Device for manufacturing green bricks and method therefor

Abstract

The invention relates to a device (2) for manufacturing green bricks from a material, such as clay material, according to the invention and a method therefor. The device (2) according to the invention comprises: - a number of mould containers (4), wherein each mould container (4) comprises a number of moulds (8); - a frame (10) for guiding the mould containers (4), comprising: - an upper track (12) for guiding the mould containers (4); and - a lower track (14) for returning the mould containers (4); - a filling device (18) for introducing the material into the moulds (8) in a filling direction; - a pressing device (28) for pressing the material into a green brick in the moulds (8) in a pressing direction; - a demoulding device (38) for removing the green brick from the moulds (8) in a demoulding direction; and - a mould container conveyor (56) arranged for coupling to one or more mould containers (4) and configured to transport the mould containers (4) over the frame (10); characterized in that a number of moulds (8) is provided with a bottom (96) configured to receive a force exerted on the mould (8) by the pressing device (40), and wherein the bottom (96) is arranged movably in the mould (8).

Description

[0001] The invention relates to a device for manufacturing green bricks, for instance bricks, for instance from a clay material. Said device is particularly a device for manufacturing bricks. Such a device can additionally also relate to a device for manufacturing brick slips, corner strips and similar products from a clay material, or from another material such as self-curing or solidifying products, thermoplastics or thermosets.

[0002] Devices for manufacturing green bricks are known in practice in the form of for instance mould conveyors and / or frames and / or mould containers which are displaced over their whole length. Such devices known in practice are provided with shafts and ring gears with a circulating drive.

[0003] A limitation of such devices is that these ring gears become relatively large when the individual frames or mould containers become longer as seen in the transport direction, and the polygon effect also begins to play a larger part. This thereby limits the useful length of the individual frames or mould containers. Depending on the specific embodiment, a problem in such devices can be that displacing mould conveyors over shafts and ring gears over the whole length results in a great deal of resistance. This has the result that the drive for such a system must produce a great deal of force in order to make the mould conveyor go round. Such a drive of the specific embodiment is thereby usually heavy and expensive. Additionally, a relatively large amount of energy is required for the driving.

[0004] The present invention has for its object to provide a device whereby the above stated problems are obviated or at least reduced, such that green bricks can be manufactured by such a device in an effective manner.

[0005] This object is achieved with the device for manufacturing green bricks from a material, such as clay material, according to the invention, the device comprising: a number of mould containers, wherein each mould container comprises a number of moulds; a frame for guiding the mould containers, comprising: an upper track for guiding the mould containers; and a lower track for returning the mould containers; a filling device for introducing the material into the moulds in a filling direction; a pressing device for pressing the material into a green brick in the moulds in a pressing direction; a demoulding device for removing the green brick from the moulds in a demoulding direction; and a mould container conveyor arranged for coupling to one or more mould containers and configured to transport the mould containers over the frame; characterized in that a number of moulds is provided with a bottom configured to receive a force exerted on the mould by the pressing device, and wherein the bottom is arranged movably in the mould.

[0006] The device according to the invention is provided with mould containers, wherein each mould container comprises a number of moulds. It is noted that 'a number of moulds' is understood to mean one, two, three, and so on, preferably nine or more.

[0007] In a currently preferred embodiment the material comprises clay material. It is however also possible to envisage the material comprising concrete stone or other mouldable materials, such as metals or EPS (Expanded Polystyrene). Additionally, it is possible to manufacture green bricks from recycled and ground construction materials that cure with specific binding and / or curing agents without being fired.

[0008] The mould containers comprise on at least one side of the mould container a recess, cavity, hollow or space. Such a hollow in the mould container is a mould. Moulds can also extend wholly through the mould container and so have a plurality of, therefore two, three, four or any other suitable number of, openings in the mould container. If a mould extends wholly through the mould container, an open frame can also be referred to. The moulds are for instance situated in the mould containers both in a direction in which the mould container is transported over the frame and in a (width) direction at right angles thereto. A number of rows of moulds is understood to mean the number of moulds in a direction in which the mould container is transported over the frame. In an advantageous embodiment the mould containers further comprise wheels, which are preferably arranged on the side of the mould containers and whereby the mould containers roll over the frame. It is however also possible to envisage the mould containers comprising no wheels and, instead of rolling over the frame, sliding over the frame or being advanced in other manner.

[0009] The frame of the device according to the invention is configured to guide the mould containers, comprising an upper track and a lower track. In a preferred embodiment according to the invention the upper track and the lower track run substantially parallel to and respectively above and below each other. On the upper track the mould containers are guided over the frame and in a currently preferred embodiment of the present invention processes are performed on the mould containers at or on or close to the upper track. The mould containers are returned via the lower track to the opposite end of the frame and, if desired, processes can also be performed on the mould containers and / or moulds here. It is also possible to envisage that processes can be performed on mould containers situated between the upper track and the lower track. It is also possible to envisage that processes located between the upper track and the lower track can be performed on mould containers that are situated on the upper track or lower track.

[0010] The upper track and the lower track preferably comprise a number of rails over which the mould containers, preferably provided with wheels, are guidable. In another embodiment according to the invention the upper track, and preferably also the lower track, comprises a slide plate for guiding the mould containers. In a further embodiment the mould containers are slidable over the frame. An advantage of a slide plate under the mould containers is that it can serve as bottom for the moulds if the moulds extend wholly through the mould container. Such a slide plate is preferably provided with a number of recesses for providing access to the side of the mould container sliding over the slide plate. Such a slide plate under the mould containers is particularly suitable for guiding moulds which are filled with dry mouldable material which have a relatively low stickiness and can be moved over a slide plate easily. Relatively dry and granular material, which can also be dosed easily, is especially preferred here. In a currently preferred embodiment according to the invention this material is a dry clay material with a moisture percentage of less than 20% by mass, particularly less than 18% by mass, more particularly less than 15% by mass, preferably less than 12% by mass, more preferably less than 10% by mass and most preferably less than 8% by mass. Manufacturing green bricks from a dry clay material is attractive from an energy viewpoint, since less energy is required for drying the green bricks. The moulds are however preferably provided with a bottom, particularly if use is made of a stickier material which produces more resistance when moved over a slide plate.

[0011] Processes which can be performed on the upper track and / or the lower track comprise of filling the moulds, in the mould containers, with material, pressing the material in the moulds and demoulding / removing / releasing the material. Such processes for instance also comprise of cleaning, moistening, sand-covering, steaming and / or cooling the moulds, the mould containers and / or the material / the green bricks. For each process there is a (sub-)device, such as a filling device for introducing the material into the moulds in a filling direction and a pressing device for pressing the material in a pressing direction. A demoulding device removes the material, i.e. the green bricks, from the moulds. It is also possible to envisage a single device being able to perform a plurality of processes, such as for instance filling and pressing in a single filling-pressing device. The same process can also be performed multiple times, be it at the same location or at a different location, optionally by means of the same device, or by means of a separate device. It is however also possible to envisage no process being performed on the mould container.

[0012] The filling device in the device according to the invention preferably comprises a hopper, provided with a number of openings, which is preferably funnel-shaped, and a number of outlets. The material to be moulded is introduced into the hopper via the number of openings and is introduced into one or more moulds via the number of outlets. Such a filling device can fill one or more moulds simultaneously. In a particular embodiment the filling device fills a plurality of rows of moulds simultaneously. The filling device is preferably filled with one type of material. It is however also possible to envisage the moulds being filled with different materials having different properties. This is for instance possible by introducing the different materials into the same hopper or by providing each of a plurality of filling devices or a plurality of hoppers in a single filling device with a material having different properties. Green bricks consisting of a plurality of layers can for instance be obtained by filling moulds with materials with different properties. Additionally, the capacity of the device can for instance be increased by providing the device with a plurality of filling units.

[0013] The pressing device in the device according to the invention is configured to compress the material or at least give it the desired form. It is possible here, if desired, to apply texture, logos, text and the like to a number of sides of the green bricks. Such a pressing device preferably comprises a number of pressing elements which preferably fit close-fittingly in the moulds, such that the material in the moulds can be pressed without the material being able to reach along the sides of the pressing elements via the sides of the moulds. The pressing elements are preferably driven by a pressing drive, which is particularly hydraulic, mechanical or electrical. In a currently preferred embodiment the pressing device comprises a number of cylinders, such as hydraulic cylinders.

[0014] The demoulding device in the device according to the invention is configured to remove the material, be it pressed or unpressed, from the moulds. The demoulding device can be situated on the upper track and / or on the lower track. The openings of the mould containers, i.e. the moulds, are preferably situated on the side of the mould container that is directed downward on the lower track, whereby the effect of the force of gravity contributes to demoulding of the material. In an advantageous embodiment the force of gravity alone suffices to demould the material. In such an embodiment the demoulding device comprises of rotating the mould containers by means of the frame. In a currently preferred embodiment according to the invention the demoulding device further comprises a vibrating device, a knocking device or another suitable device configured to overcome the resistance of the walls of the moulds on the material and release the material from the moulds. If the moulds extend wholly through the mould container, it is also possible to envisage the demoulding device comprising a number of push-out members which, just as the pressing elements, preferably fit close-fittingly in the moulds and which push the material from one side of the mould container out of the moulds on the other side of the mould container. In a particular embodiment use is made here of a slide plate for guiding the moulds, which slide plate is provided with recesses for providing such a push-out member access to the side of the mould container sliding over the slide plate. In an embodiment according to the invention such a push-out member is provided, if desired, with texture in order to apply logos, text and the like to a number of sides of the green bricks.

[0015] It is also possible to envisage the system and / or the device for manufacturing green bricks from a material comprising a gripper which is configured to grip the already demoulded material or the already demoulded green brick for further transport. Such a conveyor device is particularly suitable if the material has sufficient stiffness and / or plasticity, making the material grippable. Grippable is understood to mean that the material substantially retains its shape when engaged. Such a gripper comprises for instance a number of gripper plates in order to thus clamp the material between the gripper plates and transport the green brick for further processing.

[0016] In the device according to the invention the mould containers are transported over the frame, comprising the upper track and the lower track, by the mould container conveyor. The mould container conveyor is preferably arranged for coupling to one or more mould containers, for instance by means of a number of coupling mechanisms whereby the mould container conveyor engages on the number of mould containers. In a currently preferred embodiment the mould containers comprise on their sides two protruding parts to create a slot, in which or on which an arm of the mould container conveyor can engage on the mould containers. The mould containers can also have recesses on their sides, on which recesses an arm of the mould container conveyor can engage. In another possible embodiment the mould containers comprise recesses on other sides, or elements which protrude thereagainst and on which for instance an arm of the mould container conveyor can engage. It will be apparent that other manners of engagement are also possible according to the invention.

[0017] It is additionally also possible to envisage the different devices for performing processes at or on the moulds being transported along the different mould containers instead of the mould containers being transported over the frame along the different devices.

[0018] The device according to the invention has the result that the device according to the invention is relatively simple, with few movable parts. The mould container conveyor only transports the number of mould containers on the upper track or the lower track, whereby less force is required to transport the mould containers. This results in a less heavy and less expensive device. It is now possible to work with a linear transport means, for instance with hydraulics. Depending on the specific embodiment, it can also affect wear, resistance and contamination of the device. The relatively small number of movable parts thus provides the advantage that the device according to the invention gathers less dirt, this reducing the risk of malfunction. The relatively small number of movable parts can additionally reduce the resistance and wear of the device. This enables the device to be more energy-efficient since transporting of the mould containers experiences less resistance.

[0019] The mould containers, and the moulds therein, are additionally situated compactly together, this being favourable for the production capacity. The device according to the present invention can thus manufacture a large number of green bricks per unit of time at relatively low cost.

[0020] In a possible alternative embodiment the mould containers are not connected to each other and the mould containers are transported over the frame in that the mould container conveyor engages on one or more mould containers. Because the mould container conveyor transports the one or more mould containers, the mould containers on which the mould container conveyor does not engage co-displace with the remaining mould containers in that the mould containers are in contact with each other and advance each other. This simplifies the whole construction of the device as a whole.

[0021] In a currently preferred embodiment according to the invention the mould containers are mutually connected in an endless series by means of a pivoting connection.

[0022] In such an embodiment with pivoting connection the mould containers are transported from the upper track to the lower track and vice versa by the pivoting action. It is advantageous here for the distance between the lower track and the upper track to be equal to or greater than the distance between two adjacent pivot points, because such a pivoting principle is not possible, geometrically speaking, when the distance between two adjacent pivot points is greater than the distance between the upper track and the lower track without involving more than two mould containers in the pivoting movement. The distance between two pivot points is preferably also the length of a mould container, which means that the pivot points are provided at the outer ends of the mould containers where they are in contact with adjacent mould containers.

[0023] The mould containers connected in an endless series by means of the pivoting connection provide the advantage that the mould containers can circulate in the system without separate support. In such an embodiment according to the invention the mould containers are transportable between the two tracks by the pivoting action between the mould containers. Because no separate parts are required for this, the device according to the invention is relatively simple in respect of costs and risk of malfunction.

[0024] In an alternative embodiment according to the invention the mould containers are for instance transportable from the upper track to the lower track, and vice versa, preferably by lifts provided at the outer ends of the upper track and lower track. It is possible here, although not essential, to provide a pivoting connection between two adjacent mould containers. Such lifts comprise lifting lifts and / or lowering lifts for respectively lifting and / or lowering mould containers from the lower track to the upper track and lifting and / or lowering mould containers from the upper track to the lower track. It is likewise possible to envisage such a lift comprising a platform large enough to provide space for a number of mould containers. In such an embodiment the platform lies at substantially the same height as the upper track and / or the lower track and the platform is substantially in contact with at least one side with an end of the upper track and / or the lower track in order to receive the mould containers on the platform. The lifts become operative as soon as a number of mould containers has been pushed onto the lift by the mould container conveyor, be it directly or be it indirectly by the advancing action of the contact with other mould containers.

[0025] In a further advantageous embodiment the mould container conveyor comprises a rail and a coupling mechanism movable over this rail and configured to engage on one or more mould containers. In such an embodiment the mould container conveyor comprises a number of wheels whereby the coupling mechanism is guidable over the rail. It is however also possible to envisage that the coupling mechanism can be moved over the rail in other manner, for instance by sliding. In such an embodiment the mould container conveyor further comprises a mould container conveyor drive for driving the coupling mechanism.

[0026] The advantage of such a rail and a coupling mechanism according to the invention movable over this rail is that the device according to the invention transports the mould containers over the frame in a relatively simple manner. The simplicity of the device makes the device less susceptible to defects, and makes the defects easier to detect and, if present, to solve. This also reduces the costs of (use of) the device according to the invention.

[0027] The rail preferably comprises one or more end points for the coupling mechanism which function as end stop for the coupling mechanism. This has the advantage that the coupling mechanism is unable to shoot off the rail at the end of the rail, and is stopped by the end points. Such end points can be upright edges or similar stop mechanisms.

[0028] In a currently preferred embodiment the device according to the present invention further comprises a blocking mechanism which is arranged for coupling to one or more mould containers and is configured to block the one or more mould containers.

[0029] The blocking mechanism has for its object to block mould containers on the upper track and / or on the lower track, preferably while mould containers are being transported on the other track by the mould container conveyor. This has the advantage that, if desired, standstill of the mould containers on the upper track and / or the lower track can be guaranteed. Such a blocking mechanism also fulfils a centring function for extra precise positioning of the mould containers, this providing an advantage for performing processes on the mould containers more accurately. The blocking mechanism can engage on a number of mould containers, i.e. on the protruding parts or recesses on sides, preferably on the sides, of the mould containers, in the same way as the mould container conveyor. It has been found that a combination of the blocking mechanism with centring function is highly effective.

[0030] In a further embodiment according to the invention the blocking mechanism comprises an upper blocking element and a lower blocking element. The upper blocking element is here arranged for coupling to the mould containers on the upper track, while the lower blocking element is arranged for coupling to the mould containers on the lower track. Such a blocking element preferably comprises a bar provided with a number of arms which is arranged engageably on a number of mould containers. The advantage of an upper and a lower blocking element is that the two blocking elements are individually couplable to respectively the upper track and the lower track. The position of the blocking elements relative to each other can thus be adjusted in order to block both the upper track and the lower track, for instance when the device is not operative. It is however also possible to envisage the blocking elements being connected and not being individually couplable, so that the state of the upper blocking element affects the state of the lower blocking element, and vice versa. This for instance increases the safety of working with the device according to the invention further.

[0031] In an embodiment according to the invention a number of adjacent mould containers is connected rigidly to each other, such that they are rotatable relative to the surrounding area only as a unit. A number is two, three, four or any other suitable number. By connecting mould containers to each other in this way the device comprises fewer movable parts, such as the pivot points. The advantage of such a multiple mould container principle, for instance with a two-part mould container or a three-part mould container, is that costs are saved in that the complexity of the device is reduced further. It is here also advantageous for the distance between the lower track and the upper track to be equal to or greater than the distance between two adjacent pivot points, because such a pivoting principle is not possible, geometrically speaking, when the distance between two adjacent pivot points is greater than the distance between the upper track and the lower track without involving more than two mould containers in the pivoting movement. Connecting a number of mould containers in this way thus increases the minimum distance between the upper track and the lower track, this creating more space between the two tracks. Some devices require more space than others. By providing more space between the upper track and the lower track there is also space here for processes to be performed by such devices. These processes can be performed on one of the two tracks, preferably on both tracks. In such an embodiment according to the invention processes can be performed between the upper track and the lower track instead of for instance only from the upper side of the upper track and from the underside of the lower track. This space particularly makes it possible to perform heavier operations between the upper and lower track. Connecting a number of mould containers in this manner for instance enables demoulding of the material between the upper and lower track. Said configurations provide a great deal of freedom for preferably successively connecting the different devices in a relatively simple system, while the speed of the mould transport system is high. It is once again important here that the distance between two adjacent pivot points is not greater than the length of the upper track or the lower track and that an optional rail for the mould container conveyor is long enough to guide the multiple mould container over the frame. This embodiment, wherein a number of adjacent mould containers is connected rigidly to each other, such that they are rotatable relative to the surrounding area only as a unit, can also be applied without a number of moulds being provided with a bottom configured to receive a force exerted on the mould by the pressing device.

[0032] In a currently preferred embodiment according to the invention the mould containers are transported over the frame in steps. This means that the mould container conveyor, which can engage on a number of mould containers on the upper track or the lower track, transports the number of mould containers over a determined transport distance in a single movement, preferably while the optional blocking mechanism is engaged on a number of mould containers on the other track. After the movement of the mould container conveyor over the transport distance the mould container conveyor, and thereby the number of mould containers to which the mould container conveyor is coupled, are stationary. During standstill of the mould containers a number of said processes can be performed on the moulds and / or the mould containers. The transport distance is preferably the distance corresponding with the dimensioning of a mould, such that adjacent moulds can be filled, pressed and demoulded, among other things, in subsequent steps. After completion of such processes the mould container conveyor once again transports the number of mould containers over the transport distance, after which the mould containers once again come to a standstill and processes can be performed, and so on. After running through said steps a number of times, the mould container conveyor uncouples from the number of mould containers on the upper track lower track during standstill and the mould container conveyor couples to a number of mould containers on the other track. At the same time, the optional blocking mechanism uncouples from the other track and couples to the opposite track. The mould container conveyor now moves back over the optional rail while it is coupled to a number of mould containers on the track opposite to the track to which it was coupled on the way out. In addition to the stepwise character of the mould container conveyor, the stepwise transport of the mould containers can thereby also mean that the mould containers on the upper track and lower track are transported alternately. The advantage thereof is that the mould container conveyor transports only the number of mould containers on the upper track the lower track at a time. This results in less force being required to transport the mould containers, this resulting in a less heavy and less expensive device and reducing wear. In an alternative embodiment according to the invention it is however also possible to envisage the mould containers being transported over the frame continuously.

[0033] In a further advantageous embodiment of the present invention the mould container conveyor transports a number of mould containers over the frame over the length of one mould container in a single movement of the mould container conveyor. The transport distance over which the mould container conveyor transports a number of mould containers is here thus equal to the distance between two adjacent pivot points. The advantage thereof is that a number of steps of the mould container conveyor take place in a single movement, whereby the manufacturing process progresses more efficiently. All moulds in a single mould container can thus be filled simultaneously, after which the mould container conveyor transports the number of mould containers over the frame over the length of preferably one mould container in a single movement, after which all moulds in the mould container are pressed simultaneously, and so on. In such an embodiment it is however also possible to envisage that for instance the filling device, the pressing device, the demoulding device and so on are successive processes which are situated one mould length apart and which can be performed on the different moulds of a single mould container simultaneously. The first row of moulds is filled, while the second row of moulds is pressed, while the third row of moulds is demoulded, and so on. After the processes have been completed, the number of mould containers is transported over the frame over the length of preferably one mould container in a single movement of the mould container conveyor, where all processes have moved up by one mould in the subsequent step. The first row of moulds is for instance pressed here, the second row of moulds demoulded, the third row of moulds rinsed, and so on. In an alternative embodiment it is however also possible for the mould container conveyor to transport a number of mould containers over the frame over the length of at least one mould container in a single movement of the mould container conveyor.

[0034] In a preferred embodiment according to the invention the device further comprises a discharge conveyor for transporting the demoulded material. Such a discharge conveyor can for instance comprise a conveyor belt on which the green bricks come to lie after the material has been demoulded by the demoulding device. The green bricks can come to lie on the discharge conveyor in different ways. Examples hereof are by the effect of the force of gravity or by a gripping mechanism which picks up the green brick and place it onto the conveyor. Other mechanisms are however also possible. The advantage of such a discharge conveyor is that the manufactured green bricks are discharged from the device to a location where they can for instance be treated further or can be picked up by a user.

[0035] In a further embodiment according to the invention a number of moulds is provided with a bottom for receiving a force exerted on the mould by the pressing device. If a mould has no bottom, the slide plate is configured to receive this force. In the case that a mould has a bottom, this can mean that the mould does not extend wholly through the mould container and is hollowed out on only one side of the mould container. In that case the bottom is connected integrally to the mould container and the bottom is not arranged movably in the mould. In such an embodiment according to the invention the height of the mould, and preferably the height of the green brick, is fixed. In an embodiment according to the invention the bottom is provided with texture in order to apply logos, text and the like to a number of sides of the green bricks.

[0036] It is however also possible for the bottom to be arranged movably in the mould. In that case the bottom is not connected integrally to the mould container and the bottom fits close-fittingly in the mould, such that the material remains in the moulds and is unable to reach along the sides of the bottom via the sides of the moulds. The position of the bottom can be adjusted here, for instance by a bottom adjusting device which controls the position of the bottom in the mould. Depending on the position of the bottom, a thinner or thicker green brick can be manufactured in that the position of the bottom affects the maximum amount of material in the mould. In addition, a movable bottom can function as demoulding device by pushing the manufactured green brick from the mould. A movable bottom can also form part of the pressing device by moving the bottom toward the pressing elements during pressing with the pressing elements, while the pressing elements move toward the bottom as usual. In this way the material is pressed from two sides, which can be particularly advantageous in the case of thicker products. The material can hereby be distributed more uniformly and the shape can be retained better. The structure of the material can also become more compact and stronger, and pressing from two sides can reduce any deformation during drying and firing, allowing the final product to be more accurate and uniform. Such a movable bottom is driven by a bottom drive, which is particularly hydraulic, mechanical or electrical.

[0037] In a further preferred embodiment of the present invention the optional bottom of the mould is provided with a recess for engaging on the bottom of the mould. In the case that the bottom is not movable, this recess can for instance function to engage on the mould and / or the mould container. The bottom is preferably arranged movably in the mould and the recess in the bottom makes it possible to engage on the bottom and to change the position of the bottom, particularly to retract the bottom. It is however also possible to envisage that the bottom is retracted by the effect of the force of gravity, and that the position of the bottom can be adjusted by a push-out member or the like. The recess in the bottom thus provides a point of engagement on the bottom, with the advantage that the position of the bottom can be adjusted so that the thickness of the green brick can be influenced. Such a recess can for instance have the shape of a dovetail, a T, a circle or the like. Said recess in the bottom preferably continues on the underside of the bottom by means of a slot in the transport direction of the mould containers, such that the mould containers can slide over a fitting part lying further along, wherein the position of the bottom can once again be changed. It has been found that retracting the movable bottom is highly effective.

[0038] The invention further relates to a method for manufacturing green bricks from a material, such as clay material, comprising of: providing a device according to an embodiment according to the invention; transporting the mould containers over the frame by means of the mould container conveyor; guiding the mould containers and performing processes, comprising of: introducing the material into the moulds by means of the filling device; pressing the material into a green brick in the moulds by means of the pressing device; and removing the green brick from the moulds by means of the demoulding device; and returning the mould containers on and / or via the lower track.

[0039] Such a method provides similar advantages and effects as described for the device.

[0040] In an advantageous embodiment of the present invention the method further comprises of engaging on one or more mould containers by means of the mould container conveyor. The engaging on a number of mould containers enables the number of mould containers to be transported over the frame. The engaging on the one or more mould containers is possible in one or more of the described ways, for instance by an arm of the mould container conveyor which engages on protruding parts of the mould containers or recesses in the mould containers.

[0041] In a particular embodiment according to the invention the method further comprises of blocking the upper track and / or the lower track by means of the blocking mechanism. Blocking of the upper track and / or the lower track ensures standstill of the number of mould containers on such a track. Such a blocking mechanism also fulfils a centring function for extra precise positioning of the mould containers, this providing an advantage for being able to perform processes on the mould containers more accurately. The blocking mechanism can engage on a number of mould containers, i.e. on the protruding parts or recesses on sides, preferably on the sides, of the mould containers, in the same way as the mould container conveyor. It has been found that a combination of the blocking mechanism with centring function is highly effective.

[0042] In a further advantageous embodiment of the present invention the method further comprises of transferring the mould containers between the upper track and the lower track. The transferring of the mould containers is possible in one or more of the described ways. If the mould containers are not connected, the mould containers are preferably transferred by means of lifting and lowering lifts which are provided particularly at the outer ends of the frame. If the mould containers are pivotally connected, the mould containers are preferably transferred by means of the pivoting action of the mould containers in combination with the transporting action of the mould container conveyor.

[0043] According to the invention, the system and the method can also be used for other applications, such as for handling materials in general. An example thereof is manufacture of for instance concrete stone and other mouldable materials. With a device according to the invention it is also possible to make for instance facing bricks from recycled and ground construction materials that cure with specific binding and / or curing agents without being fired. It is further possible to envisage handling of casting moulds for metal products, expansion of EPS in moulds, and other applications.

[0044] It is noted that, besides being used in combination with the (movable) bottom, the different embodiments can also be used independently thereof, optionally in combination with each other.

[0045] Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which: Figures 1A-Hshow a first embodiment of a device according to the invention; Figure 2 shows schematically a method according to the invention; Figure 3 shows a second embodiment of a device according to the invention; Figures 4A-D show a view of an alternative embodiment of a device according to the invention; and Figures 5A-B show a further embodiment of a device according to the invention.

[0046] In the shown embodiment device 2 (Figures 1A-H) is represented as a circulating system. The device is elucidated in respect of application of the present invention to manufacture of bricks from a clay material. Mould containers 4 are mutually connected in an endless series by means of a pivoting connection 6. Pivoting connection 6 can also be absent in one or more mould containers 4, whereby a number of adjacent mould containers 4 are connected to each other rigidly instead of pivotally, such that they are rotatable relative to the surrounding area only as a unit. Mould containers 4 can optionally be provided with (movable) bottom(s) 96, which will be discussed in more detail below.Mould containers 4 have length L, width W and height H. Each mould container comprises a number of moulds 8 with length 1, width w and height h. Device 2 comprises frame 10 for guiding mould containers 4, comprising upper track 12 and lower track 14 at distance Z from each other. In the shown embodiment upper track 12, as well as lower track 14, is a rail on which mould containers 4 are arranged guidably, particularly movably by means of mould container wheels 16. Mould containers 4 are transported over frame 10 in transport direction T.

[0047] Hopper 20 comprising filling device 18 is situated on upper track 12. Hopper 20 comprises hopper opening 22, through which material 24 is introduced into hopper 20. Via hopper 20 material 24 is introduced through hopper outlet 26 into moulds 8 in filling direction F. In a particular embodiment hopper 20 is provided with an outlet flap (not shown) in order to control the feed of material 24 to mould containers 4. Such an embodiment further comprises an outlet flap drive (not shown) and an outlet flap controller (not shown).

[0048] Located adjacently of filling device 18 is pressing device 28, comprising pressing elements 30. Pressing elements 30 have substantially the same length 1 and width w as moulds 8 and press material 24 in moulds 8 in pressing direction P. Pressing device 28 is driven by pressing drive 32, which pressing drive 32 is controlled by pressing controller 34. In a particular embodiment pressing device 28 is hydraulically driven and pressing device 28 further comprises pressing cylinders 36 for providing pressure for pressing elements 30.

[0049] Demoulding device 38 is configured to remove material 24, i.e. green brick 46, from moulds 8 in demoulding direction O. In the shown embodiment demoulding device 38 comprises push-out member 40 for removing material 24 from moulds 8 in a substantially vertical direction. Push-out member 40 is driven by demoulding drive 42, which is controlled by demoulding controller 44. In the shown embodiment the removed material 24, i.e. manufactured green brick 46, is collected on discharge conveyor 48. This can for instance be achieved in that material 24 / green brick 46 is engaged by a gripper (not shown). This can also be achieved by the effect of the force of gravity if discharge conveyor 48 is situated directly below mould container 4 and push-out member 40 removes material 24 from moulds 8 in the direction of discharge conveyor 48. Discharge conveyor 48 transports material 24 / green brick 46 in discharge direction R. Discharge conveyor 48 is driven by discharge drive 52, which is controlled by discharge controller 54.

[0050] Mould containers 4 are transported over frame 10 by mould container conveyor 56. In the shown embodiment mould container conveyor 56 comprises rail 58 and a coupling mechanism 60 which is movable over rail 58 in conveyor direction A and which is configured to engage on one or more mould containers 4. In the shown embodiment rail 58 is provided with one or more end points 62 which are configured to obstruct coupling mechanism 60 at the outer ends of rail 58. Coupling mechanism 60 is provided with coupling wheels 64, whereby coupling mechanism 60 is arranged movably on rail 58. In the shown embodiment coupling mechanism 60 further comprises coupling arm 66 which is movable in coupling direction K relative to coupling mechanism 60 and which engages on a number of mould containers 4. Coupling arm 66 particularly engages on the side of mould container 4 which is provided with protruding parts 68 that create slot 70. Mould container conveyor 56 is driven by mould container conveyor drive 72, which is controlled by mould container conveyor controller 74.

[0051] Mould containers 4 can be halted on frame 10 by blocking mechanism 76. Blocking mechanism 76 is arranged for coupling to one or more mould containers 4 and is also configured to centre one or more mould containers 4. In the shown embodiment blocking mechanism 76 comprises upper blocking element 78 and lower blocking element 80 which are both arranged for moving in blocking direction B. In the shown embodiment blocking mechanism 76 engages on mould containers 4 in a similar manner as mould container conveyor 56, i.e. in slot 70. Blocking mechanism 76 is driven by blocking drive 82, which is controlled by blocking controller 84.

[0052] In a particular embodiment of the present invention device 2 further comprises other devices for performing other processes. These other devices are shown schematically in figure 1A. Such devices comprise cleaning device 86, moistening device 88, sand-covering device 90, steaming device 92 and cooling device 94. It will be apparent that other devices for performing other processes are also possible. Such processes, including filling, pressing and demoulding, can be performed both on upper track 12 and on lower track 14, as well as between upper track 12 and lower track 14.

[0053] In the shown embodiment mould containers 4 are provided with bottom 96 for receiving a force exerted on mould 8 by pressing device 28. In such an embodiment bottom 96 is connected integrally to mould container 4, whereby bottom 96 is arranged non-movably in mould 8. In a preferred embodiment bottom 96 is however arranged movably in mould 8, making the height of bottom 96 adjustable. In a further advantageous embodiment bottom 96 further comprises bottom recess 98 on which a bottom gripper (not shown) can engage in order to influence the position of bottom 96.

[0054] In figure 1A mould container conveyor 56 is engaged on mould container 4 on upper track 12. Blocking mechanism 76 is engaged on mould container 4 on lower track 14. Relative to figure 1A, figure 1B shows a situation in which mould container conveyor 56 has transported mould containers 4 over length 1 of one mould 8 on upper track 12. In figure 1C mould container conveyor 56 has once again transported mould containers 4 over length 1 on upper track 12. In addition, figure 1C shows that pressing elements 30 of pressing device 28 move in pressing direction P and that push-out member 40 of demoulding device 38 moves in demoulding direction O in order to push material 24 / manufactured green bricks 46 out of moulds 8. Figure 1D further shows that pressing elements 30 and push-out member 40 return to their original position. Figure 1D also once again shows a movement of mould containers 4 on upper track 12 over length 1, driven by mould container conveyor 56. Figure 1E shows that upper blocking element 78 of blocking mechanism 76 couples to mould container 4 on upper track 12. In addition, figure 1E shows that pressing elements 30 of pressing device 28 move in pressing direction P and that push-out member 40 of demoulding device 38 moves in demoulding direction O. Figure 1F shows a further excursion of pressing elements 30 and push-out member 40, as well as coupling arm 66 of coupling mechanism 60 which uncouples from mould container 4 on upper track 12 and couples to mould container 4 on lower track 14. In figure 1G lower blocking element 80 of blocking mechanism 76 uncouples from mould container 4 on lower track 14. Figure 1G additionally shows that push-out member 40 returns toward the original position, while pressing elements 30 once again increase their excursion. Figure 1H shows that mould container conveyor 56 transports mould containers 4 on lower track 14 over lower track 14 over length L of one mould container 4 in a single movement of mould container conveyor 56, and that pressing elements 30 and push-out member 40 return to their original position. From the situation shown in figure 1H, mould container conveyor 56 can uncouple from mould container 4 on lower track 14 and couple to mould container 4 on upper track 12, and blocking mechanism 76 can uncouple from mould container 4 on upper track 12 and couple to mould container 4 on lower track 14 so as to return to the situation shown in figure 1A.

[0055] The block diagram representation of Figure 2 shows a method 102 for manufacturing green bricks from a material. Method 102 comprises the step of providing 104 a raw material.

[0056] Method 102 preferably subsequently comprises the step of cleaning 106 mould containers 4 by means of the cleaning device (not shown). This provides the advantage that moulds 8 and mould containers 4 are cleaned before material 24 is introduced into moulds 8. This improves the quality of, particularly the surface texture of, green brick 46.

[0057] In an advantageous embodiment according to the invention method 102 also comprises the step of moistening 108 mould containers 4 by means of the moistening device (not shown). This step is advantageous because moistening 108 of moulds 8 and mould containers 4 makes method 102 more efficient, for instance in that less force is required to demould green brick 46 from moulds 8.

[0058] In a currently preferred embodiment according to the invention method 102 further comprises the step of covering with sand 110 of moulds 8 by means of the sand-covering device (not shown). Such a step provides a similar advantage as moistening 108 of moulds 8, whereby less force is required to demould green brick 46 from moulds 8. In addition, sand-covering 110 is advantageous for the (surface) texture of green brick 46 since sand-covering 110 of mould 8 can improve the aesthetics of green brick 46.

[0059] Method 102 further comprises the step of introducing 112 the raw material into moulds 8 by means of filling device 18. Material 24 is preferably introduced through hopper opening 22 into hopper 20 and introduced through hopper outlet 26 into moulds 8.

[0060] Method 102 further comprises the step of transporting 114 mould containers 4 over frame 10 by means of mould container conveyor 56. In a preferred embodiment according to the invention mould containers 4 are transported 114 by means of coupling mechanism 60.

[0061] Method 102 further comprises the step of pressing 116 the raw material in moulds 8 by means of pressing device 28. In a preferred embodiment according to the invention material 24 is pressed 116 in moulds 8 by means of pressing elements 30.

[0062] In a preferred embodiment according to the invention method 102 subsequently comprises of steaming 118 mould containers 4 by means of the steaming device (not shown). Steaming 118 of mould containers 4, wherein the raw material is situated in moulds 8, can improve the quality of green brick 46.

[0063] In a further embodiment according to the invention method 102 further comprises of cooling 120 mould containers 4 by means of the cooling device (not shown). This step provides a similar advantage as steaming 118 of mould containers 4, since cooling 120 also enhances the quality of green brick 46.

[0064] Method 102 further comprises the step of removing 122 the raw material from moulds 8 by means of demoulding device 38. In a preferred embodiment according to the invention the removed raw material is discharged by discharge conveyor 48.

[0065] Method 102 further comprises the step of obtaining 124 manufactured green brick 46. It will be apparent that the method 102 shown in figure 2 and described above can also comprise more or fewer steps. The steps can also take place in a different order and each step can be performed multiple times.

[0066] Figure 3 shows a currently preferred embodiment of the device according to the invention 202, wherein filling device 18 comprises hopper 20 with a plurality of hopper outlets 26 and pressing device 28 comprises a plurality of rows of pressing elements 30. Such a preferred embodiment according to the invention 202 can fill a plurality of rows of moulds 8 by means of filling device 18 and press them by means of pressing device 28 when mould containers 4 are stationary. Other processes can also be performed in such a manner. The embodiment according to the invention 202 shown in figure 3 is preferably combined with the preferred embodiment according to the invention wherein mould container conveyor 56 transports a number of mould containers 4 over frame 10 over length L of preferably one mould container 4 in a single movement of mould container conveyor 56. The advantage hereof is that a number of steps of mould container conveyor 56 take place in a single movement, whereby the manufacturing process takes place more quickly and efficiently.

[0067] Figures 4A-D show a bottom view at an angle of mould container 4 which is situated on upper track 12 or lower track 14 in an embodiment according to the invention 302, wherein moulds 8 are provided with bottom 96. Bottom 96 is particularly arranged movably in mould 8 and bottom 96 further comprises bottom recess 98. In the shown embodiment bottom recess 98 comprises bottom slot 304 over length 1 of mould 8. Figures 4A-Dalso show a number of push-out members 40 provided on the upper side with protrusion 306. Protrusion 306 is formed such that it corresponds with bottom recess 98 in bottom 96. In this way protrusion 306 is configured to engage on bottom 96 of mould 8. Relative to figure 4A, figure 4B shows that mould container 4 is guided over frame 10 and that bottom recesses 98 of bottoms 96 are here guided over protrusions 306 of push-out members 40, such that push-out members 40 are engaged on bottoms 40 in figure 4B.

[0068] Figure 4C shows that push-out members 40, engaged on bottoms 96 of moulds 8, push bottoms 96 out of moulds 8 in demoulding direction O. Owing to the shape of protrusions 306 of push-out members 40 and the corresponding shape of bottom recesses 98, push-out members 40 remain connected to bottoms 96 when push-out members 40 return to their original position in a direction opposite to the demoulding direction. In addition, figure 4D shows an alternative embodiment of the embodiment shown in figures 4A-C, wherein protrusions 306 and bottom recesses 98 are T-shaped. In figures 4A-C protrusions 306 are dovetail-shaped.

[0069] Figures 5A-B show an alternative embodiment of the present invention 402, wherein mould containers 4 are not mutually connected. Figure 5B shows a front view of the device shown in figure 5A. In the shown embodiment according to the invention mould containers 4 are transported by mould container conveyor 56, which comprises a number of pushers 404 in Figures 5A-B. Such a pusher 404 comprises support plate 406 on which pusher 404 supports, push plate 408 which engages on a number of mould containers 4, and push rod 410 which is connected to push plate 408. In the shown embodiment pushers 404 are provided close to both outer ends of upper track 12 and lower track 14. Depending on the desired direction in which mould containers 4 are transported over frame 10, only one of the two pushers 404 is operative per track 12, 14. In the views of the shown embodiment shown in Figures 5A-B the mould containers 4 circulate over the frame 10 in clockwise direction.

[0070] The device 402 shown in Figures 5A-B also comprises a number of lifts 412 for lifting and / or lowering a number of mould containers 4. Such a lift comprises platform 414 for receiving a number of mould containers 4 and lift rod 416 for providing the lifting and / or lowering action of lift 412. In the shown embodiment according to the invention one lift is provided at each outer end of frame 10. Depending on the desired direction in which mould containers 4 are transported over frame 10, one lift 412 is preferably configured to lift mould containers 4 and the other lift 412 is preferably configured to lower mould containers 4.

[0071] In the embodiment according to the invention shown in Figures 5A-B lifts 412 are operative and lifts 412 are respectively lifting and lowering mould container 4. As soon as lifts 412 lie substantially at the same height as upper track 12 and / or lower track 14, platform 414 is substantially in contact with at least one side with an end of upper track 12 and / or lower track 14. One pusher 404 then transports mould containers 4 on upper track 12 and one other pusher transports mould containers 4 on lower track 14. When mould container 4 which is pushed off platform 414 of lift 412 is no longer in contact with platform 414, lift 412 returns to the position at the height of the other track 12, 14 in order to there receive the next mould container 4.

[0072] The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.

Claims

1. Device for manufacturing green bricks from a material, such as clay material, comprising: - a number of mould containers, wherein each mould container comprises a number of moulds; - a frame for guiding the mould containers, comprising: - an upper track for guiding the mould containers; and - a lower track for returning the mould containers; - a filling device for introducing the material into the moulds in a filling direction; - a pressing device for pressing the material into a green brick in the moulds in a pressing direction; - a demoulding device for removing the green brick from the moulds in a demoulding direction; and - a mould container conveyor arranged for coupling to one or more mould containers and configured to transport the mould containers over the frame; characterized in that a number of moulds is provided with a bottom configured to receive a force exerted on the mould by the pressing device, and wherein the bottom is arranged movably in the mould.

2. Device according to the foregoing claim or the preamble thereof, wherein the mould containers are mutually connected in an endless series by means of a pivoting connection.

3. Device according to claim 1 or 2 or the preamble of claim 1, wherein the mould container conveyor comprises a rail and a coupling mechanism movable over this rail, configured to engage on one or more mould containers.

4. Device according to the foregoing claim, wherein the rail comprises one or more end points for the coupling mechanism.

5. Device according to any one of the foregoing claims or the preamble of claim 1, further comprising a blocking mechanism which is arranged for coupling to one or more mould containers and is configured to block the one or more mould containers.

6. Device according to the foregoing claim, wherein the blocking mechanism comprises an upper blocking element and a lower blocking element.

7. Device according to one of the two foregoing claims, wherein the blocking mechanisms is configured such that it is simultaneously couplable to one of the upper track and the lower track.

8. Device according to any one of the foregoing claims or the preamble of claim 1, wherein a number of adjacent mould containers is connected rigidly to each other, such that they are rotatable relative to the surrounding area only as a unit.

9. Device according to any one of the foregoing claims or the preamble of claim 1, wherein the mould container conveyor transports a number of mould containers over the frame over the length of one mould container in a single movement of the mould container conveyor.

10. Device according to any one of the foregoing claims or the preamble of claim 1, further comprising a discharge conveyor for transporting the manufactured green brick.

11. Device according to any one of the foregoing claims, wherein the bottom is provided with a recess for engaging on the bottom of the mould.

12. Method for manufacturing green bricks from a material, such as clay material, comprising of: - providing a device according to any one of the foregoing claims; - transporting the mould containers over the frame by means of the mould container conveyor; - guiding the mould containers and performing processes, comprising of: - introducing the material into the moulds by means of the filling device; - pressing the material into a green brick in the moulds by means of the pressing device; and - removing the green brick from the moulds by means of the demoulding device; and - returning the mould containers on and / or via the lower track.

13. Method according to the foregoing claim, further comprising of engaging on one or more mould containers by means of the mould container conveyor.

14. Method according to claim 12 or 13, further comprising of blocking the upper track and / or the lower track by means of the blocking mechanism.

15. Method according to any one of the claims 12-14, further comprising of transferring the mould containers between the upper track and the lower track.

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