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Title:
MANUFACTURING DEVICE AND METHOD FOR THE CASTING OF PRODUCTS
Document Type and Number:
WIPO Patent Application WO/2012/009748
Kind Code:
A1
Abstract:
A device (100) for forming products has a plurality of moulds (6) arranged generally in a row R- Each mould has a cavity for receiving a liquid mixture, the cavity being open at the bottom to allow the formed product to be removed from the cavity. A line (7) is operatively connected to the moulds, the line extending in a direction generally parallel to the row R of moulds. The moulds (6) and the line (7) are arranged such that as the line is lifted from one end, the moulds are Lifted successively along the row. The device may have a locating frame (20) having a plurality of rails (19,23) adapted to guide the location of the moulds (6).

Inventors:
ATKINSON FRANCIS STEWART (AU)
Application Number:
PCT/AU2011/000907
Publication Date:
January 26, 2012
Filing Date:
July 19, 2011
Export Citation:
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Assignee:
ATKINSON FRANCIS STEWART (AU)
International Classes:
B28B5/04; B28B7/00; B28B13/00; B28B21/84; B28B21/90
Foreign References:
US4067941A1978-01-10
US3758067A1973-09-11
GB1468631A1977-03-30
Attorney, Agent or Firm:
BROWN, Michael, S et al. (Level 22 State Insurance Tower,1 Willis Street,P O Box 94, Wellington 6015, NZ)
Download PDF:
Claims:
WH AT I CI .AIM TS:

1■ A device for forming products comprising:

a plurality of moulds arranged generally in a row, each mould comprising a cavity for receiving a liquid mixture, the cavity being open at die bottom to allow a formed product to be removed from the cavity and

a line operauvely connected to the moulds, the line extending in a direction generally parallel to the row of moulds;

wherein the moulds and the line are arranged such that as the line is lifted from one end, d e moulds are lifted successively along the row.

2. A device according to claim 1, wherein the oaentation of each mould is substantially maintained as the line is lifted. 3. Λ device according to claim 1 , wherein each mould is pivotally connected to the line at a pivot.

4. A device according to claim 3, wherein the pivot is offset from the center of the mould so chat as the mould is lifted, one side of die mould starts to lift before the other side of die mould starts to lift

5. A device according to any one of claims 1 to 4, wherein each of rhe moulds comprises a plurality of spaced apart cavities. 6. A device according to claim 5, wherein the cavities are spaced apart in a direction that is generally transverse to the row of moulds.

7. A device according to claim 6, wherein the cavities are spaced apart in a direction that is generally perpendicular to the tow of moulds.

8. Λ device according to any one of the preceding claims, wherein the line comprises a chain having a plurality of links.

9. A device acemding to claim 8, wherein each of the links is pivotally connected to an adjacent link at a chain pivot point.

10. A device according to claim 8 or claim 9, wherein each of the moulds is connected to at least one chain Hnk at a mould pivot point

11. A device according to claim 10, wherein at least a majority of the moulds and two respective adjacent links are connected together at a single pivot point.

12. A device according to any one of the preceding claims, wherein the moulds are releasably connectable to the line so mat additional moulds can be connected to the line or one or more of the moulds can be removed.

13. A device according to any one of the preceding claims wherein the moulds comprise notches.

14. A device according to any one of the preceding claims, further comprising shrouds for masking joints between moulds. 5. A dev kc according to any one of the preceding claims, further comprising a locating frame, the loca ling frame comprising a plurality of rails adapted to guide the location of the moulds.

16. Λ device according TO claim 15, wherein the rails comprise longitudinal rails and cross rails.

17. A method for forming products comprising:

a) providing a device according to any one of the preceding claims; b) pouring a mixture into the plurality of moulds,

c) allowing the mixture to at least partially set; and

d) lifting the line from one cad such that the moulds arc lifted successively along the row. 18. A method according rn claim 17, wherein the line is lifted from both ends such that the moulds are lifted successively from each end along the mw.

1 . A method according to claim 17 or 18, wherein the orientation of each mould is substantially maintained as the line is lifted.

20. A method according to any one of claims 1 to 1 , wherein the mixture comprises an unset concrete mixture.

21. A method according to any one of claims 17 to 20, wherein step d) occurs about one to two hours after step b).

22. A method according to any one of claims 17 to 21 , wherein the moulds are releasably connectable to the line and step a) comprises connecting additional moulds to he device or removing one or more of the moulds from the device.

23. A method according to any one of claims 17 to 22, wherein the length of the line can be lengthened or shortened as the number of moulds is altered.

24. A method according to any one of claims 17 to 23, wherein the moulds comprises notches and step b) comprises allowing the mixture ro seep our of the mould t rough the notches.

25. A product when produced by the method of anyone of claims 17 to 24.

Description:
MANUFACTURING DEVICE AND METHOD FOR THE CASTING OF

PRODUCTS

FIELD OF THE INVENTION

The invention relates to a device and method for casting products. In particular, but not exclusively, the present invention relates to the field of articulating concrete block mattresses which are used in a wide number of applications such as erosion control, flexible paving, revetments, pipeline anchors and other such uses.

BACKGROUND OF THE INVENTION

JVcscnt methods of manufacturing articulating concrete block mattresses are twofold The most common method is precast concrete block units cast with appropriate holes through the units to receive the necessary cables to create the mattress. The blocks are arranged in a mattress pattern and the cables arc threaded through the precast holes and secured with formed loops for Ufting with a suitable spreader bar.

Another method is to cast the mattress in a flat steel mould containing suitable cavities. Cables are threaded through notches near the bottom of the cavities, if the mattress is poured bottom down, or near the top of die cavity if the mattress is poured bottom up, all prior to filling with concrere. After curing, usually one day, the mould is removed from the formed rnartress and prepared for the next pnur. The removal of the mould in one piece requires the mould to be substantial as the mattresses are typically 2.4 metres wide and up to 15 metres long.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise^ reference to such external documents or such sources of information is not to be construed as an admission that such documents ot such sources of information, tn any jutisdiction, are prior art or form port of the common general knowledge in the art It is an object o f the present invention to provide an improved device and method for forming products.

SUMMARY OF THE INVENTION In accordance with a first aspect of the invention, there is provided a device for forming products comprising:

a plurality of moulds arranged generally in a row, each mould comprising a cavity for receiving a liquid mixture, the cavity being open at die bottom to allow a formed product 10 be removed from the cavity, and

a line opera tivcly connected to the moulds, the line extending in a direction generally parallel to the row of moulds

wherein the moulds and the line arc arranged such that as the line is lifted from one end, the moulds are lifted successively along the row. III nti embodiment, the orienlaOun of each mould is substantially maintained as the line is lifted.

Tn en embodiment, each mould is pivorally connected to the lire at a pivot. The pivot is preferably offset from the center of the mould so that as the mould is lifted, one side of the mould starts to lift before the other side of the mould starts to lift.

In an embodiment, each of the moulds comprises a plurality of spaced apart cavities.

In an embodiment, the cavities are spaced apart in a direction that is generally transverse to the row of moulds. Preferably, the cavities are spaced apart in a direction that is generally perpendicular to the row of moulds.

In an embodiment, the moulds comprises notches. In an embodiment, the notches are adapted to receive one or more of the lines or cables thai will interconnect the blocks in the completed product. In an alternative embodiment, the notches allow liquid mixture to partly seep out of the moulds.

Jn an embodiment the line comprises a chain having a plurality of links. Hach of the links is preferably prvotally connected to an adjacent link at a chain pivot point. Preferably, each of the moulds is connected to at least one chain link at a mould pivot point In an embodiment, at least a majority of the moulds and two respective adjacent links arc connected together at a single pivot point

In an embodiment, the moulds are releasably connected to the line. In this embodiment, the relcasablc connection allows additional moulds to be added to the device or removed from the device, as required.

In an embodiment, the moulds are teleasably conncctablc to the line so that additional moulds can be connected to the line or one or more of the moulds can be removed.

In an embodiment, the device further comprises a locating frame, the locating frame comprising a plurality of rails adapted to guide the location of the moulds. The rails preferably comprise longitudinal rails and cross rails.

In accordance -with a second aspect of the invention, there is provided a method for forming products comprising:

a) providing a device according to the first aspect;

b) pouring a mixture into the plurality of moulds;

c) allowing the mixture to at least partially set; and

d) lifting the fine from one end such that the moulds are lifted successively along the row.

In an embodiment, the line is lifted from both ends such that the moulds are lifted successively from each end along the row. In an embodiment. The orientation of each mould is substantially maintained as the line is lifted.

In an embodiment, the mixture comprises an unset concrete mixture.

In an embodiment, step d) occurs about one to two hours after step b).

In an embodiment, the moulds are releasably connectable to the line and step a) comprises connecting additional moulds to the device or removing one or more of the moulds from the device. Preferably, the length of the line can be lengthened or shortened as the number of moulds is altered.

[n an embodiment, the moulds comprises notches and step b) comprises allowing the mixture to seep out of Ihe mould through the notches.

In accordance with a third aspect of the invention, there is provided a product when produced by the method of the second aspect.

The term "comprising" as used in this specification means "consisting at least in part of. When interpreting statements in this specification and claims which include the term

"comprising", other features besides the features prefaced by this term in each statement can also be present Related terms such as "comprise" and "comprised" are to be interpreted in a similar manner.

It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numhers within that range (for example, 1, 1 -1, 2, 3, 3 9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub- ranges of all ranges expressly disclosed herein arc hereby expressly disclosed. These arc only examples of what is specifically intended and all possible combinations of numerical values between me lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in t e appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth. As used herein the term "(s)" following a noun means the plural and/or singular form of that noun.

As used herein the term "and/or" means "and" or "or", or where the context allows both.

The invention consists in the foregoin and also envisages constructions of which the following gives examples only.

An embodiment of the present invention provides a method of manufacture that enables multiple daily casts using a single complete mould that is easily removed as soon as the concrete is set, usually one ox two hours. The system may be two parts, an articulating mould assembly and a preparation frame. Multiple preparation frames may be used with each mould depending on the daily pour rate possibilities,

In an embodiment, the articulating mould assembly has pivoting "rows" of mould cavines joined with suitably spaced linked chains terminating at a lifting bar at each end of the assembly. As this assembly is lifted it hangs in a catenary. As the "rows" of moulds are freely mounted on a bar they will hang with base parallel to the ground. During both setting down and lifting off this feature allows each line of mould to act independently. This is especially significant in stripping of the mould as it. concentrates the stripping action on one "row" at a time. In an embodiment, the preparation frame has of a series of tapered guides arranged in the mattress form. The guides have notches to receive the cables and are spaced to minimise drooping of the cables both longitudinally and laterally. Multiple preparation frames can be prepared with cables fitted ready to receive the mould prior to casting. The curing tnattiess may remain with the frame until moved to storage.

In one embodiment, the articulating mould assembly can be independently used for in situ casting of pavemen s revetments and erosion control protection usually over a filter fabric. The advantage of this alternative system is that the wet concrete adheres to the fibres of the filter cloth thereby creating a securely spaced matrix.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which:

Figure 1 is a plan view of a typical product produced by the device and method of this invention;

Figure 2 is a plan view of an alternative embodiment product produced by the device and method of this invention in the form of a mattress with blocks capable of being vegetated after installation as may be used for erosion control;

Figure 3 is a plan view of a further alternative embodiment product produced by the device and method of this invention in the form of mattress with lock snd key blocks integrally moulded within the mattress allowing secure joining of one mattress to another

Figure A is a plan view of a section of the articulating mould assembly of the device of the invention showing the "rows" arranged in longitudinal columns with interconnecting linked chains and a lifting bar,

Figure 5 is a pictorial view of a part of the articulating mould assembly of the device of the invention showing the pivoting block "row", the pivoting feeing rod, and the "row" fixing hige and the cable notches;

Figure 6 is a further pictorial view of a part of two mould block "lines" showing chain links, pivoting fixing rods, and cable notching; Figure 7 is a partial longitudinal view of the articulating mould assembly shotting the mould rows hanging from the chain links in a catenary as being lifted during stripping of the poured product;

Figure 8 is a schematic side elevation of the complete articulating mould assembly lifted by crane or fork lift attached 'with a spreader bar connected to the lifting bars, so that the rows of moulds hang in a catenary;

Figure 9 is a pictorial view an alternative one piece mound "row", spaced fixing lugs, and pivo ing rod;

Figure 10 is a cross section of a locating frame of the device of the invention showing the side frame, the longitudinal locating rails and the cable locating notches;

Figure 11 is a longitudinal section of the locating frame of Figure 10 showing the cable loop frame extension, cross frame, the cross locating rails, and the cable notches;

Figure 2 is a plan view of a section of the articulating mould assembly of the device of the invention;

Figure 1 is a perspective view of the device of the invention;

Figure 14 is a partial side view of the device of the invention before the moulds are lifted and shows a possible lifting mechanism;

Figure 15 is a side view of the device of the invention after the moulds have been lifted and

Figure 16 is a perspective view of a mould of the device of the invention;

Figure 17 is a perspective view of the locating frame of Figures 10 and 1 ;

Figure 18 is a partial longitudinal cross-sectional view in the of the locating frame of Figure 17 and moulds;

Figure 1 is a partial lateral cross-sec (iotial view in the of the locating frame of Figure 7 and moulds;

Figure 20 is a plan view of the locating frame of Figures 10 and 11;

Figure 21 is a plan view of the locating frame of Figures 10 and 11 together with cables; and

Figure 22 is a plan view of Figures 10 and 11 together with cast products; and Figure 23 is a side view of a pair of moulds with shrouds and lifting yokes DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

1 ixarrplrs of the concrete product produced by the device and method described below are shown in Figures 1 to 3. Figure 1 shows the product in the form of mattress with substantially square or rectangular blocks that arc spaced apart in rows and columns. The product has cables 1 that are shown looped at the ends allowing for lifting of the mat with a suitably designed lifting bar 5 as shown in Figure 8. ITie block 2 is a typical module as may be used as permeable paving or pipeline anchors.

Figure 2 shows an alternative embodiment in which the blocks 3 of the mattress have indentations or cavities 3a to allow vegetation to grow through. Figure 2 shows each block 3 having partly circular indentations that together form a substantially circular aperture when the blocks ore formed into a mattress.

Figure 3 shows a further alternative embodiment in which the blocks at the ends of the mattress are lock blocks 4 and key blocks 5 to allow for mattresses to be securely joined together. In further alternative embodiments, the mattress may be formed with both the indentations or cavities and the lock and key blocks.

Wirh reference to Figures 4 ιο 11, a preferred embodiment device for casting a concrete product is shown. The device comprises an articulating mould assembly 100 shown in Figure 4 and a locating frame 20 shown in Figure 10. Thr device can be used ro form a mattress of concrete blocks 2, also known as a revetment mattress. Thr blocks are preferably connected together with cables 1 or other flexible members. The device 100 has a plurality of moulds 6 spaced apart generally in a row R. In the form shown, each mould 6 has a plurality of spaced apart cavities 6b for receiving concrete. The cavities are spaced apart in a direction that is generally transvme to the row of moulds. In the embodiment shown, the cavities are spaced apart in a direction that is generally perpendicular to the row of moulds forming a grid of cavities, which in turn form a concrete mattress having blocks formed in a grid. Figure 4 shows the rows arranged in longitudinal columns with interconnecting Unkcd chains 7 connecting adjacent rows, and a lifting bar 8. With reference to Figures 10 ,11 18 end 19, the locating frame 20 comprises a side frame 18, longitudinal locating rails 19, cross frame 21, and cross locating rails 23. Additionally, the locating frame has cable locating notches 13a and a cable loop frame extension 22. The locating frame acts as a guide for the position and alignment of the moulds 6 and the cables . Additionally, the locating frame rninimizes the amount of liquid that seeps out of the moulds, for example, through the notches 13 of the moulds. Another use of the locating frame is to provide pre-stressing of the cable, if required. The number of rails and the position of the rails will depend on the droop of the cable, which in turn depends on the strain applied at the cable terminals. The locating frame may take a variety of forms and may be formed from angle iron or folded sheet steel, for example.

MOULDS

With reference to Figures 5 to 7, a preferred embodiment mould is shown. Each mould 6 has a plurality of mould cavities 6b. Each cavity 6b is defined by four walls 6a that define a substantially square or rectangular cavity 6b, which in turn form a substantially square or rectangular concrete block 2. The cavity shape will be chosen or designed depending on the required shape of the concrete block. For example, the mould 6 will have protrusions extending into the cavity to form indentions required for the mattress shown in Figure 2.

Each cavity 6b is open at the top to aUow concrete to be poured into the cavity. Each cavity 6b is open at the bottom to allow set concrete to be removed from the cavity. In addition, the walls 6a have a downwardly-diverging taper or draft to assist removal of the mould away from the concrete block. The walls of the moulds 6 have notches 13 fo receive one or more of the lines or cables 1 that will interconnect the blocks 2 in the comp ted product. In some embodiments, the final product may not have lines or cables interconnecting the blocks. In those embodiments, the notches 13 in the moulds alow liquid mixture to seep out of the moulds and form ribs extending between the blocks. With reference to Figures 5, and 9, the moulds 6 have fixing lugs ,9 with apertures for receiving a rod, in the form of a pivoting fixing rod 10. Figures 13 and 23 show a modification to the device in which the fixing lug 9 is attached to the mould via a yoke 9b so that the centre of the mould is unobstructed. Figures 13 and 23 also show shrouds 11 that mask the joints between the row of moulds. LINE

The articulating mould assembly of the device 100 also has one or more lines operauVely connected to the moulds. The line(s) extend(s) in a direction generally parallel to the row of moulds to connect the rows of moulds. In the pre feared embodiment shown, the line is a chain having a plurality of links 7. Bach of the links 7 is pivorally connected to an adjacent link at a chain pivot point 7a.

PTVOT CONNECTION

Each mould 6 is pivotally connected to the chain links 7 at a mould pivot point. In the preferred embodiment shown, the mould pivot point comprises an aperture 9a in the fixing lug 9, as shown in Figure 16. The aperture 9& is preferably offset from the center of the mould so mat as the mould is lifted, one side of the mould starts to lift before the other side of the mould starts to lift However, the aperture may be substantially in line with the center of the mould, if desired. In the preferred embodiment shown, each of the moulds and two adjacent links are connected together at the same point.

Figures 5 and 16 show an embodiment in which each mould 6 has a single mould cavity. A plurality of moulds will be positioned adjacent each other in each of the longitudinal and transverse directions of the articulating mould assembly. Alternatively, each mould may be a one-piece mould 6', having two or more cavities, as shown in Figure 9. In the alternative embodiment shown in Figure 9, the fixing lugs 9' are spaced part with a plurality of cavities between the lugs.

The moulds 6 are releasably connectahlc to the line so that additional moulds can be connected to the line or one or more of the moulds can be removed, as requited. The links are also releasably connected to adjacent links so that the length of the line can be lengthened or shortened as the number of moulds is altered. I -THOD

A preferred method of casting a concrete product using the device described above will now be described The device is prepared with the locating frame acting as a guide for the moulds and the cables. Figure 20 shows the locating frame ready for the cables and Figure 21 shows the cables positioned in the frame. The first step is to pour liquid concrete into the plurality of moulds and the concrete is then allowed to at least partially set Ihis part of the method takes from about one hour to about two hours. The concrete could be left in the cavities to set fully; however, using the preferred embodiment device described it is possible to remove the concrete without the concrete being fully set.

Aftct the concrete has at least partially set, the links 7 arc lifted from one end, or both ends, such that the moulds 6, 6' arc lifted individually along the row R. If necessary, prior to lifting the moulds, the moulds could be tapped or vibrated to release the products from the moulds. With reference to Figures 8, 14 and 15. the links arc lifted using a suitable lifting device, such as a crane 14 or ones of a forklift 14a for example. The device may further comprise a spreader bar 15 connected to the lifting bars 8, to maintain (lie lifting barb in a desired spaced apart position. The moulds may be suspended f om the pivot point such that the orientation of each mould is suberanftalh/ maintained as the line is lifted, as shown in Figure 7. The moulds 6 w31 hang in a catenary 16 as they are being lifted, as shown in Figure 15.

In one embodiment, cables 1 will be placed in the device before the concrete is poured into the moulds 6. The cables 1 arc placed in the device to extend in a direction along the rows R of moulds and/or interconnecting adjacent rows of moulds. When the product is formed, the cables 1 will connect the blocks together. Figure 22 shows the cast product and the locating frame. Figure 21 shows a single locating frame pre fitted with cables. I Iowever, it will be appreciated that there may be a plurality of locating frames, for example fo"ur or five locating frames. As one frame and set- of moulds is being filled, the other frames are prepared with cables in the slots.

In an alternative embodiment, cables will nor be placed in the device In this embodiment, when liquid is poured into the moulds 6, the notches 13 in the moulds allow liquid mixture to seep out of the moulds. When the liquid sets, the seeped liquid will form ribs extending between adjacent blocks. This alternative embodiment is formed on a textile material, preferably a filter cloth. Hie wet concrete adheres to the fibres of the filter cloth thereby creating a securely spaced matrix. In addition, the ribs will act as spacers between the blocks. When the mat flexes, the ribs will break free from the blocks, but will still act as spacers.

The method described above may be carried out of sitc and the concrete mattress then transported to a site where it will be placed. Alternatively, the tneiiio l described above may be carried out on site, for example, when Conning a runway at au airport.

Preferred embodiments of the invention have been described by way of example only and modifications may be made thereto without departing from the scope of the invention.

For example, the line that connects that moulds has been described as a chain. Alternatively, the line could be a cable or rope to which the moulds may be attached.

The preferred embodiment method and device is used to cast concrete components. However it will be appreciated that die device and method may be used to cast other components including metallic or polymeric components.




 
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