TECHNICAL FIELD

This disclosure relates to a system, apparatus and method for the cleaning of bricks used in construction (e.g. in buildings, dwellings, etc.) to enable recycling/reuse of the bricks. The system, apparatus and method find particular application in the cleaning of bricks that have a soft mortar adhered to one or more faces thereof, such a soft mortar typically comprising lime mortar, although the system, apparatus and method can be applied to other mortar types such as pozzolanic mortar, gypsum mortar, etc.

BACKGROUND ART

Prior to the introduction and use of cement mortar and polymer cement mortar, bricks used in construction were bound together in masonry walls using soft mortars, principally lime-based mortars. Portland cement-based mortars set hard and are very difficult to remove. Softer mortars can be removed, whereby the bricks can be recycled for re-use in construction and related applications.

Systems are known that automate the cleaning of bricks, although typically these are embodied in permanent, factory-based installations. In addition, there are few systems that offer a near-complete handling methodology, including feeding of to-be-cleaned bricks, dealing with mortar dust removed from the bricks, and delivery of a clean brick (e.g. to a pallet).

US 4,557,246 discloses a brick cleaning machine that comprises breaker means for breaking and dislodging mortar, a penetration means operable to penetrate a layer of mortar, and scraper means for scraping and providing a finished surface on a brick. The penetration means takes the form of three sets of teethed sprocket pairs, the pairs located on respective opposite sides of the brick, the teeth of each sprocket pair arranged to penetrate into mortar located at the respective brick side. The teeth of the sprockets protrude into the path of an oncoming brick and are of sufficient hardness to penetrate the mortar without damaging the brick. The sprockets are rotated by the action of the brick moving therepast. The brick cleaning machine of US 4,557,246 requires three separate cleaning means, including a scraper means for removing the mortar still left on the brick after it passes through the penetration means. It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

SUMMARY

Disclosed herein is an apparatus, system and method for the cleaning of bricks that have mortar adhered to one or more faces thereof. As set forth above, typically the mortar is a soft mortar such as lime mortar, although the system, apparatus and method can be applied to other mortar types such as pozzolanic mortar, gypsum mortar, etc.

In a first aspect, there is disclosed an apparatus for cleaning a brick that has a forward end, a rear end and mortar adhered to one or more faces thereof. As set forth above, the mortar can be a soft mortar, such as lime mortar, a pozzolanic mortar, a gypsum mortar, etc.

The apparatus comprises a mechanism configured to arrange the brick (i.e. the brick to be cleaned) in an axial direction extending from the rear end to the forward end. For example, the brick arrangement mechanism may take the form of a conveyor that conveys one or more bricks through the brick cleaning apparatus. As set forth below, the brick cleaning apparatus may comprise further mechanisms for arranging the brick in the axial direction.

The apparatus also comprises a removal apparatus configured to be moved in relation to the brick cleaning apparatus so as to remove the mortar adhered to the one or more faces of the brick. In accordance with the present disclosure, the removal apparatus is arranged to be moved through the mortar in a direction that is generally opposite to the axial direction.

By moving the removal apparatus through the mortar in a direction that is generally opposite to the axial direction, a significant amount of mortar can be removed from the brick in e.g. a single pass through the brick cleaning apparatus. As set forth below, the opposite movement can also be advantageously availed to assist with maintaining brick orientation.

In one variation, the mechanism may be configured to move the brick forward in the axial direction. The movement forward can be in relation to a remainder of the brick cleaning apparatus. In another variation, the mechanism may be configured to hold the brick in the axial direction. The holding of the brick can again be in relation to a remainder of the brick cleaning apparatus. In either case, the removal apparatus can be arranged to be moved through the mortar whilst the mechanism either moves the brick forward or holds the brick in the axial direction.

In an embodiment, the removal apparatus may be configured to be rotated so as to remove the mortar adhered to the one or more faces of the brick. Thus, the direction of rotation of the removal apparatus at the brick can be generally opposite to the axial direction. Rotation of the removal apparatus can assist with providing the requisite mortar-removal force. The rotational force can also be availed to assist with brick orientation (e.g. when the rotation axis is skewed relative to the axial direction of the brick, the rotation of the removal apparatus can drive the brick downwards - e.g. against a conveyor).

In a simple variation, the removal apparatus may comprise a single removal device. In this case, the brick-to-be-cleaned may need to be passed multiple times through the brick cleaning apparatus.

In another variation, the removal apparatus may comprise a number of removal devices that are arranged to operate at one mortar-covered side of the brick. Again, the brick may need to be passed multiple times through the brick cleaning apparatus.

However, in a typical variation of the brick cleaning apparatus, the removal apparatus may comprise at least one pair of removal devices. Each device in the at least one pair may be configured to be located at a respective opposite side of the brick. Thus, the removal device may be moved into the mortar located at respective and opposite brick sides and may thereby remove mortar from the brick opposite sides at the same time.

In an embodiment, the removal apparatus may comprise two pairs of removal devices. Each device of each pair may be configured to be located at a respective opposite side of the brick. For example, the removal apparatus may comprise a fore pair that is arranged to engage a leading end of the brick. The fore pair may then be adapted to remove a bulk of the mortar from opposite sides of the brick. The aft pair can be arranged to engage the brick leading end after it has passed through the fore pair. The aft pair may then be adapted to remove a remainder of mortar from the opposite sides of the brick. Thus, the removal apparatus can be configured to clean the brick (i.e. to satisfactorily remove a bulk of the mortar therefrom), typically in a single pass through the apparatus.

In this embodiment, each removal device in the fore pair may comprise a coarse mortar- removing material such as a plurality of coarse wires (e.g. each wire of a metal alloy that is resistant to the mortar material). The coarse mortar-removing material can be configured to remove a bulk of mortar from a respective face of the brick. In this embodiment, each removal device in the aft pair may comprise a fine mortar-removing material such as a plurality of fine wires (e.g. again, each wire of a metal alloy that is resistant to the mortar material). The fine mortar-removing material can be configured to remove a remainder of mortar from the respective face of the brick (e.g. finer mortar particles not removed by the coarse material).

In an embodiment, the removal apparatus may comprise at least one brush. The at least one brush may be configured to be moved into and through so as to remove the mortar adhered to a given face of the brick. For example, each removal device may take the form of a brush that moves into and through the mortar. In an embodiment, each brush may comprise a rotary brush. The rotary brush can have a central rotary axis. A plurality of radially extending filaments (e.g. of the coarse or fine wire, or even a combination thereof) may each project out from the central rotary axis around a circumference of the brush. For example, the brush can have the form of a rotary-type cylindrical brush.

In an embodiment, the central rotary axis may be skewed with respect to the axial direction of the brick. When viewed from the side, the skewing can be such as to form an acute angle between the axial direction of the brick (i.e. the angle formed above the main brick axis) and the central rotary axis. As set forth above, this skewing of the rotary axis, when coupled with a contra-rotation of the or each removal device can work to drive the brick downwards (i.e. towards and into engagement with the brick arrangement mechanism), thereby assisting with the maintenance of brick orientation.

In an embodiment, the brick cleaning apparatus may be configured such that a rotational speed of each removal device is able to be adjusted (e.g. such as when the removal device has the form of a rotary-type cylindrical brush). For example, the rotational speed of each removal device may be controlled in response to a changing resistance of the mortar to be removed and/or in response to a changing (i.e. diminishing) size of each removal device due to wear over time, etc.

In an embodiment, the or each removal device may be mounted to a respective arm. The arm may be articulated whereby the or each removal device may be moved into engagement with the mortar adhered to the one or more faces of the brick (e.g. selectively moved into engagement). The arms may be caused to deflect outwardly when the brick is moved relatively forwards in the axial direction.

For example, each arm may be arranged to be biased such that each removal device may be biased into engagement with the mortar adhered to the one or more faces of the brick as the brick moves relatively past the removal device. The biasing can maintain a constant pressure of the removal device against the mortar. The degree of bias may also be adjustable such that the force of contact (i.e. load) of each removal device at the mortar may be adjusted. The amount of bias applied may optionally be detected by a sensor, which sensor may also be used to detect when each removal device eventually makes contact with an underlying brick surface (i.e. as a result of mortar removal) whereby the movement or bias of the arm may then be reduced, removed or stopped.

In an embodiment, the mechanism that arranges the brick in the axial direction may comprise a conveyor that is configured to move the brick forward in the axial direction. The conveyor may be configured to convey a plurality of axially aligned bricks through the brick cleaning apparatus. The conveyor can be driven in a manner such that it drives each brick forwards (e.g. with sufficient force) to pass through the removal apparatus. Thus, the conveyor and the removal apparatus can work together to maximise the amount of mortar removed in a single pass (i.e. the conveyor moves forwards, the removal device generally moves backwards).

In an embodiment, the brick cleaning apparatus may further comprise one or more guides that are arranged to maintain a brick in alignment with the axial direction. The guides may take the form of one or more lineal brushes. The lineal brushes may be arranged laterally of the brick and/or vertically over the brick. The lineal brushes may be arranged in the brick cleaning apparatus to act on a given brick both prior to and after it has passed through the removal apparatus. The guides can work in conjunction with the conveyor and the mortar removal apparatus to maintain each brick in alignment with the axial direction.

Also disclosed herein is an apparatus for cleaning a brick that has a forward end, a rear end and mortar adhered to one or more faces thereof. The brick cleaning apparatus can be as defined above. In this regard, the brick cleaning apparatus comprises a mechanism (e.g. as set forth above) that is configured to arrange the brick in an axial direction extending from the rear end to the forward end. The apparatus also comprises a removal apparatus (e.g. as set forth above) that is configured to be moved in relation to the brick cleaning apparatus so as to remove the mortar adhered to the one or more faces of the brick. The removal apparatus can be arranged to be moved through the mortar in a direction that is generally skewed to the axial direction of the brick.

For example, as set forth above, the removal apparatus can be moved (e.g. it can rotate) on an axis that can be skewed with respect to the axial direction of the brick. When viewed from the side, the skewing of the axis can be such that it forms an acute angle with the axial direction of the brick. As set forth above, this skewing, in conjunction with the contra-movement (e.f. contra-rotation) of the removal apparatus can work to drive the brick downwards (i.e. towards the brick arrangement mechanism), thereby assisting with brick orientation.

Also disclosed herein is an apparatus for cleaning a brick that has mortar adhered to one or more faces thereof. Again, the brick cleaning apparatus can be as set forth above. In this regard, the brick cleaning apparatus comprises a removal apparatus (e.g. as set forth above) that is configured to be moved into so as to remove the mortar adhered to the one or more faces of the brick. The brick cleaning apparatus also comprises a biasing mechanism configured to bias the removal apparatus against the mortar in a manner that maintains a constant pressure of the removal apparatus against the mortar. As set forth above, this constant pressure can enhance mortar removal, with the constant pressure typically being maintained to account for varying degrees of mortar hardness, and/or to adjust as the removal apparatus wears over time, etc.

In another aspect, there is disclosed herein a system for cleaning a brick that has mortar adhered to one or more faces thereof. The system comprises a brick cleaning apparatus (e.g. as set forth above) that is configured to remove the mortar adhered to the one or more faces of the brick whereby mortar particulates (e.g. mortar dust) can become airborne (i.e. during and as a result of mortar removal). The system also comprises a collection apparatus that is configured to capture the airborne mortar particulates from an airstream removed from the brick cleaning apparatus. The system can produce a cleaned airstream for release to atmosphere. In an embodiment, the collection apparatus may comprise a housing with an inlet for receiving the airstream bearing the mortar particulates from the brick cleaning apparatus. The collection apparatus may also comprise a filtration apparatus that is arranged within the housing to filter the airborne mortar particulates from the airstream. The collection apparatus may further comprise an extractor that is arranged to draw the airstream into the housing via the inlet so that the airstream bearing the mortar particulates passes through the filtration apparatus.

In an embodiment, the filtration apparatus may comprise a plurality of filter bags. Each filter bag may have an open upper end. Each bag may be supported at its open upper end to hang from a wall of a plenum chamber of the housing. Each bag may have a tubular configuration and may comprise internal bracing to maintain its tubular shape during use. A respective aperture may be provided through the plenum wall to align with each bag open upper end. The extractor may be arranged to draw the airstream into the housing by applying a vacuum to the plenum chamber. The vacuum applied to the plenum chamber can cause the airstream to pass through each bag and into the plenum chamber via each bag’s open upper end and via each bag’s respective aligned aperture.

In an embodiment, the housing may comprise a plurality of filtration compartments. Each filtration compartment may be arranged to house a respective filtration apparatus therein. Each filtration compartment may be further configured to enable collection of the filtered mortar particulates from the compartment. For example, each filtration compartment may taper towards a narrow, lower outlet whereby mortar particulates can fall towards the outlet and be collected thereat (e.g. in a solids sack). By employing a plurality of filtration compartments, the filtration capacity of the system can be increased.

In an embodiment, the system may further comprise a back-pressure apparatus that can be configured to apply a back pressure of air to the filtration apparatus to periodically dislodge mortar particulates from the filtration apparatus (e.g. particulates that have formed a cake at the or each filter bag. For example, the back-pressure may be applied as a shot or pulse of air that takes the form of a reverse airstream that passes via the plenum chamber to be directed back through an aligned aperture and into the open upper end of each bag, and to flow in reverse across each bag. A series of back-pressure discharge pipes can be arranged in the plenum chamber, each pipe having a plurality of discharge nozzles, each nozzle directed to a respective aligned aperture and bag open upper end. The resultant dislodged mortar particulates can e.g. drop down from each bag and into a respective fdtration compartment to be collected from the compartment at its lower outlet, along with the otherwise normally filtered mortar particulate drop-outs.

In an embodiment, the system may further comprise a brick infeed conveyor that is configured to feed bricks into the brick cleaning apparatus. For example, the brick infeed conveyor may be adapted to convey the bricks to the brick cleaning apparatus in a manner whereby the bricks are moved into adjacency of one another for subsequent close movement through the brick cleaning apparatus (i.e. the brick infeed conveyor may act as an overspeed conveyor). Thus, the bricks can be passed into the brick cleaning apparatus in a continuous line.

In an embodiment, the system may also comprise an output conveyor configured to receive cleaned bricks from the brick cleaning apparatus and convey them away. The output conveyor can take a number of forms as set forth below.

In a further aspect, there is disclosed herein a method of cleaning a brick that has a forward end, a rear end and mortar adhered to one or more faces thereof. The method comprises arranging the brick in an axial direction extending from the rear end to the forward end. The method also comprises removing the mortar adhered to the one or more faces of the brick by moving a removal apparatus through the mortar in a direction that is generally opposite to the axial direction. In a variation of the method, the removal apparatus may additionally or alternatively be moved through the mortar in a direction that is generally skewed to the axial direction. In yet a further variation of the method, the removal apparatus may additionally or alternatively be moved in a manner that maintains a constant pressure of the removal apparatus against the mortar.

The method may be deployed using the apparatus as set forth above. The method may be deployed using the system as set forth above.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only, with reference to the accompanying drawings in which: Figure 1 is a perspective view of a system for removing e.g. a lime mortar from bricks to enable their recycling;

Figure la is another perspective view of a system for recycling bricks showing an alternative arrangement for the output conveyor.

Figures 2A and 2B respectively show a perspective view and a side plan view of an infeed conveyor of the system;

Figure 3 is a perspective view of a brick cleaning machine of the system with a housing thereof partially removed to show internal components;

Figure 4 is a sectional side plan view of the brick cleaning machine with housing partially removed to show internal components;

Figure 5 is another perspective view of the brick cleaning machine with housing partially removed to show internal components;

Figure 5a is a top plan view of the brick cleaning machine;

Figure 6 is a side plan view of the brick cleaning machine with housing partially removed to show internal components;

Figure 7 is another side plan view of the brick cleaning machine with housing partially removed to show internal components;

Figure 8A is a perspective view of the motorised brick cleaning assembly with articulated arms in an inwardly biased configuration;

Figure 8B is a plan view of the underside of the motorised brick cleaning assembly with articulated arms in the inwardly biased configuration;

Figure 9A is a perspective view of the motorised brick cleaning assembly with articulated arms orientated outwards;

Figure 9B is a plan view of the underside of the motorised brick cleaning assembly with the articulated arms orientated outwards;

Figure 10 is a perspective view of the motorised brick cleaning assembly with articulated arms in an inwardly biased configuration; Figure 11 is a perspective view of a dust collector assembly;

Figure 12 is a top plan view of the dust collector assembly;

Figure 13 is a side plan section view of the dust collector assembly taken through section B- B in Figure 12.

DETAILED DESCRIPTION

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

In the following description, a system, apparatus and method for the cleaning of bricks for use in construction (e.g. in buildings, dwellings, etc.) will be set forth in detail. The system, apparatus and method allow for recycling/reuse of the bricks. The following description is directed to the cleaning of bricks that have a soft mortar adhered to one or more faces (e.g. a lime mortar,) but can be applied to other mortar types such as pozzolanic mortar, gypsum mortar, etc.

Automatic Brick Recycling System

Figures 1 & la each depict all of the main components of the system. Each of these components will be described separately hereafter in further detail.

The system comprises an apparatus 10 for removing e.g. lime mortar from recycled bricks. The apparatus 10 as depicted is portable and can be delivered to a site (e.g. a building and/or demolition site) to enable cleaning of bricks on site. However, it should be understood that the apparatus 10 can be incorporated into a permanent installation, in a factory or other facility, in which case, bricks to be cleaned would be delivered to the installation. The apparatus can also be scaled up as required. The brick cleaning apparatus 10 comprises a brick cleaning machine 12, an infeed conveyor 14, a collection apparatus in the form of a dust collector assembly 16 and an output conveyor 18. Brick cleaning machine 12 is enclosed by machine base 20, clam shell doors 22a and 22b, outer covers 24a and 24b and chutes 26. In the absence of a dust collector assembly 16, the mortar debris can be removed from the machine 12 via the chutes 26. Otherwise, the chutes 26 are normally closed.

Infeed conveyor 14 and output conveyor 18 are mounted to opposing ends of machine base 10. Infeed conveyor 14 abuts outer cover 24a and output conveyor 18 abuts outer cover 24b. Dust collector assembly 16 is coupled to brick cleaning machine 12 through exhaust ducts 28a and 28b. Hydraulic oil cooler assembly 17 is attached to brick cleaning machine 12 by mounting to roll cage 19. A second hydraulic cooler 17 is attached to dust collector assembly 16. These oil coolers function to cool hydraulic oil used in the system.

The embodiment of Figure la is identical in all respects to the embodiment in Figure 1 other than the output conveyor 18 being reconfigured. In this regard, the output conveyor 18 of Fig. la comprises two opposing and transversely extending gravity driven output conveyors. It should be understood that other infeed conveyor and output conveyor arrangements can be adopted and are within the scope of this disclosure.

In general overview, a plurality of prior-separated bricks that are ready to be cleaned

(hereafter recycled bricks 30) are delivered to the apparatus 10 (e.g. stacked on a pallet or loaded onto a table to be located next to the infeed conveyor 14). The bricks can also be delivered to the infeed conveyor 14 via another, separate conveyor.

A user loads the recycled bricks 30 lengthwise onto the infeed conveyor 14 (or other conveyor) where they are conveyed by infeed conveyor 14 up to enter the brick cleaning machine 12 through the outer cover 24a thereof. The bricks then pass into the machine 12 where they are cleaned of mortar (as described below). In the course of mortar removal, mortar debris, mortar dust and airborne mortar particulates are generated and can be extracted via exhaust ducts 28a and 28b to the dust collector assembly 16. The dust collector assembly 16 removes the mortar debris, dust and particulates from the exhaust air to enable discharge to atmosphere of a cleaned airstream. The cleaned bricks pass out of the brick cleaning machine 12 where they are either conveyed linearly (Fig. 1) or transversely (Fig. la) by the output conveyor 18. At the end of the output conveyor 18 the cleaned bricks may be re stacked on a pallet, ready for reuse. Infeed Conveyor 14

Referring now to Figures 2A and 2B, it will be seen that the apparatus 10 includes an infeed conveyor 14 used to transport mortar covered recycled bricks 30, with a clean side thereof facing downward on an infeed conveyor belt 32 of conveyor 14, the mortar covered bricks 30 then passing into brick cleaning machine 12. The infeed conveyor 14 typically operates (i.e. moves linearly) at a faster speed than a conveyor belt 38 of the brick cleaning machine 12. This means that the spacing between bricks on the conveyor 14 can be closed when the bricks reach the entrance passage in the outer cover 24a of machine 12. The differential conveyor speed arrangement also serves as a buffer to remove gaps between inconsistently placed bricks, allowing a generally steady (constant) flow of bricks to be continuously supplied into the brick cleaning machine 12. This arrangement also assists to stabilise brick movement during the cleaning method.

Power is provided to the infeed conveyor 14 by means of a hydraulic drive assembly 34 that is positioned proximal to the brick cleaning machine 12. An infeed conveyor drive roller 36 is directly mounted to hydraulic drive assembly 34 and translates power to rotate the conveyor belt 32 in use. The hydraulic oil of drive assembly 34 is cooled in cooler assembly 17.

Referring now to Figure 3, it will be seen that recycled bricks 30 enter brick cleaning machine 12 through a specially shaped passage in outer cover 24a. The recycled brick 30 moves from infeed conveyor belt 32 onto the conveyor belt 38 of transport conveyor 40. Transport conveyor 40 is typically driven independently from infeed conveyor 14 and thus allows infeed conveyor 14 to be operated at higher speeds than transport conveyor 40, as set forth above.

Brick Cleaning Machine 12

Figures 3 through 7 shows the internal components of brick cleaning machine 12. The brick cleaning machine 12 can be portable. For example, the machine 12 can be mounted on caterpillar tracks to enable it to be moved on site to a suitable operating location.

Brick transport conveyor 40 is mounted to the machine base 20 and defines a path along which a recycled brick 30 travels through cleaning machine 12, from the infeed conveyor 14 to output conveyor 18. The conveyor belt 38 is supported by a plurality of conveyor drive rollers 42, defining a lower portion of the brick transport conveyor 40. The transport conveyor 40 is configured to convey a plurality of axially aligned bricks (i.e. in an axial direction) through the brick cleaning machine 12.

The brick cleaning machine 12 comprises one or more guides that are arranged to maintain each brick in alignment with an axial direction of travel of the brick through machine 12. In this regard, vertical and horizontal movement of a brick 30 along conveyor belt 38 is limited by a guide in the form of brush assembly 44. Further, the brush assembly 44 comprises a top brush assembly 45 that is oriented parallel to and is suspended above conveyor belt 38. The top brush assembly 45 restricts vertical movement of each brick as it travels through machine 12. As best shown in Figures 4, 6 & 7, the brush assembly 44 also comprises parallel, laterally arranged input brush assemblies 46 which are supported over conveyor belt 38, extend generally perpendicular to conveyor belt 38 and are located at distal ends of the transport conveyor 40 (i.e. the input brush assemblies 46 are located at both input and output ends of transport conveyor 40). The input brush assemblies 46 function to restrict lateral movement of a brick 30 outside the path taken by conveyor belt 38 (i.e. as the brick travels through machine 12). The brush assembly 44 further comprises removal apparatus for the removal of mortar layers in the form of two motorised brick cleaning assemblies 48a and 48b which are located intermediate brush assemblies 46. The top brush assembly 45, input brush assemblies 46 and motorised brick cleaning assemblies 48a and 48b will now be described in further detail.

Brush Assembly - Top & Parallel Brush Assemblies 45 & 46

Referring firstly to Figures 4 & 5, as bricks 30 enter the brick cleaning machine 12 to travel along transport conveyor 40, the top brush assembly 45 and input brush assemblies 46 have a plurality of filaments in the form of projecting bristles 50 that protrude into the path taken by bricks 30. The bristles are arranged to provide sufficient downward and lateral forces to maintain contact with the brick, and to enhance contact between the brick 30 and conveyor belt 38. The brushes of top 45 and input 46 brush assemblies are typically of a different material to the brushes of the motorised brick cleaning assemblies 48a and 48b. The brushes of top 45 and input 46 brush assemblies are typically also shorter in length. For example, the top and parallel brush assemblies can be of a polymer that has shape memory and that is durable (e.g. a polyurethane).

The top 45 and input 46 brush assemblies are positioned on either side of the assemblies 48a and 48b. Because the bristles 50 on top 45 and input 46 brush assemblies are also arranged to protrude into the path taken by bricks 30, they provide sufficient downwards and lateral forces to maintain alignment of brick 30 along conveyor belt 38. Bristles 50 in brush assemblies 45, 46 and 48a, 48b are composed of yieldable materials but of sufficient hardness (e.g. metal/alloy wire) to stabilise the movement of bricks 30 along a substantial length of transport conveyor 40 and, in the case of assemblies 48a and 48b, to remove mortar from the bricks 30. The materials of bristles 50 are typically resistant to chemical and mechanical wear from contact with mortar.

Brush Assembly - Motorised Brick Cleaning Assemblies 48a and 48b

Referring now to Figures 6 to 10, it will be seen that the motorised brick cleaning assembly 48 (i.e. fore assembly 48a and aft assembly 48b) comprises removal devices in the form of two brush wire wheels shown generally at 52, each mounted for rotation at a respective arm in the form of articulated cleaning arm 54. The brush wire wheels 52 each rotate on a central rotary axis. The two articulated cleaning arms 54 are mounted to either side of an elongate top plate 56 of the brick cleaning assembly 48. The motorised brick cleaning assemblies 48a and 48b comprise the primary mechanism for removing mortar from the recycled bricks.

In this regard, the brick cleaning assemblies 48a and 48b penetrate mortar on bricks moving along brick transport conveyor 40 by means of the bristles of the rotating brush wire wheels 52 moving against and into the mortar. Because the materials of the wire wheels 52 are typically chosen to be resistant to chemical and mechanical wear from contact with mortar, they can have a relatively long wear life (e.g. up to a few months of constant use). Further, the material of the wheels 52 typically has sufficient hardness to penetrate the mortar attached to bricks 30, but without damaging the bricks 30 themselves.

In the fore assembly 48a, the brush wire wheels 52a take the form of coarse knotted wire, with fore assembly 48a being located proximal to infeed conveyor 14. Aft assembly 48b is substantially identical in structure to fore assembly 48a but contains fine knotted wire wheels 52b. Aft assembly 48b is located adjacent to fore assembly 48a but proximal to output conveyor 18. Thus, fore assembly 48a precedes aft assembly 48b in terms of conveyor forward movement and brick contact. The coarse knotted wire of fore wheels 52a serves to primarily dislodge the bulk of the mortar from the mortar-bearing faces of bricks 30. Further, the fine wire wheels 52b in aft assembly 48b are configured to remove any remaining small pieces of mortar, such that the bricks 30 leaving machine 12 are sufficiently clean to be ready for reuse. In the course of mortar removal, mortar dust and airborne mortar particulates are generated, to be captured as outlined below.

As best shown in Figures 6 & 7, the assemblies 48a and 48b are offset (i.e. each plate 56 is angled) with respect to an elongate axis of travel of the conveyor 38 through the brick cleaning machine 12. In addition, the orientation of plate 56 of fore assembly 48a is rotated 180 degrees to the plate 56 of aft assembly 48b (i.e. such that the arms 54 and wheels 52 of the assemblies extend generally towards each other and are located on opposite sides of an angled plane extending between the assemblies 48a and 48b; this angled plane forms an acute angle above the elongate axis of travel of the conveyor 38).

The resultant angling of the wheels 52 (i.e. with respect to opposing mortar-covered sides of an adjacent brick being cleaned) ensures a maximised area of coverage, directs removed mortar downwards, and also ensures that, when the wheels are rotated in a contra-direction to that of the travelling brick, the brick being cleaned is forced downwardly, as explained in further detail below. In a specific embodiment, both motorised brick cleaning assemblies 48a and 48b are orientated at an acute angle of approximately twenty degrees to the elongate axis of travel of conveyor belt 38. As above, this angle also ensures a vertical alignment between the face of each wire wheel 52 and a respective full side of the brick 30 that is moving through the assemblies 48a and 48b. As above, this wire wheel orientation along with a contra-rotation of wire wheels 52 applies a downwards force vector to each recycled brick 30 as it is urged forwards by conveyor 30 between the assemblies 48a, 48b, thereby improving the mortar removal action, whilst also increasing traction and stability of bricks on conveyor belt 38 (i.e. the bricks are driven forward against a contra-acting mortar removal force).

Each motorised brick cleaning assembly 48a, 48b includes hydraulic motors 58 located vertically adjacent to wire wheels 52 to provide direct power for rotation of the wire wheels 52. As above, the hydraulic motors 58 are configured to rotate wire wheels 52 in a direction opposite to the direction of travel of bricks on conveyor belt 38 (i.e. at the point of contact between the wheels and mortar) to thereby oppose the conveyor directional force and to drive the wire brushes of each wheel 52 into the relatively soft mortar. The combined contra rotation, along with the angling of the wheels 52 also directs removed/dislodged mortar debris downwards towards exhaust ducts 28a and 28b of the brick cleaning machine 12.

As best shown in Figures 8A & 8B, the shafts 62 of the articulated cleaning arms 54 are typically biased (typically hydraulically, but can be via spring-loading, etc.) such that the wheels 52 of a given assembly 48a, 48b are urged together so as to protrude into the travel path taken by bricks 30 moving along transport conveyor 40 (i.e. Figures 8A&B show an inwardly biased configuration where the wire wheels 52 are adjacent/abutting, being their configuration prior to machine operation). However, as illustrated by Figures 9A & 9B, the wheels 52 and arms 54 can be moved apart into a machine-operation configuration, but still spaced together more closely than the width of a given conveyor-driven brick 30. The wheels 52 and arms 54 can then be moved further apart by a brick contacting the wheels (i.e. the travel-forward force on the brick is sufficient to overcome the biasing on the shafts 62 to the machine -operation configuration) .

During operation of brick cleaning machine 12, the wire wheels 52 of each motorised brick cleaning assembly 48a, 48b are moved apart to the machine operating position (Figs. 9A/B) and are rotated at speed by power delivered from the hydraulic motors 58. Typically, the speed of rotation or each wire wheel 52 is constant but is adjusted according to the diameter or each wire wheel 52. In this regard, over time, each wire wheel 52 will wear, whereby the rotational speed of each wire wheel 52 is adjusted to maintain a constant speed at the interface between the wire wheel circumference and the mortar.

Further, to ensure better control, typically in the machine-operating position, each of the articulated cleaning arms 54 are held at that orientation by a sensed level of hydraulic pressure. Again, due to wear of wire wheel 52, the pressure applied to each wire wheel 52 via the arms 54 is adjusted to maintain a constant pressure (or loading) at the interface between the wire wheel circumference and the mortar. The hydraulic pressure on arms 54 is imparted via a hydraulic pressure manifold 60, whereby the orientation of the arms 54 is inward, but in a non-abutting, non-rotating position of the wheels 52. During machine operation, the articulated cleaning arms 54 are caused to rotate outwards from their inwardly biased orientation to the non-abutting position of Figs. 9A&B (i.e. a position that is determined by the wire wheel 52 diameter) with the wheels then each being motor-rotated. Then, as uncleaned bricks 30 enter the motorised cleaning assembly 48, the wire wheels 52 contact the leading end and then the mortar-bearing sides of bricks. Articulated cleaning arms 54 in contact with both sides of brick 30 rotate out and independently about shaft 62 whilst in contact with brick 30 and are configured so as to apply a constant loading to the variable mortar thickness. Variation - inverted orientation of motorised brick cleaning assembly

In a variation to the arrangement shown in Figures 6 to 10, the orientation of the motorised brick cleaning assembly 48 (i.e. fore assembly 48a and aft assembly 48b) can be inverted, whereby the brush wire wheels 52 are located above the articulated cleaning arms 54, which are in turn are mounted to either side of, but so as to locate above the support plates 56 of the brick cleaning assembly. With this orientation, reduced size/structure of the bearing assembly for each of the wheels 52 and arms 54 can be adopted, as the loading and weight can be better supported by the underlying support plates 56.

Dust Collector Assembly 16

Referring now to Figures 11 to 13, the dust collector assembly 16 is provided to remove mortar dust and airborne mortar particulates that are generated in the course of mortar removal. The dust collector assembly 16 comprises a housing 63, the housing 63 comprising a plenum chamber 64, and an inlet duct 65 that is connected to dust collector inlet 66 arranged at the housing 63. The inlet duct 65 is, in turn, connected via a manifold to the brick cleaning machine exhaust ducts 28a and 28b. The dust collector assembly 16 also comprises an extractor in the form of an exhaust fan 74 mounted adjacent to the plenum chamber 64 and communicating therewith so as to apply a vacuum to the chamber.

The dust collector assembly 16 additionally comprises internal channel walls 78, bag support plate 68, and a number of filtration compartments, in this embodiment taking the form of two converging catchments 70 that each comprise a filtration apparatus arranged therewithin (although the housing could be configured to have more than two catchments 70). In this regard, the catchments 70 can each be internally lined with a series of elongate tubular filter bags 79, each bag functioning to filter airborne mortar particulates, including mortar dust, from an airstream extracted from the brick cleaning machine via the exhaust ducts 28a and 28b. One such tubular filter bag 79 is illustrated schematically, via dotted outline, in Figure 13. In practice, multiple such filter bags 79 are arranged in each catchment 70. Each bag can be internally reinforced with e.g. wire bracing that preserves and holds its tubular shape in use, and prevents collapse under air pressure.

The bag support plate 68 is shown exposed but, in practice, the plenum chamber 64 is enclosed by assembly cover plates (not shown) to define the plenum chamber 64 as a filtered exhaust air chamber. Air that has been filtered of particulates, including dust and debris, is able to pass into the plenum chamber 64 before being exhausted from the chamber 64 to atmosphere via the exhaust fan 74 that communicates therewith. The plate 68 has a number of apertures 69, with a respective array of apertures being provided in the plate above a respective converging catchment 70. An open upper end of each elongate tubular filter bag 79 is secured to open onto the underside of a respective aperture 69 at plate 68, with each bag extending into, so that an array of bags nest inside, a respective converging catchment 70.

The dust collector assembly 16 further comprises a caterpillar track assembly 72. The caterpillar track assembly 72 enables the dust collector assembly 16 itself to be portable (i.e. to enable the apparatus 10 as a whole to be portable). The dust collector assembly 16 additionally comprises compressed air cylinders 80. The compressed air cylinders 80 enable the periodic discharge from the assembly 16 of filtered particulates (dust/debris) that has been caught by the tubular filter bags 79, as set forth below.

In use, the exhaust fan 74 applies an air suction force to plenum chamber 64, which causes a mortar particulate (dust/debris) -laden airstream to be sucked into the dust collector assembly 16 via the inlet duct 65. The inlet 66 is located to open onto the hollow interior of the assembly 16 at a location below the bag support plate 68. The airstream decelerates as it passes into the larger volume of catchment 70, whereby heavier, large particulates (e.g. dust and debris particles) are able to drop out of the airstream and into the adjacent converging catchments 70, including via such particles and debris impacting at the fdter bags and slowing down and dropping as a result. The particulates (dust and debris) fall, via the tapered ends of the catchments 70, so as to pass out of a lower open end of the catchments and into a respective collection cannisters (not shown), each of which is secured to a respective open lower end of each catchment 70.

Whilst some smaller particles will drop out of the open lower end of each catchment 70, generally the smaller particles tend to accumulate and deposit at the tubular filter bags 79, forming a type of particulate“filter cake” layer thereat (which cake also helps with filtering of the airborne fines). The air passes through the bags and filter cake, up and out of the apertures 69 of plate 68, via the bag open upper ends, to enter the plenum chamber 64, with the filtered air then exiting to atmosphere through exhaust fan 74. Eventually, the filter cake layer builds up at the tubular filter bags 79 to a thickness whereby the load on the exhaust fan 74 is at a level requires a“back-flush” of the bags. Hence, the compressed air cylinders 80 are operated to provide a back-pressure to enable the periodic discharge of the particulate filter cake layer formed at each of the tubular filter bags 79.

The compressed air cylinders 80 communicate with a series of back-pressure air discharge pipes (not shown) that in use are arranged in the plenum chamber. The series of back pressure discharge pipes can be arranged in parallel in the plenum chamber, each pipe in line with a respective line of apertures 69, and each pipe having a plurality of air discharge nozzles. Each air discharge nozzle is located above and directed towards a respective aligned aperture and thus towards an open upper end of each bag 79. The nozzles each provide a blast/shot of air, typically periodically, into a respective bag 79 to dislodge the filter cake therefrom. The resultant dislodged mortar particulates can drop down from each bag and into a respective catchment 70 to be collected from the at its lower outlet, along with the otherwise normally filtered mortar particulate drop-outs.

In use, a load sensor on the motor of exhaust fan 74 and/or pressure sensors mounted on either side of bag support plate 68 (i.e. sensor on the clean air side and a sensor on the dirty air side) can form part of a control sequence for the apparatus 12. The sensors can be used to monitor changes (i.e. increases) in pressure drop occurring across the tubular filter bags 79 during machine operation, and to trigger a“back-flush” of the filter bags 79, as set forth below. In a further variation, a sensor can be positioned with one or more of the tubular filter bags 79.

The sensors are generally configured to activate the compressed air cylinders 80 in response to the amount of clogging occurring at the tubular filter bags 79 (i.e. which in turn restricts the airstream flow into inlet 66). In general, a reduced passage of airflow across the filter bags causes the pressure differential between the air surrounding the tubular filter bags 79 and the air inside the tubular filter bags 79 to increase. When the tubular filter bags 79 have become significantly laden and clogged, the compressed air cylinders 80 are actuated, typically in a pulsed manner, to release pressurised air into the plenum chamber 64, which pressurised air backflow is applied as an air blast to the inside of the tubular filter bags 79, the air blast passing across and dislodging the particulate filer cake from each bag. The particulate filter cake also drops/falls to the tapered ends of the catchments 70, passing out of the catchment lower open ends and into respective cannisters (e.g. air-tight metal cannisters that are attached with toggle clamps to the lower ends of the catchments 70). The changes in exhaust fan motor load and/or air pressure drop across the tubular filter bags 79 are typically monitored for the duration of machine operation, with the compressed air cylinders 80 being operated cyclically to discharge pressurised air according to the aforementioned feedback loop.

It will also be seen that the first converging catchment 70 is divided from the second converging catchment by a dividing wall 76 and internal channel walls 78. Inlet 66 directs the incoming airstream between the channel walls 78, with the air forced to flow into the smaller volume channel wall chamber before flowing down to the dividing wall 76, whereupon it flows into the larger volume converging catchments 70. This tortuous path slows the air down, helping to facilitate particulate drop-out into the converging catchments 70. Also, by virtue of dividing wall 76 and internal channel walls 78, the dust collector assembly 16 is effectively divided into two catchment regions and this can allow for a doubling of the collector bag surface area, thereby providing for increased capacity and extraction of particulates from air when compared to a single catchment.

Output Conveyor 18

Finally, the apparatus 10 comprises an output conveyor 18. In each of the embodiments of Figs. 1 & la, the output conveyor 18 can be arranged adjacent to the end of conveyor 40 at a location that is distal to infeed conveyor 14.

In the embodiment of Fig. 1, the output conveyor 18 is orientated to transports cleaned bricks linearly away from brick cleaning machine 12 - i.e. in line with the elongate axis of travel of the conveyor 40 through the brick cleaning machine 12. Output conveyor 18 can receive the bricks directly from outer cover 24b, and can then convey the cleaned bricks on a plurality of rollers or via a hydraulically powered conveyor that is identical to infeed conveyor 14.

An alternative embodiment of output conveyor 18 is shown in Fig. la. In this arrangement, the output conveyor 18 directs clean bricks away from machine 12 in one or more directions of travel other than in line with the elongate axis of travel of the conveyor 40. For example, a single output conveyor 18 can be orientated at an acute angle or transversely to the elongate axis of travel of the conveyor 40. A curved path can be provided at the outlet of outer cover 24b to direct a cleaned brick onto the acutely or transversely extending single output conveyor 18.

In another alternative, two opposing and transversely extending (e.g. gravity-driven) output conveyors 18 can be located adjacent to an exit of outer cover 24b. A selective director/altemator can also be arranged at the exit of outer cover 24b to alternate the out- conveying of cleaned bricks to the two output conveyors 18. The alternating can also be controlled by the apparatus 10 (e.g. to feed clean bricks onto one conveyor until a pallet of clean bricks has been filled on one side of the machine, and to then change the feed of clean bricks onto the other conveyor).

Such alternative orientations of the output conveyor 18 can be beneficial to operation of the brick cleaning apparatus 10 in tight or space-restricted locations, or when used on site at sloped or undulating terrain, such as where the position of the output conveyor 18 needs to be changed to avoid obstacles, slopes, drop-offs, etc. and/or to ensure stable operating conditions.

As shown e.g. in Figs. 4 and 5, each output conveyor 18 is arranged to receive a clean brick and convey it away (e.g. under the influence of gravity) from brick cleaning machine 12 after it has been cleaned by the machine. The clean bricks can e.g. be removed at the end of the conveyor 18 by a user and stacked on a pallet, ready for reuse at a site, or for transportation away to another site.

It should be understood that variations and modifications can be made to the system, apparatus and method as set forth above, without departing from the spirit and ambit of the disclosure as set forth herein.

For example, a number of brick cleaning system/apparatus can be provided in series, whereby a first such machine operates to remove mortar from specific surfaces of the mortar-covered brick, and a second such machine in the series operates to remove mortar from different surfaces of the mortar-covered brick, and so on. For example, the first machine in the series may be configured to remove mortar from one set of opposing sides of brick 30 and the second machine can be configured to remove mortar from the opposing ends of the brick. Bricks may be transferred between the first and second machines in series either by hand or conveyed continuously by adjoining transport conveyors 40, optionally with the brick orientation being changed between machines. In the claims which follow and in the preceding description, except where the context requires otherwise due to express language or necessary implication, the word“comprise” or variations such as“comprises” or“comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the system, apparatus and method.