CONTINUOUS BUILDING MATERIALS MOULDING DEVICE

Abstract: The invention is related to a continuous moulding device of building materials comprising two pairs of drive sprockets (22) oppositely positioned at the inlet and the outlet of the device, a pair of chain conveyors (24) wound on said drive sprockets (22) and having a connecting part (24a) on each of their links, a series of bottom plates (26) each of which is connected to opposite connecting parts (24a) of said links, side wall members (27) pivotally connected to the sides of each said bottom plate to form a unit mould transversely, and end pieces (30, 30') connected to each said bottom plate (26) to resiliently contact the ends of each unit mould. According to another aspect of the invention, said unit mould can be formed by side wall members (127) and a bottom member (128), or by a bottom wall (210a) and side walls (210b, 210c) of a moulding conveyor belt (210). The device makes it possible to maintain dimensional tolerances of the moulded products, concrete beams, door frames, or aluminum blocks, within +/- 1mm, because, by suitable means, the end pieces and the side walls of each mould are positioned vertical with the bottom plates during moulding and automatically pivoted outward during removing. In addition, articles having a natural wood grain appearance can be produced by providing a separate bottom forming member on the bottom plate, the bottom forming member having on its surface desired wood grains embossed or engraved.

Description: CONTINUOUS BUILDING MATERIALS MOULDING DEVICE Background of The Invention The present invention relates to a moulding device of building materials, such as concrete beams or door frames, and aluminum blocks, using conveyor belt moulding frames. Particularly, the invention relates to a device capable of continuously moulding the materials as well as automatically removing them from the mould frames. Numerous devices and methods for continuous moulding of building materials, such as wall plates and ceiling plates made of plaster or concrete have been proposed up to now. Japanese Laid-Open (Unexamined) Patent Publication (sho) 53-110621 discloses a conveyor moulding system in which moulding material is poured through the conveyor inlet into the moulds of the conveyor, and hardened during progress, with the moulded product being removed from the moulds at the conveyor outlet where the drive roller rotates in a curved path, as illustrated in Figure 1A. According to this reference, side conveyors 12 are installed at both sides of a moving conveyor 11 and moved at the same running speed as that of the moving conveyor 11. An L-shaped supply bath 14 having a flat portion 13 between the side conveyors 12 is installed above the moving conveyor 11. A plaster slurry having a viscosity of 10 to 100 poise from a line 15 is injected continuously into a moulding part of predetermined length consisting of the flat portion 13, the moving conveyor 11 and the side conveyors 12. The slurry in the supply bath 14 is maintained at almost a constant level, and the slurry is poured through an opening, which is provided in the flat portion 13 and has dimensions conforming to the products' dimensions, and is spread and harcened on the conveyor 11. After the slurry is hardened, the hardened products are removed from the moulds, cut, and then dried. The above system can be used for the production of -._n plates such as wall plates, ceiling plates, and so on. However, it cannot be used for the production of large door frames which have complex sectional structures and diverse dimensions. In addition, according to the above system, since the moulding frame is constructed by holding side conveyors 12 to both sides of the horizontal conveyor 11 tightly, the intersections between conveyors become square. Consequently, the above system can produce products having square corners as sharp as a blade, and also having seam portions; however it cannot be used to produce products such as door frames which require round edges. In addition, Japanese Laid-Open (Unexamined) Patent Publication (sho) 49- 27509 discloses a continuous moulding device and a method for manufacturing plates using a belt conveyor system, as illustrated in Figure IB. According to this reference, an integrated moulding frame 18 is installed on a conveyor 17 by inserting it between edges of the conveyor. The conveyor 17 is driven by the driving force of a rotating drum 16 and the moulding frame 18 can be bent repeatedly. The frame 18 is separated into several partitions by separating walls 18a, 18b and made of soft, resilient material. Plaster material 19 is filled in each partition of the moulding frame 18 and hardened during the conveyors' 17 movement. Then, each product 19a is automatically removed from the moulding frame 18 as the rotating drum 16 rotates. In the above method, as the mating surfaces between the bottom of the hardened product 19a and the conveyor 17 are spaced from each other by the rotation of the rotating drum 16, the product is removed. However, in case of the removal of the hardened product from the separating walls 18a, 18b which separates the moulding frame into several partitions, since the detachment is forced, with the surfaces sliding on each other by the rotation of the rotating drum 16, use of the above method is impossible if the height of the separating walls 18a, 18b must be high. Specifically, since the upper surfaces of high separating walls will rotate along a larger arc when being bent by rotation, the separating walls should be adequately extendable along the arc in order to rotate; if not, the walls will be misaligned with the conveyor making normal rotation practically impossible. In addition, if a wood grain moulding frame on which protruded points and lines are formed, is provided in the separating walls, the protruded points and lines are embedded into the product's surface when moulding the products. Therefore, the product's surface (protruding par.), should be spaced vertically when the product is removed so that normal removal becomes possible. However, since in the above method, removal is done with the separating walls twisted, moulded wood grain finishes on the products are almost impossible and the detachment itself is practically impossible. Furthermore, in such conveyor moulding systems, the moulding frame is constructed in the moving direction of the conveyor, that is, longitudinally. Therefore, when a product of narrow width (e.g., about 15 cm), and long length (e.g., about 2 m), such as a long beam and a door frame, is to be moulded, the length of the conveyor moulding system must be very long and the use of the system is impractical. Therefore, although the prior art methods are appropriate for continuous moulding of thin plates such as wall plates and ceiling plates, the methods cannot be used for moulding building materials, such as door frames and window frames which have large dimensions and in which three-dimensional structures such as doorsills and grooves for roller rails are indispensable. Specifically, it is virtually impossible to apply the prior art methods in making better moulded finishes such as wood grains. In addition, with the conventional methods according to the two Japanese references, a steel plate or a flat belt should be used. Therefore, when the volume and the weight of the building material to be moulded is large, a plurality of guide rollers supporting the belt are required and there is great difficulty in driving the belt only with driving rollers. To solve this problem, use of chain conveyors capable of transporting heavy articles may be considered. It is practically impossible, however, because when the links of the chain conveyors pass over drive rollers, the connecting portions between the links form a partial polygon instead of an arc resulting in the deformation of the mould itself and in cracks in the building material being moulded. The prior art methods cannot be used in casting aluminum blocks. Up to now, aluminum blocks have been cast by individual casting frames, which is uneconomical due to waste of time and work. Brief Summary of The Invention An object of this invention is to provide a continuous building materials moulding device which eliminates the problems and can continuously mould and automatically remove standard aluminum blocks as well as concrete beams or door frames. Another object of the invention is to provide a moulding device, which can easily mould large building materials having wood grain surfaces and rounded edges, and/or by which hinge attaching means, recesses for door lock pins, and rails can be incorporated into the moulded products. These objects can be accomplished by a continuous building materials moulding device according to the present invention, comprising two pairs of drive sprockets oppositely positioned at the inlet and the outlet of the device, a pair of chain conveyors wound on the drive sprockets and having a connecting part on each of their links, a series of bottom plates each of which is connected to opposite connecting parts of the links, side wall members pivotally connected to the sides of each bottom plate to form a unit mould transversely, and end pieces connected to each bottom plate to resiliently contact the ends of each unit mould. The objects of the invention can be also accomplished by providing a continuous building materials moulding device comprising two pairs of drive sprockets oppositely positioned at the inlet and outlet of the device, a pair of chain conveyors wound on the drive sprockets and having a connecting part on each of their links, a series of bottom plates each of which is connected to opposite connecting parts of the links, side wall members and bottom members connected alternately to the bottom plates and respectively forming side walls and bottoms of unit moulds, and end pieces connected to each bottom plate to resiliently contact the ends of each unit mould. The objects of the invention can also be accomplished by a continuous building materials moulding device comprising two pairs of drive sprockets oppositely positioned at the inlet and the outlet of the device, a pair of chain conveyors wound on the drive sprockets and having a connecting part on each of their links, a series of bottom plates each of which is connected to opposite connecting parts of the links, a moulding conveyor belt in which unit moulds are formed transversely and connected to each other, and end pieces connected to each bottom plate to resiliently contact the ends of each unit mould. The invention allows the economic mass production of moulded parts because moulded parts are hardened in a short period moulding process, removed automatically, and do not need post processing. In the continuous moulding device according to the invention, a unit mould is installed transversely on each pitch of the links of the chain conveyers driven by the sprockets. The device makes it possible to maintain dimensional tolerances of the moulded products, concrete beams, door frames, or aluminum blocks, within ±1 mm, because, as described later, by suitable means, the side walls of each mould are positioned vertical with the bottom plates during moulding and automatically pivoted outward during removing. In addition, articles having a natural wood grain appearance can be produced by providing a separate bottom forming member on the bottom plate, the bottom forming member having on its surface desired wood grains embossed or engraved. The end pieces are positioned removably at the ends of the unit mould of the device, which correspond to the upper and lower ends of door frames, aluminum blocks, etc. to be moulded. In case of moulding door frames, structures for receiving the tenons of the upper and lower door frame members i.e. mortises are formed integrally with the end pieces or bottom plates. The integral end piece functions to separate moulded door frames by a given length automatically and facilitates assembling of the upper and lower door frame members. The members can be produced by the device of the invention. Brief Description of The Drawings Embodiments of the invention are described below more ully in connection with the accompanying drawings. It should be understood that the invention is not confined to the embodiments. In the drawings: Figures 1A and IB are perspective views of the continuous moulding devices of sheets according to prior art; Figure 2A is a perspective view of the continuous building materials moulding device according to the first embodiment of the invention; Figure 2B is a partial enlarged perspective view of part A of Figure 2A; Figure 3 is a sectional view taken along the line B-B of Figure 2; Figure 4 is a sectional view taken along the line C-C of Figure 2; Figure 5 is a plan view showing another embodiment of the end pieces; Figure 6A is a perspective view of the continuous building materials moulding device according to the second embodiment of the invention; Figure 6B is a longitudinal sectional view of Figure 6A; Figure 7 A is a sectional view taken along the line D-D of Figure 6A; Figure 7B is a view similar to Figure 7A showing a structure for forming door frames; Figure 8A is a perspective view of the continuous building materials moulding device according to the third embodiment of the invention; Figure 8B is a partial enlarged perspective view of part E of Figure 8 A; Figure 9A is a sectional view taken along the line F-F of Figure 8A; Figure 9B is a perspective view of the retainer; Figure 10 is a perspective view of the support member: Figure 11 is a partial enlarged view of the hinge attaching means; Figure 12A is a sectional view of the modified door frame mould; Figure 12B is a perspective view of the door frame moulded by the mould of Figure 12 A; and Figure 12C is a sectional view of the modified groove for assembling rails. Description of the Preferred Embodiments Figures 2A and 2B show a continuous moulding device 20 according to the first embodiment of the invention. The device comprises two pairs of drive sprockets 22 oppositely positioned at the inlet and the outlet of the device and rotated by a suitable drive means, a pair of chain conveyors 24 wound on the drive sprockets 22 and having a connecting part 24a on each of their links, a series of bottom plates 26 each of which is connected to opposite connecting parts 24a of the links, side wall members 27 pivotally connected to the sides of each bottom plate 26 to form a unit mould transversely, and end pieces 30 connected to each bottom plate 26 to resiliently contact the ends of each unit mould. Each component can be made of steel or stainless steel plates. The device 20 may be provided with known means, such as a moulding material supply device installed at the upstream end, a planing means such as a scraper or a roller to plane the upper surface of the moulding material (concrete) before hardening, and a hardening means to harden supplied moulding material (concrete). (In case of moulding aluminum blocks, planing means and hardening means are not needed, but a cooling means is needed instead.) Since these means are not included in the scope of the invention and are apparent to those skilled in the technical filed of the invention, they are not further explained in this specification. Referring to Figure 2, the drive sprockets 22 are positioned in pairs at the inlet and outlet of the device and each tooth of the drive sprockets 22 is engaged with each pivot axis of the link to drive the chain conveyor. The chain conveyors 24 have links spaced equally and is provided with connecting parts 24a protruding inwardly to the moulding frame. Such drive sprockets 22 and chain conveyors 24 are well known and are not explained further. The bottom plates 26 with the ends connected to the connecting parts 24a of the links of the chain conveyors 24 have semihollow-shaped sections. Observing the continuous moulding device 20 as a whole, the drive sprockets 22 are oppositely positioned in pairs at the front and rear ends of the device 20, the chain conveyors 24 with the connecting parts 24a directed inward are wound on the front and rear drive sprockets 22, and the semihollow bottom plates 26 are positioned between opposite connecting parts 24a. The shape of the bottom plate is not limited to the semihollow-shaped section and may be simply flat or of a channel shape. Now, the unit mould of the continuous moulding device is explained with reference to Figure 3. As shown in Figure 3, the unit mould of the continuous moulding device 20 comprises one bottom plate 26 and two side wall members 27 positioned vertical with the bottom plate 26 during moulding and outwardly pivotable during removing. Each side wall member 27 is connected pivotally with hinges 33 to the bottom plate 26. One side of the hinge 33 is connected to the bottom plate 26 and the other side is connected to the side wall member 27. The hinge cannot be open more than 90° and spacers 31 are provided between adjacent side wall members 27. Therefore, when moulding, the side wall member 27 is prevented from pivoting by the hinge 33 inside the mould and by the spacer 31 outside the mould and the side wall member 27 is maintained vertically with the bottom plate 26. Adjacent side wall members 27 are connected each other by resilient connecting wires 29. By such construction, as shown in Figures 2A and 2B, when the unit mould passes the outlet of the continuous moulding device, that is. the links of the chain conveyor 24 move over the drive sprocket 22, the links are pivoted about their pivot axes, and the distance between the upper ends of the adjacent side walls of the moulded products is increased. But since the side wall members 27 connected by connecting wires 29, the side wall members 27 are pivoted outward from the side wall of the moulded product 25. That is, removal of the moulded product from the mould is done automatically. The resilient connecting wires 29 can be replaced by cloth or rope of unwoven fabric or leather. As shown in Figures 2A and 2B, and Figure 4, the end pieces 30 are attached on the bottom plate 26 to be in close contact with the ends of the unit mould of the continuous moulding device. The end piece 30 has the shape of a hinge and one side is fixed on the bottom plate 26 while the other side is biased by springs 30a to be in contact with the ends of the side wall members 27. One end of each wire 30b is connected to one of the upper corners of the other side of the end pieces 30 and the other side of each wire is connected to the adjacent bottom plate 26. The length of the wire 30b is determined not to pull the end piece 30 when the bottom plate 26 moves on a plane. But, as shown in Figures 2A and 2B, when the bottom plate 26, or the chain conveyor 24 moves over the drive sprockets 22, adjacent bottom plates are slanted with each other and the wires 30b are pulled. Accordingly, the end pieces are pivoted outward and separated from the moulded product 25. As described before, the side wall member 27 is separated from the moulded product 25 when the chain conveyor 24 moves over the drive sprocket. Therefore, as shown in the left of Figure 2 A, the whole moulded product is removed automatically from the mould and drops to a suitable transport means provided at the outlet. Figure 5 shows another embodiment of the end pieces. The end pieces 30 shown in Figure 2 A to Figure 4 are flat. But the end piece 30' shown in Figure 6, comprises a body contacting the end surface of the side wall member 27, and two wings bent inward by 30° to 40°. With this construction, when the side wall members 27 are pivoted at the outlet, the upper corner of the side wall member pushes the upper portion of the wing of the end piece 30', and the end piece 30' is pivoted about its pivot axis and spaced from the moulded product 25, i.e, separation is done automatically. Therefore the separate wires 30b need not be provided in this embodiment. The above-described continuous moulding device can mould aluminum beams and concrete beams. The device can also mould door frames by attaching an auxiliary door frame moulding member 35 to the bottom plate by adhesive, etc. Since the door frame moulding member 35 is usually made of hard rubber, etc., a wood grain moulding member may be constructed by forming patterns comprising dots and lines. in addition, it will be understood that a door frame with 3 wood grain surfaces can be moulded by attaching such a wood grain moulding member to the inside of the side wall member 27. Figures 6A and 6B show a continuous moulding device 120 according to the second embodiment of the invention. The device 120 comprises two pairs of drive sprockets 122 oppositely positioned at the inlet and the outlet of the device and rotated by a suitable drive means, a pair of chain conveyors 124 wound on the drive sprockets 122 and having an connecting part 124a on each of their links, a series of bottom plates 126 each of which is connected to opposite connecting parts 124a of the links, a series of side wall members 127 and bottom members 128 attached alternately to the bottom plates 126 and forming the side walls and bottoms of the unit moulds transversely, and end pieces 130 connected to each bottom plate 126 to resiliently contact the ends of each unit mould. Each component can be made of steel or stainless steel plates. As in the first embodiment, the continuous moulding device 120 according to the second embodiment may be provided with known means, such as a moulding materials supply device installed at the upstream end, a pi aning means such as a scraper or a roller to plane the upper surface of the moulding material (concrete) before hardening, and a hardening means to harden supplied moulding material (concrete). These known means are not explained further for the same reason as that of the first embodiment. In addition, the drive sprockets 122 and the chain conveyors 124 are not further explained since their constitution and operation are the same as those of the drive sprockets 22 and the chain conveyors 24 of the first embodiment. The side wall members 127 and bottom plates are explained with reference to Figures 7A and 7B. Figure 7A shows the unit mould of the continuous moulding device of the invention comprising the side wall members 127 and the bottom member 128. The side wall member 127 is a rod having a channel-shaped section and is fixed to the bottom plate 126 by welding, etc. The side wall member 127 may be provided with reinforcing members 127c at its center as shown in Figure 6B. In this embodiment, the side wall member 127 has a channel-shaped section and is fixed by welding, etc. But, if desired, it may have a semihollow shape and fixed on the bottom plate 126 by bolting, etc. The bottom member 128 is fixed on the upper surface of the bottom plate 126 by suitable means. This fixing means comprise bolts 131 formed integrally with the bottom member 128 on the lower protruding surface of the bottom member 128 in at least two rows, and nuts (not shown) engaging with the bolts 131. The bolts 131 pass through bolting holes 126a. It should be noted that the dimensions and number of the bolts and bolting holes are not confined to the described example; all that is required is for the bottom plate and the bottom member 128 not to separate. This embodiment is intended to mould beam shaped products such as beams or blocks made of concrete or aluminum. Therefore, it can be understood that aluminum blocks having gambrel-shaped sections can be moulded by installing triangular beams at the sides of the bottom member 128 as shown in dotted lines in accordance with the shapes of the beams or blocks. Figure 7B shows another embodiment for moulding door frames 125a. The constitution of this embodiment is similar to that shown in Figure 7A, but different in that a second bottom member 129 made of rubber, etc. is closely attached to the upper surface of the bottom member 128. Attaching the second bottom member 129 to the bottom member 128 can be done by using adhesives, bolts, rivets, etc. In addition, patterns for reproducing wood grain on the surface of the moulded product, i.e., the door frame, can be embossed or engraved. If desired, separate side wall forming members made of rubber may be attached to the side wall members 127 to make door frames having three wood grain surfaces. Returning to Figures 6A and 6B, the side walls 127a, 127b of the side wall members 127 are positioned vertically when forming moulds and outwardly pivot at the outlet of the moulding device to remove the moulded product 125. When the chain conveyors 124 move over the drive sprockets 122, the side walls 127a, 127b of the side wall member 127 pivot around the pivot axes of the links of the chain conveyors 124 about the bottom members 128 or the second bottom members 129. Therefore, normal removal is possible when the unit moulds are wood grain moulds with patterns comprising lines and dots. As shown in Figures 6A, 6B, and 7B, the mould for forming each door frame 125a comprises the second bottom member 129 and two side wall members 127 positioned vertically, and two end pieces 130 positioned at the ends of two side walls. The second bottom member 129 and the side wall members 127 make right angles when moulding, but rounded edges are formed by the second wall member and the two side wall members so that rounded edges of the moulded products can be formed. This is an important advantage of the invention over Japanese Laid-Open Patent Publication (sho) 53-110621, which cannot form rounded edges. Therefore, the moulded product according to the invention i.e., the door frame, has improved saiety against accidental collisions against the edges by children or the elderly and the weak. In addition, by suitable construction of the second bottom member 129, the bottom surface of the second bottom member can be provided with hinge attaching means for installing a hinge type door at the moulded concrete door frame and/or a recess for receiving a door lock pin. The constitution and operation of the end pieces 130 are the same as the end pieces 30 of the first embodiment and are not explained further. Figures 8A and 8B show a continuous moulding device 220 according to the third embodiment of the invention. Among the components of this embodiment, two pairs of drive sprockets 222, a pair of chain conveyors 224, a series of bottom plates 226, and the end pieces 230, 30' are the same in their constitution and operation as those of the first and the second embodiments. However, the unit moulds of this embodiment are different from those of the first and the second embodiments in that they are formed in a conveyor belt 210 made of highly flexible and resilient materials. In addition, connecting parts 244a of the chain conveyors 224, moulded products 225, springs 230a, and wires 230b are the same as those of the first and the second embodiments and are not explained further. Referring now to Figure 9, the structure of the moulding conveyor belt 210 will be explained below. As shown in Figure 9 A, the unit mould of the moulding conveyor belt 210 comprises a bottom wall 210a, and two side walls 210b which can be bent with respect to the bottom wall 210a. The unit moulds are joined by joining parts 210d at the side walls. The unit moulds can be made individually, or any number of unit moulds can be made integrally to have the above-described construction. Joining parts 210d of the unit moulds which are made individually or integrally, are joined to each other by support members 235, Figure 10 as explained below. However, it can be understood that they can be joined to each other by using appropriate means, such as adhesives, etc., other than the support members. Also, the unit moulds are fixed tightly on the upper surface of each bottom plate 226 by a suitable means. Such a means for fixing the unit mould tightly comprises: protrusions 231 formed integrally with the lower surface of the bottom wall 210a of the moulding conveyor belt 210 in at least two rows; grooves 231a for receiving retainers; holes 231b provided in the bottom plates 226 for the protrusions; and retainers 231c, Figure 9B inserted into the grooves 231a of the protrusions. The protrusions 231 pass through the holes 231b. It should be noted that the dimensions and number of the protrusions and the holes are not confined to the described example; all that is required is for the bottom plates 226 and the moulding conveyor belt 210 not to separate when moulding. Insertion of the retainers 231c into the grooves 231a of the protrusions 231 facilitates the attachment of the protrusions 231. Consequently, the moulding conveyor belt 210 can be attached closely and removably onto the upper surface of the bottom plates 226. The way of attaching the moulding conveyor belt 210 onto the bottom plates 226 is not confined to the above but may be accomplished by using adhesives, bolts, rivets, etc. In addition, patterns 210e, for simulating wood grain on the surface of the moulded product, can be embossed or engraved on the inner surfaces (the bottom wall and the side walls) of the moulding conveyor belt. Referring again to Figures 8 and 9, the side walls 210b, 210c of the moulding conveyor belt 210 are positioned vertically when forming moulds and are bent with respect to the moulded product 225 at the outlet of the device to remove the moulded product 225. In addition, round-cut edges 232, shaped as a quarter circle, are formed longitudinally along the outer and lower edges of the moulding conveyor belt 210. Preferably, the cut edges 232 maintain adequate thickness so that they do not collapse due to the weight of the side walls 210b, 210c. The cut edges 232 facilitate the outward bending of the side walls 210b, 210c of the moulding conveyor belt 210 with respect to the bottom wall 210a. Consequently, the side walls 210b, 210c are separated almost vertically from the surface of the hardened product. Therefore, normal removal is possible even when the moulds of the moulding conveyor belt 210 has a wood grained finish on which patterns comprising lines and dots are formed. By this construction, when the chain conveyors 224 move over the drive sprockets 222, the links of the chain conveyors 224 pivot about their pivot axes, and the distance between the side walls of the moulded product is increased, and the flexible side walls of the moulding conveyor belt are bent away from the side walls of the moulded product 225. In addition, the support members 235 are fitted in the joining parts 210d of the side walls. As shown in Figure 10, the support member 235 is a long channel-shaped rod. The support members not only join the joining part 210d of the unit mould of the moulding conveyor belt 210, attached on the bottom plate 226, with the joining part of the adjacent unit moulds, but also prevent the side walls 210b. 210c from bending outward by the weight of moulding material when the chain conveyors 224 move horizontally. The support members 235 are fixed to the joinr.g parts 210d only on their upper parts by bolts. As can be seen from Figures 8 and 9, in the third embodiment, the mould for forming the moulded product 225 comprises the bottom wall 210a of the moulding conveyor belt 210, the two side walls 210b, 210c positioned vertically, and the end pieces 230 positioned at the ends of the side walls. The integrally formed bottom wall 210a and two side walls 210b, 210c are positioned orthogonally when moulding but the edges formed by the bottom wall and the two side walls are rounded in order to mould products having rounded edges. This is an important advantage of the invention over Japanese Laid-Open Patent Publication (sho) 53-110621 which cannot form rounded edges. Therefore, the moulded product according to the invention, i.e., the door frame, has improved safety against accidental collisions against the edges by children or the elderly and the weak. In addition, as described below, the bottom surface of the moulding conveyor belt 210 can be provided with hinge attaching means for installing a hinge type door at the moulded concrete door frame and/or a recess for receiving a door lock pin. As shown in Figures 9 and 11,, attaching means 233 for attaching hinges for installing doors at the concrete door frame can be embedded in the door frame during moulding. Referring to figure 11, at first, resilient pins 241 are fixed at pre-determined points of the moulding conveyor belt 210 in a pre-determined arrangement so that the pins 241 penetrate the belt 210 from the outer lower surface to the inside of the mould and the hinge attaching means233 are fitted in their screw holes 242 with the pins 241. The screw holes 242 are aligned with the screw holes of the hinges to be attached and the arrangement of the pins 241. The hinge attaching means are provided on their back surface with pin holders 243 into which the pins 241 are inserted and anchors 244 for fixing the means firmly into the concrete. The resilient pins 241 may be replaced by metal pins, and in this case the pin holders 243 may be resilient bodies. The pins 241 supporting the hinge attaching means 233 can be inserted through the recess 245 provided in the lower surface of the moulding conveyor belt 210 and the pin inserting holes 246 provided in the moulding conveyor belt 210. As shown in Figure 11, after the hinge attaching means 233 are fitted with the pins 241 and the pin holders 243 are fitted to the protruded ends of the pins 241, concrete mortar is injected into the mould and hardened. Then, when removing the moulded product, the pins 241 easily come out from the hinge attaching means 233 and the hinge attaching means 233 with their anchors 244 embedded are fixed firmly to the moulded product, i.e., the door frame. Therefore, hinges are easily assembled by screwing them to the screw holes 242 of the hinge attaching means 233. Recesses for receiving latch pins of door locks can be provided similarly. Figures 12A to 12C are sectional views of a modified embodiment of the moulding conveyor belt. As the moulding conveyor belt 210 shown in Figures 8 and 9, the moulding conveyor belt 250 shown in Figure 12 A comprises a bottom wall 250a and two side walls 250b, 250c which can be bent with respect to the bottom wall 250a. The basic structure of the unit moulds of the moulding conveyor belt 250 is the same as that of the moulding conveyor belt 210 in that they are joined at their side walls by joining parts 250d, but they are primarily for moulding door frames for sliding doors. The shape of the lower section of the moulding conveyor belt 250 is the reverse of the lower part of the door frames to be moulded. Figure 12 shows two grooves 253a, 253b for assembling rails provided on the elevated portion 252 of the bottom wall 250a of the moulding conveyor belt 250. The moulds are constructed to insert rails 254a, 254b into the grooves 253a, 253b before injecting concrete mortar into the mould. In addition, as shown in Figure 12A, small protrusions 255 comprising protruding lines and dots forming wood grain are provided on the inner surfaces of the mould of the moulding conveyor belt 250 to form wood grain 256 on the moulded product 251. It should be understood that although only two rails 254a, 254b are shown in Figure 12B, in general four rails can be attached. Another embodiment of a rail 254c and a groove for assembling rails 253c is shown in Figure 12C. Protrusions 257 are provided at the two side walls of the groove 253c and recesses 258 are provided at the two side walls of the rail 254c for receiving the protrusions 257. Accordingly, the groove 253c and the rail 254c of Figure 12c are combined more firmly than the grooves 253a, 253b and the rails 254a, 254b of Figures 12A and 12B and are more stable when injecting concrete. The end pieces 30, 30', 130, 230 have been described to be flat. But it can be understood that in case of a door frame, additional end pieces may be formed integrally at the positions corresponding to the upper and lower ends of the door frame in order to receive the tenons of the upper and lower door frame members i.e., to form mortises, or the additional end pieces may be formed integrally with the bottom plates 26, 126, 226 in front of the end pieces 30, 30', 130, 230. As can be understood from the above, the unit moulds of the continuous moulding devices 20, 120, 220 of the invention are formed perpendicular to the moving direction, i.e., transversely. Therefore, the invention can substantially reduce the length of the continuous moulding device 20, 120, 220, which moulds long and narrow building materials such as beams or door frames, as compared to the known device. For example, in case of moulding beams or door frames having a width of 15 cm and a length of 200 cm, since the known device moulds longitudinally, if a moulding device 10 m long and 20 to 30 cm wide is used, only approximately five usable moulds result. However, by the continuous mounding device 20, 120, 220 of the invention, since the moulds are formed transversely, and considering the width and clearance of each mould, the longitudinal length occupied by one mould in the moulding device is above 20 cm. Therefore the number of usable moulds amounts to about 50. Consequently, productivity is enhanced by a factor of approximately ten when compared with the known device. In addition, as described with reference to Figures 1A and IB, the known conveyor belt type moulding device uses a steel conveyor belt below the moulding conveyor belt forming moulds, but steel conveyor belts are expensive and not suitable for transferring heavy articles. But since the invention uses the semihollow-shaped bottom plates 26, 126, 226 which have far better strength than steel conveyor belts, and support each unit mould individually, and since the chain conveyors 24, 124, 224 and the drive sprockets 22, 122, 222 are stable and can transfer a much larger driving force than the conventional device, the mould is stable and heavy products can be transferred without difficulty. Although the above embodiments describes mainly the moulding method of moulding products 25, 125, 125a, 225, 251, i.e., concrete beams and door frames, and aluminum beams and blocks, it can be understood that other buiiding materials such as interior and exterior decorative materials for buildings, and materials for landscape architecture having the shape of a beam and a suitable pattern reproduced thereon, can be manufactured by the invention. The compositions of the moulding materials are knowr. and various kinds of materials can be used. Aluminum blocks can be moulded by u___ng fused aluminum as the moulding material. In addition, as a different material, t e mixture of portland cement and sand (diameter 1 to 3 mm) by weight ratio 1:3 is mixed with water and with a small amount of vinyl acetate-ethylene copolymer addiπve, with the resulting mixture being used for moulding concrete products. Ar.other example is a thermosetting resin mortar which is used for interior and exterior decorative materials. The thermosetting resin comprises phenol resin, urea resin, epoxy resin, or unsaturated polyester resin. Another example is foamed plaster slurry made by agitating and forming bubbles in a mixture of 24 kg of water, 0.6 kg of polyvinyl alcohol, and 40 kg of sodium lauryl sulfate, and adding 20 kg of plaster and 1.2 kg of asbestos. The material is used as an interior decorative material. The hardening rate of the moulding materials is set preferably as fast as possible considering the operational efficiency, and is set at about 10 minutes by adjusting the composition. Such compositions are known and are not explained further. According to the invention, in addition to the products described, other moulding product having various shapes, e.g., octagonal beams, can be moulded.

Claims: We claim: 1. A continuous moulding device of building materials comprising two pairs of drive sprockets 22 oppositely positioned at the inlet and the outlet of the device, a pair of chain conveyors 24 wound on said drive sprockets 22 and having a connecting part 24a on each of their links, a series of bottom plates 26 each of which is connected to opposite connecting parts 24a of said links, side wall members 27 pivotally connected to the sides of each said bottom plate to form a unit mould transversely, and end pieces 30, 30' connected to each said bottom plate 26 to resiliently contact the ends of each unit mould. 2. The device according to Claim 1 wherein said side wall member 27 is connected to the bottom plate 26 with hinges 33, and adjacent side wall members 27 are connected to each other on their upper parts by connecting wires 29, and spacers 31 are attached to outside surface of said side wall member 27 to maintain a constant distance with the adjacent side wall member. 3. The device according to Claim 2 wherein said end pieces 30, 30', having the shape of a hinge, are attached on the bottom plate 26 and biased by resilient springs 30a to be in close contact with the ends of the side wall members 27. 4. The device according to Claim 3 wherein wires 30b are provided to automatically separate said end pieces 30 at the outlet of the device and one end of said wire is connected to the adjacent bottom plate 26 and the other end of said wire is connected to the upper corner of the end piece 30. 5. The device according to Claim 3 wherein said end piece 30' has wings bent by 30° to 40° between adjacent side wall members 27. 6. The device according to any one of Claims 1 to 5 wherein a door frame moulding member 35 having patterns for reproducing wood grain is attached to said bottom plate 26. 7. A moulded product moulded by the device according to any one of Claims 1 to 6. 8. A continuous moulding device of building materials comprising two pairs of drive sprockets 122 oppositely positioned at the inlet and outlet of the device, a pair of chain conveyors 124 wound on said drive sprockets 122 and having a connecting part 124a on each of their links, a series of bottom plates 126 each of which is connected to opposite connecting parts 124a of said links, side wall members 127 and bottom members 128 connected alternately to the bottom plates 126 and respectively forming side walls and bottoms of unit moulds, and end pieces 130, 30' connected to each said bottom plate 126 to resiliently contact the ends of each unit mould. 9. The device according to Claim 8 wherein a second bottom member 129 is attached on the upper surface of said bottom member 128. 10. The device according to Claim 8 or 9 wherein said end pieces 130, 30', have the shape of a hinge, are attached on the bottom plate 126 and biased by resilient springs 130a to be in close contact with the ends of the side wall members 127. 11. The device according to Claim 10 wherein wires 130b are provided to automatically separate said end pieces 130 at the outlet of the device and one end of said wire is connected to the adjacent bottom plate 126 and the other end of said wire is connected to the upper corner of the end piece 130. 12. The device according to Claim 10 wherein said end piece 30' has wings bent by 30° to 40° inward from the ends of the side walls 127a, 127b of the side wall members 127. 13. The device according to Claim 8 or 9 wherein said bottom member 128 is removably fixed to each bottom plate 126 by fixing means. 14. The device according to Claim 13 wherein said fixing means comprise bolts 131 formed integrally with the bottom member 128 on the lower protruding surface of the bottom member in at least two rows, bolting holes 126a provided in the bottom plate 126, and nuts engaging with said bolts 131. 15. The device according to Claim 9 wherein the edge connecting the side wall of said side wall member 127 and the second bottom member 129 is rounded. 16. The device according to Claim 9 or 15 wherein patterns are formed on the surface of said second bottom member 129 for reproducing wood grain. 17. A moulded product moulded by the device according to any one of Claims 8 to 16. 18. A continuous moulding device of building materials comprising two pairs of drive sprockets 222 oppositely positioned at the inlet and the outlet of the device, a pair of chain conveyors 224 wound on said drive sprockets 222 and having a connecting part 224a on each of their links, a series of bottom plates 226 each of which is connected to opposite connecting parts 224a of said links, a moulding conveyor belt 210, 250 in which unit moulds are formed transversely and are connected to each other, and end pieces 230, 30' connected to each said bottom plate 226 to resiliently contact the ends of each unit mould. 19. The device according to Claim 18 wherein each unit mould of the moulding conveyor 210; 250 comprises a bottom wall 210a; 250a, two side walls 210b, 210c; 250b, 250c which can be bent with respect to said bottom wall, and a joining part 210d to connect adjacent unit moulds together. 20. The device according to Claim 18 wherein said end pieces 230, 30', having the shape of a hinge, are attached onto the bottom plate 226 and biased by springs 230a to be in close contact with the ends of said side walls 210b, 210c; 250b, 250c. 21. The device according to Claim 20 wherein wires 230b are provided to automatically separate said end pieces 230 at the outlet of the device and one end of said wire is connected to the adjacent bottom plate 226 and the other end of said wire is connected to the upper corner of the end piece 230. 22. The device according to Claim 20 wherein said end piece 30' has wings bent by 30° to 40° between adjacent side walls 210b, 210c; 250b, 250c. 23. The device according to Claim 19 wherein the edges between the side walls 210b, 210c; 250b, 250c and the bottom wall 210a; 250a have a rounded shape. 24. The device according to Claim 19 wherein said moulding conveyor belt 210, 250 is detachably connected to each bottom plate 226 by at least two rows of tight engaging means. 25. The device according to Claim 24 wherein said tight engaging means comprises retainers 231c having, a shape of a ring, protrusions 231 integrally formed with said moulding conveyor belt 210, 250 and provided with a groove for said retainer to be inserted thereto, and protrusion receiving holes 231b provided in said bottom plate 226. 26. The device according to Claim 19 wherein adjacent said side walls 210b, 210c; 250b, 250c of the moulding conveyor belt 210, 250 are supported together by a supporting member 235. 27. The device according to Claim 19 wherein patterns are formed on the surfaces of said bottom wall 210a, 250a and side walls 210b, 210c; 250b, 250c of the moulding conveyor belt 210, 250 for reproducing decorative surfaces. 28. The device according to any one of Claims 18 to 27 wherein a plurality of pins 241 are fixed through the moulding conveyor belt 210, 250 through pin inserting holes 246. 29. The device according to Claim 28 wherein hinge attaching means 233 having screw holes 242 are embedded in the moulding conveyor belt 210, 250, and said pins 241 correspond to and are inserted into said screw holes 242. 30. The device according to one of Claims 18 to 27 wherein grooves 253a, 253b, 253c for assembling rails are formed in said bottom wall 210a, 250a of the moulding conveyor belt 210, 250. 31. A moulded product moulded by the device according to any one of Claims 18 to 30.

Inventors: SUH KUN HEE, SUH, KUN, HEE
Applicants: SUH KUN HEE, SUH, KUN, HEE
Application year: 1993
Main classification: B28B5
IPC codes: B22D5, B28B5, B28B23