Variable wall concrete molding machine

• US 6,086,349 A
• Filed: 01/22/1993
• Issued: 07/11/2000
• Est. Priority Date: 05/26/1992
• Status: Expired due to Fees

• Current Assignee: Ernest J. Del Monte
• Original Assignee: Ernest J. Del Monte
• Inventors: Del Monte, Ernest J.
• Primary Examiner(s): Mackey, James P.
• Application Number:
  US08/007,838
• Time in Patent Office: 2,727 Days
• Field of Search: 425/62, 425/432, 425/444, 425/447, 425/449, 249/27, 249/33, 249/66.1, 249/67, 249/79, 249/81, 249/109, 249/111, 249/120, 249/133, 249/139, 249/155, 249/161, 249/163, 251/326, 137/862
• US Class Current: 425/62
• CPC Class Codes: B28B 13/0215 Feeding the moulding material in measured quantities from a container or silo
• CPC Class Codes: B28B 15/002 Mobile plants, e.g. on vehicles or on boats
• CPC Class Codes: B28B 7/0008 Venting channels, e.g. to avoid vacuum during demoulding or allowing air to escape during feeding, pressing or moulding
• CPC Class Codes: B28B 7/245 using transportable mould batteries
• CPC Class Codes: B28B 7/42 for heating or cooling, e.g. steam jackets , by means of treating agents acting directly on the moulding material
• CPC Class Codes: B28B 7/44 for treating with gases or degassing, e.g. for de-aerating treating with hot gases or vapour B28B7/42
• CPC Class Codes: E04G 21/0472 Details of connection of the hose to the formwork, e.g. inlets
• CPC Class Codes: E04G 21/16 Tools or apparatus devices for erecting fences E04H17/26

Abstract

A portable concrete molding apparatus for forming concrete structures of a predetermined configuration, either on-site or at a central manufacturing facility. The apparatus includes a trailer having furnace plenum bounded by a pair of fixed walls. Each fixed wall cooperates with a movable wall for forming a mold therebetween. Each movable wall includes a concrete inlet for introducing concrete into the bottom portion of the mold. The fixed and movable walls include push-off valves for ensuring separation of a concrete structure from the mold walls, as the mold walls are separated.

Claims

1. A concrete molding apparatus for forming a planar concrete structure, comprising:

(a) a frame having a longitudinal axis;

(b) a first fixed wall affixed to the frame, the first fixed wall including a first outer substantially planar mold surface and a first plenum surface, the first fixed wall including a first plurality of rib members extending from the first plenum surface to form a first plurality of heating channels adjacent the first plenum surface;

(c) a second fixed wall affixed to the frame parallel to the first fixed wall and spaced apart from the first fixed wall by a given distance, the second fixed wall including outer substantially planar second mold surface and a second plenum surface, the second fixed wall including a second plurality of rib members extending from the second plenum surface to form a second plurality of heating channels adjacent the second plenum surface, wherein the second plenum surface opposes the first plenum surface;

(d) a housing extending between the first fixed wall and the second fixed wall to form a furnace plenum there between, the furnace plenum including a return duct fluidly connected to the heating channels adjacent the first fixed wall and the second fixed wall, the furnace plenum having an inlet exposed to the heating channels of the first fixed wall and the second fixed wall and an outlet exposed to the return duct;

(e) a heater having an inlet and an outlet, wherein the heater outlet is fluidly connected to the furnace plenum inlet and the heater inlet is fluidly connected to the furnace plenum outlet to form a substantially closed fluid circuit between the heater and the furnace plenum;

(f) a plurality of support channels connected to the frame transverse to the longitudinal axis;

(g) a first set of transverse beams slidably disposed within the support channels;

(h) a second set of transverse beams slidably disposed within the support channels;

(i) a first movable wall connected to the first set of transverse beams for movement relative to the first fixed wall between a casting position adjacent the mold surface of the first fixed wall for forming a first mold there between and a discharging position remote from the first fixed wall, the first mold including a first concrete inlet lower than mid-height of the first movable wall for introducing concrete into the first mold; and

(j) a second movable wall connected to the second set of transverse beams for movement relative to the second fixed wall between a casting position adjacent the mold surface of the second fixed wall for forming a second mold there between and a discharging position remote from the second fixed wall, the second mold including a second concrete inlet lower than mid-height of the second movable wall for introducing concrete into the second mold.

2. The concrete molding apparatus of claim 1, further comprising:

(a) a plurality of push-off valves connected to one of the first and the second movable walls, the push-off valves movable between a first casting position coplanar with an adjacent surface of said one wall and a second position extending into a corresponding mold.

3. The concrete molding apparatus of claim 1, further comprising;

(a) a divider substantially separating one of the first and the second molds into compartments, wherein each compartment is fluidly connected to the associated concrete inlet.

4. The concrete molding apparatus of claim 1, further comprising;

(a) insulation on a portion of one of the first and the second molds for reducing thermal transfer from said one mold.

5. The concrete molding apparatus of claim 1, further comprising;

(a) a plurality of vibrators connected to one of the first and the second molds for consolidating concrete in said one mold.

6. The concrete molding apparatus of claim 1, further comprising;

(a) a lock mechanism for releasably locking one of the first fixed wall and the second fixed wall relative to one of the first movable wall and the second movable wall, respectively.

7. A concrete molding apparatus for forming a planar concrete structure, comprising:

(a) a frame;

(b) a first fixed wall affixed to the frame, the first fixed wall including an outer substantially planar first mold surface and a first plenum surface, the first fixed wall including a plurality of rib members extending from the first plenum surface to form a plurality of heating channels adjacent the first fixed wall;

(c) a second fixed wall affixed to the frame parallel to the first fixed wall and spaced apart from the first fixed wall by a fixed distance, the second fixed wall including an outer substantially planar second mold surface and a second plenum surface, the second fixed wall including a plurality of rib members extending from the second plenum surface to form a plurality of heating channels adjacent the second plenum surface, wherein the second plenum surface opposes the first plenum surface;

(d) a housing extending between the first fixed wall and the second fixed wall to form a furnace plenum there between, the furnace plenum including a return duct fluidly connected to the heating channels adjacent the first fixed wall and the second fixed wall, the furnace plenum having an inlet exposed to the heating channels and a remote outlet exposed to the return duct;

(e) a heater having an inlet and an outlet, wherein the heater outlet is fluidly connected to the furnace plenum inlet and the heater inlet is fluidly connected to the furnace plenum outlet to form a substantially closed fluid circuit;

(f) a first movable wall connected to the frame and movable relative to the first fixed wall between a casting position adjacent the mold surface of the first fixed wall for forming a first mold there between and a discharging position remote from the first fixed wall, the first mold including a first tapered transition orifice located below mid-height of the first mold for introducing concrete into the first mold, the first transition orifice having a first diameter adjacent the first mold and second smaller diameter remote from the first mold;

(g) a first cutoff valve fluidly connected to the first transition orifice for selectively permitting passage of concrete through the first transition orifice;

(h) a second movable wall connected to the frame and movable relative to the second fixed wall between a casting position adjacent the mold surface of the second fixed wall for forming a second mold there between and a discharging position remote from the second fixed wall, the second mold including a second tapered transition orifice located below mid-height of the second mold for introducing concrete into the second mold, the second transition orifice having a first diameter adjacent the second mold and a second smaller diameter remote from the second mold; and

(i) a second cutoff valve fluidly connected to the second transition orifice for selectively permitting passage of concrete through the second transition orifice.

8. The concrete molding apparatus of claim 7, wherein the first cutoff valve further comprises;

(a) a valve housing having an inlet aperture and a remote outlet aperture, wherein the outlet aperture is intermediate of the inlet aperture and the first transition orifice; and

(b) a cutoff blade having a central aperture and movably connected to the valve housing for movement between a first position fluidly connecting the inlet aperture and the outlet aperture and a second position precluding fluid communication from the inlet aperture to the outlet aperture.

9. The concrete molding apparatus of claim 8, wherein the cutoff blade includes a vent for fluidly connecting the inlet aperture to an ambient pressure upon the cutoff blade being disposed in the second position.

10. The concrete molding apparatus of claim 7, further comprising;

(a) a plurality of push-off valves connected to one of the first and the second movable walls, the push-off valves movable between a first casting position coplanar with an adjacent surface of said one wall and a second position extending into a corresponding mold.

11. The concrete molding apparatus of claim 7, further comprising;

(a) a divider substantially separating one of the first and the second molds into compartments, wherein each compartment is fluidly connected to a corresponding transition orifice.

12. The concrete molding apparatus of claim 7, further comprising;

(a) insulation on a portion of one of the first and the second molds for reducing thermal transfer from said one mold.

13. The concrete molding apparatus of claim 7, further comprising;

(a) a plurality of vibrators connected to one of the first and the second molds for consolidating concrete in said one mold.

14. The concrete molding apparatus of claim 7, further comprising;

(a) a lock mechanism connected to one of the first fixed wall and the second fixed wall for releasably locking said one fixed wall relative to one of the first movable wall and the second movable wall, respectively.

15. A concrete molding apparatus, comprising:

(a) a frame having a longitudinal axis;

(b) a first fixed wall affixed to the frame, the first fixed wall including an outer substantially planar first mold surface and a first plenum surface;

(c) a second fixed wall affixed to the frame parallel to the first fixed wall and spaced apart from the first fixed wall by a given distance, the second fixed wall including an outer substantially planar second mold surface and a second plenum surface;

(d) a housing extending between the first fixed wall and the second fixed wall to form a furnace plenum there between, the furnace plenum including a return duct an inlet and an outlet exposed to the return duct;

(e) a heater having an inlet and an outlet, wherein the heater outlet is fluidly connected to the furnace plenum inlet and the heater inlet is fluidly connected to the furnace plenum outlet to form a substantially closed fluid circuit between the heater and the furnace plenum;

(f) a plurality of support channels connected to the frame transverse to the longitudinal axis;

(g) a first set of transverse beams slidably disposed within the support channels;

(h) a second set of transverse beams slidably disposed within the support channels;

(i) a first movable wall connected to the first set of transverse beams for movement relative to the first fixed wall between a casting position adjacent the first mold surface of the first fixed wall for forming a first mold there between and a discharging position remote from the first fixed wall, the first mold including a first concrete inlet lower than mid-height of the first movable wall for introducing concrete into the first mold;

(j) a second movable wall connected to the second set of transverse beams for movement relative to the second fixed wall between a casting position adjacent the second mold surface of the second fixed wall for forming a second mold there between and a discharging position remote from the second fixed wall, the second mold including a second concrete inlet lower than mid-height of the second movable wall for introducing concrete into the second mold;

(k) a plurality of push-off valves connected to one of the first and the second movable walls, the push-off valves movable between a first casting position substantially coplanar with an adjacent surface of said one movable wall and a second position nonplanar with said one movable wall;

(l) insulation on a portion of one of the first and the second molds for reducing thermal transfer;

(m) a plurality of vibrators connected to the first and the second molds for consolidating concrete in the first and the second mold; and

(n) a lock mechanism connected to one of the first fixed wall and the second fixed wall for releasably locking said one fixed wall relative to one of the first movable wall and the second movable wall, respectively.