System for making composite blocks

Abstract: A system is provided for making a composite block comprising a block body (a) formed of mortar or concrete and a covering material (b), such as a tile, natural stone or mortar sheet, applied to one outer surface of the block body (a). The system comprises applicator means (31,32,38,39) for applying an adhesive material (c) to the block body (a) or covering material (b), pressing means (50) for applying vibration and/or pressure to a composite block assembly (K) including the block body (a) and the covering material (b) placed thereon to compress the adhesive material (c) therebetween, and finishing means (62,63 ) for finishing the pressed composite block assembly into a composite block by passing it through an aperture (62) in a scraper (63) of flexible material, the aperture (62) being of a shape substantially the same as the exterior contour of the composite block (K).

Description: FIELD OF THE INVENTION The present invention relates to a system for making composite blocks, each comprising a block body formed of mortar or concrete and a covering material therefore, such as tile, natural stone or mortar sheet, applied to the upper surface of the block body. PRIOR ART Heretofore, there has been no system which would automatically apply covering materials, such as tiles, to concrete blocks, etc. The production of such composite blocks is thus very low, because they are made exclusively manually with simple tools or individual machines (see e.g. WO89/00626). Because automation is not used, there are differences in the product produced by different people and this makes it very difficult to obtain composite blocks of uniform quality. SUMMARY OF THE INVENTION The present invention seeks therefore to reduce or obviate the above problem by the provision of a system which renders it possible to make composite block products automatically of uniform quality with high production rate. According to the invention, there is provided a system for making a composite block comprising a block body formed of mortar or concrete and a covering material, such as a tile, natural stone or mortar sheet, applied to one outer surface of the block body, said system comprising applicator means for applying an adhesive material to the block body or covering material, pressing means for applying vibration and/or pressure to a compsite block assembly including the block body and the covering material placed thereon to compress the adhesive material therebetween, and finishing means for finishing the pressed composite block assembly into a composite block by passing it through an aperture in a scraper made of flexible material, the aperture being of a shape substantially the same as the exterior contour of the composite block,said adhesive material applicator means for applying the adhesive material to the back surface of the covering material or that surface of the block body of the composite block assembly which is to be bonded to the covering material including a mask sheet having at least one aperture therein, a carriage for either relatively moving and positioning the covering material with its front surface downwards and its back surface upwardly to and below the mask sheet or relatively moving and positioning the block body with said surface to be bonded facing upwards to and below the mask sheet, an elevator for bringing the covering material or the block body into contact with the undersurface of the mask sheet when the covering material or the block body is positioned to underlie the mask aperture, and an adhesive material hopper for depositing the adhesive material into a recess defined by the mask aperture and the back surface of the covering material or the surface to be bonded of the block body in contact with the undersurface of the mask sheet, the adhesive material hopper being designed to move along the upper surface of the mask sheet over the aperture,in which the peripheral wall defining the aperture in said mask sheet includes an upper wall portion having a downwardly inclined slope. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described in greater detail, by way of example, with reference to the accompanying drawings which illustrate embodiments of the invention in which tiles are applied to the surfaces of paving blocks, and in which:- Figure 1 is a schematic plan view showing the general structure of one embodiment of the present invention; Figure 2 is a perspective view showing a pallet and a stack of block bodies placed thereon; Figure 3 is a plan view of a part of the structure of figure 1 showing delivery of a pallet from a predetermined position on a pallet delivery path to an elevator position; Figures 4 to 8 are front views of a part of the structure of figure 1 showing a sequence of operations whereby the uppermost stage of the block bodies is positioned at a predetermined height by the elevator shown in figure 3 and gripped by a transfer device and then placed on a block feeding conveyor; Figure 9 is a front view of a part of the structure illustrating an operation for pushing the last row of block bodies placed on the block feeding conveyor with a pushing attachment, thereby advancing the whole stage by a distance of one row onto a movable table group; Figure 10 is a front view of a part of the structure illustrating an operation for advancing the movable table group of figure 9 to space the block bodies on the movable table group slightly away from the next row of block bodies; Figure 11 is a plan view of a part of the structure illustrating an operation for spacing the movable tables forming the movable table group of figures 9 and 10 away from each other to space the block bodies away from each other; Figure 12 is a plan view of a part of the structure illustrating an operation of pushing the block bodies on the movable table group of figures 9, 10 and 11 onto a moving table; Figures 13 to 16 are front views of a part of the structure illustrating a sequence of operations for placing a covering material onto a predetermined position of a covering material delivery path formed by two wire ropes by suction and delivery means; Figure 17 is a front view of a part of the structure illustrating the operation of moving the covering material to below a mask sheet of adhesive material applying means on the covering material delivery path; Figure 18 is a front view of a part of the structure in which the covering material is shown pressed against the lower face of the mask sheet shown in figure 17 and an adhesive material hopper is shown; Figure 19 is a front view similar to figure 18, but showing the adhesive material hopper moving forward, Figure 20 is a front view similar to figures 18 and 19 but showing the covering material having the adhesive material applied on its back surface by the forward movement of the adhesive material hopper, the covering material being lowered back onto the covering material delivery path from the lower face of the mask sheet; Figure 21 is a sectional view of a mask aperture in the mask sheet; Figure 22 is a front view of a part of the structure illustrating the operation of moving the covering material to a covering material inverter by operation of the covering material delivery path; Figure 23 is a plan view showing part of the covering material inverter; Figure 24 is a front view of the covering material inverter shown in plan view in figure 23; Figure 25 is a front view of part of the covering material inverter of figure 24 showing the movement of the covering material with the adhesive material applied on its back surface onto a suction port of a swing arm; Figure 26 is a front view of part of the covering material inverter illustrating the operation of inverting the covering material placed on the suction port of the swing arm and placing it on the block body; Figure 27 is a front view of a part of the structure illustrating the operation of pushing the block assembly, on which the covering material has been placed with the adhesive in contact with the block body, to the next carrying means; Figure 28 is a front view of pressing means illustrating the operation of positioning the composite block assembly, from figure 27, thereon; Figure 29 is a front view similar to figure 28 but illustrating the operation of compressing the composite block assembly; Figure 30 is a front view similar to figures 28 and 29 but illustrating the operation of pushing the composite block assembly, compressed by the pressing means, to the next carrying means; Figure 31 is a front view of a part of the structure showing the mechanism of finishing means; Figure 32 is a front view of the finishing means shown in figure 31 showing the finished composite block being pushed onto vertically displaceable rails of gap reducing means; Figures 33 and 34 are views of a part of the finishing means illustrating a sequence of operations for reducing gaps between the composite blocks to zero using gap reducing means; Figure 35 is a partial front view of the finishing means showing the feed of the composite blocks forward by the rotation of a roller conveyor after the vertically displaceable rails of the gap reducing means have descended; Figures 36 to 40 are views of apart of the structure showing a sequence of the operations for successively stacking the composite blocks from the finishing means on an empty pallet supplied to the terminal of the pallet delivery path from the transfer device; Figure 41 is an enlarged view illustrating the structure of the finishing means of figure 31; Figure 42 is a side view of the structure of the finishing means shown in figure 41; Figure 43 is a view illustrating the sequence of operation of the finishing means; Figure 44 is a front view of one example of a cleaning device used in conjunction with the transfer device of figures 4 to 8; Figure 45 is a partly sectioned front view showing an example of part of an adhesive material applying means for applying the adhesive material onto the surface of a block body; Figure 46 is a front view showing part of another example of an adhesive material applying means for applying the adhesive material onto the surface of a block body, and Figure 47 is a plan view showing the relation between one example of a mask aperture and the position at which a stop is mounted. DESCRIPTION OF THE PREFERRED EMBODIMENT As illustrated in Figures 1 to 3, a pallet delivery path A is formed by a conveyor 13 comprising a pair of chains 11 running in parallel with each other at a set spacing on sprockets 12. Below a given position of the delivery path A , there is provided an elevator 14 for raising a pallet, positioned on the delivery path A and lying above the elevator 14, to a predetermined height above the conveying path. As illustrated in Figure 2, a stack of sets of block bodies a , arranged in rows, are provided on a pallet 16 which is carried from an input position 15 of the pallet delivery path A to a location above the elevator 14. An optical sensor (not shown) is provide at a location where the upper surfaces of the block bodies a of the uppermost stage can be detected, and control means are provided, responsive to the optical sensor, for controlling the elevator 14 to position the upper surfaces of the block bodies a of the uppermost stage at a predetermined desired height. As illustrated in Figures 4 to 8, a transfer device, generally shown at 21, is provided to grip and retain the block bodies a′ of the uppermost stage, the transfer device having an integral water sprinkling nozzle 17 - see Fig. 44 - for sprinkling water over the uppermost surface of the block body and having a brush 16/air blower 19 combination for cleaning up concrete tailings and blowing off the remainder of water sprinkled beforehand. A block feeding conveyor 22 is provided to receive the block body a′ held by the transfer device 21. As illustrated in Figures 9 to 12, a pusher attachment 23 is provided for moving the whole of the uppermost stage forward by a distance of one row by pushing the last row of the block bodies a′ on the conveyor 22. A group 25 of movable tables 24 are provided on which the row of the block bodies a′ pushed off the conveyor 22 are individually placed, the number of tables 24 corresponding to the number of the block bodies a′ in the row. The group 25 of tables 24 is moved forward to separate slightly the block bodies a′ from the block bodies a″ in the next row. Block arranging means 26 is provided to separate the movable tables 24 from each other so as to space the block bodies a′ away from each other. The thus arranged block bodies a′ are then pushed forward by a block pusher 27 descending from its normal position located above the block bodies a′ . The block bodies a′ pushed on by the block pusher 27 are located on a moving table 28 which is intermittently controlled in such a manner that it supplies the block bodies to a predetermined position on a block delivery path B . As illustrated in Figures 13 to 16, a covering material delivery path C is provided, which is constructed from two wire ropes 29 running in parallel with the block delivery path B . There is provided suction means 30 for applying suction to covering materials b , such as tiles, which are stacked with their front surfaces lowermost and their back surfaces, to which bonding is to take place, uppermost to pick them up and feed them onto the upper surface of the covering material delivery path C at a predetermined position thereon. As shown in Figure 17, a mask sheet 32 is provided, which is of uniform cross-sectional thickness and is provided with a line of rectangular mask apertures 31 at predetermined intervals. The mask sheet 32 has a thickness of about 4 mm., while each of the mask apertures 31 has inclined edges 40 extending from its surface inwardly towards its opening to a depth of about 3 mm. As illustrated in Figure 18, the covering materials b with their surfaces 33 facing downwards and their back surfaces 34 facing upwards are then moved to below the mask sheet 32, and are located relative to the mask apertures 31. The tile used as the covering material b is about 92 mm. by about 192 mm. in size and about 10 mm. in thickness. The block body a is about 96 mm. by about 196 mm. in size and about 70 mm. in thickness. An elevator 37 is provided, which pushes the covering material b up along a covering material positioning guide 36 provided around the bottom of each mask aperture 31, such that each covering material b is located in correspondence with each mask aperture 31. Above the mask sheet 32, there is provided an adhesive material hopper 38 for storing a large amount of an adhesive material c , such as mortar, which is kneaded to the required viscosity. As illustrated in Figure 19, the adhesive material hopper 38 is designed in such a manner that its lower outlet 39 is movable along the upper face of each mask aperture 31. Whenever the hopper 38 moves, the adhesive material c is smeared with a thickness corresponding to the thickness of the mask sheet 32 onto a predetermined central position of the back surface of the covering material b positioned underneath the bottom of each mask aperture 31 of the mask sheet 32. As already mentioned, each mask aperture 31 has inclined edges 40 extending from its surface inwardly towards its opening (see Figure 21). Thus the viscous adhesive material c entering the mask aperture 31 is drawn along in the direction along which the lower outlet 39 of the hopper 38 moves, so that it comes away from the inclined edge of the mask aperture 31, thus clearing this side of the mask aperture. If, thereafter, the hopper operates in the opposite direction, the opposite side of the aperture is cleared. Alternatively, if the lower part of the mask sheet 32 at the aperture 31 has a thickness as thin as about 1 mm, the covering material b is released and the adhesive flows down easily from the mask sheet 32. It is thus unlikely that the adhesive material c will be deposited around the mask aperture 31 to reduce its size or distort its shape. This ensures that the adhesive material is applied on the predetermined area of the back surface of the covering material b . First and second scrapers 41 and 42, which engage or disengage from the mask sheet 32, are hingedly coupled at their upper portions to the lower end of the adhesive material hopper 38. Provided in association with the scrapers 41 and 42 are scraper-operating cylinder means 43 and 44 which are designed to lift up the first scraper 41 and let down the second scraper 42, when the hopper 38 moves forward, and lift up the second scraper 42 and let down the first scraper, when the hopper moves backward, whereby an excess amount of the adhesive material smeared onto the upper face of the mask sheet 32 is recycled into the outlet 39 of the hopper 38 and can thus be reused to avoid waste. The adhesive material c is smeared onto that back surface 34 with a thickness corresponding to the thickness of the mask sheet 32 by the forward or backward movement of the adhesive material hopper 38. If a vibrator 45 or 46 is additionally provided associated with the scrapers 41 and 42 in this case, then the adhesive material c is uniformly smeared on the back surface 34 of the covering material by the vibration thereof. After the smearing of the adhesive material onto the back surface 34 of the covering material is completed, the elevator 37 descends, as shown in Figure 20, to place the covering material b on the covering material delivery path C , as shown in Figure 22. Then, the covering material b is transferred to the next stage. Underneath the path C . a pivot arm 48 is provided, as shown in Figures 23 to 27, the pivot arm having a suction port 47 for applying suction to the covering material b having the adhesive material c applied on its back surface 34. The pivot arm 48 is pivoted through 180° between the path C and the block delivery path B . It provides an inverting means 49 for inverting the covering material b and placing it on a block body a positioned along the block delivery path B by pivoting the pivot arm 48 through 180° towards the block delivery path B . At the next position along the block delivery path B , there is provided pressure means 50, as illustrated in Figures 28 to 30, for applying vibration and/or pressure to a composite block assembly K in which the covering material b has been engaged with the block body a through the adhesive material c by being placed thereon by the covering material inverting means 49. As illustrated in Figure 43, any overflow of adhesive material c is deposited around the composite block K , which is then placed on a block receiving table 52 provided at a predetermined position within a machine frame 51. As illustrated in Figure 41, the block receiving table 52 is connected at its lower face with one end of a cylinder 53 for vertically displacing it to the required position at which it supports the block, thereby forming, with the block receiving table, vertical displacing means 54. At the lowermost position of the block receiving table 52, a stop 56 with a forward/backward displacing cylinder 55 is provided for defining the position at which the forward movement of the composite block K is stopped. The stop 56 is movably located on a guide shaft 57 carried by the machine frame 51. As illustrated in Figure 42, there is provided a guide 58 for guiding the composite block K towards its predetermined position in a transverse direction. A pusher means 61 comprises a pusher 60, movably mounted on the guide shaft 57 and driven by means of a reciprocating cylinder 59. It acts to push the composite block K into the position set by the stop 56 along the guide 58. Above the positioned defined by the stop 56, guide 58 and pusher means 61, a third scraper 63 is fixedly located, which scraper is provided with a through aperture 62 of a size substantially identical with the contour of the composite block K and is made of a flexible material. After the composite block K is guided to and located at the positione defined by the stop 56, guide 58 and pusher means 61, the stop 56 and pusher means 61 are retracted to release a restraining force on the composite block. Thereafter, the vertical displacing means 54 is driven upward to push the composite block K through the aperture 62 in the scraper 63. In the process of forcing the composite block K through the aperture 62 in the scraper 63, the adhesive material c which had overflowed the composite block K is scraped off by the scraper 63. In this manner, the composite block K is finished into a composite block product. The composite block product is then fed to the predetermined recovery route by the forward movement of pusher means 66 comprising a pusher 65 with a forward/backward displacing cylinder 64. The pusher 65 is movably mounted on a guide shaft 67 located horizontally at a predetermined position above the guide shaft 57. The scraper 63 is mechanically connected to a vibrator 68 is energised during the operation of the system to apply vibrations to the scraper 63 to vibrate it. A part of the adhesive material scraped off during the above finishing process is unavoidably deposited around the aperture 62 in the scraper 63. However, it is completely scraped off by the vibration of the scraper 63, as mentioned above. After a series of finishing steps have been completed, the movable parts return to their original positions for finishing the next composite block. As illustrated in Figure 31, there is provided a vertically displaceable rail 69 on which the composite block K , pushed out by the pusher means 66 is placed on a roller conveyor 70 at such a spacing thereon that it is vertically displaceable. As illustrated in Figures 33 and 34, pusher means 71 is provided for pushing together a row of composite blocks which were pushed out onto the rail 69 by the pusher means 66. By this means, the gaps between the composite blocks are reduced to zero. After the rail 69 descends, as illustrated in Figure 35, the composite block placed on the roller conveyor 70 is fed forward by the rotation of the roller conveyor 70. As illustrated in Figures 36 to 40, the composite blocks fed out by the conveyor 70 are successively stacked up, as desired, on an empty pallet 16 fed to the terminal of the pallet delivery path A and are then discharged. In the foregoing embodiment, the adhesive material is applied to the back surface of the covering material. In what follows, reference will be made to the application of the adhesive material on the surface of the block body. As illustrated in Figure 45, the block body is positioned below the aperture in the applicator for an adhesive material such as mortar, and the adhesive material is applied by the movement of an adhesive material hopper. Subsequent pressing and finishing work may be carried out with similar pressing and finishing means as mentioned above. If the block body has ribs on its upper surface, such as are shown in Figure 46, a stop 81 is provided on the lower surface of the mask sheet, as illustrated, to adjust the thickness of mortar. In order that mortar is well spread over the back surface of the covering material, a mask of such a shape as shown in Figure 47 is used. In this case, the stops 81 may be attached at the positions illustrated. This stop means has the advantage of dispensing with the inversion of the covering material and so simplifying the system. As will be understood from the foregoing, the present invention provides a system for making composite block products, which is fully automated, and so makes a great contribution to increased productivity as well as improvement in uniformity of product quality.

Claims: A system for making a composite block comprising a block body (a) formed of mortar or concrete and a covering material (b), such as a tile, natural stone or mortar sheet, applied to one outer surface of the block body (a), said system comprising applicator means (31,32,38,39) for applying an adhesive material (c) to the block body (a) or covering material (b), pressing means (50) for applying vibration and/or pressure to a compsite block assembly including the block body (a) and the covering material (b) placed thereon to compress the adhesive material (c) therebetween, and finishing means (62,63 ) for finishing the pressed composite block assembly into a composite block by passing it through an aperture (62) in a scraper (63) made of flexible material, the aperture (62) being of a shape substantially the same as the exterior contour of the composite block (K),said adhesive material applicator means (31,32,38,39) for applying the adhesive material (c) to the back surface of the covering material (b) or that surface of the block body (a) of the composite block assembly which is to be bonded to the covering material (b) including a mask sheet (32) having at least one aperture (31) therein, a carriage (29) for either relatively moving and positioning the covering material (b) with its front surface downwards and its back surface upwardly to and below the mask sheet (32) or relatively moving and positioning the block body (a) with said surface to be bonded facing upwards to and below the mask sheet (32), an elevator (14) for bringing the covering material (b) or the block body (a) into contact with the undersurface of the mask sheet (32) when the covering material (b) or the block body (a) is positioned to underlie the mask aperture (31), and an adhesive material hopper (38) for depositing the adhesive material (c) into a recess defined by the mask aperture (31) and the back surface of the covering material (b) or the surface to be bonded of the block body (a) in contact with the undersurface of the mask sheet (32), the adhesive material hopper (38) being designed to move along the upper surface of the mask sheet (32) over the aperture (31), characterised in that the peripheral wall defining the aperture (31) in said mask sheet (32) includes an upper wall portion having a downwardly inclined slope (40). The system as according to claim 1, wherein the the mask sheet (32) has a substantially uniform thickness in cross section and a plurality of mask apertures (31) of the same shape, arrayed in a row at predetermined intervals. The system according to claim 1 or 2, wherein the adhesive material hopper (38) is provided at its lower outlet (39) with first and second scrapers (41,42) with operating cylinders (43,44) adapted to move the scrapers (41,42) between a first position where the scrapers (41,42) are in engagement with the mask sheet (32) and a second position where the scrapers (41,42) are disengaged from the mask sheet (32), each of the scrapers (41,42) being further provided with a vibrator (45,46). The system according to claim 3, wherein the scrapers (41,42) are arranged such that when the adhesive material hopper (38) moves forward, the first scraper (41) is lifted up while the second scraper (42) is let down with the vibrator (45) provided thereon in operation and that when the hopper (38) moves backward, the second scraper (42) is lifted up while the first scraper (41) is let down with the vibrator (46) provided thereon in operation. The system according to any one of claims 1 to 4, wherein the finishing means (62,63) includes a positioning stop (56) with a double acting cylinder (55) for moving the bonded composite block (K) forward to a predetermined stop position, a guide (58) for guiding the composite block (K) in a transverse direction, pushing means (61) for pushing the composite block (K) into the positioning stop (56) along the guide (58), a scraper (63) provided above the position defined by the stop (56), guide (58) and pushing means (61), the scraper (63) being provided with a through aperture (62) of a size and shape substantially the same as the exterior contour of the composite block (K) and formed of a flexible material, vertically displaceable means (54) with a block receiving table (52) for pushing the composite block (K) through the aperture (62) in the scraper (63), and reciprocating means (65) for pushing the composite block (K) after it has passed through the aperture (62) in a predetermined transverse direction. The system according to claim 5, wherein the scraper (63) of the finishing means (62,63) is additionally provided with a vibrating mechanism (68).

Inventors: KODAMA OSAMU C O KANREN SEIHIN, KUROTAKI ATSUTOSHI C O KUMAGAY, MUNAKATA HIDEYUKI, SHIRAKURA SHOUICHI C O KANREN, SUDA SHIGEO C O KANREN SEIHIN, SUEMITSU TADAO TOKYO FACTORY C, TANIKAWA TAKUMI, URASHI MASAYUKI TOKYO FACTORY, YANAI KIMIO, KODAMA, OSAMU, C/O KANREN SEIHIN HOMBU, KUROTAKI, ATSUTOSHI, C/O KUMAGAYA FACTORY, MUNAKATA, HIDEYUKI, SHIRAKURA, SHOUICHI, C/O KANREN SEIHIN HOMBU, SUDA, SHIGEO, C/O KANREN SEIHIN HOMBU, SUEMITSU, TADAO, TOKYO FACTORY, CHIYODA TECHNICAL, TANIKAWA, TAKUMI, URASHI, MASAYUKI, TOKYO FACTORY, CHIYODA TECHNICAL, YANAI, KIMIO
Applicants: CHIYODA TECH & IND, ILB KK, INAX CORP, CHIYODA TECHNICAL & INDUSTRIAL CO. LTD., ILB CO., LTD., INAX CORPORATION
Application year: 1990
Main classification: B28B11
IPC codes: B28B11, B28B13, B05C11