Abstract:
A portable single station apparatus is provided including a structure for receiving a quantity of soil to be compressed into a building block, an enclosed system which provides a linear process for receiving soil, compressing soil and ejecting a formed compressed soil building block from the apparatus. The apparatus is comprised of a stationary chamber equipped with an internal adjustable cavity in which the desired block is to be formed. A pair of opposing pressure heads capable of moving toward and away from each other in unison or independently to receive soil, compress soil, and eject the desired soil building block.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to a linear self-enclosed apparatus for compressing freshly dug soil into compressed blocks suitable for the creation of a structure.  
         BACKGROUND OF THE INVENTION  
         [0002]    The formation of building blocks from soil and clay is a well known process utilized throughout the world. Throughout the years various applications designed to automate this process have been produced. Previously designed apparatus, however, have involved complex mechanical procedures. A need exists for a design and process in which building blocks of different sizes and thickness can be formed simultaneously. An additional need exists for a design which allows for two or more systems to be joined and operated simultaneously or independently, while maintaining an easy access to replaceable components.  
           [0003]    Examples of previous known form of presses similar to the present invention are disclosed in U.S. Pat. Nos. 4,640,671; 6,224,359.  
         SUMMARY OF THE INVENTION  
         [0004]    The main objective of this invention is to provide a new and improved linear building block forming apparatus which is self-contained and capable of receiving a quantity of soil, forming building blocks of adjustable dimensions uniformly, and ejecting said blocks within a single multiple function case.  
           [0005]    It is also an object of the invention to provide a new and improved linear building block forming process that is linear and contained within a multiple purpose case.  
           [0006]    It is also an object of the invention to provide a new and improved linear building block forming process in which opposing compression heads are moved toward and away from one another with the purpose of receiving an adjustable quantity of soil, moving said soil, compressing said soil into a block and ejecting a compressed soil block.  
           [0007]    It is also an object of the invention to provide a new and improved linear building block forming process in which opposing compression heads are moved toward and away from one another by any mechanical means.  
           [0008]    It is therefore an object of the invention to provide a new and improved linear building block forming apparatus that may be mounted on a trailer chassis and may be towed to the site of construction.  
           [0009]    It is another object of the invention to provide a new and improved linear building block forming apparatus that will create building blocks of different plan sizes utilizing a heavy textured clay, preferably without any addition of moisture or binder material with minimal skill or effort from the operator.  
           [0010]    It is the objective of the invention to provide a new and improved linear building block forming apparatus that will compress the soil under high pressure to produce a building block so dense when ejected from the multiple function case that it will be instantly ready for use and need not be cured before use.  
           [0011]    It is a further object of the invention to provide a new and improved linear building block forming apparatus that is modular in nature to allow for the addition of one or more multiple function cases, which may be controlled simultaneously or independently.  
           [0012]    It is therefore also an object of the invention to provide a new and improved linear building block forming apparatus that is modular in nature to allow for higher production yields or to allow for production of blocks of different dimensions simultaneously or independently.  
           [0013]    It is also an objective of the invention to provide a new and improved linear building block forming apparatus that produces uniform blocks dimensionally of adjustable sizes, which can be used to construct a structure by progressively dampening the upper course of the structure with water or light mud slurry, and placing the next course directly on top of this course.  
           [0014]    It is still another object of the invention to provide a new and improved linear building block forming apparatus that is of durable construction.  
           [0015]    It is also another object of the invention to provide a new and improved linear building block forming apparatus that requires low maintenance and is easily serviced.  
           [0016]    It is yet another object of the invention to provide a new and improved linear building block forming apparatus that can be assembled and operated with a minimal of skill and attention.  
           [0017]    It is still a further object of this invention to provide a new and improved linear building block forming apparatus that loads soil into the soil receiving area of the multiple function case efficiently and in a more compacted state by the use of a high-frequency vibration apparatus mounted directly to the soil receiving hopper. These and other advantages, features and objects of the invention will become more apparent from the following description taken in connection with the illustrative embodiment in the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]    [0018]FIG. 1 is a side lateral view of a four wheel mounted trailer form of the instant invention;  
         [0019]    [0019]FIG. 2 is a top view of the invention mounted atop a four wheeled trailer chassis in which the soil hopper and a pair of hydraulic actuators have been fragmented to illustrate the multiple function case;  
         [0020]    [0020]FIG. 3 is a partially fragmented top view of the multiple function case in which the compression heads and hydraulic actuators are more clearly illustrated;  
         [0021]    [0021]FIG. 4 is a partially fragmented rear view of the invention mounted atop a four wheeled trailer chassis;  
         [0022]    [0022]FIG. 5 is a rear lateral view of the invention showing a pair of multiple function cases, in which one contains a positioning control apparatus, which have been joined together about their corresponding connecting panels;  
         [0023]    [0023]FIG. 6 is a sectional view taken about line  6  - 6  in FIG. 3 showing the locations and positions of the soil hopper, adjustable compression heads and their components, multiple function case and its components, and loose soil prior to compaction;  
         [0024]    [0024]FIG. 7 is a partially fragmented side lateral view of the multiple function case showing the movement and positions of the compression heads, multiple function case and its components, compressed soil block and loose soil at compaction;  
         [0025]    [0025]FIG. 8 is a partially fragmented side lateral view of the multiple function case showing the movement and positions of the compression heads, multiple function case and its components, compressed soil block and loose soil at the moment the compressed soil block is ejected from the multiple function case; FIG. 9 is a fragmentary diagrammatic view illustrating the manner in which the hydraulic actuators may be controlled for the purpose of achieving desired compression between compression heads, and  
         [0026]    [0026]FIG. 10 is a rear lateral view of the invention showing a plurality of multiple function cases, in which one contains a positioning control apparatus, which have been joined together about their corresponding connecting panels.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0027]    Referring now more specifically to the drawings, the numeral  15  generally designates a trailer frame which may be towed behind a towing vehicle (not shown) and which includes a pair of wheeled axle assemblies  21  and  22  on its rear end as well as a jack structure  16 . The jack structure  16  may be utilized (in order) to (stationarily) support the trailer frame  15  from the ground  23 .  
         [0028]    The trailer frame  15  supports a case support frame  33 , a hydraulic tank  29 , a programmable logic control (PLC) unit  95 , a control panel  97 , a hydraulic pump  99 , an electrical motor  101 , a pair of roller conveyors  35 , as well as a hopper support frame  19 .  
         [0029]    As seen in FIGS. 1 and 4, the hopper support frame  19  contains the soil hopper  17  positioned above the pair of multiple function cases  27  and  28 , in a stationary position.  
         [0030]    Said soil hopper  17  is supported by a pair of braces  43  about its discharge area.  
         [0031]    The case support frame  33  supports a pair of multiple function cases  27  and  28 , each with a pair of hydraulic actuators  25  attachable at a point generally referred to by the numeral  37  as seen in FIGS. 2 and 4.  
         [0032]    The multiple function cases  27  and  28  are representative of a possible combination whereby both cases will function in unison to create compressed soil blocks uniform in size, thickness, and density (See FIG. 3). As illustrated in FIG. 5, the multiple function cases  27  and  28  are symmetrical about their connecting panels  44 .  
         [0033]    As is illustrated in FIGS. 3, 5 and  6 , the multiple function cases,  27  and  28 , are composed of compression heads, generally designated by numerals  46  and  47 , side cover panels  45 , connecting panels  44 , upper covers  41  and  42  and lower covers  38  and  40 . As can be seen in the previously mentioned FIGS., the upper covers  41  and  42 , along with bottom covers  38  and  40  and panels  44  and  45  are joined to form an enclosed area. Said enclosed area contains two apertures designated by numerals  48  and  80 . It is within said enclosed area that a compression case area, generally designated by numeral  60  is formed. Within said compression case area  60  compression case wear plates  61 ,  63 ,  65  and  67  are mounted securely. Said wear plates are to be constructed of a hardened steel alloy capable of withstanding high abrasion.  
         [0034]    As illustrated in FIGS. 3 and 6, the compression heads  46  and  47  are comprised of compression head frames  73  and  77 . Compression head wear plates  57 ,  59 ,  69  and  71  are securely mounted to said compression head frames as illustrated. Said wear plates are to be constructed of a hardened steel alloy capable of withstanding high abrasion.  
         [0035]    The compression heads  46  and  47  are introduced within the compression case area  60  at opposite ends of said compression case and are secured by rear compression head plates  75  and  79  as seen in FIG. 6. As can be seen in FIG. 3, the rear compression head plates  75  and  79  are then attached to the hydraulic actuators  25  and  26  by means of actuator rods  31  and  32  at connection points generally designated by numerals  36  and  37 , respectively.  
         [0036]    In reference to FIGS. 1, 3 and  6 , as soil  51  is loaded into the soil hopper  17  by manual or mechanical means. At commencement of the “first stage” of operation, a high-frequency vibration apparatus  39  increases the force by which loose soil  51  passes downwardly through said soil hopper  17  and into an adjustable soil receiving area  49 . The downward force of the soil, aided by gravity and said vibration apparatus will uniformly fill and compact soil in said receiving area. At a preset interval of time the first stage of operation terminates as the PLC system  95  will disengage the high-frequency vibration apparatus  39 .  
         [0037]    As can be seen in FIG. 3, during the initial process, anterior hydraulic actuators  25  will be in fully retracted positions, while posterior hydraulic actuators  26  will be fully extended. Said actuators are coupled to anterior  46  and posterior  47  compression heads at connection points generally designated by numeral  37 . The positions of said actuators and respectively, said compression heads hereby aid in forming a soil receiving area  49 , which is adjustable in accordance to the positions of said compression heads within the compression case area  60 . In reference to FIG. 7, as the “second stage” of operation begins, both anterior and posterior hydraulic actuators (not shown) engage the anterior compression head  46  and posterior compression head  47 . Said compression heads travel to preset destinations as shown in FIG. 7. As is illustrated in FIG. 7, the posterior compression head  47  will stop and remain stationary, as the anterior compression head  46  remains engaged. Thus, the “third stage” of operation begins. As the anterior compression head  46  travels within the compression case area  60  towards the posterior compression head  47  the soil  51  between said compression heads will become compacted further, until a block of compacted soil  10  is formed between said heads.  
         [0038]    In reference to FIGS. 7 and 9, the compression of the soil  51  between said compression heads will create a rise in hydraulic pressure in hydraulic line  118 . When an initial preset pressure is reached in said hydraulic line, an adjustable pressure switch  103  will engage, and the PLC unit  95  will actively engage valve assembly  106  to increase pressure in hydraulic line  112 . Hence, the posterior hydraulic actuator (not shown) will be engaged along with the posterior compression head  47  to travel towards the anterior compression head  46 . The dual compression of said compressed soil block will continue to elevate hydraulic pressure within hydraulic lines  112  and  118 . Upon reaching an optimal preset compression pressure in said hydraulic lines the adjustable pressure switch  104  will engage, and the PLC unit  95  will actively engage valve assembly  106  to disengage pressure in hydraulic line  112 , thus diverting the hydraulic pressure to hydraulic line  120 .  
         [0039]    As illustrated on FIG. 8, whereas a compressed soil block  10  has been successfully formed within the compression case area  60  by utilizing opposing compression heads  46  and  47 , the “fourth stage” of operation commences. As the posterior hydraulic actuator (not shown) retracts, the posterior compression head  47  is withdrawn to the position illustrated in FIG. 8. As the anterior hydraulic actuator (not shown) continues through the compression case area  60 , the anterior compression head forces the compressed soil block  10  into the block discharge area  80 . Subsequent to the completion of a fill operation, the discharged compressed soil block  10  will exit the invention. FIG. 8 generally illustrates the completion of the “fourth stage” of operation, and more specifically, the general locations of compression heads  46  and  47 . Whereas the “fourth stage” is completed, the hydraulic actuators  25  and  26  will return to their original ‘base’ positions. The PLC unit  95  will then re-engage the high-frequency vibrating apparatus  39 .  
         [0040]    With attention now invited more specifically to FIG. 9, it may be seen that the hydraulic actuators  25  and  26  are serially connected within a hydraulic circuit  108  including a pump  99  for pumping hydraulic fluid from a reservoir  29 , to the actuators  25  and  26  and then back to the reservoir  29 . The hydraulic circuit  108  includes valve assemblies  105  and  106  serially connected therein and the valve assemblies  105  and  106  are under the control of a pair of solenoids  107  and  109  actuated by output conductors  148 ,  150 ,  152 ,  154 ,  156 ,  158 ,  160  and  162 , from a PLC unit  95 . A plurality of proximity switches  90 ,  1 ,  92 ,  93  and  94  are mounted stationary relative to the compression heads  46  and  47  and corresponding proximity switch actuators  83 ,  84 ,  85 ,  87  and  89  are adjustably mounted on the positioning control apparatus  81 . In addition, adjustable pressure switches  103  and  104  are communicated with circuits  105  and  106  on the side thereof pressurized to extend the actuator rods  31  and  32 . The proximity switches  90 ,  91 ,  92 ,  93  and  94  and pressure switches  103  and  114  are supplied current from a supply (not shown) and are connected to a PLC unit  95 . The pressure switches  103  and  104  including their own output lines  146  and  147 , respectively, comprising an input to PLC unit  95 . Similarly, the proximity switches  90 ,  91 ,  92 ,  93  and  94  including their own output lines  140 ,  142 ,  144 ,  136  and  138 , respectively, comprising an input to PLC unit  95 .  
         [0041]    The valves  105  and  106 , actuated by the PLC unit  95  through output lines  148 ,  150 ,  152 ,  154 ,  156 ,  158 ,  160  and  162 , are operable to connect the output line  110  from the pump  99  to either the input lines  112 ,  114 ,  116  and  118  for extending the actuator rods  31  and  32  or lines  120 ,  121 ,  123  and  125  for retracting the actuator rods  31  and  32 . Of course, if the output line  110  from the pump  99  is communicated with lines  112 ,  114 ,  118  and  120 , lines  120 ,  121 ,  123  and  125  are communicated with the return lines  128 ,  130 ,  132  and  134  to the reservoir  29 . On the other hand, if the line  110  is communicated with lines  120 ,  121 ,  123  and  125 , lines  112 ,  114 ,  118  and  120  are communicated with the  128 ,  130 ,  132  and  134  to the reservoir  29 .  
         [0042]    By removing the individual compression heads  46  and  47  from the compression case area  60 , individual working components of the apparatus may be readily renewed, if desired.  
         [0043]    Further, by utilizing variations of the compression case area  60  and compression heads  46  and  47 , the size and shape of the compressed soil blocks  10  to be formed may be varied. Mounted on the frame are two support frames,  19  and  33 , which support the hopper  17  and multiple function cases generally designated by the numeral  27 .  
         [0044]    As soon as the compressed soil block  10  is discharged onto the conveyor  35 , it is ready to use in the building process. With the use of the apparatus as depicted, the operator only has two tasks: first, to place soil into the hopper  17 , and second, to assemble the compressed soil blocks  10  into a structure.  
         [0045]    The blocks  10  should be laid flat. After a course of blocks  10  has been laid, the upper flat surfaces of the blocks may be sprayed with water or mud slurry, so as to be slightly moistened when the next course of blocks is placed on it.  
         [0046]    The embodiment of the invention as depicted can be summarized as follows. A plurality of linear multiple function cases.  27  and  28 , each having a soil receiving area  49 . The soil receiving area  49  is open vertically to the sky. The compression heads,  46  and  47 , are positioned as to provide the lateral walls within the soil receiving area  49 . The hopper  17  containing pre-granulated soil is mounted stationary above multiple function cases  27  and  28 . Mounted along the frame of the hopper is a vibration apparatus  39  which, when in operation along with gravity, feeds granulated soil into the soil receiving area  49  and in doing so, maximizing the soil density. This is most important for the production of high quality uniform building blocks.  
         [0047]    When the hopper has filled the soil receiving area  49  the hydraulic actuators are activated, and the compression heads,  46  and  47 , move the soil within the multiple function case to its intended second stage location. It is at this second stage that the posterior compression head  47  remains in a fixed position momentarily while the anterior compression head  46  remains engaged and begins to lightly compact the soil  51 .  
         [0048]    The soil compression process is completed during the third stage whereas the posterior compression head  47  is re-engaged to travel in the direction of the anterior compression head  46 . Simultaneously, the anterior compression head  46 , continues to press the soil in its travel towards the posterior compression head  47 . Hence, with the combined forces and relative applied pressure to the soil between said compression heads, the lightly compacted soil is compressed into a high density compressed soil block  11 .  
         [0049]    During the following fourth stage, both compression heads,  46  and  47 , are moved within the multiple function cases,  27  and  28  toward the block discharge area  80 , at which the finished compressed soil block  10  falls away free of the trailer  15  and onto a conveyor system  35  for use.  
         [0050]    The apparatus mounted on a heavy frame suitable to sustain the hydraulic forces of the hydraulic actuators  25  and  26  and compression heads,  46  and  47 .  
         [0051]    While there is shown and described herein certain specific structure embodiments in the invention, it may be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of he underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.