AU624327B2 - Method of and apparatus for manufacturing a faced block material - Google Patents

Description

_L_;ti AUSTRALIA (s5) PATENTp (43) 6.12.88 AU-A-17225/88 WORLD INTELLECTUAL PROPERTY ORGANIZATION International Bureau INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (51) International Patent Classification 4: (11) Internatioyal Publcation Number: WO 88/ 08781 B28D 1/18 Al (43) IntPtiofi P tio ate s ;4 No ber 1988 (17.11.88) (21) International Application Number: PCT/AU88/00140 (81) Designated States: AT, AT (European patent), AU, BE (European patent), BR, CH, CH (European patent), (22) International Filing Date: 16 May 1988 (16.05.88) DE, DE (European patent), DK, FI, FR (European patent), GB, GB (European patent), IT (European patent), JP, KR, LU (European patent), NL, NL (Eu- (31) Priority Application Number: PI 1939 ropean patent), NO, SE, SE (European atent), SU,

US.

(32) Priority Date: 15 May 1987 (15.05.87) 1 (33) Pnihlihepd 1 j SSECTION 34(4)(a) DIRECTION SEE FOLIO_ (71)! NAME DIRECTED 0uth-u-eof Li es'-.fone P. L-d Tec hnolo^/ Cefde-- 2 r-odi'_- H.al Drvc., 3e, Iley, Wesk.r, J (72) I nve tor anai A- ;sf-r r, I I7\ I Ai;n /fr r mI Qv r -I A. U. J. 4 -T tt lnt rv o rpp o oi., ey .lY l, Paul, Edward [AU/AU]; 143 Parkin Street, Rockingham, W.A. 6168 (AU).

(74) Agent: LORD, Kelvin, Ernest; 4 Douro Place, West Perth, W.A. 6005 (AU).

AUSTRALIAN

6 DEC 1988 PATENT OFFICE (54) Title: METHOD OF AND APPARATUS FOR MANUFACTURING A FACED BLOCK MATERIAL (57) Abstract An apparatus (10) and method for facing blocks of stone material, especially stone aggregate material, comprising a conveyor belt (14) with plates (16) arranged to transport blocks through a work station. A rotatable facing member (28) provided with a plurality of hard projections (32) is located at the work station and is arranged to remove a face from a block of stone material transported through the work station by the conveyor belt (14).

i -1- TITLE METHOD OF AN APPARATUS FOR MANUFACTURING A FACED BLOCK

MATERIAL

DESCRIPTION

The present invention relates to a method of and an apparatus for manufacturing faced block material.

FIELD OF THE INVENTION Limestone and sandstone blocks are sometimes used in building structures and produce a structure with-an 10 extremely attractive appearance. The blocks are produced e by sawing through massive stone.. However, stone blocks are expensive to produce'and stone of requisite quality is difficult to find.

It has now been found that block material can be produced

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15 from aggregate material which block material has an S. appearance similar to that of sawn massive block material.

The aggregate material from which the aggregate blocks are produced is cheaper than massive material.

SUMMARY OF THE INVENTION In accordance with one aspect of the present invention there is provided a method of manufacturing block material with an appearance similar to sawn massive material, .i characterised by forming an aqueous slurry of a mixture of.- aggregate limestone or sandstone and cement, placing a quantity of the slurry in a mould, allowing the moulded mixture to cure, removing a face from the so produced cast block by passing the block through an apparatus comprising a conveyor means which transports the block of.material ;through a work station, a rotatable isc having a generally

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vrM^hq, efal r 1 V~r4 i s y L -^j^wCi.Mi r'^ 1 r i 1i 1 11 1 1 i c la flat face adjacent the conveyor means which generally flat face is studded with a plurality of hard projections the generally flat face of the disc engaging a face of the block as the block is transported by the conveyor means and removing material from the engaged face of the block to produce a block with a face having an appearance similar to that of sawn massive stone.

The mixture may be allowed to cure in the mould to form a casting, then removed from the mould and then subjected to 10 the facing step.

The blocks produced by the method of the present invention comprise a matrix of cement binding together particles of stone such as limestone, sandstone or any other stone.

In accordance with another aspect of the present invention i. 15 there is provided an apparatus for facing blocks of stone aggregate material characterised in that the apparatus comprises a conveyor means for transporting blocks of the stone aggregate material through a work 'station, a rotatable facing member located at the work station and arranged to engage faces of the blocks of stone aggregate material transported by the conveyor and remove material from the engaged faces of the blocks to produce blocks with faces having an appearance similar to that of sawn massive stone, wherein the rotatable facing member is in the form of a rotatable disc having a generally flat face adjacent the conveyor which generally flat face is studded with a plurality of hard projections. i Preferably, the stone material faced by the apparatus of i:j the present invention is an aggregate material comprising a -i T I i v7' k. 1 1 v -2 matrix binding together particles of stone.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:- Figure 1 is a front elevation of an apparatus in accordance with the present invention; Figure 2 is a plan view of the apparatus of Figure 1; Figure 3 is an end elevation of the apparatus of Figure 1; 10 and Figure 4 is a front perspective view of the apparatus of Figure 1.

DESCRIPTION OF THE INVENTION 9e i| 1 ;4 1 i i In the drawings there is shown an apparatus 10 comprising a framework 12. The framework 12 has supported thereon an endless conveyor belt 14 which comprises a plurality of flat !j outer plates 16. The plates 16 each abut adjacent plates 16 when'the conveyor 14 is substantially flat. Thus, in the upper run of the conveyor 14, the plates 16 provide a smooth conveying surface for blocks to be transported as will be described. In this connection there is provided a support 17 which supports the conveyor belt 14 in its upper run and ensures that the conveyor belt is flat in its upper run.

The conveyor 14 comprises a pair of flexible chains 18 which are attached to the inner faces of respective opposite edges of the plates 16 and extend around and engage with a pair of end rollers 20. Each chain 18 has alternate links 18a welded to inner faces of the outer plates and intermediate links 18b pivotally connected to the 'links 18a. Each roller has a pair'of opposed sprockets 21 corresponding with and engaged with a respective chain 18. i One of the rollers 20 is arranged to be rotatably driven by i an hydraulic motor 22 (see Figures 2 and 3) by means of a shaft 23 whilst the other roller 20 is an idler roller. A control lever 24 is provided to vary the speed of the motor 22 via a main electrohydraulic drive motor 26.

Further, the apparatus 10 comprises a rotatable disc 28 which is arranged to be rotated by an hydraulic motor The disc 28 is disposed to one side of the conveyor 14 and has a vertical face 29 adjacent the conveyor 14 which face 29 is studded with hard projections 32 set in a ring adjacent the circumference of the disc 28. A safety guard WO 88/08781 PCT/AU88/00140 41 1 1 1 1 1 i t 33 is mounted about the upper end of the disc 28.

Also, the apparatus 10 includes a control lever 34 by which the speed of the motor 30 may be varied via the main electrohydraulic drive motor 26.

Still further, the apparatus 10 comprises an upper guide means 36 for blocks of material being transported on the conveyor 14. The upper guide means 36 comprises a plurality of rollers 38 which engage with the upper edges of blocks.

Further, the guide means 36 is urged downwardly by a plurality of coil springs 39 and in operative condition the rollers 38 are spring urged into engagement with the blocks by the springs 39.

Also, there is a lateral guide bar 40 extending longitudinally of the conveyor 14 and spaced from the disc 28. There is also an additional longitudinal guide bar 41 which is in alignment with the face 29 of the disc 28. The guide bars 40 and 41 ensure that the blocks are, in use, in the correct lateral position .for engagement with the disc 28.

The position of the guide bar 40 may be adjusted to enable the apparatus 10 to accommodate blocks of different widths.

In use, the aggregate stone material which may be low grade waste material, may be formed into blocks by forming an aqueous slurry mixture of the aggregate stone material with cement, placing a quantity of the slurry mixture in a mould and allowing the mixture in the mould to cure to form a casting. The cured blocks may then be removed from the mould and placed in the apparatus 10.

In this connection, the conveyor 14 is caused to move by the lil i:; i! i-

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^9 SW088/08781 PCTF/AU88/00140 S- driven roller 20 which is rotated by the motor 22. Then the chain 18 is pulled over the rollers 20 and plates 16 are caused to move correspondingly.

The guide means 36 and 40 are set to accommodate the blocks. The disc 28 is also caused to rotate by the motor Blocks are transported along the upper run of the conveyor 14 in such manner that a face of each block is contacted by the disc 28 and the studs 32 so that a face of each block is removed by the studs 32. Typically, about 2mm of the face of a block is removed. This leaves a block with a face with an appearance similar to that of massive stone which block is far cheaper to produce than conventional massive stone but is suitable for production of walls with attractive appearance.

The proportion of cement used may vary widely. However, it has been found that, for example a proportion of 6 parts of limestone to one part cement produces satisfactory results.

The studs 32 may be formed of diamond or tungsten carbide.

Further, a cylindrical member could be used in place of the disc 28. The cylindrical member could have a curved surface with studs mounted therein and arranged to face blocks of aggregate material. The technique of the present invention could be used to produce patterns on the faced surfaces.

Still further, the disc 28 could be mounted above the conveyor belt 14 so that the disc 28 and the studs 32 contact the uppermost surface of a block and remove an upper face from the block. In this way a rectangular block could i be laid flat on the conveyor belt 14 and have a major face removed in the manner described above. This arrangement W O. I WO 88/08781 PCT/AU88/0014

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i could give superior results compared to the results obtained with the apparatus of Figures 1 to 4 and a rectangular block mounted on edge.

Modifications and variations such as would be apparent to a skilled addressee are deemed within the scope of the present invention r: 'r i 1 l 1 1

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Claims (15)

1. A method of manufacturing block material with an appearance similar to sawn massive material, characterised by forming an aqueous slurry of a mixture of aggregate limestone or sandstone and cement, placing a quantity of the slurry in a mould, allowing the moulded mixture to cure, removing a face from the so produced cast block by passing the block through an apparatus comprising a conveyor means which transports the block of material 10 through a work station, a rotatable disc having a generally flat face adjacent the conveyor means which generally flat face is studded with a plurality of hard projections the generally flat face of the disc engaging a face of the block as the block is transported by the conveyor means and *15 removing material from the engaged face of the block to produce a block with a face having an appearance similar to so 3: *see that of sawn massive stone.

2. An apparatus for facing blocks of stone aggregate *material characterised in that the apparatus comprises a conveyormeans for transporting blocks of the stone aggregate material through a work station, a rotatable facing member located at the work station and arranged to engage faces of the blocks of stone aggregate material transported by the conveyor and remove material from the engaged faces of the blocks to produce blocks-with faces having an appearance similar to that of 'sawn massive stone, wherein the rotatable facing member is in the form of a rotatable disc having a genera-..,ly flat face adjacent the conveyor which generally flat face is studded,with a fl I Q~T I ~.~t4f lit 31 nn n i -8- plurality of hard projections.

3. An apparatus according to claim 2, characterised in r that the conveyor is an endless belt having an substantially flat upper run adjacent to the rotatable facing member, and extending around rollers.

4. An apparatus according to claim 2 or 3, characterised in that the conveyor comprises a plurality of flat outer plates, which plates are each arranged to abut adjacent plates in the upper run of the conveyor. 10

5. An apparatus according to claim 4, characterised in that the plates are mounted on one or more endless flexible chains which engage with sprockets on the rollers.

6. An apparatus according to any one of claims 3 to characterised in that one of the rollers is arranged to be fe* 15 rotatably driven and the other is an idler roller. a

7. An apparatus according to claim 6, characterised in that the roller which is arranged to be rotatably driven.is driven by means of a hydraulic motor.

8. An apparatus according to any one of claims 2 to 7, characterised in that the face adjacent the conveyor is upright.

9. An apparatus according to claim 8, characterised in that the hard projections extend in a ring adjacent the circumference of the disc.

10. An apparatus according to any one of claims 2 to 9, characterised in that the disc is arranged to be rotatably driven by a hydraulic motor.

11. An apparatus according to any one of claims 2 to characterised in that there is also provided' adjustable 7 Y 9" :W T i -9 guide means for guiding blocks on the conveyor means through the work station.

12. An apparatus according to claim 11, characterised in that at least part of the guide means is spring biased, in use, against a block.

13. An apparatus according to claim 12, characterised in that at least part of the guide means is provided with rollers arranged to contact the blocks in use.

14. A method of manufacturing block material with an appearance similar to sawn massive material substantially as hereinbefore described with reference to any one of the "accompanying drawings.

15. An apparatus for facing blocks of stone aggregate material substantially as hereinbefore described with 15 reference to any one of the accompanying drawings. DATED FEBRUARY 27 1992 CULTURED LIMESTONE PTY LTD By their Patent Attorneys S: KELVIN LORD AND COMPANY PERTH, WESTERN AUSTRALIA T 0" r O-j«: i