plain block or a
block with a coloured architectural face on one side
can be produced. The centre block can be a solid
block prepared for splitting or a pair of block
segments adhesively secured together with a desired
textured surface previously cast or etched on the
surfaces to be exposed. The interior block surfaces
to be bonded together by foam insulation can have
vertical or horizontal dovetail anchor slots moulded
into said surfaces to enhance adhesion and securement
of the block components together into a monolithic
sandwich construction. Reproducability of the foam
layer and containment of foam during forming are
provided by the method and apparatus of the invention
to provide uniformity of product at an economic cost.
It will be understood that modifications can
be made in the embodiment of the method and apparatus
of the invention illustrated and described herein
without departing from the scope and purview of the
invention as defined by the appended claims~
