Patent Abstract:
An apparatus for manufacturing lightweight concrete composite blocks includes a form, a station conveyor, a form-loading station, a form assembly station, a curing oven, and a block removal station. The station conveyor conveys the form or a multitude of forms around the apparatus in a continuous loop to produce a desired rate of production of lightweight concrete composite blocks. The form-loading station fills the form with a lightweight concrete composite. The form assembly station assembles the form to seal the composite within the form. The curing oven cures the lightweight concrete composite into a lightweight concrete composite block. The block removal station removes the lightweight concrete composite block from the form prior to the return of the form to the form-loading station for re-use.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation-in-part of application Ser. No. 09/887,369, which was filed Jun. 22, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to lightweight concrete and, more particularly, but not by way of limitation, to unitary lightweight concrete composite blocks, an apparatus and corresponding method for manufacturing unitary lightweight concrete composite blocks, and a method of using unitary lightweight concrete composite blocks.  
           [0004]    2. Description of the Related Art  
           [0005]    The primary building materials utilized today are wood and concrete. Wood unfortunately has become extremely expensive due to reduced supplies caused by restrictions resulting from today&#39;s environmentally conscious society. Further, wood often does not provide the structural safety available from other building materials, such as concrete. Concrete is unfortunately expensive, which restricts its use to projects requiring the structural safety advantages associated with concrete.  
           [0006]    Thus, the building industry constantly seeks to reduce building costs while at least meeting or actually improving upon structural safety standards. One such improved product consists of lightweight concrete, which is composed of water, cement, and polystyrene. Lightweight concrete provides reduced costs in materials by replacing cement with less expensive polystyrene. Lightweight concrete further provides structural safety comparable to cement and improved over wood.  
           [0007]    Unfortunately, the reduced materials costs of lightweight concrete are counteracted through manufacturing difficulties, which drive up costs. Currently, lightweight concrete is virtually manufactured manually in that lightweight concrete slurries are poured into molds and allowed to cure but, upon removal from molds, must be glued together and trimmed before a block sufficient for use exists. Furthermore, there does not currently exist lightweight concrete blocks suitable for use in constructing interior walls. Accordingly, unitary lightweight concrete composite blocks that are easy to manufacture and are suitable for use in constructing interior walls would significantly improve over the foregoing related art.  
         SUMMARY OF THE INVENTION  
         [0008]    In accordance with the present invention, lightweight concrete composite blocks are suitable for use in constructing walls. Such blocks are lightweight concrete composite that may be cured into the shape of a wall, which includes first and second sidewalls, first and second endwalls, and first and second faces including a depth therebetween. A conduit may be disposed within the depth between the first and second faces. At least one end of the conduit typically protrudes from the block, and the conduit may be plumbing piping or electrical conduit. One end of the conduit may connect to an electrical box disposed within the depth between the first and second faces. The first sidewall may include a tongue and the second sidewall may include a groove.  
           [0009]    An apparatus for manufacturing lightweight concrete composite blocks includes a form, a form loading station, a form assembly station, a station conveyor, a curing oven, and a block removal station. The form defines a desired shape that holds a volume of composite. The form loading station receives composite and delivers the composite to the form. The form assembly station facilitates assembly of the form. The station conveyor conveys the form about the apparatus in a continuous loop. The curing oven cures the composite into a lightweight concrete composite block. The block removal station removes the lightweight concrete composite block from the form.  
           [0010]    The form includes a bottom assembly and a cap that seats on the bottom assembly. The form further includes a mating assembly that couples the bottom assembly with the cap. The form still further includes an insert that shortens the form to produce smaller lightweight concrete composite blocks. The bottom assembly includes walls, mating assemblies that couple the walls together, and a conduit notch that supports a conduit within the bottom assembly at a designated depth. Upon the curing of the composite into a lightweight concrete composite block, the conduit remains disposed within the block at the designated depth.  
           [0011]    The form loading station includes a cap removal/replacement assembly that removes and replaces a cap of the form and a screed assembly that receives composite and delivers the composite into a bottom assembly of the form. The cap removal/replacement assembly includes lifting rails adapted to engage a cap bracket of the form, a stabilizer bar connecting the lifting rails, and a lifting cylinder attached to the stabilizer bar that moves between an engagement position and a raised position. The screed assembly includes a screed track extending over the station conveyer, a screed box coupled with the screed track, a screed cylinder coupled with the screed box that conveys the screed box along the screed track between a retracted position and a loading position, a leveling hopper disposed within the screed box that fills and levels the form with composite, an auger disposed within the leveling hopper that evenly distributes composite into the form, a screed motor for rotating the auger, and a leveling cylinder coupled with the leveling hopper that slides the leveling hopper back and forth inside the screed box.  
           [0012]    The station conveyor conveys the form or a multitude of forms around the apparatus in a continuous loop to produce a desired rate of production of lightweight concrete composite blocks. A first station conveyor conveys unloaded forms to the form loading station. A loading conveyor receives from the first station conveyor unloaded forms for filling with composite and delivers loaded forms from the form loading station. A first roller conveyor receives from the loading conveyor loaded forms and delivers the loaded forms to the form assembly station. A second station conveyor receives from the first roller conveyor loaded forms and conveys loaded and assembled forms from the form assembly station through the curing oven and to the block removal station. An unloading conveyor receives from the second station conveyor forms filled with cured composite and delivers unloaded forms from the block removal station. A second roller conveyor receives from the unloading conveyor unloaded forms and delivers the unloaded forms to the first station conveyor.  
           [0013]    The block removal station includes a cap removal/lockdown assembly that removes and replaces a cap of the form and that locks down a bottom assembly of the form, a dispatch assembly that removes a cured block from a locked down bottom assembly of the form, a frame that supports the cap removal/lockdown assembly and the dispatch assembly, and a dispatch conveyor that receives a removed cured block from the dispatch assembly and conveys the removed cured block therefrom. The cap removal/lockdown assembly includes at least one lifting rail adapted to engage a cap bracket attached to the cap of the form, at least one lockdown rail pivotally connected to the lifting rail and adapted to engage a pin attached to the bottom assembly of the form, and at least one lifting cylinder attached to the lifting rail and movable between an engagement position whereby the lifting rail engages the cap bracket and a lockdown position whereby the lifting cylinder raises the lifting rail to remove the cap from the bottom assembly and pivots the lockdown rail such that the lockdown rail engages the pin to lock down the bottom assembly of the form. The dispatch assembly includes at least one dispatch cylinder mounted on the frame and a ram plate hingedly attached to the dispatch cylinder for pushing a lightweight concrete composite block from the form.  
           [0014]    A method for manufacturing lightweight concrete composite blocks includes loading composite into a form of a desired shape, assembling the form loaded with composite, curing the composite into a lightweight concrete composite block, and removing the lightweight concrete composite block from the form. The method for manufacturing lightweight concrete composite blocks further includes placing a conduit within the form at a designated depth prior to loading composite into a form. Loading the composite into a form of desired shape includes removing a cap of the form from a bottom assembly of the form, delivering composite into the bottom assembly of the form, and replacing the cap onto the bottom assembly. Assembling the form loaded with composite includes depressing a cap of the form onto a bottom assembly of the form and coupling a latch attached to the cap with a catch attached to the bottom assembly. Removing the lightweight concrete composite block from the form includes uncoupling the latch attached to the cap of the form from the catch attached to the bottom assembly of the form, removing the cap from the bottom assembly, locking down the bottom assembly of the form, uncoupling latches securing sidewalls of the bottom assembly to endwalls of the bottom assembly, rotating the sidewalls away from the endwalls, and pushing a lightweight concrete composite block from the locked down bottom assembly.  
           [0015]    A method of assembling lightweight concrete composite blocks into a structure includes erecting a support frame, inserting blocks into the support frame, securing the blocks together, and securing the blocks to the support frame. The method of assembling lightweight concrete composite blocks into a structure further includes erecting a second level support frame, inserting blocks into the second level support frame, securing the blocks together, and securing the blocks to the second level support frame. The method of assembling lightweight concrete composite blocks into a structure further includes cutting an opening into a block and installing a door or window in the opening. The method of assembling lightweight concrete composite blocks into a structure further includes attaching a cabinet support frame to a block, inserting a cabinet into the cabinet support frame, and securing the cabinet to the cabinet support frame and to the block.  
           [0016]    It is therefore an object of the present invention to provide lightweight concrete composite blocks suitable in building walls.  
           [0017]    It is another object of the present invention to provide an apparatus and corresponding method for manufacturing lightweight concrete composite blocks.  
           [0018]    It is a further object of the present invention to provide a method of using lightweight concrete composite blocks in constructing a structure.  
           [0019]    Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is a perspective view illustrating a preferred embodiment of a form.  
         [0021]    [0021]FIG. 2 is an end view illustrating a preferred embodiment of the form.  
         [0022]    [0022]FIG. 3 is a perspective view illustrating a preferred embodiment of a cap of the form.  
         [0023]    [0023]FIG. 4 is a perspective view illustrating a preferred embodiment of a bottom assembly of the form including an insert therein.  
         [0024]    [0024]FIG. 5 is a perspective view illustrating an insert of the form.  
         [0025]    [0025]FIG. 6 is an end view illustrating the form with the cap removed.  
         [0026]    [0026]FIG. 7 is a perspective view illustrating a screed assembly for loading and leveling a form.  
         [0027]    [0027]FIG. 8 is a side view illustrating the screed assembly for loading and leveling a form.  
         [0028]    [0028]FIG. 9 is a perspective view illustrating a block removal station with a cap removal assembly raised to an upper level, a dispatch assembly in a closed position, and an unloading conveyor.  
         [0029]    [0029]FIG. 10 is a plan view illustrating an apparatus for manufacturing unitary lightweight concrete composite blocks according to the preferred embodiment.  
         [0030]    [0030]FIG. 11 is a perspective view illustrating a standard installation.  
         [0031]    [0031]FIG. 12 is a front view illustrating a second level installation.  
         [0032]    [0032]FIG. 13 is a front view illustrating a framing installation and a heavy cabinet installation.  
         [0033]    [0033]FIG. 14 is an overhead view illustrating a framing installation and a heavy cabinet installation. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0034]    As illustrated in FIG. 11, the preferred embodiment of the block  10 A discloses a rectangular block with a top end, a bottom end, and two sides. One side defines a raised tongue  106  while the opposite side defines a recessed groove  107 , whereby blocks can be assembled in a successive fashion by fitting a tongue side into a groove side. In addition, the block  10 A includes electrical conduit  200  and electrical boxes  201  for running electrical wire and making electrical connections. While the preferred embodiment discloses electrical conduit  200  and electrical boxes  201 , those of ordinary skill in the art will recognize that any multitude of items normally used inside building walls may be substituted, such as plumbing piping, air ducts, and the like. The ability of the block  10 A to contain electrical conduit and electrical boxes makes it ideal for use as an interior wall in buildings.  
         [0035]    As illustrated in FIG. 10, an apparatus  1  for manufacturing unitary lightweight concrete composite blocks  10 A includes a form  10 , a conveyor system  2 , a form-loading station  3 , a form assembly station  4 , a curing oven  5 , and a block removal station  6 . The apparatus  1  utilizes a method for manufacturing unitary lightweight concrete composite blocks  10 A that includes the steps of loading a form with lightweight concrete composite, curing the lightweight concrete composite, and removing a unitary lightweight concrete composite block  10 A from the form.  
         [0036]    As illustrated in FIGS.  1 - 6 , a form  10  is used to cure the lightweight concrete composite into a desirable shape, which, in the preferred embodiment, is a unitary lightweight concrete composite block  10 A. Thus, the preferred form  10  includes a bottom assembly  11  and a cap  12 . Although the preferred embodiment discloses a unitary block  10 A, those of ordinary skill in the art will recognize that a form producing any desirable shape, such as a square, circle, or angle may be utilized.  
         [0037]    In the preferred embodiment, the bottom assembly  11  is a rectangular plate  14  with two sidewalls  15  and two endwalls  16 . Each sidewall  15  is hingedly attached along a respective long length of the rectangular plate  14 . In addition, each sidewall  15  defines a lengthwise channel  17  for forming a tongue  106  or groove  107  along the sides of each block. In the preferred embodiment, one sidewall  15  defines a channel  17  for forming a tongue  106 , while the opposite sidewall  15  defines a channel  17  for forming a groove  107  (see FIG. 11). Consequently, finished blocks can be assembled in a successive fashion by fitting a tongue side into a groove side. While, the preferred embodiment discloses a bottom assembly  11  with sidewalls  15  with one tongue channel and one groove channel, those of ordinary skill in the art will recognize that, any combination of tongue and groove channels  17 , or any channel profile, may be utilized. Furthermore, the long edge of each sidewall  15  terminates in an L-shaped lip. Also, T-shaped latches  18  are hingedly attached to each corner of each sidewall  15 , which rotate between locked and unlocked positions.  
         [0038]    Referring to FIGS. 2 and 6, each endwall  16  is attached along a respective short length of the rectangular plate  14 . Catches  19  are fixedly attached by any suitable means, such as welding, at each corner and in the middle of each endwall  16  for coupling with the latches  18 . The long edge of each endwall  16  terminates in an L-shaped lip, and pins  24  extend outward perpendicularly from each corner of each endwall  16 . In addition, one endwall  16  defines conduit notches  23  for supporting electrical conduit and electrical boxes inside the form  10 . The conduit notches  23  suspend the electrical conduit and electrical boxes at a designated depth during the curing process. Consequently, the electrical conduit and electrical boxes will reside at the designated depth in the finished block  10 A. While the preferred embodiment of the insert discloses three conduit channels  23 , those of ordinary skill in the art will recognize that any number of conduit channels  23  may be utilized to support any multitude of different objects.  
         [0039]    To assemble the bottom assembly  11 , the sidewalls  15  rotate up to a vertical position, thereby forming a rectangular box. Next, the latches  18  rotate to the locked position and couple with the catches  19 , thereby securing the bottom assembly  11 . This will be referred to as the assembled position. To disassemble the bottom assembly, the latches  18  uncouple from the catches  19  and the sidewalls  15  rotate down to a horizontal position. This will be referred to as the disassembled position.  
         [0040]    Referring to FIG. 3, the cap  12  is a rectangular plate with each long edge terminating in an L-shaped lip. Two L-shaped cap brackets  20  are attached by any suitable method, such as welding, to each end of the cap  12  so that the cap brackets  20  are parallel with the two short edges of the cap  12  and face inward, thereby defining slots between the top of the cap  12  and each cap bracket  20 . An L-shaped short bracket  25  is attached by any suitable method, such as welding, to a front edge of the cap  12  so that the L-shape is facing outward. An L-shaped tall bracket  26  is attached by any suitable method, such as welding, to a back edge of the cap  12  facing the same direction as the short bracket  25 . A latch  18  is hingedly attached to middle of each short edge of the cap  12 , which rotates from an unlocked to a locked position. The perimeter dimensions of the cap  12  match the perimeter dimensions of the bottom assembly  11 . When placed onto a bottom assembly  11  in the assembled position, the latches  18  of the cap  12  couple with the catches  19  of the bottom assembly  11  to seal the form  10 , which will be referred to as the locked position. The latches 18  may also be uncoupled from the catches  19  of the bottom assembly  11  to release the cap  12 , which will be referred to as the unlocked position.  
         [0041]    Referring to FIGS. 4 and 5, an insert  13  is a rectangular plate with two sidewalls  21  and two endwalls  22 . The dimensions of insert  13  are such that the insert  13  fits inside the bottom assembly  11 . The two sidewalls terminate in an L-shaped lip. The insert  13  prevents lightweight composite concrete from filling the area of the form  10  occupied by the insert  13 . Thus, the insert  13  shortens the overall length of the form  10  to produce a shorter block  10 A. While the preferred embodiment discloses an insert  13  that shortens the form  10  by approximately ⅓, those of ordinary skill in the art will recognize that any size insert  13  may shorten the length of the form  10  by any length. One endwall  22  defines conduit notches  22 A for supporting electrical conduit and electrical boxes inside the form. The conduit notches  22 A suspend the electrical conduit and electrical boxes at a designated depth during the curing process. Consequently, the electrical conduit and electrical boxes will reside at the designated depth in the finished block  10 A. While the preferred embodiment of the insert discloses three conduit notches  22 A, those of ordinary skill in the art will recognize that any number of conduit notches  22 A may be utilized to support any multitude of different objects.  
         [0042]    As illustrated in FIGS.  7 - 10 , a conveying system  2  routes a plurality of forms  10  in a continuous loop simultaneously through all the stations of the apparatus  1 , thereby creating a time efficient process. The conveyor system  2  includes a first station conveyor  7   a,  a loading conveyor  8   a,  a first roller conveyor  9   a,  a second station conveyor  7   b,  an unloading conveyor  8   b,  and a second roller conveyor  9   b.  The first station conveyor  7   a  is the station conveyor disclosed in U.S. patent application Ser. No. 09/887,369, the disclosure of which is incorporated herein by reference. While the preferred embodiment discloses the station conveyor in U.S. patent application Ser. No. 09/887,369, those of ordinary skill in the art will recognize that any type of conveying apparatus may be utilized. The loading conveyor  8   a  is a belt conveyor well known to those of ordinary skill in the art. While the preferred embodiment discloses a belt conveyor, those of ordinary skill in the art will recognize that any conveying apparatus may be utilized. The second station conveyor  7   b  is the station conveyor disclosed in U.S. patent application Ser. No. 09/887,369, the disclosure of which is incorporated herein by reference. While the preferred embodiment discloses the station conveyor in U.S. patent application Ser. No. 09/887,369, those of ordinary skill in the art will recognize that any type of conveying apparatus may be utilized. The unloading conveyor  8   b  is a belt conveyor that is well known in the art. While the preferred embodiment discloses a belt conveyor, those of ordinary skill in the art will recognize that any conveying apparatus may be utilized.  
         [0043]    The form-loading station  3  includes a cap removal/replacement assembly  30  and a screed assembly  40 . Referring to FIGS. 1 and 8, the cap removal/replacement assembly  30  includes a lifting cylinder  31 , a stabilizer bar  32 , a short lifting rail  33 , and a tall lifting rail  34 . The lifting cylinder  31  is vertically suspended above the loading conveyor  8   a  and connects by any suitable means, such as a pin, to the center of the stabilizer bar  32  so that the stabilizer bar resides in a horizontal plane. The short lifting rail  33  is an L-shaped rail that is attached to a back end of the stabilizer bar  32 . The tall lifting rail  34  is an L-shaped rail that is attached to a front end of the stabilizer bar  32 . When the lifting cylinder  31  extends, the short lifting rail  33  and tall lifting rail  33  lower to a position where they may engage a corresponding tall cap bracket  26  and short cap bracket  25 , which will be referred to as the engagement position. When the lifting cylinder  31  retracts, the short lifting rail  33  and the tall lifting rail  34  raise to a position above the screed assembly  40 , which will be referred to as the raised position.  
         [0044]    The screed assembly  40  includes a frame  50  having supporting legs and screed tracks  50 A attached thereto. The legs mount to the foundation on either side of the conveying system  3  by any suitable means, such as brackets attached to each leg and bolts sunk into a foundation. The screed assembly  40  further includes a screed box  41 , a leveling hopper  42 , an auger  43 , a screed motor  44 , two leveling cylinders  45 , a screed cylinder  46 , a filling conveyor  47 , and a mounting bracket  48 . The screed box  41  is a rectangular box with an open top and a slot in the bottom the same size as the top opening of the form  10 . The edges of the screed box  41  rest within the screed tracks  50 A, which run perpendicular to the loading conveyor  8   a.  The screed cylinder  46  is connected to the frame  50  between an end of the screed track  50 A and a side of the screed box  41 . When the screed cylinder  46  extends, it slides the screed box  41  directly over the loading conveyor  8 A, which will be referred to as the loading position. When the screed cylinder  46  retracts, it slides the screed box  41  to a position adjacent the loading conveyor  8 A, which will be referred to as the retracted position.  
         [0045]    The leveling hopper  42  resides inside the screed box  41 . The two leveling cylinders  45 , which are any suitable hydraulically or pneumatically operated cylinders, connect from the screed box  41  to the leveling hopper  42  using a mounting bracket  48 . The leveling cylinders  45  extend and retract their pistons to slide the leveling hopper  42  inside the screed box  41 . The auger  43  is mounted inside the leveling hopper  42  using any suitable means, such as bearings. The screed motor  44  is coupled to the end of the auger  43  through a lengthwise slot in the screed box  41 . The slot allows the screed motor  44  and auger  43  to slide along with the leveling hopper  42  when the leveling cylinders  45  extend and retract.  
         [0046]    In operation, the first station conveyor  7   a  conveys a form  10  onto a disabled loading conveyor  8   a.  When the form  10  arrives at the form-filling station  3 , the bottom assembly  11  is in the assembled position with the cap  12  resting on top in the unlocked position. The lifting cylinder  31  begins in the engagement position so that, as the form  10  arrives at the form filling station  3 , the short lifting rail  33  and the tall lifting rail  33  engage a corresponding tall cap bracket  26  and a short cap bracket  25 . Upon conveyance onto the loading conveyor  8   a,  the form  10  engages a micro-switch that outputs a signal that overrides the first station conveyor  7   a.  Thus, first station conveyor  7   a  remains disabled during the filling of the form  10 . The micro-switch further outputs a signal that retracts the lifting cylinder  31  to the raised position, thereby removing the cap  12 . With the cap  12  removed, the operator inserts all necessary electrical conduit or electrical boxes into the form. Next, the lifting cylinder  31 , in its retracted position, engages a micro-switch that outputs a signal directing the screed cylinder  46  to extend the screed box  41  to the loading position directly over the bottom assembly  11 . In the loading position, the leveling hopper  42  is located directly underneath a filling conveyor  47 , which is any suitable conveyor, such as a belt conveyor. As the screed box  40  reaches the loading position, it engages a micro-switch, which outputs a signal that opens a lightweight concrete composite source and activates the filling conveyor  47  to deliver the lightweight concrete composite to the leveling hopper  42 . The lightweight concrete composite source in the preferred embodiment is the lightweight concrete composite source disclosed in U.S. patent application Ser. No. 09/887,369, the disclosure of which is incorporated herein by reference. The micro-switch further outputs a signal that activates the screed motor  44 , thereby rotating the auger  43  to evenly distribute the lightweight concrete composite throughout the leveling hopper  42 . A micro-switch positioned within the leveling hopper  42  or the lightweight concrete composite source senses when either the leveling hopper  42  is full or the lightweight concrete composite source is empty. Upon sensing either condition, the micro-switch outputs a signal closing the lightweight concrete composite source and deactivating the filling conveyor  47  and the screed motor  44 .  
         [0047]    As generally illustrated in FIGS. 7 and 8, the micro-switch further outputs a signal that activates the leveling cylinders  45 , which slowly move the leveling hopper  42  forward over the bottom assembly  11  to a position beyond the bottom assembly  11 . When the leveling hopper  42  travels fully beyond the bottom assembly  11 , it engages a micro-switch that reverses the leveling cylinders  45 , which slowly move the leveling hopper  42  backward over the bottom assembly  11  to the loading position. The movement of the leveling hopper  42  over the bottom assembly  11  fills and levels the bottom assembly  11  with the lightweight concrete composite contained in the leveling hopper  42 . As the leveling cylinders  45  fully retract, the leveling hopper  42  engages a micro-switch that outputs a signal resulting in the screed cylinder  46  returning the screed box  41  to the retracted position. When the screed cylinder is fully retracted, a micro-switch outputs a signal that activates the lifting cylinder  31  to extend to the engagement position, thereby replacing the cap  12  back onto the bottom assembly  11 . Upon replacement of the cap  12 , a micro-switch outputs a signal that activates the loading conveyor  8   a  to move the form  10  forward toward the next station, the form assembly station  4 , via the first roller conveyor  9   a.  Upon conveyance of the form  10  from the loading conveyor  8   a,  a micro-switch signals the loading conveyor  8   a  to disable in preparation to receive another form  10 .  
         [0048]    In the preferred embodiment, the form assembly station  4  is a manually operated station. First, the operator depresses the cap  12  onto the bottom assembly  12 , thereby compressing the lightweight concrete composite within the form. Next, the operator couples the latches  18  of the cap  12  to the catches of the bottom assembly  11 , thereby sealing the form. Finally, the operator delivers the form from the first roller conveyor  9   a  to the second station conveyor  7   b  to convey the form through the curing oven. While the preferred embodiment discloses a manually operated form assembly station  4 , those of ordinary skill in the art will recognize that the form assembly station  4  may be automated.  
         [0049]    As illustrated in FIG. 10, the dotted line designates an area of the station conveyor  2  enclosed by the curing oven  5 . The second station conveyor  7   b  moves the form  10  through the curing oven  5 , which is at a temperature sufficient to accelerate curing. As the form  10  travels through the curing oven  5 , the lightweight concrete composite cures. The curing oven  5  should be of a sufficient size to allow adequate time for proper curing to occur. When the form  10  exits the curing oven  5 , the lightweight concrete composite has hardened into a unitary lightweight concrete composite block  10 A. The second station conveyor  7   b  continues to move the form  10  to the block removal station  6 .  
         [0050]    As illustrated in FIGS. 9 and 10, the last station is a block removal station  6 . The block removal station  6  includes a frame  150 , a cap removal/lockdown assembly  60 , a dispatch assembly  70 , and a dispatch conveyor  51 . The frame  150  includes four vertical bars and four horizontal crossbars attached together by any suitable means, such as welding, to form a wire-frame box directly over the unloading conveyor  8   b.  The four vertical bars are attached to a base that mounts to a foundation using any suitable means, such as bolts, sunk into the foundation.  
         [0051]    The cap removal/lockdown assembly  60  includes lifting cylinders  61 , lifting rails  62 , rail rods  63 , pivot rods  64 , support brackets  65 , lockdown rods  66 , and lockdown rails  67 . The lifting cylinders  61  are vertically suspended directly above the frame for extending and retracting from a raised position to an engagement position. The lifting rails  62  are C-shaped rails attached to the ends of the lifting cylinders  61  for engaging the cap brackets  20  of the form  10 . Support brackets  65  attached to the frame  150  couple with the pivot rods  64  by any suitable means, such as bearings, so that the pivot rods  64  rotate freely. The rail rods  63  fixedly attach by any suitable means, such as welding, to the pivot rods  64 , thereby extending perpendicularly to hingedly attach to the lifting rails  62 . The lockdown rods  66  are fixedly attached to the ends of the pivot rods  64  opposite the rail rods  63 , thereby extending perpendicularly to hingedly attach to the lockdown rails  67 . The lockdown rails  67  are L-shaped channels with a locking tab  68  attached in the center by any suitable means, such as welding, for engaging the pins  24  of the form  10 . When the lifting cylinders  61  extend, the lifting rails  62  lower to a position where they may engage the cap brackets  20 . Simultaneously, the rail rods  63  rotate the pivot rods  64 , which rotate the lockdown rods  66 , thereby raising the lockdown rails  67  to a level sufficient to clear any forms  10  located on the unloading conveyor  8   b.  This position will be referred to as the engagement position. Oppositely, when the lifting cylinders  61  retract, thereby raising the lifting rails  62  to remove the cap  12 , the lockdown rails  67  lower to engage the pins  24  of the bottom assembly  11 . This will be referred to as the lockdown position.  
         [0052]    The dispatch assembly  70  includes dispatch cylinders  71 , mounting brackets  72 , and a ram plate  73 . The dispatch cylinders  71  mount horizontally to the frame  150  via the mounting brackets  72 . Both dispatch cylinders  71  are hingedly attached to the ram plate  73 , whereby the ram plate  73  can rotate between a ram position and a bypass position. When the dispatch cylinders  71  extend, the ram plate  73  remains in a vertical position to strike a concrete composite block  10 A and push the concrete composite block  10 A onto the dispatch conveyor  51 , which will be referred to as the ram position. When the dispatch cylinders  71  retract, the ram plate  73  rotates to a horizontal position to bypass the form  10 , which will be referred to as the bypass position.  
         [0053]    In operation, the second station conveyor  7   b  delivers a form  10  onto a disabled unloading conveyor  8   b.  In this preferred embodiment, the forms  10  are spaced along the conveyor system  2  such that a form  10  enters the block removal station  6  at the same time another form  10  enters the form-loading station  3 . Consequently, the block removal station  6  controls the stopping and starting of the first station conveyor  7   a.  Nevertheless, those of ordinary skill in the art will recognize that the form-loading station  3 could control the first station conveyor  7   a.    
         [0054]    Furthermore, although this preferred embodiment discloses the synchronous operation of the block removal station  6  and the form-loading station  3 , those of ordinary skill in the art will recognize other control schemes for regulating the movement of the forms through the block removal station  6  and the form-loading station  3 .  
         [0055]    The lifting cylinders  61  of the cap removal/lockdown assembly  60  begin in the engagement position so that, as the form  10  arrives at the block removal station  6 , the cap rails  62  engage the cap brackets  20  of the cap  12 . Upon conveyance onto the unloading conveyor  8   b,  the form  10  engages a micro-switch that outputs a signal that overrides the second station conveyor  7   b.  Thus, second station conveyor  7   b  remains disabled during the removal of the block  10 A. In addition, the micro-switch outputs a signal that informs an operator to unlock the cap  12  from the bottom assembly  11  by uncoupling the corresponding latches  18  from the catches  19 . After this is done, the operator engages a micro-switch that outputs a signal that retracts the lifting cylinders  61  to the lockdown position, thereby removing the cap  12  and locking down the bottom assembly  11 . Upon lockdown of the bottom assembly  11 , a micro-switch outputs a signal that informs the operator to uncouple the remaining latches  19  on the bottom assembly  11  and rotate the sidewalls  15  down to a horizontal position. Next, the operator engages a micro-switch that outputs a signal to the dispatch cylinders  71  to extend and retract, thereby pushing the finished block  10 A onto the dispatch conveyor  51 . Then the operator reassembles the bottom assembly  11 . Once the finished block  10 A is removed and the bottom assembly is reassembled, the operator engages a micro-switch, which outputs a signal to extend the lifting cylinders  61  to the engagement position, thereby placing the cap  12  onto the bottom assembly  11 . Finally, the unloading conveyor  8   b  advances the form to the second roller conveyor  9   b  to start the process all over again.  
         [0056]    The preferred embodiment employs a micro-switch control scheme whereby the engaging of various micro-switches controls the conveyor system  2 , the form-loading station  3 , and the block removal station  6 . The micro-switches employed are of a type well known to those of ordinary skill in the art, such as optical sensing switches, pressure switches, mechanically activated switches, and the like. Further, the use of such switches to control the components of the apparatus for manufacturing lightweight concrete composite blocks  10 A is well known and understood by those of ordinary skill in the art. It should be understood, however, that a computer control scheme could be implemented in the apparatus for manufacturing lightweight concrete composite blocks  10 A.  
         [0057]    To assemble the lightweight concrete blocks  10 A into a functional structure, four types of installation methods are used, standard installation, second level installation, framing installation, and heavy cabinet installation. Standard installation is intended for installation on the first floor of a structure. Second level installation is intended for installation of floors above the first floor. Finally, framing installation is intended for installation around doors and windows, and cabinet installation is intended for the mounting of cabinets onto the lightweight concrete blocks  10 A.  
         [0058]    In a standard installation, the first step is to erect a support frame. As shown in FIG. 11, the support frame  100  in the preferred embodiment includes a side support  101 , a base support  102 , and a top support  103 . All three supports are made from “C” channel, which is erected using application methods commonly known in the industry. After erecting the support frame, matching sides of the base support  102  and the top support  103  are folded parallel with the foundation. Next, an adhesive, such as glue, is applied to the inside of the support frame  100 . A first block  104  is then placed vertically into the support frame  100  so that it rests at the farthest end of the support frame  100 , and the adhesive is allowed to dry. After applying more adhesive, a second block  105  is placed vertically into the support frame so that the tongue of the block  105  inserts into the groove of the first block  104 . The above process is thus repeated until the entire support frame  100  is filled with blocks. At that time, the base support  102  and top support  103  are folded back to the original “C” channel shape. Finally, the entire structure is secured by installing screws through the support frame  100  into the blocks.  
         [0059]    Referring to FIG. 12, to install a second level or higher, a first or lower level must be installed as described above. Then, an intermediate support  110 , which is a “C” channel, must be attached with any suitable method such as glue or screws, to the top support  103  with the “C” facing down. Next, a base support  106 , which is a “C” channel, is mounted facing up to the intermediate support  110  using any suitable method, such as glue or screws. With the base support  102  mounted, the rest of level is installed according to the steps described above in the standard installation.  
         [0060]    Referring to FIGS. 13 and 14, windows and doors may be “framed” with methods that are well known in the trade. Illustratively, an opening for a window or door is cut into a block. A frame for the window or door is then secured to the block at the edges of the opening using any suitable technique such as screws or adhesives. The window or door is then installed in the frame using techniques well known to those of ordinary skill in the art.  
         [0061]    Referring to FIGS. 13 and 14, heavy cabinet installation requires a section of wall to be installed as described above. After erecting the wall, a lower “C” channel and an upper “C” channel are attached to a block of the wall using a suitable means, such as screws. Next, a left “C” channel and a right “C” channel are attached to either the block of the wall or more preferably to the “C” channel of the support frame using a suitable means, such as screws. Then, the outer sections of upper, lower, left, and right “C” channels are folded perpendicular to the wall so that a cabinet may be received therein. Finally a cabinet is placed in the upper, lower, left, and right “C” channels and secured to the wall and the upper, lower, left, and right “C” channels using any suitable means, such as screws.  
         [0062]    Although the present invention has been described in terms of the foregoing embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing description; rather, it is defined only by the claims that follow.

Technology Classification (CPC): 1