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Title:
SYSTEM, METHOD AND APPARATUS FOR FABRICATING ENVIRONMENTAL MASONRY UNITS
Document Type and Number:
WIPO Patent Application WO/2015/089294
Kind Code:
A4
Abstract:
Masonry units, such a blocks, are fabricated in a sequential process, using improved mold structures, such as within a production corridor of a corresponding fabrication system. A compressible masonry feedstock or formulated material, which can be de-agglomerated before use, is filled within a block mold having releasable elements. The feedstock or formulated material is then compressed within the mold structure. The compressed workpiece can be further processed, such as for any of final height adjustment, the establishment of a surface feature, or to remove cores. The block mold, having releasable elements or sides, such as using hinges or springs, is released from the formed block, wherein the formed masonry unit can be removed for curing, and wherein the block mold can be reused to fabricate a subsequent masonry unit.

Inventors:
EASTON DAVID CARR (US)
EASTON KHYBER (US)
Application Number:
PCT/US2014/069768
Publication Date:
October 01, 2015
Filing Date:
December 11, 2014
Export Citation:
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Assignee:
WATERSHED MATERIALS LLC (US)
International Classes:
B28B3/00
Attorney, Agent or Firm:
GLENN, Michael, A. et al. (P.O. Box 1247Seattle, WA, US)
Download PDF:
Claims:
AMENDED CLAIMS

received by the International Bureau on 13 JUN 2015 (13.06.2015)

This listing of the claims will replace all prior versions and listings of claims in the application.

1. A process, comprising:

filling an interior region of a masonry block mold with a masonry feedstock, wherein at least a portion of the masonry block mold is releasable;

consolidating the masonry feedstock within the masonry block mold;

dynamically compressing the consolidated masonry feedstock to form a masonry block having a face;

laterally releasing the masonry block mold from the face of the masonry block;

removing the masonry block from the released masonry block mold;

moving the masonry block to a curing area; and

curing the masonry block;

wherein the processed is performed at a plurality of sequential stations, wherein a production corridor is defined between the plurality of sequential stations.

2. The process of Claim 1 , wherein the masonry feedstock is compressible.

3. The process of Claim 1 , further comprising:

de-agglomerating the masonry feedstock before the filling of the interior region of a masonry block mold.

4. The process of Claim 1 , further comprising:

leveling off the filled masonry feedstock within the masonry block mold.

5. The process of Claim 1 , further comprising:

compressing the consolidated masonry feedstock within corners of the masonry block mold.

6. The process of Claim 1 , wherein the dynamically compressing the consolidated feedstock comprises:

simultaneously compressing and applying an impact force to the consolidated feedstock within the masonry block mold.

7. The process of Claim 1 , further comprising:

adjusting the height of the formed masonry block within the masonry block mold.

8. The process of Claim 1 , further comprising:

removing a cell center of the formed masonry block within the masonry block mold.

9. The process of Claim 1 , wherein the masonry block mold includes an insert within the interior region, wherein a feature the masonry block is formed by the insert.

10. The process of Claim 1, wherein the plurality of sequential stations include:

a filling station configured for the filling of the masonry block mold with the masonry feedstock;

a consolidation station configured for the consolidating the masonry feedstock within the masonry block mold;

a dynamic compression station for dynamically compressing the consolidated masonry feedstock to form the masonry block; and

a de-molding station for removing the masonry block from the released masonry block mold.

1 1. The process of Claim 1 , wherein the masonry block mold includes any of springs or hinges to release the masonry block mold from the formed masonry block.

12. A system for production of masonry blocks, comprising:

a masonry block mold having an interior defined therein, wherein at least a portion of the masonry block mold is configured to be releasable away from a face of a masonry block formed within the interior;

a filling mechanism configured for filling the interior region of the masonry block mold with a masonry feedstock;

a consolidation mechanism configured for consolidating the masonry feedstock within the masonry block mold; and

a dynamic compression mechanism configured for dynamically compressing the consolidated masonry feedstock to form a masonry block;

wherein the formed masonry block is removable from the masonry block mold when the masonry block mold is in a released position; and

wherein the system is configured as a plurality of sequential stations; and

wherein a production corridor is defined between the plurality of sequential stations.

13. The system of Claim 12, wherein the masonry feedstock is compressible.

14. The system of Claim 12, further comprising:

a de-agglomerator configured for de-agglomerating the masonry feedstock before the interior region of the masonry block mold is filled with the masonry feedstock.

15. The system of Claim 12, further comprising:

a leveling mechanism configured to level off the filled masonry feedstock within the masonry block mold.

16. The system of Claim 12. further comprising:

a compression mechanism for compressing corners of the consolidated masonry feedstock within the masonry block mold.

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17. The system of Claim 12, wherein the dynamic compression mechanism is configured to simultaneously compress and apply an impact force to the consolidated feedstock within the masonry block mold.

18. The system of Claim 12, further comprising:

a finishing mechanism configured to act upon a top surface of the formed masonry block within the masonry block mold.

19. The system of Claim 12, further comprising:

a cell center removal mechanism configured for removing a cell center of the formed masonry block within the masonry block mold.

20. The system of Claim 12, wherein the masonry block mold includes an insert within the interior region, wherein the insert is configured to form a feature of the masonry block.

21. The system of Claim 12, wherein the masonry feedstock includes an aggregate matrix, and wherein the system comprises a mechanism for de-agglomerating the masonry feedstock to break apart or distribute constituents within the aggregate matrix.

22. The system of Claim 1, further comprising:

a mechanism for moving the masonry block mold through the production corridor between the plurality of sequential stations.

23. The system of Claim 12, wherein the masonry block mold includes any of springs or hinges that are configured to release the masonry block mold from the formed masonry block.

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24. An apparatus for fabricating masonry units, comprising:

a block mold body having an interior defined therein,

wherein the block mold body is configured to be filled with a masonry feedstock, and wherein the block mold body is further configured to allow compression of the masonry feedstock to form a masonry unit having a face; and

a release mechanism configured to release the block mold body away from the face of the formed masonry unit;

wherein the apparatus is configured to be moved through a production corridor defined between a plurality of sequential stations.

25. The apparatus of Claim 24, wherein the release mechanism includes any of a hinge or a spring.

26. The apparatus of Claim 24, wherein the release mechanism is configured to preserve a cosmetic character of the formed masonry unit.

27. The apparatus of Claim 24, wherein the release mechanism is configured to reduce energy required to remove the formed masonry unit from the block mold body.

28. The apparatus of Claim 24, further comprising:

an insert that is configured to be located within the interior region, wherein the insert is configured to form a feature of the masonry unit.

29. The apparatus of Claim 28, wherein the insert is configured for any of embossing, de- bossing, a signature, a brand, a random pattern, a geometric pattern, a rough finish, or a smooth finish.

30. The apparatus of Claim 24, wherein the masonry feedstock includes an aggregate matrix, and wherein the masonry feedstock is de-agglomerated to break apart or distribute constituents within the aggregate matrix.

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