An apparatus and a method for recycling used bricks

Abstract

Apparatus for recycling used bricks (10) by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said apparatus comprising a transport conveyor for receiving the used bricks sequentially, said bricks being placed on said conveyor and advanced in a transport direction through a cleaning process in the apparatus, a first cleaning unit (4) comprising at least one first hammer station (11) and a first brushing station (12) arranged in sequence along said conveyor for removing building material residue of a first set of two opposing sides of the bricks, a first turning station (5) for turning the bricks such that a second set of opposing sides of the bricks can be processed, a second cleaning unit (6) comprising a second hammer station (11) and a second brushing station (12) arranged in sequence for removing building material residue of said second set of opposing sides of the bricks, a second turning station (7) for turning the bricks such that a third set of opposing sides of the bricks can be processed, and a third cleaning unit (8) comprising a third hammer station and a third brushing station arranged in sequence for removing building material residue of said third set of opposing sides of the bricks. The invention also concerns a method of recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a method and an apparatus for recycling used bricksBACKGROUND OF THE INVENTION

[0002] Used bricks and the like from demolished buildings can be reused if the mortar is removed from them. Used bricks are aesthetically desirable for new buildings designed in a traditional style or in reconstruction of older buildings.

[0003] To recycle the used bricks when taking down such existing masonry structure, for replacement, repair or restauration for example, the used bricks first need to have the mortar that is stuck to them removed before they can be reused. This is typically done manually by using manual and powered hand tools. This is hard and time-consuming work and can damage some of the bricks being cleaned. The alternative to cleaning the brick is disposing of the bricks. However, this can be costly and is not environmentally friendly.

[0004] Therefore in a desire for a brick cleaning system that can clean bricks more easily and quickly, some automated brick cleaning systems exists. Examples of such automated machines are known from WO 91 / 03361 A1, WO 2022 / 256940 A1 and GB 2 288 363 A.

[0005] However, some of these systems are very large and cannot be provided at a construction or demolition site. Even if they can, they cannot easily be taken from one site to another due to their large size. Old bricks may not have perfectly flat surfaces and some of these known brick cleaning systems are not sufficiently precise and do not clean the bricks sufficiently and / or can damage many of the bricks whilst cleaning.

[0006] Therefore with this background it is an object for the present invention to provide a method and apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, which addresses at least some of the inconveniences present in the known brick cleaning systems.SUMMARY OF THE INVENTION

[0007] This object is achieved in a first aspect of the invention by providing an apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said apparatus comprising: a transport conveyor for receiving the used bricks sequentially, said bricks being placed on said conveyor and advanced in a transport direction through a cleaning process in the apparatus; a first cleaning unit comprising at least one first hammer station and a first brushing station arranged in sequence along said conveyor for removing building material residue of a first set of two opposing sides of the bricks; a first turning station for turning the bricks such that a second set of opposing sides of the bricks can be processed; a second cleaning unit comprising a second hammer station and a second brushing station arranged in sequence for removing building material residue of said second set of opposing sides of the bricks; a second turning station for turning the bricks such that a third set of opposing sides of the bricks can be processed; and a third cleaning unit comprising a third hammer station and a third brushing station arranged in sequence for removing building material residue of said third set of opposing sides of the bricks.

[0008] By the invention it is utilised that bricks generally have a rectangular cubic shape. Bricks for buildings are characteristic in that they are all cubic in shape and have two opposite large sides and perpendicular to these large sides, there are two long sides and two end sides, where the long sides and the end sides are also perpendicular to each other.

[0009] By the invention, the traditional manual brick cleaning method is replicated in an automated form. Accordingly, in the hammer stations, hammers are arranged such that the hammers are tapping on the mortar on each side of the brick, Hereby the hammers are loosening building material residue, such as the mortar, from the surface of the sides of the brick.

[0010] By the invention there is provided a compact apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The three cleaning units clean the three pairs of sides of each brick one set of sides at the time. In between the cleaning units the bricks are turned so that a pair of sides yet to be cleaned is oriented correct for the next cleaning station. Advantageously, the apparatus according to the invention can be provided on site so that the used bricks can be cleaned on site.

[0011] Each of the hammer stations preferably comprise two opposing oscillating hammers moving in a plane substantially perpendicular to the transport conveyor. The opposing hammers in each of the hammer stations are arranged to be oscillating towards and away each other in a plane substantially perpendicular to the transport direction and thereby tapping on the brick sides and said hammers are provided with a predefined gap between said hammers corresponding to the brick size. This gap is preferably adjustable and individually adjusted for each hammer station in accordance with the dimensions of the used bricks that are to be cleaned.

[0012] In one embodiment of the invention, the transport conveyor may be a belt conveyor, preferably with flights for advancing the bricks in a row through the apparatus. The conveyor may be driven with continuously with a constant speed or intermittently. The transport direction is preferably straight, which provides for a simple lay-out of the brick cleaning apparatus.

[0013] In a preferred embodiment, the first cleaning unit comprises two first hammer stations in sequence for removing building residue on the first set of two opposing sides of the bricks. Hereby, the bricks may be oriented with their largest sides facing the hammers in the hammer stations and this larger surface, which is typically where most mortar is left on a used brick, can get an extra cleaning operation to remove the mortar.

[0014] The first and second turning stations preferably each turn the bricks substantially 90° such that the two sides to be cleaned are parallel to the transport direction. The used bricks are preferably fed into the first cleaning unit in an upright position with the two large sides of the brick being substantially parallel to the transport direction. Thus, the first turning station turns the bricks 90° along an axis parallel to the transport direction, so that the second cleaning unit can clean the long sides of the bricks. Then after the second cleaning unit, the second turn station turns the bricks 90° along an axis perpendicular to the transport direction so that the end sides of the bricks can be cleaned by the third cleaning unit.

[0015] Preferably, the first, second and third brushing stations comprise a set of rotary brushes on each side of the transport conveyor for removing lose building material from the surface sides on the bricks. The brushes may comprise sweeping brushes made of steel wires, plastic material or the like. The choice of material for the brushes may depend on the type of used bricks and how soft the bricks are. The brushes are then chosen so that the bricks are not damaged by the brushes sweeping the bricks.

[0016] Advantageously, the apparatus may be provided in a housing container, preferably a standard-sized container, e.g. a 20' container. Hereby, a container with the apparatus can be provided on a construction or demolition site so that the used bricks can be cleaned on site rather than having to be collected and transported to a separate cleaning site.

[0017] In a preferred embodiment of the invention, an automatic stacking mechanism is provided at the end of the transport conveyor for stacking the used bricks on a transport pallet or the like. Hereby, the used bricks are being cleaned and then stacked on a pallet ready for being transported to a new building site.

[0018] In a second aspect of the invention there is provided a method of recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said method comprising the steps of: receiving the used bricks sequentially by placing said bricks on a transport conveyor and advancing the bricks on the conveyor through a series of cleaning operations, which includes: removing building material residue of a first set of two opposing sides of the bricks in a first cleaning unit by tapping said first set of sides of the brick in at least one first hammer station and cleaning said first set of sides in a first brushing station arranged downstream along said transport conveyor; and then turning the bricks in a first turning station such that a second set of opposing sides of the bricks can be processed; removing building material residue of the second set of two opposing sides of the bricks in a first cleaning unit by tapping said second set of sides of the brick in a second hammer station and cleaning said second set of sides in a second brushing station arranged downstream along said transport conveyor; and then turning the bricks in a second turning station such that a third set of opposing sides of the bricks can be processed; and then removing building material residue of the third set of two opposing sides of the bricks in a first cleaning unit by tapping said third set of sides of the brick in a third hammer station and cleaning said third set of sides in a third brushing station arranged downstream along said transport conveyor.

[0019] This method may advantageously be performed by an apparatus according to the first aspect of the invention as described above in relation to various embodiment of said apparatus.

[0020] By the term "tapping" is meant any type of controlled knocking by the hammers on the bricks to loosen any mortar or other building material residues on the used bricks.DETAILED DESCRIPTION

[0021] In the following, the invention is described in more detail with reference to the embodiments shown in the accompanying drawings, in which: Fig. 1 is a perspective view of a first embodiment of an apparatus according to the invention; Fig. 2 is a top view of same; Fig. 3 is a perspective view of the apparatus according to the invention housed in a container; Fig. 4 is a perspective top view of a cleaning unit according to an embodiment of the invention; Fig. 5 is a perspective bottom view of same; and Fig. 6 is a schematic, perspective view of the pair of hammers in the hammer station according to an embodiment of the invention.

[0022] With reference to the figures 1 and 2, there is shown an embodiment of an apparatus according to the invention for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The apparatus comprises a transport conveyor 2 for receiving the used bricks 10 sequentially. The bricks 10 being placed on the conveyor 2 and advanced in a transport direction T through a cleaning process in the apparatus.

[0023] Bricks are characteristic in that they are all cubic in shape and have two opposite large sides and perpendicular to these large sides, there are two long sides and two end sides, where the long sides and the end sides are also perpendicular to each other. The generic geometric shape is utilized in the present invention.

[0024] The cleaning process comprises three cleaning units 4, 6, 8 downstream of each other.

[0025] The first cleaning unit 4 comprises two hammer stations 11 and a brushing station 12 arranged in sequence along the conveyor 2 for removing building material residue, in particular mortar, of a first set of two opposing sides of the bricks 10.

[0026] As shown in the figures, the first cleaning unit 4 comprises two first hammer stations 11 in sequence for removing building residue on the first set of two opposing sides of the bricks. On the transport conveyor 2, the bricks are provided with the orientation having their largest sides facing to the sides in the hammer stations 11 and by having two hammer stations 11 after each other this larger surface, which is typically where most mortar is left on a used brick, undergoes an extra cleaning operation to remove the mortar.

[0027] Immediately downstream of the first cleaning unit 4 there is provided a first turning station 5 for turning the bricks such that a second set of opposing sides of the bricks can be processed in the subsequent second cleaning unit 6.

[0028] This second cleaning unit 6 comprises a second hammer station 11 and a second brushing station 12 arranged in sequence for removing any building material residue of said second set of opposing sides of the bricks.

[0029] After this second cleaning process, the bricks 10 are transported to a second turning station 7 for turning the bricks such that a third set of opposing sides of the bricks can be processed.

[0030] The first and second turning stations 5, 7 preferably each turn the bricks 10 substantially 90° such that the two sides to be cleaned are parallel to the transport direction T. The used bricks 10 are preferably fed into the first cleaning unit 4 in an upright position with the two large sides of the brick 10 being substantially parallel to the transport direction T. Thus, the first turning station 5 turns the bricks 90° along an axis parallel to the transport direction T, so that the second cleaning unit 6 can clean the long sides of the bricks 10. Then after the second cleaning unit 6, the second turn station 7 turns the bricks 90° along an axis perpendicular to the transport direction so that the end sides of the bricks 10 can be cleaned by the third cleaning unit 8.

[0031] Thus, the third set of opposing sides of the bricks is processed in the third cleaning unit 8, which also comprises a hammer station 11 and a brushing station 12.

[0032] The transport conveyor is a belt conveyor with flights which extends through the entire apparatus onto the stacking mechanism 9 at the end of the conveyor 2. By the automatic stacking mechanism 9, the used bricks 10 that have been cleaned in the cleaning units 4, 6, 8 are stacked on a transport pallet or the like.

[0033] As it is apparent from the figures, the transport direction T is straight with the cleaning units 4, 6, 8 and turning units 5, 7 arranged sequentially along the conveyor 2. The units 4, 5, 6, 7, 8 are controlled by control units 3 provided alongside the conveyor 2 as well. This allows for a compact footprint of the apparatus. Accordingly, as shown in fig. 3, the apparatus may be provided in a housing container 1, in particular a standard-sized container, e.g. a 20' container, which can be provided on a construction site for onsite cleaning of used bricks of a building demolition process so that the used bricks can be transported away from the site in a state where the bricks are ready to be reused.

[0034] In figures 4 and 5 more detailed views are shown of the hammer station 11, including the brushing stations 12. The hammer station 11 comprises two opposing oscillating hammers 11a (see fig. 5 and 6) moving in a plane substantially perpendicular to the transport conveyor T. These two opposing hammers 11a are oscillating towards and away each other for beating on the sides of the bricks 10. The hammers 11a are provided with a predefined gap which corresponding to the brick size. This gap is adjustable, so that the hammer stations 11 can be adjusted to the actual size of the bricks to be cleaned in the apparatus. Also, the hammer stations 11 in each of the cleaning units 4, 6, 8 will be adjusted to different gaps depending on which pair of brick sides that are to be cleaning in the particular hammer station.

[0035] In fig. 6 the cleaning principle is shown in more detail. The two opposing oscillating hammers 11a are provided opposite each other and are moving in and out as indicated by the arrows H in a plane substantially perpendicular to the transport conveyor 2 and the transport direction T. The hammers 10a are arranged with a predetermined gap such that the hammers are substantially simultaneously hammering / tapping on the mortar on each side of the brick 10, thereby loosening the mortar 10a from the surface of the sides of the brick 10. The two hammers 10a both have a leading edge which tap on the brick side.

[0036] It is well known that bricks may vary in dimensional size and in types of material from building to building. Therefore, the gap between the hammers 10a is variable so that the gap can be adjusted to the actual dimensions of the used bricks to be cleaned. Hereby, the traditional manual brick cleaning method is replicated in an automated form.

[0037] The hammers 10a are provided opposite each other so that the hammers 10a tap the bricks without causing the brick to be rotate on the transport conveyor 2. The frequency at which the hammers are tapping is variable and may be adjusted according to the type of the building material to be removed and / or the type of brick 10, such as the softness and the brittleness of the bricks and the building residues / mortar on the bricks.

[0038] The hammers 10a are preferably hitting the mortar on each side of the brick 10 in a simultaneously manner while the brick 10 is being advanced in the transport direction T on the transport conveyor 2 (see figs 1 and 2). The precise timing of the two hammering actions from the two sides may be simultaneously or alternating but with the essentially same frequency. This frequency of the oscillation may be varied and the transport velocity of the bricks 10 on the conveyor 2 may be varied.

[0039] As shown in figs. 4 and 5, immediately downstream a hammer station 11 there is provided a brushing station 12. The first, second and third brushing stations 12 all comprise a set of rotary brushes 12a on each side of the transport conveyor 2 for removing lose building material from the surface sides on the bricks 10. The brushes 12a can be exchanged and may be steel brushes, plastic brushes or the like depending on the softness of the bricks 10 to be cleaned.

[0040] Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is set out by the accompanying claim set. In the context of the claims, the terms "comprising" or "comprises" do not exclude other possible elements or steps. Also, the mentioning of references such as "a" or "an" etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.

[0041] Above, the invention is described with reference to some currently preferred embodiments. However, by the invention it is realised that other embodiments and variants may be provided without departing from the scope of the invention as defined in the accompanying claims.

Examples

Embodiment Construction

[0021]In the following, the invention is described in more detail with reference to the embodiments shown in the accompanying drawings, in which:

Fig. 1 is a perspective view of a first embodiment of an apparatus according to the invention; Fig. 2 is a top view of same; Fig. 3 is a perspective view of the apparatus according to the invention housed in a container; Fig. 4 is a perspective top view of a cleaning unit according to an embodiment of the invention; Fig. 5 is a perspective bottom view of same; and Fig. 6 is a schematic, perspective view of the pair of hammers in the hammer station according to an embodiment of the invention.

[0022]With reference to the figures 1 and 2, there is shown an embodiment of an apparatus according to the invention for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The apparatus comprises a transport conveyor 2 for receiving the used bricks 10 sequentially. The bricks 10 be...

FIELD OF THE INVENTION

[0001] The present invention relates to a method and an apparatus for recycling used bricksBACKGROUND OF THE INVENTION

[0002] Used bricks and the like from demolished buildings can be reused if the mortar is removed from them. Used bricks are aesthetically desirable for new buildings designed in a traditional style or in reconstruction of older buildings.

[0003] To recycle the used bricks when taking down such existing masonry structure, for replacement, repair or restauration for example, the used bricks first need to have the mortar that is stuck to them removed before they can be reused. This is typically done manually by using manual and powered hand tools. This is hard and time-consuming work and can damage some of the bricks being cleaned. The alternative to cleaning the brick is disposing of the bricks. However, this can be costly and is not environmentally friendly.

[0004] Therefore in a desire for a brick cleaning system that can clean bricks more easily and quickly, some automated brick cleaning systems exists. Examples of such automated machines are known from WO 91 / 03361 A1, WO 2022 / 256940 A1 and GB 2 288 363 A.

[0005] However, some of these systems are very large and cannot be provided at a construction or demolition site. Even if they can, they cannot easily be taken from one site to another due to their large size. Old bricks may not have perfectly flat surfaces and some of these known brick cleaning systems are not sufficiently precise and do not clean the bricks sufficiently and / or can damage many of the bricks whilst cleaning.

[0006] Therefore with this background it is an object for the present invention to provide a method and apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, which addresses at least some of the inconveniences present in the known brick cleaning systems.SUMMARY OF THE INVENTION

[0007] This object is achieved in a first aspect of the invention by providing an apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said apparatus comprising: a transport conveyor for receiving the used bricks sequentially, said bricks being placed on said conveyor and advanced in a transport direction through a cleaning process in the apparatus; a first cleaning unit comprising at least one first hammer station and a first brushing station arranged in sequence along said conveyor for removing building material residue of a first set of two opposing sides of the bricks; a first turning station for turning the bricks such that a second set of opposing sides of the bricks can be processed; a second cleaning unit comprising a second hammer station and a second brushing station arranged in sequence for removing building material residue of said second set of opposing sides of the bricks; a second turning station for turning the bricks such that a third set of opposing sides of the bricks can be processed; and a third cleaning unit comprising a third hammer station and a third brushing station arranged in sequence for removing building material residue of said third set of opposing sides of the bricks.

[0008] By the invention it is utilised that bricks generally have a rectangular cubic shape. Bricks for buildings are characteristic in that they are all cubic in shape and have two opposite large sides and perpendicular to these large sides, there are two long sides and two end sides, where the long sides and the end sides are also perpendicular to each other.

[0009] By the invention, the traditional manual brick cleaning method is replicated in an automated form. Accordingly, in the hammer stations, hammers are arranged such that the hammers are tapping on the mortar on each side of the brick, Hereby the hammers are loosening building material residue, such as the mortar, from the surface of the sides of the brick.

[0010] By the invention there is provided a compact apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The three cleaning units clean the three pairs of sides of each brick one set of sides at the time. In between the cleaning units the bricks are turned so that a pair of sides yet to be cleaned is oriented correct for the next cleaning station. Advantageously, the apparatus according to the invention can be provided on site so that the used bricks can be cleaned on site.

[0011] Each of the hammer stations preferably comprise two opposing oscillating hammers moving in a plane substantially perpendicular to the transport conveyor. The opposing hammers in each of the hammer stations are arranged to be oscillating towards and away each other in a plane substantially perpendicular to the transport direction and thereby tapping on the brick sides and said hammers are provided with a predefined gap between said hammers corresponding to the brick size. This gap is preferably adjustable and individually adjusted for each hammer station in accordance with the dimensions of the used bricks that are to be cleaned.

[0012] In one embodiment of the invention, the transport conveyor may be a belt conveyor, preferably with flights for advancing the bricks in a row through the apparatus. The conveyor may be driven with continuously with a constant speed or intermittently. The transport direction is preferably straight, which provides for a simple lay-out of the brick cleaning apparatus.

[0013] In a preferred embodiment, the first cleaning unit comprises two first hammer stations in sequence for removing building residue on the first set of two opposing sides of the bricks. Hereby, the bricks may be oriented with their largest sides facing the hammers in the hammer stations and this larger surface, which is typically where most mortar is left on a used brick, can get an extra cleaning operation to remove the mortar.

[0014] The first and second turning stations preferably each turn the bricks substantially 90° such that the two sides to be cleaned are parallel to the transport direction. The used bricks are preferably fed into the first cleaning unit in an upright position with the two large sides of the brick being substantially parallel to the transport direction. Thus, the first turning station turns the bricks 90° along an axis parallel to the transport direction, so that the second cleaning unit can clean the long sides of the bricks. Then after the second cleaning unit, the second turn station turns the bricks 90° along an axis perpendicular to the transport direction so that the end sides of the bricks can be cleaned by the third cleaning unit.

[0015] Preferably, the first, second and third brushing stations comprise a set of rotary brushes on each side of the transport conveyor for removing lose building material from the surface sides on the bricks. The brushes may comprise sweeping brushes made of steel wires, plastic material or the like. The choice of material for the brushes may depend on the type of used bricks and how soft the bricks are. The brushes are then chosen so that the bricks are not damaged by the brushes sweeping the bricks.

[0016] Advantageously, the apparatus may be provided in a housing container, preferably a standard-sized container, e.g. a 20' container. Hereby, a container with the apparatus can be provided on a construction or demolition site so that the used bricks can be cleaned on site rather than having to be collected and transported to a separate cleaning site.

[0017] In a preferred embodiment of the invention, an automatic stacking mechanism is provided at the end of the transport conveyor for stacking the used bricks on a transport pallet or the like. Hereby, the used bricks are being cleaned and then stacked on a pallet ready for being transported to a new building site.

[0018] In a second aspect of the invention there is provided a method of recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said method comprising the steps of: receiving the used bricks sequentially by placing said bricks on a transport conveyor and advancing the bricks on the conveyor through a series of cleaning operations, which includes: removing building material residue of a first set of two opposing sides of the bricks in a first cleaning unit by tapping said first set of sides of the brick in at least one first hammer station and cleaning said first set of sides in a first brushing station arranged downstream along said transport conveyor; and then turning the bricks in a first turning station such that a second set of opposing sides of the bricks can be processed; removing building material residue of the second set of two opposing sides of the bricks in a first cleaning unit by tapping said second set of sides of the brick in a second hammer station and cleaning said second set of sides in a second brushing station arranged downstream along said transport conveyor; and then turning the bricks in a second turning station such that a third set of opposing sides of the bricks can be processed; and then removing building material residue of the third set of two opposing sides of the bricks in a first cleaning unit by tapping said third set of sides of the brick in a third hammer station and cleaning said third set of sides in a third brushing station arranged downstream along said transport conveyor.

[0019] This method may advantageously be performed by an apparatus according to the first aspect of the invention as described above in relation to various embodiment of said apparatus.

[0020] By the term "tapping" is meant any type of controlled knocking by the hammers on the bricks to loosen any mortar or other building material residues on the used bricks.DETAILED DESCRIPTION

[0021] In the following, the invention is described in more detail with reference to the embodiments shown in the accompanying drawings, in which: Fig. 1 is a perspective view of a first embodiment of an apparatus according to the invention; Fig. 2 is a top view of same; Fig. 3 is a perspective view of the apparatus according to the invention housed in a container; Fig. 4 is a perspective top view of a cleaning unit according to an embodiment of the invention; Fig. 5 is a perspective bottom view of same; and Fig. 6 is a schematic, perspective view of the pair of hammers in the hammer station according to an embodiment of the invention.

[0022] With reference to the figures 1 and 2, there is shown an embodiment of an apparatus according to the invention for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The apparatus comprises a transport conveyor 2 for receiving the used bricks 10 sequentially. The bricks 10 being placed on the conveyor 2 and advanced in a transport direction T through a cleaning process in the apparatus.

[0023] Bricks are characteristic in that they are all cubic in shape and have two opposite large sides and perpendicular to these large sides, there are two long sides and two end sides, where the long sides and the end sides are also perpendicular to each other. The generic geometric shape is utilized in the present invention.

[0024] The cleaning process comprises three cleaning units 4, 6, 8 downstream of each other.

[0025] The first cleaning unit 4 comprises two hammer stations 11 and a brushing station 12 arranged in sequence along the conveyor 2 for removing building material residue, in particular mortar, of a first set of two opposing sides of the bricks 10.

[0026] As shown in the figures, the first cleaning unit 4 comprises two first hammer stations 11 in sequence for removing building residue on the first set of two opposing sides of the bricks. On the transport conveyor 2, the bricks are provided with the orientation having their largest sides facing to the sides in the hammer stations 11 and by having two hammer stations 11 after each other this larger surface, which is typically where most mortar is left on a used brick, undergoes an extra cleaning operation to remove the mortar.

[0027] Immediately downstream of the first cleaning unit 4 there is provided a first turning station 5 for turning the bricks such that a second set of opposing sides of the bricks can be processed in the subsequent second cleaning unit 6.

[0028] This second cleaning unit 6 comprises a second hammer station 11 and a second brushing station 12 arranged in sequence for removing any building material residue of said second set of opposing sides of the bricks.

[0029] After this second cleaning process, the bricks 10 are transported to a second turning station 7 for turning the bricks such that a third set of opposing sides of the bricks can be processed.

[0030] The first and second turning stations 5, 7 preferably each turn the bricks 10 substantially 90° such that the two sides to be cleaned are parallel to the transport direction T. The used bricks 10 are preferably fed into the first cleaning unit 4 in an upright position with the two large sides of the brick 10 being substantially parallel to the transport direction T. Thus, the first turning station 5 turns the bricks 90° along an axis parallel to the transport direction T, so that the second cleaning unit 6 can clean the long sides of the bricks 10. Then after the second cleaning unit 6, the second turn station 7 turns the bricks 90° along an axis perpendicular to the transport direction so that the end sides of the bricks 10 can be cleaned by the third cleaning unit 8.

[0031] Thus, the third set of opposing sides of the bricks is processed in the third cleaning unit 8, which also comprises a hammer station 11 and a brushing station 12.

[0032] The transport conveyor is a belt conveyor with flights which extends through the entire apparatus onto the stacking mechanism 9 at the end of the conveyor 2. By the automatic stacking mechanism 9, the used bricks 10 that have been cleaned in the cleaning units 4, 6, 8 are stacked on a transport pallet or the like.

[0033] As it is apparent from the figures, the transport direction T is straight with the cleaning units 4, 6, 8 and turning units 5, 7 arranged sequentially along the conveyor 2. The units 4, 5, 6, 7, 8 are controlled by control units 3 provided alongside the conveyor 2 as well. This allows for a compact footprint of the apparatus. Accordingly, as shown in fig. 3, the apparatus may be provided in a housing container 1, in particular a standard-sized container, e.g. a 20' container, which can be provided on a construction site for onsite cleaning of used bricks of a building demolition process so that the used bricks can be transported away from the site in a state where the bricks are ready to be reused.

[0034] In figures 4 and 5 more detailed views are shown of the hammer station 11, including the brushing stations 12. The hammer station 11 comprises two opposing oscillating hammers 11a (see fig. 5 and 6) moving in a plane substantially perpendicular to the transport conveyor T. These two opposing hammers 11a are oscillating towards and away each other for beating on the sides of the bricks 10. The hammers 11a are provided with a predefined gap which corresponding to the brick size. This gap is adjustable, so that the hammer stations 11 can be adjusted to the actual size of the bricks to be cleaned in the apparatus. Also, the hammer stations 11 in each of the cleaning units 4, 6, 8 will be adjusted to different gaps depending on which pair of brick sides that are to be cleaning in the particular hammer station.

[0035] In fig. 6 the cleaning principle is shown in more detail. The two opposing oscillating hammers 11a are provided opposite each other and are moving in and out as indicated by the arrows H in a plane substantially perpendicular to the transport conveyor 2 and the transport direction T. The hammers 10a are arranged with a predetermined gap such that the hammers are substantially simultaneously hammering / tapping on the mortar on each side of the brick 10, thereby loosening the mortar 10a from the surface of the sides of the brick 10. The two hammers 10a both have a leading edge which tap on the brick side.

[0036] It is well known that bricks may vary in dimensional size and in types of material from building to building. Therefore, the gap between the hammers 10a is variable so that the gap can be adjusted to the actual dimensions of the used bricks to be cleaned. Hereby, the traditional manual brick cleaning method is replicated in an automated form.

[0037] The hammers 10a are provided opposite each other so that the hammers 10a tap the bricks without causing the brick to be rotate on the transport conveyor 2. The frequency at which the hammers are tapping is variable and may be adjusted according to the type of the building material to be removed and / or the type of brick 10, such as the softness and the brittleness of the bricks and the building residues / mortar on the bricks.

[0038] The hammers 10a are preferably hitting the mortar on each side of the brick 10 in a simultaneously manner while the brick 10 is being advanced in the transport direction T on the transport conveyor 2 (see figs 1 and 2). The precise timing of the two hammering actions from the two sides may be simultaneously or alternating but with the essentially same frequency. This frequency of the oscillation may be varied and the transport velocity of the bricks 10 on the conveyor 2 may be varied.

[0039] As shown in figs. 4 and 5, immediately downstream a hammer station 11 there is provided a brushing station 12. The first, second and third brushing stations 12 all comprise a set of rotary brushes 12a on each side of the transport conveyor 2 for removing lose building material from the surface sides on the bricks 10. The brushes 12a can be exchanged and may be steel brushes, plastic brushes or the like depending on the softness of the bricks 10 to be cleaned.

[0040] Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is set out by the accompanying claim set. In the context of the claims, the terms "comprising" or "comprises" do not exclude other possible elements or steps. Also, the mentioning of references such as "a" or "an" etc. should not be construed as excluding a plurality. The use of reference signs in the claims with respect to elements indicated in the figures shall also not be construed as limiting the scope of the invention. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.

[0041] Above, the invention is described with reference to some currently preferred embodiments. However, by the invention it is realised that other embodiments and variants may be provided without departing from the scope of the invention as defined in the accompanying claims.

Examples

Embodiment Construction

[0021]In the following, the invention is described in more detail with reference to the embodiments shown in the accompanying drawings, in which:

Fig. 1 is a perspective view of a first embodiment of an apparatus according to the invention; Fig. 2 is a top view of same; Fig. 3 is a perspective view of the apparatus according to the invention housed in a container; Fig. 4 is a perspective top view of a cleaning unit according to an embodiment of the invention; Fig. 5 is a perspective bottom view of same; and Fig. 6 is a schematic, perspective view of the pair of hammers in the hammer station according to an embodiment of the invention.

[0022]With reference to the figures 1 and 2, there is shown an embodiment of an apparatus according to the invention for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks. The apparatus comprises a transport conveyor 2 for receiving the used bricks 10 sequentially. The bricks 10 be...

Claims

1. An apparatus for recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said apparatus comprising: a transport conveyor for receiving the used bricks sequentially, said bricks being placed on said conveyor and advanced in a transport direction through a cleaning process in the apparatus, a first cleaning unit comprising at least one first hammer station and a first brushing station arranged in sequence along said conveyor for removing building material residue of a first set of two opposing sides of the bricks, a first turning station for turning the bricks such that a second set of opposing sides of the bricks can be processed, a second cleaning unit comprising a second hammer station and a second brushing station arranged in sequence for removing building material residue of said second set of opposing sides of the bricks, a second turning station for turning the bricks such that a third set of opposing sides of the bricks can be processed, and a third cleaning unit comprising a third hammer station and a third brushing station arranged in sequence for removing building material residue of said third set of opposing sides of the bricks.

2. An apparatus according to claim 1, wherein each of the hammer stations comprise two opposing oscillating hammers moving in a plane substantially perpendicular to the transport conveyor, said hammers being arranged for tapping on the brick sides and thereby loosening the mortar from the surface of the sides of the brick.

3. An apparatus according to claim 1, wherein the two opposing hammers in each of the hammer stations are oscillating towards and away each other in a plane substantially perpendicular to the transport direction and said hammers are provided with a predefined gap between said hammers corresponding to the brick size.

4. An apparatus according to claim 3, wherein said gap is adjustable.

5. An apparatus according to any of the previous claims, wherein the transport conveyor is a belt conveyor, preferably with flights for advancing the bricks in a row through the apparatus.

6. An apparatus according to any of the previous claims, wherein the transport direction is straight.

7. An apparatus according to any of the previous claims, wherein the first cleaning unit comprises two first hammer stations in sequence for removing building residue on the first set of two opposing sides of the bricks.

8. An apparatus according to any of the previous claims, wherein the first and second turning stations each turn the bricks substantially 90° such that the two sides to be cleaned are parallel to the transport direction.

9. An apparatus according to any of the previous claims, wherein the first, second and third brushing stations comprise a set of rotary brushes on each side of the transport conveyor for removing lose building material from the surface sides on the bricks.

10. An apparatus according to claim 9, wherein the brushes comprise sweeping brushes made of any one of steel wires, plastic material or the like.

11. An apparatus according to any of the previous claims, wherein the apparatus is provided in a housing container, preferably a standard-sized container, e.g. a 20' container.

12. An apparatus according to any of the previous claims, wherein an automatic stacking mechanism is provided at the end of the transport conveyor for stacking the used bricks on a transport pallet or the like.

13. A method of recycling used bricks by cleaning said used bricks by removing building material residue, such as mortar, from the bricks, said method comprising the steps of: - receiving the used bricks sequentially by placing said bricks on a transport conveyor and advancing the bricks on the conveyor through a series of cleaning operations, which includes: - removing building material residue of a first set of two opposing sides of the bricks in a first cleaning unit by tapping said first set of sides of the brick in at least one first hammer station and cleaning said first set of sides in a first brushing station arranged downstream along said transport conveyor; and then - turning the bricks in a first turning station such that a second set of opposing sides of the bricks can be processed; - removing building material residue of the second set of two opposing sides of the bricks in a first cleaning unit by tapping said second set of sides of the brick in a second hammer station and cleaning said second set of sides in a second brushing station arranged downstream along said transport conveyor; and then - turning the bricks in a second turning station such that a third set of opposing sides of the bricks can be processed; - removing building material residue of the third set of two opposing sides of the bricks in a first cleaning unit by tapping said third set of sides of the brick in a third hammer station and cleaning said third set of sides in a third brushing station arranged downstream along said transport conveyor.

14. A method according to claim 13, whereby the turning of the bricks at the first and second turning stations is substantially 90° such that the two sides to be cleaned are parallel to the transport direction.

15. A method according to claim 13 or 14, whereby an automatic stacking is provided at the end of the transport conveyor where the cleaned used bricks are stacked on a transport pallet or the like.

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