Abstract:
An apparatus for manufacturing a molded item having a corner is provided. The apparatus includes a mold support for holding an angled mold having an inside corner. A hopper having an outside corner that corresponds to the inside corner of the mold and a screen at the outside corner mates with the mold. A vibration device is provided for causing a material contained in the hopper to pass through the screen, such as by applying a predetermined force for a predetermined period of time required to fill the mold. Different sized openings in the screen combined with the flowability of the material and the amount of vibration can determine how much material flows through the screen.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention pertains to the field of filling containers and specifically molded items, and more specifically to a mold filling apparatus and method of operation that allows a mold having a corner to be filled in a single procedure. 
       BACKGROUND OF THE INVENTION 
       [0002]    Molded items are known in the art. Molded items made from materials such as cast masonry compounds require special handling, due to the density and flowability of the materials as well as shape of the finished goods. As a result, when such cast masonry molded items are fabricated, it is often necessary to do so in steps, so as to allow a one section of the molded item to filled, set, or cured before adding or filling a second and subsequent parts of the molded item to the structure. These sequential steps add additional time and processing costs to the manufacturing process for molded items, but generally can not be avoided because the density of the masonry compound prevents molding techniques that can be used for items formed from materials that flow more easily and harden more quickly, such as plastics, from being utilized. 
       SUMMARY OF THE INVENTION 
       [0003]    In accordance with the present invention, a material dosing and mold filling apparatus and method of operation are provided that allow a molded items with varying cavity volumes, such as one made from cast masonry materials, to be fabricated or filled in a single step. 
         [0004]    In accordance with an exemplary embodiment of the present invention, an apparatus for manufacturing a molded item having a corner is provided. The apparatus includes a mold support for holding an angled mold having an inside corner. A hopper having an outside corner that corresponds to the inside corner of the mold and a screen at the outside corner mates with the mold. A vibration device is provided for causing a material contained in the hopper to pass through the screen, such as by applying a predetermined force for a predetermined period of time required to fill the mold. Different sized openings in the screen combined with the flowability of the material and the amount of vibration can determine how much material flows through the screen. 
         [0005]    Those skilled in the art will further appreciate the advantages and superior features of the invention together with other important aspects thereof on reading the detailed description that follows in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a diagram of a material dosing apparatus for filling a corner mold in accordance with an exemplary embodiment of the invention; 
           [0007]      FIG. 2  is a diagram of a material dosing apparatus for filling a corner mold in accordance with an exemplary embodiment of the invention; 
           [0008]      FIG. 3  is a diagram showing placement of a mold cover on a mold in accordance with an exemplary embodiment of the present invention; 
           [0009]      FIG. 4  is a diagram of a method for making a molded item having an inside corner in accordance with an exemplary embodiment of the present invention; 
           [0010]      FIG. 5  is a diagram of a material dosing apparatus for filling a container in accordance with an exemplary embodiment of the invention; 
           [0011]      FIG. 6  is a diagram of a method for filling a container in accordance with an exemplary embodiment of the present invention; and 
           [0012]      FIG. 7  is a diagram of a system for controlling a filling apparatus in accordance with an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0013]    In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness. 
         [0014]      FIG. 1  is a diagram of an apparatus  100  for filling a corner mold in accordance with an exemplary embodiment of the invention. Apparatus  100  allows a mold for an item having an inside corner to be filled in a single process, so as to eliminate the need to perform multiple steps to form different sides of the item. Apparatus  100  can also be used for other suitable molded items, included molded items having shapes other than those including an inside corner. 
         [0015]    Apparatus  100  includes mold  102 , which includes a mold cavity  104  for forming a molded item. In one exemplary embodiment, the molded item formed in mold cavity  104  can be used for an outside corner, such as for external corners of buildings, columns, or other structures, where the molded item is used to provide a veneer or for other suitable purposes. Mold  102  can be prepared prior to placement in apparatus  102 , such as by cleaning debris left over in mold cavity  104  from forming previously molded items, by providing a lubricant or other coatings on the surfaces of mold cavity  104  to improve the ease of removing the molded item, or in other suitable manners. 
         [0016]    Hopper  106  is configured to mate with mold  102 , and includes screen  108  that is used to transfer a suitable filler material such as a masonry compound from hopper  106  to mold cavity  104 . In one exemplary embodiment, screen  108  is a 1.5″ flattened expanded metal #9 mesh wire mesh or other suitable screens that are selected based on the ability to hold the filler material in place prior to vibration, such that the filler material does not flow through screen  108  until apparatus  108  is configured to fill mold  102 . 
         [0017]    Mold support  110  holds mold  102  and allows mold  102  to be vibrated by vibration unit  112 . In one exemplary embodiment, vibration unit  112  can include two 0.5 horsepower electric motors rated to provide 1100 pounds force based upon eccentric weight alignment, such as a VIBCO 2P-450-1 single phase vibrator or a VIBCO 2P-450-3 three phase vibrator, available from VIBCO Vibrators, 75 Stilson Road, Wyoming, R.I., 02898, or other suitable devices. Vibration can be provided to the mold, the hopper, the mold and the hopper in combination, or in other suitable manners. 
         [0018]    Vibration controller  114  provides control signals to vibration unit  112  to cause filler material from hopper  106  to flow into mold cavity  104 . In one exemplary embodiment, vibration controller  114  can include a sensor input to prevent operation of vibration unit  112  prior to proper placement of hopper  106  into mold  102 . In another exemplary embodiment, vibration control  114  can cause vibration unit  112  to provide 680 pounds force for a period of thirty seconds in order to transfer sufficient filler material from hopper  106  to mold cavity  104  to fill mold cavity  104 . Vibration also helps to consolidate the fill material in the mold, such as to cause a masonry compound to flow into corners or detail features of the mold. 
         [0019]    In operation, apparatus  100  allows a mold for a molded item having an inside corner to be filled in a single operation, using a hopper having an outside corner with a screen that holds a filler material in place until vibration force is applied, at which time the filler material passes through the screen and fills the mold cavity. The mold cavity volume can be constrained by the amount or volume of materials contained in hopper  106 . In this manner, a mold cover can be placed over the mold after it has been filled and the filled and covered mold can be cured, such as by placement in an oven, by allowing time to pass, or in other suitable manners. 
         [0020]      FIG. 2  is a diagram of an apparatus  200  for filling a corner mold in accordance with an exemplary embodiment of the invention. Apparatus  200  allows a mold for an item having an inside corner to be hydraulically or mechanically lifted to fit against a hopper having an outside corner. Apparatus  200  can also be used for other suitable molded items, included molded items having shapes other than those including an inside corner. 
         [0021]    Apparatus  200  includes mold  202 , which includes a mold cavity  204  for forming a molded item. In one exemplary embodiment, the molded item formed in mold cavity  204  can be used for an outside corner, such as for external corners of buildings, columns, or other structures, where the molded item is used to provide a veneer or for other suitable purposes. Mold  202  can be prepared prior to placement in apparatus  202 , such as by cleaning debris left over in mold cavity  204  from forming previously molded items, by providing a lubricant or other coatings on the surfaces of mold cavity  204  to improve the ease of removing the molded item, or in other suitable manners. 
         [0022]    Hopper  206  is configured to mate with mold  202 , and includes screen  208  that is used to transfer a suitable filler material such as a masonry compound from hopper  206  to mold cavity  204 . In one exemplary embodiment, screen  208  is a 1.5″ flattened expanded metal #9 mesh wire mesh or other suitable screens that are selected based on the ability to hold the filler material in place prior to vibration, such that the filler material does not flow through screen  208  until apparatus  208  is configured to fill mold  202 . 
         [0023]    Mold support  216  holds mold  202  and allows mold  202  to be placed into position by hydraulic placement devices  210  and  212 . Hydraulic placement devices  210  and  212  can move mold  202  upwards until it mates with hopper  206 , can move hopper  206  downward until it mates with mold  202 , can move both mold  202  and hopper  206  towards each other until they mate, or can perform other suitable functions. Once  202  and hopper  206  are in place, they are vibrated by vibration unit  214 . In one exemplary embodiment, vibration unit  214  can include two 0.5 horsepower electric motors rated to provide 1100 pounds force based upon eccentric weight alignment, such as a VIBCO 2P-450-1 single phase vibrator or a VIBCO 2P-450-3 three phase vibrator, available from VIBCO Vibrators, 75 Stilson Road, Wyoming, R.I., 02898, or other suitable devices. 
         [0024]    Mold and vibration controller  218  provides control signals to vibration unit  214  to cause filler material from hopper  206  to flow into mold cavity  204 . In one exemplary embodiment, mold and vibration controller  218  can include a sensor input, such as from hydraulic placement devices  210  and  212 , to determine when mold  202  and hopper  206  are in proper position and to prevent operation of vibration unit  214  prior to proper placement of hopper  206  into mold  202 . In another exemplary embodiment, mold and vibration controller  218  can cause vibration unit  214  to provide 680 pounds force for a period of thirty seconds in order to transfer sufficient filler material from hopper  206  to mold cavity  204  to fill mold cavity  204 . 
         [0025]    In operation, apparatus  200  allows a mold for a molded item having an inside corner to be filled in a single operation, using a hopper having an outside corner with a screen that holds a filler material in place until vibration force is applied, at which time the filler material passes through the screen and fills the mold cavity. In this manner, a mold cover can be placed over the mold after it has been filled and the filled and covered mold can be cured, such as by placement in an oven, by allowing time to pass, or in other suitable manners. 
         [0026]      FIG. 3  is a diagram showing placement of a mold cover on a mold in accordance with an exemplary embodiment of the present invention. In  300 A, mold  302  is oriented so as to minimize the gravitation force on a filler material in mold cavity  304 . A mold cover  306  is placed over the top of mold  302 , and mold  302  is then oriented as shown in  300 B so as to allow the base of mold  302  to be placed on a flat surface, such as for curing, for transfer to an oven, or for other suitable purposes. As shown in  300 B, mold cover  306  prevents the filler material in mold cavity  304  from flowing, and allows the filler material to cure so as to form a molded item having an inside corner. 
         [0027]    In operation, the process shown in  FIG. 3  can be used to cover a mold for an item having an inside corner so as to allow the mold to be filled in a first position and then transferred to a second position for curing. This process can be used where the filler material does not readily flow but still requires support during the curing process, such as a masonry filler compound or other suitable filler materials. 
         [0028]      FIG. 4  is a diagram of a method  400  for making a molded item having an inside corner in accordance with an exemplary embodiment of the present invention. Method  400  begins at  402 , where a mold having a mold cavity is prepared for placement in a press or other suitable apparatuses. In one exemplary embodiment, the mold and mold cavity can be washed, such as by brushing, using pressurized water, or in other suitable manners. The mold cavity can also be treated with a coating material to improve the ease of removing the molded item from the mold cavity, and other suitable preparations can also or alternatively be performed. The method then proceeds to  404 . 
         [0029]    At  404 , the mold is placed in a mold support, such as by sliding the mold into the mold support laterally, by vertically placing the mold on the mold support, or in other suitable manners. The mold can also be prepared after it has been placed on the mold support where suitable. The method then proceeds to  406 . 
         [0030]    At  406 , a hopper is mated to the mold. The hopper can be lowered onto the mold, the mold can be raised to mate with the hopper, the mold and the hopper can each be moved towards the other, or other suitable processes can be used. Hydraulic devices, motorized pulleys, or other suitable drivers can also or alternatively be used to mate the hopper to the mold. The method then proceeds to  408 . 
         [0031]    At  408 , vibration of the mold and hopper is activated. In one exemplary embodiment, a sensor can be used to inhibit operation of a vibration device until the mold and hopper are properly configured, a programmable controller can be used to sequence placement and vibration of the mold and hopper, or other suitable processes can also or alternatively be used. Likewise, the vibration force, length of vibration and other suitable variables can be determined, such as from a user settings, based on a control device on a mold, or in other suitable manners. The method then proceeds to  410 . 
         [0032]    At  410 , it is determined whether the mold is filled. In one exemplary embodiment, a predetermined time can be used to vibrate the mold and hopper in order to fill the mold. In another exemplary embodiment, a sensor or other suitable device can be used to determine whether the mold has been filled, or other suitable processes or devices can also or alternatively be used. If it is determined that the mold is not filled, the method proceeds to  412  where vibration continues and the method returns to  410 . Otherwise, the method proceeds to  414 . 
         [0033]    At  414 , vibration is terminated, such as by removing power from a vibration device, motor, or other suitable vibrating units. The method then proceeds to  416 , where the mold and hopper are separated. In one exemplary embodiment, a hydraulic device can be used to raise the hopper away from the mold, to lower the mold away from the hopper, to move the mold and hopper away from each other, or other suitable processes can also or alternatively be used. The method then proceeds to  418 . 
         [0034]    At  418 , the mold is removed from the vibration apparatus, such as by sliding the mold laterally, by raising the mold vertically, or in other suitable manners. The method then proceeds to  420 , where a mold cover is placed on top of the mold. In one exemplary embodiment, the mold cover can be placed on the mold while it is still in an angled position, so as to minimize or prevent movement of a filler material in the mold cavity. The filler material can also be screeded to level the filler material and ensure that the mold cavity is uniformly filled, and other suitable processes can also or alternatively be performed. The method then proceeds to  422 , where the mold is cured, such as by placing the mold in an oven, by allowing time to pass sufficient to allow the filler material to cure, or in other suitable manners. 
         [0035]    In operation, method  400  allows a molded item having an interior corner to be formed, such as where a hopper is provided having a screen that forms an outside corner that mates with the interior corner of the mold. A filler material can be held in the hopper by coordinating the filler material and screen so that the filler material does not flow through the screen until a vibration force is applied. Likewise, method  400  can be used in other suitable applications, such as to transfer a filler material to a suitable mold or container, including molds or containers for items having other suitable shapes and/or volumes. 
         [0036]      FIG. 5  is a diagram of an apparatus  500  for filling a container in accordance with an exemplary embodiment of the invention. Apparatus  500  can be used to fill containers with fluids (such as water, oil, paint, or other suitable fluids), dry mixes (such as grains, dry masonry mixes, particulates, or other suitable dry mixes), wet mixes (such as wet plaster, wet concrete, or other suitable wet mixes), or other suitable materials. 
         [0037]    Apparatus  500  includes hopper  502  having a screen  504  disposed at the bottom. Hopper  502  can be rectangular as shown or can utilize other suitable shapes, and screen  504  can be disposed as needed to provide material into container  522 . In one exemplary embodiment, hopper  502  can be cone shaped and screen  504  can form the tip of the cone, can be circular, or can have other suitable configurations. The mesh size of screen  504  and material used to form screen  504  are selected in order to optimize control of the delivery of material through screen  504 , such as by using a smaller mesh and corrosion resistant material for corrosive liquids, a larger mesh for large particulates, and other suitable configurations. Likewise, a permeable barrier can be used in place of a screen material where suitable, such as a configuration of equally spaced parallel rods, a perforated metal barrier, a plurality of screens in series, a combination of permeable barriers, or other suitable permeable barriers. 
         [0038]    Feed system  516  and chute  518  are used to maintain a fill level of material inside of hopper  502  at a predetermined level, to periodically refill hopper  502 , or to otherwise provide material to hopper  502 . In one exemplary embodiment, level sensor  512  can be used to maintain a level of material between predetermined low and high limits, such as by activating feed system  516  when the level of material in hopper  502  reaches the low level and deactivating feed system  516  when the level of material reaches the high level, or in other suitable manners. 
         [0039]    Vibration and level controller  514  controls the operation of feed system  516  and vibration unit  506 . In one exemplary embodiment, vibration and level controller  514  can activate feed system  516  periodically based on a number of containers  504  that have been filled, based on data received from level sensor  512 , or in other suitable manners. Vibration and level controller  514  can also control the operation of vibration unit  506 , such as by activating vibration unit for a predetermined period of time at a predetermined force when container  522  is moved under hopper  502  by conveyor system  520  or in other suitable manners. Hopper supports  508  and  510  can be stationary, hydraulically controlled or otherwise configured to support hopper  502 . 
         [0040]    In operation, apparatus  500  can be used to fill containers with a predetermined quantity of material by applying a vibrational force to a hopper having a screen or other suitable permeable barrier disposed at a bottom surface. Apparatus  500  can be used to fill a suitable container with a suitable material, such as a mold (e.g. filled with masonry mix, epoxy, glass, plastic), a barrel (e.g. filled with oil, beverages), a bottle (e.g. filled with condiments, foodstuff), a rail car (e.g. filled with gravel, cotton seed), a box (e.g. filled with packing material, sawdust), a carton (e.g. filled with nails, ball bearings), or other combinations of containers and materials. In one exemplary embodiment, apparatus  500  can be used to fill a container with a material that can be dispensed through a screen or other permeable barrier, where the material exhibits a controllable flow or fill rate through the screen or permeable barrier when subjected to a predetermined vibrational force. Vibration can also or alternatively be applied to the container to help consolidate material in the container. 
         [0041]      FIG. 6  is a diagram of a method  600  for filling a container in accordance with an exemplary embodiment of the present invention. Method  600  begins at  602  where a container is prepared, such as by cleaning the container, applying a pigment or lubricant, or otherwise preparing the container. The method then proceeds to  604  where the container is moved under a hopper, such as by moving the container into position using a conveyor system, by manual placement, or in other suitable manners. The method then proceeds to  606 . 
         [0042]    At  606 , a vibration unit is activated to apply a predetermined vibrational force to the hopper so as to cause material contained in the hopper to flow through a screen or other suitable permeable barrier into the container. In one exemplary embodiment, the material can be coordinated with the screen or permeable barrier so as to result in a predetermined material flow rate, where the volume of material provided to the container can be measured based on the length of time that vibrational force is applied, the level of vibrational force, or in other suitable manners. The method then proceeds to  608 . 
         [0043]    At  608 , it is determined whether the container has been filled. In one exemplary embodiment, fill can be determined from the length of time of vibration, using a fill sensor, or in other suitable manners. If it is determined at  608  that the container is not filled, the method proceeds to  610  where vibration continues, after which the method returns to  608 . Otherwise, the method proceeds to  612 , where the vibrational force is terminated. The method then proceeds to  614 . 
         [0044]    At  614 , the container is removed, such as by activating a conveyor system, using manual processes, or in other suitable manners. The method then proceeds to  616  where it is determined whether another container should be filled. In one exemplary embodiment, method  600  can be used in a continuous container filling process, a sensor can be used to determine whether the filled container has been removed, or other suitable processes can be used. If it is determined that another container should be filled, the method returns to  602 , otherwise the method proceeds to  618  and terminates. 
         [0045]    In operation, method  600  can be used to fill containers such as molds, barrels, bottles, rail cars, boxes, cartons, or other suitable containers with a suitable material, such as a material that can be delivered through a screen or other permeable barrier at a controllable delivery rate, by applying a vibrational force to a hopper containing the material, where the hopper includes a screen or permeable barrier disposed at the bottom of the hopper, a corner of the hopper, or in other suitable locations. 
         [0046]      FIG. 7  is a diagram of a system  700  for controlling a filling apparatus in accordance with an exemplary embodiment of the present invention. System  700  can be implemented in hardware, software, or a suitable combination of hardware and software, and can be one or more software systems operating on a programmable controller or other suitable platforms. As used herein, a hardware system can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. A software system can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications or on two or more processors, or other suitable software structures. In one exemplary embodiment, a software system can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “coupled” and its cognate terms such as “couples” or “couple,” can include a physical connection (such as a wire, optical fiber, or a telecommunications medium), a virtual connection (such as through randomly assigned memory locations of a data memory device or a hypertext transfer protocol (HTTP) link), a logical connection (such as through one or more semiconductor devices in an integrated circuit), or other suitable connections. In one exemplary embodiment, a communications medium can be a network or other suitable communications media. 
         [0047]    System  700  includes mold and vibration controller  216  and hopper fill system  702 , hopper close system  704 , vibration timing system  706 , hopper open system  708  and mold eject system  710 . Hopper fill system  702  receives a user entered command, sensor data or other suitable data and activates or deactivates a material transport system to transport material to a hopper. In one exemplary embodiment, hopper fill system  702  receives a low level sensor indication that indicates that a level of material in a hopper is below a predetermined low level and activates the material transport system. Hopper fill system  702  can then receive a high level sensor indication that indicates that the hopper is filled and can deactivate the material transport system. In another exemplary embodiment, hopper fill system  702  can operate the material transport system periodically, after a predetermined number of molds or containers have been filled, or in other suitable manners. 
         [0048]    Hopper close system  704  actuates a closing mechanism for closing a hopper against a mold or container, and deactivates the closing mechanism where suitable. In one exemplary embodiment, hopper close system  704  can receive sensor data that indicates that a mold has been placed in a mold support, a manual control, or other suitable data, and activates an electric, hydraulic, pneumatic or other suitable mechanism that causes the hopper to be placed in contact with a mold or container, such as where the hopper is used to fill a mold. Hopper close system  704  can receive additional data, such as sensor data that indicates that the hopper and mold have come into contact, an inhibit signal that prohibits operation when the mold is not in a mold support or otherwise in position, or other suitable data, and can activate or deactivate the closing mechanism accordingly. 
         [0049]    Vibration timing system  706  receives control data and actuates a vibration system for a predetermined period of time at a predetermined force or in other suitable manners. In one exemplary embodiment, vibration timing system  706  can receive control data from hopper close system  704  that indicates that a hopper and/or container is in position, an inhibit override signal, or other suitable data, and can activate a vibration system to cause material contained within the hopper to pass through a screen or other suitable permeable barrier. In another exemplary embodiment, vibration timing system  706  can operate in response to a manual control, based on sensor data that indicates whether a mold or container is filled, or other suitable data. 
         [0050]    Hopper open system  708  activates a suitable mechanism to cause a hopper to separate from a mold or other container, such as to allow the mold or other container to be removed manually, by a conveyor, or in other suitable manners. In one exemplary embodiment, an electric, hydraulic, pneumatic or other suitable mechanism can be used to move the hopper from a fill position to a standby position, such as to allow an empty mold or container to be placed in position for filling. 
         [0051]    Mold eject system  710  removes a mold from a fill position, such as by using a conveyor system, by ejecting the mold for manual handling, or in other suitable manners. In one exemplary embodiment, mold eject system  710  can be used to eject a mold from a mold support, such as where the molds are moved into location by conveyor or other suitable mechanisms, and are then loaded into a mold support, filled and ejected back onto the conveyor. 
         [0052]    In operation, system  700  controls the operation of a mold or container filling apparatus that uses vibrational force to cause a material to pass through a screen or other permeable barrier. System  700  allows molds or other containers to be filled, and prevents inadvertent operation of the fill process, such as to prevent operation of the fill process when no mold is in position, when the mold is not seated against the hopper, or at other times when operation should be prevented. 
         [0053]    Although exemplary embodiments of a system and method of the present invention have been described in detail herein, those skilled in the art will also recognize that various substitutions and modifications can be made to the systems and methods without departing from the scope and spirit of the appended claims.